Tool Blade Teeth with Preformed Geometry and Abrasive Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tool blades face challenges in achieving precise control over tooth size and shape, particularly in creating sharp cutting edges and uniform abrasive layers, which affects their cutting performance and production efficiency.
Innovation Solution
A method involving a backing strip with preformed teeth that are coated with abrasive particles and a binding material using a controlled projection and heating process, allowing for precise positioning and bonding of abrasive particles, and subsequent grinding or machining to achieve desired sizes and sharpness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If teeth are preformed to be undersize relative to desired size, then the abrasive particles and binding material coating can increase tooth size to desired size, but this requires an additional coating process step
Solution Approach 1:
The teeth are preformed to be undersize before the coating process, allowing the abrasive particles and binding material to build up the tooth to the desired final size. This preliminary action enables precise size control through the coating layer thickness while simplifying the overall manufacturing process by avoiding post-coating machining operations.
2Manufacturing precision
If teeth are preformed to be undersize and coated to increase size beyond desired size, then subsequent processing can return tooth to desired size and create sharp cutting edges, but this adds grinding or machining steps
Solution Approach 1:
The teeth are preformed with the correct geometry and size before coating, so that after the abrasive and binding material are applied, the final tooth dimensions and sharp cutting edges are achieved directly without requiring subsequent grinding or machining operations. This preliminary precision forming maintains high production speed while ensuring manufacturing precision.
3Manufacturing precision
If abrasive particles are projected or streamed onto the backing strip edge, then precise positioning of particles can be achieved, but this requires controlled projection equipment
Solution Approach 1:
The mechanical projection system for abrasive particles is replaced with a chemical bonding approach where the binding material chemically adheres the abrasive particles to the tooth surfaces. This substitution eliminates the need for complex controlled projection equipment while achieving precise particle positioning through the binding action of the heating and bonding process.
4Manufacturing precision
If binding material is introduced separately to create precise positioning of abrasive particles, then particle placement accuracy improves, but this requires multiple material introduction steps
Solution Approach 1:
The introduction of binding material and abrasive particles is merged into a single simultaneous process step. The binding material is applied to the tooth surfaces and the abrasive particles are introduced at the same time, allowing the binding material to immediately adhere the particles to the correct positions. This merging eliminates the need for separate material introduction steps and the associated complex equipment while maintaining precise particle placement accuracy.
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 method enables the creation of tool blades with enhanced cutting performance and mechanical integrity, offering precise control over tooth shape and size, increased production speed, and reduced costs, while maintaining the flexibility of the backing strip.
Implementation Method 1
The binding material powder 14 and the backing strip 12 are heated in the workstation 21 by a beam of radiation 22 from a radiation source 24 to form a binder layer
Implementation Method 2
The abrasive particles may be introduced by projecting or streaming onto the edge of the backing strip
Implementation Method 3
The abrasive particles may be introduced by projecting or streaming onto the edge of the backing strip
Implementation Method 4
a high temperature bonding matrix powder may be projected or streamed separately to create precise positioning of the particles
Data Source
Figure 1~3
Figure 4~5
AI summary
There is provided a tool blade, comprising a backing strip (12) particles of abrasive material (26) and a binder layer of binding material (14) which binds the abrasive particles along an edge of the backing strip (12), wherein the edge of the backing strip (12) is pre-formed with teeth, on which the abrasive particles (26) are bound by the binding material (14). A profiled cutting portion (28) extends beyond the pre-formed teeth. The pre-formed teeth (16) are shaped as generally triangular waves or are flattened at least partially along an upper edge on which the cutting portion (28) is at least partially disposed. A method of making such a blade is also provided.