Shaped Abrasive Particles with Opening for Grinding
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Solution Overview
Problem
Existing abrasive particles lack efficiency in cut rate, wear resistance, and attachment to backing materials, leading to reduced performance over time due to wear flat formation and adhesion issues.
Innovation Solution
Shaped abrasive particles with an opening that passes through the first and second faces, reducing wear flat size, acting as a reservoir for grinding aids, and enhancing attachment to the backing through a make or size coat, thereby improving cut rate and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If shaped abrasive particles are used, then cut rate is improved, but wear flat size increases over time reducing performance
Solution Approach 1:
The abrasive particle is segmented by introducing an opening that divides the particle into distinct regions. This segmentation creates multiple wear surfaces instead of a single wear flat, effectively reducing the size of each individual wear flat and delaying the dulling effect that reduces cut rate.
Solution Approach 2:
The opening creates a porous or hollow structure within the abrasive particle. This porous design allows the particle to maintain sharper edges for longer periods by distributing wear across multiple surfaces, thereby extending the duration of effective cutting action.
2Productivity
If more grinding aid is applied to surface, then cut performance is improved, but grinding aid is quickly consumed during use
Solution Approach 1:
The opening structure acts as a nested container within the abrasive particle, allowing grinding aid to be stored inside the particle rather than only on the surface. This nested design provides a reservoir that releases grinding aid progressively during use, extending the effective duration of cut performance.
Solution Approach 2:
Grinding aid is pre-loaded into the opening structure before the abrasive particle is put into service. This preliminary action ensures that grinding aid is available from the start and is progressively released as the particle wears, maintaining cut performance throughout the particle's service life rather than requiring frequent reapplication.
3Reliability
If abrasive particles are attached to backing by adhesion, then attachment is achieved, but particles shell off during use
Solution Approach 1:
The opening in the abrasive particle creates additional surfaces that can interact with the backing material and coating. This segmentation allows the coating to penetrate into and anchor around the opening structure, creating a mechanical interlock that significantly strengthens the attachment and prevents shelling during use.
Data Source
Figure 1A~2C
Figure 3~4
Figure 5A~5C
AI summary
An abrasive comprising shaped abrasive particles each with an opening. The shaped abrasive particles are formed from alpha alumina and have a first face and a second face separated by a thickness t. The opening in each of the shaped abrasive particles can improve grinding performance by reducing the size of a resulting wear flat, can provide a reservoir for grinding aid, and can improve adhesion to a backing in a coated abrasive article.