Shaped Abrasive Particles in Bonded Wheels

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Solution Overview

Problem

There is a need for bonded abrasives with improved abrading properties and reduced costs while maintaining performance levels, as existing cut-off wheels and other abrasive articles do not effectively address the requirements for enhanced cutting efficiency and durability.

Innovation Solution

The method involves creating abrasive articles with precisely-shaped abrasive particles retained in an organic binder material, where the particles are aligned according to a predetermined three-dimensional position and orientation within a stack, using a positioning tool with cavities arranged in a specific pattern to adhere and bind the particles with a space-filling binder precursor, and then compressing and curing the stack to form a durable abrasive wheel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional abrasive particles are used in bonded abrasive wheels, then manufacturing cost is reduced, but abrading properties and cutting efficiency are insufficient

Engineering Contradiction:

Improvemanufacturing costVSAvoidabrading properties

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The invention changes the geometric parameters of abrasive particles from random shapes to precisely controlled shapes (spheres, cubes, cylinders, pyramids, prisms) with specific size ranges (0.5-5.0 mm diameter). This shape control allows optimization of particle packing density and cutting edge geometry, improving abrading properties while maintaining manufacturing feasibility through standardized production processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite structures combining precisely-shaped abrasive particles with organic binder materials in specific weight ratios (60-90% abrasive particles, 10-40% binder). This composite approach optimizes the balance between abrasive particle performance and binder holding strength, achieving improved cutting efficiency while controlling manufacturing costs through material selection

Inventive Principle:

Principle #40Composite materials

2Device complexity

If abrasive particles are randomly arranged in abrasive wheels, then manufacturing process is simplified, but grinding characteristics and cutting efficiency are poor

Engineering Contradiction:

Improvemanufacturing process complexityVSAvoidgrinding characteristics

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The invention applies preliminary action by pre-shaping abrasive particles into specific geometric forms (spheres, cubes, cylinders, pyramids, prisms) before incorporation into the wheel. This pre-shaping ensures optimal cutting edges and consistent performance, improving grinding characteristics while the standardized shapes facilitate straightforward manufacturing processes

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention applies local quality by ensuring uniform distribution of precisely-shaped particles throughout the binder matrix with controlled weight ratios. This uniform local arrangement of particles with specific shapes and sizes optimizes cutting performance across the entire wheel surface, achieving consistent grinding characteristics

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If traditional binder materials are used, then manufacturing cost is controlled, but operating temperature increases causing thermal damage to workpieces

Engineering Contradiction:

Improvemanufacturing costVSAvoidoperating temperature

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The invention changes the thermal parameters of binder materials by selecting organic binders with high heat resistance (phenolic resins, polyamides, polyimides) that can withstand operating temperatures without degrading. This parameter change allows the wheel to maintain structural integrity at lower operating temperatures, preventing thermal damage to workpieces while controlling manufacturing costs

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the potential harm of heat generation during abrasion into a benefit by using heat-resistant organic binder materials that actually reduce operating temperatures through their thermal properties. These binders dissipate heat effectively and prevent thermal buildup, transforming the heat problem into an advantage for protecting workpieces from thermal damage

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Device complexity

If abrasive particles are not precisely shaped, then manufacturing process is simpler, but durability and lifespan of abrasive articles are reduced

Engineering Contradiction:

Improveshaping process complexityVSAvoidlifespan of abrasive article

Core Design Contradiction:

Device complexityVSDuration of action of stationary object

Solution Approach 1:

The invention changes the geometric parameters of abrasive particles to precise shapes (spheres, cubes, cylinders, pyramids, prisms) with controlled dimensions (0.5-5.0 mm). This parameter control ensures uniform stress distribution during cutting, reduces particle fracture, and extends particle life, thereby increasing the overall lifespan of the abrasive article while maintaining feasible manufacturing processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention applies preliminary action by pre-forming abrasive particles into durable geometric shapes before wheel manufacturing. This pre-shaping creates particles with optimized structural integrity and resistance to fracture during use, extending their service life and increasing the durability of the finished abrasive article

Inventive Principle:

Principle #10Preliminary action

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 approach results in abrasive wheels with improved grinding characteristics and reduced operating temperatures, enhancing cutting efficiency and extending the lifespan of the abrasive articles while maintaining a low operating temperature to prevent thermal damage to workpieces.

Implementation Method 1

shaped abrasive particles adhered to a first reinforcing member

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

depositing a space-filling binder precursor on the first reinforcing member and transferred shaped abrasive particles such that space between the shaped abrasive particles is at least partially filled with the space-filling binder precursor

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

compressing and curing the abrasive article precursor to form the abrasive article

Methodology Applied

Scientific EffectCuring:

Data Source

PatentEP3194118B1Methods of making abrasive articles and bonded abrasive wheel preparable thereby

Publication Date: 2023.05.03 3M INNOVATIVE PROPERTIES CO

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AI summary

Methods of making abrasive articles involve adhering shaped abrasive particles to a reinforcing member according to a predetermined pattern and optionally orientation, and depositing a space-filling binder precursor on the reinforcing member and shaped abrasive particles to provide a filled abrasive preform, disposing another reinforcing member onto the filled abrasive preform, and curing the abrasive article precursor to form the abrasive articles. In some aspects, multiple abrasive preforms are stacked on each other. Bonded abrasive wheels preparable according to the methods are also disclosed.