Separation-Groove Structure for Trimming-Free Diamond Profile Grinding Wheels
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Solution Overview
Problem
Powder metallurgy metal-bonded diamond profiled concave-type grinding wheels require frequent trimming due to groove formation, leading to interference scratching on workpiece ends and high tooling costs, especially when users lack electrical discharge machining facilities.
Innovation Solution
A trimming-free diamond profiled grinding wheel with end face and radial separation grooves on the grinding ring, allowing detachment of worn edges and eliminating the need for trimming, combined with a base and cooling features for improved durability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a powder metallurgy metal-bonded diamond profiled concave-type grinding wheel is used for machining specially-shaped edges, then the edge grinding quality is improved, but the groove formation causes interference scratching on workpiece end faces, requiring frequent trimming
Solution Approach 1:
The grinding wheel is divided into functional zones using separation grooves: a working zone for edge grinding and a non-working zone to prevent interference scratching. The first separation groove divides the circumferential surface into these two distinct zones, allowing the grinding wheel to maintain high edge grinding quality while eliminating the harmful interference scratching effect on workpiece end faces.
2Object-generated harmful factors
If the grinding wheel is trimmed frequently to remove groove edges, then the interference scratching is eliminated, but the service life is reduced and tooling cost increases
Solution Approach 1:
The separation grooves are pre-formed during manufacturing to create distinct working and non-working zones before the grinding wheel is put into service. This preliminary structural design prevents the formation of harmful groove edges that would otherwise require frequent trimming, thereby extending service life and reducing tooling costs while eliminating interference scratching.
3Ease of repair
If the grinding wheel is returned to the manufacturer for reprocessing, then the trimming is performed correctly, but the logistics cost becomes prohibitive
Solution Approach 1:
The grinding wheel design with pre-formed separation grooves enables users to perform their own trimming operations without needing specialized equipment or manufacturer facilities. The structural design allows for simple on-site maintenance, eliminating the need for costly return logistics while ensuring proper trimming quality can be achieved by users themselves.
4Loss of energy
If users abandon the grinding wheel when trimming facilities are unavailable, then no logistics cost is incurred, but a large number of usable diamond working layers are wasted
Solution Approach 1:
The separation grooves create a non-working zone that isolates the worn groove edges from the active diamond working layers. This segmentation allows users to continue using the grinding wheel for many more cycles after the groove forms, as the non-working zone prevents interference scratching while the diamond working layers remain intact and functional, thereby eliminating waste without requiring expensive logistics.
Data Source
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AI summary
The present invention relates to a trimming-free diamond profiled grinding wheel, including a grinding ring, wherein each of an upper end face and a lower end face of the grinding ring is provided with at least one end face separation groove, and each end face separation groove extends in a circumferential direction of the grinding ring. The present invention has the following beneficial effects: a simple structure and reasonable design are achieved; and the grinding wheel requires no truing or rework and can be used until complete depletion, thereby greatly prolonging the service life of the grinding wheel and reducing the cost. And the following problem can be effectively solved: for a powder metallurgy metal-bonded diamond profiled concave-type grinding wheel, a grinding zone will continuously wear down and reduce in diameter in its radial direction during use, forming a groove having the same thickness as a workpiece; and over time, upper and lower edges of this groove gradually cause interference-type scratching and grinding on upper and lower end faces of the workpiece, negatively affecting the edge grinding quality of the workpiece.