Segmented Bonded Abrasive Article for Dressing-Free Grinding
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Solution Overview
Problem
Metal-bonded abrasive articles require frequent truing and dressing operations to maintain grinding effectiveness, which is time-consuming and inefficient, and existing bonded abrasive tools struggle to achieve low maximum chip sizes during grinding operations, especially on workpieces with low fracture toughness.
Innovation Solution
The development of bonded abrasive articles comprising two distinct bodies with different bond materials and abrasive particle ratios, where one body has a ratio of VAG(1)/VBM(1) of at least 1.3 and the other of VAG(2)/VBM(2) less than 1.3, allowing for consecutive periphery grinding operations without dressing, resulting in a maximum chip size of less than 0.0025 inches on workpiece edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metal-bonded abrasive articles are used for grinding operations, then material removal capability is achieved, but frequent truing and dressing operations are required to maintain grinding effectiveness
Solution Approach 1:
The abrasive article is divided into two distinct bodies: a first body with high abrasive particle content (VAG/VBM ≥ 1.3) for effective material removal, and a second body with lower abrasive particle content (VAG/VBM < 1.3) for maintaining grinding effectiveness without requiring frequent dressing operations
Solution Approach 2:
Different regions of the abrasive article have different compositions optimized for different functions: the first body is designed with higher abrasive concentration for aggressive material removal, while the second body has lower abrasive concentration for sustained grinding performance and reduced dressing requirements
2Manufacturing precision
If conventional bonded abrasive tools are used, then grinding operations can be performed, but achieving low maximum chip sizes is difficult, especially on workpieces with low fracture toughness
Solution Approach 1:
The first body with high abrasive particle content is specifically configured to produce fine chips and control chip size during grinding operations on brittle workpieces, while the second body provides overall structural support and sustained performance
Solution Approach 2:
The abrasive article uses a composite structure combining two different bond materials with different abrasive particle ratios, creating a material system that can simultaneously achieve fine chip size control and adaptability to brittle workpiece materials
3Productivity
If single-body abrasive articles are used, then结构简单性 is maintained, but grinding cycles require frequent interruption for dressing
Solution Approach 1:
The abrasive article consists of two distinct bodies with different compositions, where the first body enables continuous material removal and the second body maintains grinding effectiveness, allowing extended grinding cycles without dressing operations despite the increased structural complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables extended grinding cycles without the need for truing or dressing, reduces chip size significantly, and improves grinding efficiency and wear resistance, particularly on brittle workpieces, while maintaining high material removal rates and surface quality.
Implementation Method 1
Bonded abrasive tools consist of rigid, and typically monolithic, three-dimensional, abrasive composites... used in grinding and shaping certain types of workpieces
Data Source
AI summary
An abrasive article comprising: a first body comprising a first bond material having abrasive particles contained within the first bond material, wherein the first body comprising the first bond material comprises a ratio of VAG(1)/VBM(1) of at least about 1.3; a second body comprising a second bond material having abrasive particles contained within the second bond material, wherein the second body comprising the second bond material comprises a ratio of VAG(2)/VBM(2) of less than about 1.3, and wherein VAG is a volume percent of abrasive particles within a total volume of the first or second body respectively and VBM is a volume percent of the first or second bond material within the total volume of the first or second body respectively.