Shaped Abrasive Particles for Self-Orienting Electrostatic Strewing
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Solution Overview
Problem
Existing abrasive particles do not achieve optimal orientation on a support base during deposition, leading to suboptimal abrasive performance and requiring additional constraining industrial processes.
Innovation Solution
Abrasive particles with opposing major surfaces and multiple intersecting sides defining sharp protrusions, allowing for easy electrostatic strewing and optimal orientation on a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If shaped abrasive particles (e.g., triangular particles) are used to improve abrasive performance, then the rate of abrasion is improved, but the particles do not orientate properly during electrostatic strewing, requiring additional constraining industrial process steps
Solution Approach 1:
The abrasive particle is designed with asymmetric geometry featuring a first side, a second side, and a third side where the first side is longer than the second side. This asymmetric shape enables the particle to self-orientate during electrostatic strewing, with the longer first side naturally aligning in the direction of rotation of the abrasive wheel, eliminating the need for additional constraining process steps while maintaining high abrasive performance
Solution Approach 2:
Instead of using conventional symmetric shapes (like triangles) that require additional constraining steps to achieve proper orientation, the invention inverts the approach by using an inherently asymmetric shape that self-orients during the electrostatic strewing process itself, turning the orientation problem into a design feature
2Ease of manufacture
If conventional abrasive particles are used, then the manufacturing process is simple, but the abrasive performance and durability are suboptimal
Solution Approach 1:
The invention changes the geometric parameters of the abrasive particle by specifying precise side length relationships (first side longer than second side, third side having specific relationship with first and second sides) and angle parameters. These parameter optimizations enable the particle to achieve optimal orientation during electrostatic strewing, thereby improving abrasive performance and durability while maintaining ease of manufacture through the same process
3Speed
If particles with rough edges are used to increase localized contact pressure, then cutting speed is improved, but the particles experience increased wear and reduced durability
Solution Approach 1:
The invention applies local quality by creating specific geometric features at different locations of the particle. The asymmetric shape with specific side length relationships and angle parameters creates localized stress distribution patterns during grinding operations. The geometry is designed so that the longer first side provides optimal contact pressure for cutting speed, while the overall shape and edge configuration distribute wear uniformly, thereby improving durability
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 particles exhibit improved abrasive performance and durability, with enhanced deposition efficiency and reduced friability, resulting in increased metal removal and reduced wear during grinding operations.
Implementation Method 1
During the production of a coated abrasive article, electrostatic strewing of the abrasive particles is typically used
Data Source
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AI summary
The present invention relates to a shaped abrasive particle, comprising opposing and spaced apart first and second major surfaces, the spacing comprising a sidewall, each major surface comprising an inner surface and at least five and at most seven sharp outward protrusions, and where the sidewall comprises multiple intersecting sides which continuously interconnect the opposing surfaces and define the protrusions. The invention further provides abrasive articles containing such particles and a process to produce such articles.