Triangular Abrasive Platelets in Arithmetic Spiral Pattern
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Solution Overview
Problem
Existing coated abrasive discs used for high-pressure off-hand grinding of carbon steel lack optimal performance, cost-effectiveness, and lifespan.
Innovation Solution
A coated abrasive disc design featuring a disc backing with an abrasive layer composed of triangular abrasive platelets arranged in an arithmetic spiral pattern, where at least 70% of the platelets are spaced along this pattern, and one sidewall of each platelet is aligned within 10 degrees of being tangent to the spiral, enhancing the disc's abrasive efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If triangular abrasive platelets are arranged in a random orientation on the disc backing, then the manufacturing process is simpler, but the abrasive performance and lifespan are reduced
Solution Approach 1:
The abrasive layer is segmented into individual triangular platelets arranged in discrete angular positions (0°, 60°, 120°, 180°, 240°, 300°) around the disc center, with each platelet oriented at specific angles relative to the radial direction. This segmentation allows optimization of abrasive action in different directions while maintaining manufacturing feasibility through systematic placement patterns.
Solution Approach 2:
Different regions of the disc exhibit locally optimized platelet orientations. Platelets are arranged with specific angular deviations from the radial direction in different angular zones, creating areas with enhanced cutting action, areas optimized for finishing, and areas that control swarf removal. This local quality variation maximizes overall abrasive performance.
2Productivity
If triangular abrasive platelets are arranged with precise angular orientation along an arithmetic spiral pattern, then the abrasive efficiency and lifespan are improved, but the manufacturing complexity increases
Solution Approach 1:
An arithmetic spiral pattern is used to arrange the triangular abrasive platelets around the disc center, creating a curved geometric progression rather than straight radial lines. This spiral arrangement ensures progressive engagement of platelets during rotation, optimizing the sequence of abrasive action and enhancing overall productivity while maintaining a mathematically definable pattern for manufacturing.
Solution Approach 2:
The platelet orientation parameters are systematically varied according to the spiral pattern, with angular position and radial distance following specific mathematical relationships. This parameter change strategy optimizes the cutting action through different stages of disc rotation, improving abrasive efficiency while providing a reproducible manufacturing template.
3Reliability
If more triangular abrasive platelets are arranged in the arithmetic spiral pattern, then the performance is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The triangular platelets are oriented with asymmetric angular deviations from the radial direction, creating a non-uniform distribution of cutting edges. This asymmetric arrangement ensures that platelets engage the workpiece in an optimized sequence during rotation, extending disc lifespan by distributing wear more evenly while reducing the stringency of angular alignment tolerances required during manufacturing.
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 coated abrasive disc exhibits superior performance in high-pressure off-hand abrading of carbon steel, offering improved cost, performance, and lifespan compared to previous designs.
Implementation Method 1
triangular abrasive platelets secured to a major surface of the disc backing by at least one binder material
Implementation Method 2
frictionally contacting a portion of the abrasive layer of a coated abrasive disc according to the device claims with a workpiece, and moving at least one of the workpiece and the coated abrasive disc relative to the other to abrade the workpiece
Data Source
Figure 1
Figure 1A
Figure 1B
AI summary
A coated abrasive disc includes a disc backing having an outer circumference. An abrasive layer is disposed on the disc backing. The abrasive layer comprises triangular abrasive platelets secured to a major surface of the disc backing by at least one binder material. The triangular abrasive platelets are disposed at least 70 percent of regularly-spaced points along an arithmetic spiral pattern extending outwardly toward the outer circumference. Each one of the triangular abrasive platelets has respective top and bottom surfaces connected to each other, and separated by, three sidewalls. On a respective basis, one sidewall of at least 90 percent of each of the triangular abrasive platelets disposed facing and proximate to the disc backing, and is lengthwise aligned within 10 degrees of being tangent to the arithmetic spiral pattern. Methods of making and using the coated abrasive disc are also disclosed.