Workpiece-to-Workpiece Abrasion for Surface Irregularity Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods using grinding wheels and polishing pads face limitations in effectively removing surface irregularities from workpieces made of certain materials, leading to inefficiencies and increased costs due to material wear.
Innovation Solution
A surface irregularity reducing method and apparatus that involves holding two workpieces of the same material in contact with each other and moving them relative to each other to abrade their surfaces, followed by grinding, to efficiently remove irregularities while minimizing grinding wheel consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grinding wheels or polishing pads are used to process workpieces, then surface irregularities can be removed, but material consumption of the grinding wheel increases and processing efficiency decreases for certain materials
Solution Approach 1:
The workpiece surfaces are made to abrade each other directly, allowing the workpieces to self-process their surface irregularities without relying on external grinding wheels or polishing pads. This self-service approach eliminates grinding wheel material consumption while effectively removing surface irregularities.
Solution Approach 2:
A liquid medium is introduced as an intermediary between the two workpiece surfaces during relative movement. This liquid facilitates the abrasion process, helps control the interaction between surfaces, and enables effective surface irregularity removal while minimizing direct contact wear.
2Manufacturing precision
If grinding wheels are used to grind workpieces made of hard materials, then surface irregularities are removed, but processing time increases and costs rise
Solution Approach 1:
The workpieces themselves perform the surface finishing function by abrading each other during relative movement. This eliminates the need for time-consuming grinding operations while achieving the desired surface flatness, significantly reducing processing time for hard materials.
Solution Approach 2:
The surfaces are pre-conditioned through controlled abrasion between workpieces before final grinding. This preliminary action removes major surface irregularities and prepares the surfaces for faster, more efficient final processing, reducing overall processing time.
3Manufacturing precision
If conventional grinding methods are used, then surface irregularities can be removed, but the complexity of the processing system increases
Solution Approach 1:
The system uses the workpieces themselves to perform the surface finishing function, eliminating the need for complex grinding wheels, polishing pads, and associated adjustment mechanisms. This self-service approach simplifies the processing apparatus while maintaining surface quality.
Solution Approach 2:
The relative movement mechanism serves multiple functions: it positions the workpieces, controls the abrasion process, and facilitates surface finishing. This multi-functionality reduces the need for separate specialized components, simplifying the overall system.
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 approach allows for efficient reduction of surface irregularities at lower costs by using the workpieces to abrade each other before grinding, reducing material consumption of the grinding wheel and shortening processing time.
Implementation Method 1
moving the first holder and the second holder relatively to each other while the first workpiece held on the first holder and the second workpiece held on the second holder are being kept in contact with each other, thereby removing surface irregularities
Implementation Method 2
applying a laser beam having a wavelength transmittable through the ingot to the ingot while positioning a focused spot of the laser beam in the ingot at a depth from an end face of the ingot
Data Source
AI summary
A surface irregularity reducing method includes a holding step of holding a first workpiece on a first holder and holding a second workpiece that is of the same material as the first workpiece on a second holder, and a surface irregularity reducing step of moving the first holder and the second holder relatively to each other while the first workpiece held on the first holder and the second workpiece held on the second holder are being kept in contact with each other, thereby removing surface irregularities of a contact surface of at least either the first workpiece or the second workpiece.