Segmented Profiled Grinding Wheel with Laser Welded Abrasive Segments
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Solution Overview
Problem
Conventional diamond abrasive grinding wheels are expensive to manufacture and maintain, with high material and labor costs, and suffer from imprecise grinding due to non-segmented abrasive portions and weak metallurgical bonds, leading to reduced productivity and increased costs.
Innovation Solution
A segmented profiled wheel with a metal bonded core and abrasive segments that are sintered diamond bonded, allowing for precise alignment and strong bonding, reducing material usage and processing steps, and enabling continuous contact for improved grinding performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional diamond abrasive grinding wheels are manufactured using traditional methods with large metal blanks, then the wheel structure is simple and manufacturing process is straightforward, but material waste is high (75% of metal blank is wasted) and manufacturing cost is high
Solution Approach 1:
The abrasive portion is divided into multiple separate abrasive segments that are attached to the wheel core, rather than forming a single integrated abrasive layer. This segmentation allows each segment to be manufactured independently with minimal material waste, and only the necessary abrasive material is used for each segment.
Solution Approach 2:
The abrasive portion is extracted as a separate component (abrasive segments) from the metal blank, rather than being formed by machining the blank itself. This extraction approach eliminates the need to remove large amounts of metal to create the abrasive structure.
2Ease of manufacture
If conventional grinding wheels have non-segmented abrasive portions formed in secondary operations, then the wheel structure is simple, but manufacturing cost increases due to extensive labor and equipment costs
Solution Approach 1:
The abrasive portion is segmented into separate units that can be manufactured using automated processes and then attached to the wheel core, eliminating the need for complex secondary operations to form the abrasive profile.
Solution Approach 2:
The abrasive segments are pre-formed with their final profile and geometry before attachment to the wheel core, so no secondary machining or profiling operations are needed after the segments are mounted on the wheel.
3Manufacturing precision
If conventional grinding wheels use non-segmented abrasive portions, then the wheel structure is simple, but grinding precision is reduced due to imprecise alignment and weak bond strength
Solution Approach 1:
The abrasive portion is divided into separate segments that can be precisely positioned and independently bonded to the wheel core, ensuring accurate alignment and consistent bonding strength for each segment.
Solution Approach 2:
Each abrasive segment is designed with specific local characteristics including precise geometry, positioning features, and bonding surfaces that optimize both grinding precision and bond strength at each location on the wheel.
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
The segmented wheel reduces manufacturing costs by 50-70% and extends the life of the wheel due to consistent abrasive segments and improved bond strength, enhancing grinding performance and longevity.
Implementation Method 1
a segmented abrasive portion with a plurality of abrasive segments coupled with terminal ends located adjacent to one another about the core and wherein the workpiece contacts the cutting surface profile as the wheel rotates for grinding
Data Source
AI summary
A segmented profiled wheel for grinding a glass or non-metallic workpiece including a segmented abrasive portion formed of a plurality of abrasive segments that are attached to a core of the wheel and method for making same. The plurality of abrasive segments have a cutting surface profile and sufficient abrasive grit to contour and grind the workpiece. Terminal ends of the plurality of abrasive segments are adjacent to one another and the cutting surface profiles align to form a substantially continuous rim of profiled abrasive segments for substantially continuous contact with a workpiece while the wheel rotates. The method includes the steps of forming the plurality of abrasive segments having a metal bonding matrix using automated processes, machining a metal blank to form a core, and attaching the plurality of abrasive segments to the core by laser welding and/or brazing.