Sintered Ceramic Abrasive Elements for Resin Bonded Cut-Off Wheels

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing resin bonded cut-off wheels face limitations in performance due to the use of abrasive grains with undefined cutting edges, and there is a need for improved abrasive materials that can enhance the efficiency and effectiveness of these wheels.

Innovation Solution

Sintered polycrystalline flat-shaped geometrically structured ceramic abrasive elements are developed, which replace traditional abrasive grains. These elements have a homogeneous microstructure, consistent chemical composition, and a uniformly structured geometry, with specific dimensions and porosity to optimize grinding performance. They are made from ductile ceramic precursors sintered to achieve high hardness and toughness, and can be designed as round disks or segments with tailored geometries and porosity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional abrasive grains are used in resin bonded cut-off wheels, then the manufacturing process is simple, but the cutting performance and efficiency are limited due to undefined cutting edges

Engineering Contradiction:

Improvecutting efficiencyVSAvoidabrasive element structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention changes the geometric parameters of abrasive elements from random shapes to defined geometric shapes (spheres, polyhedrons, platelets with specific diameter-to-thickness ratios). This parameter change creates consistent cutting edges and improves cutting efficiency while maintaining manufacturability through controlled formation processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite ceramic materials (alumina, silica, magnesia, titania, zirconia) sintered together to create abrasive elements that combine hardness, toughness, and geometric precision. This composite approach achieves superior cutting performance compared to traditional single-material abrasive grains

Inventive Principle:

Principle #40Composite materials

2Reliability

If geometrically structured abrasive elements are used, then cutting performance improves, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveabrasive element consistencyVSAvoidproduction process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention forms abrasive elements with defined geometries before sintering, using preliminary shaping processes (forming spheres, polyhedrons, or platelets from ceramic precursors). This preliminary geometric formation ensures consistent cutting edges after sintering while simplifying the overall manufacturing process compared to attempting to create complex geometries after sintering

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention controls the diameter-to-thickness ratio parameter of platelet-shaped abrasive elements to be greater than 30, creating a specific geometric parameter range that optimizes cutting performance. This parameter control is achieved through controlled formation processes that maintain geometric consistency while simplifying manufacturing

Inventive Principle:

Principle #35Parameter changes

3Productivity

If high quality abrasive grains with defined shapes are used, then cutting performance improves, but the cost and manufacturing difficulty increase

Engineering Contradiction:

Improvewheel performanceVSAvoidabrasive material structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention changes the shape parameters of abrasive elements to simple geometric forms (spheres, regular polyhedrons, platelets) with controlled diameter-to-thickness ratios. These parameter changes improve cutting performance through consistent cutting edges while avoiding the complexity of intricate geometries, achieving a balance between performance and manufacturability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates homogeneous distributions of geometrically similar abrasive elements within the resin bonded wheel structure. This homogeneity ensures consistent cutting performance across the wheel surface while simplifying the manufacturing process compared to using heterogeneous or irregularly shaped abrasive grains

Inventive Principle:

Principle #33Homogeneity

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 sintered ceramic abrasive elements significantly improve the performance of resin bonded grinding wheels by providing enhanced hardness, toughness, and customized geometries that maintain consistent porosity and abrasion conditions, leading to improved cutting efficiency and extended tool life.

Implementation Method 1

which are sintered to polycrystalline flat-shaped geometrically structured ceramic abrasive elements

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS11618129B2Sintered polycrystalline flat-shaped geometrically structured ceramic abrasive element, method of making and use thereof

Publication Date: 2023.04.04 IMERTECH SAS

AI summary

The present invention relates to sintered polycrystalline flat-shaped geometrically structured ceramic abrasive elements designed for the use in resin bonded wheels, particularly in cut-off wheels. The present invention also relates to a method of making such sintered polycrystalline flat-shaped geometrically structured ceramic abrasive elements and the use thereof.