Vitrified Super-Abrasive Wheels With Thin Bridges for Stable Sharpness
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Solution Overview
Problem
Conventional vitrified bond super-abrasive grinding wheels suffer from short lifetime and unstable grinding resistance due to uneven distribution of abrasive grains and vitrified bond, leading to poor self-sharpening function and increased wear.
Innovation Solution
A vitrified bond super-abrasive grinding wheel with uniformly distributed abrasive grains and thinly dispersed vitrified bond bridges, where at least 80% of grains are joined by bridges with thickness equal to or smaller than the grain size and length greater than the thickness, maintaining appropriate joining power for long-term sharpness and reducing lump formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional vitrified bond super-abrasive grinding wheels are used, then they can perform grinding operations, but they suffer from short lifetime and unstable grinding resistance
Solution Approach 1:
The patent applies local quality by creating bond bridges with specific dimensional characteristics (thickness equal to or smaller than average grain size, length greater than thickness) that are locally optimized for self-sharpening function. This local structural quality ensures uniform wear and stable grinding resistance, resolving the contradiction between lifetime and reliability.
2Ease of manufacture
If abrasive grains are unevenly distributed with vitrified bond, then manufacturing is simpler, but self-sharpening function is poor and wear increases
Solution Approach 1:
The patent changes the critical parameter of bond bridge dimensions (thickness equal to or smaller than average grain size, length greater than thickness) to achieve optimal self-sharpening. This parameter optimization ensures uniform grain distribution and reduces wear while maintaining manufacturing feasibility, resolving the contradiction between ease of manufacture and grain loss.
3Strength
If bond bridges have excessive thickness, then joining power is strong, but self-sharpening function is reduced and sharpness is not maintained
Solution Approach 1:
The patent optimizes the thickness parameter of bond bridges to be equal to or smaller than the average grain size, which maintains sufficient joining power while enabling effective self-sharpening. This precise parameter control resolves the contradiction between strength and manufacturing precision by finding the optimal threshold value.
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 solution achieves long-term continuation of excellent sharpness and extended lifetime by ensuring uniform wear and reduced grain fall, allowing for low-load and low-wear grinding with stable sharpness maintenance.
Implementation Method 1
a vitrified bond super-abrasive grinding wheel includes: a core; and a super-abrasive grain layer provided on the core, wherein the super-abrasive grain layer includes a plurality of super-abrasive grains and a vitrified bond that joins the plurality of super-abrasive grains
Data Source
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AI summary
There is provided a vitrified bond super-abrasive grinding wheel including: a core; and a super-abrasive grain layer provided on the core, wherein the super-abrasive grain layer includes a plurality of super-abrasive grains and a vitrified bond that joins the plurality of super-abrasive grains, and the vitrified bond has a plurality of bond bridges located between the plurality of super-abrasive grains to join the plurality of super-abrasive grains, not less than 80% of the plurality of super-abrasive grains are joined to the super-abrasive grains adjacent thereto by the bond bridges, and not less than 90% of the plurality of bond bridges in a cross section of the super-abrasive grain layer have a thickness equal to or smaller than an average grain size of the super-abrasive grains, and have a length greater than the thickness.