Shaped Abrasive Particles with Controlled Corner Radii
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Solution Overview
Problem
Current abrasive particles and articles lack consistency and shape fidelity, leading to reduced performance and efficacy in material removal operations.
Innovation Solution
The method involves forming shaped abrasive particles with controlled corner radii and shapes using a process that includes extrusion, cutting, and sintering, where a mixture of ceramic material is extruded through a die and cut into green particles, which are then dried and sintered to create particles with precise shapes and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fusion, sintering, or chemical ceramic processes are used to produce abrasive particles, then abrasive particles can be formed with various shapes, but the particles lack consistency and shape fidelity
Solution Approach 1:
The patent applies preliminary action by forming green particles with precise geometric shapes (triangular, rectangular, square, or diamond cross-sections) before sintering. The extrusion process creates particles with controlled corner radii and consistent dimensions, establishing the desired shape fidelity before the final sintering step. This preliminary shaping ensures that the final abrasive particles maintain high consistency and shape fidelity.
2Manufacturing precision
If extrusion process is used to form green particles, then particles can be shaped with controlled corner radii, but the process complexity increases
Solution Approach 1:
The patent applies parameter changes by controlling the corner radius of extruded green particles within a specific range (0.004 inches to 0.060 inches, or 0.1 mm to 1.5 mm). By optimizing this geometric parameter during extrusion, the process achieves high shape fidelity without requiring overly complex equipment. The controlled corner radius becomes a key parameter that enables precise shape control while maintaining process simplicity.
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 resulting shaped abrasive particles exhibit high shape fidelity and consistency, enhancing their performance and life in applications such as grinding and polishing by maintaining precise shapes and dimensions throughout processing.
Implementation Method 1
contacting at least a portion of the body to a hydrophobic material and changing the first corner radius to a modified first corner radius
Implementation Method 2
sintering the free-standing droplet to form a shaped abrasive particle having an elliptical shape
Data Source
AI summary
Various shaped abrasive particles are disclosed. Each shaped abrasive particle includes a body having at least one major surface and another surface extending from the major surface.