U.S. patent application number 15/096672 was filed with the patent office on 2016-08-04 for apparatuses, systems and methods for aligned abrasive grains.
This patent application is currently assigned to United Technologies Corporation. The applicant listed for this patent is United Technologies Corporation. Invention is credited to JOHN P. RIZZO, JR..
Application Number | 20160221153 15/096672 |
Document ID | / |
Family ID | 53681846 |
Filed Date | 2016-08-04 |
United States Patent
Application |
20160221153 |
Kind Code |
A1 |
RIZZO, JR.; JOHN P. |
August 4, 2016 |
APPARATUSES, SYSTEMS AND METHODS FOR ALIGNED ABRASIVE GRAINS
Abstract
Systems and methods for creating grinding wheels are provided.
The systems and methods may employ aligned abrasive grains. In this
regard, the abrasive grains may have a known polarity and cutting
orientation. The abrasive grains may be alignable in response to
being exposed to an electrical current and/or a magnetic field. The
abrasive grains may be aligned of a film that is processed into a
grinding wheel.
Inventors: |
RIZZO, JR.; JOHN P.;
(Vernon, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
United Technologies Corporation |
Hartford |
CT |
US |
|
|
Assignee: |
United Technologies
Corporation
Hartford
CT
|
Family ID: |
53681846 |
Appl. No.: |
15/096672 |
Filed: |
April 12, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/US2015/011178 |
Jan 13, 2015 |
|
|
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15096672 |
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61930222 |
Jan 22, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B24D 5/02 20130101; B24D
2203/00 20130101 |
International
Class: |
B24D 5/02 20060101
B24D005/02 |
Claims
1. A method comprising: depositing a plurality of abrasive grains
on a film; aligning the abrasive grains on the film; depositing a
bond on the film, wherein the bond is configured to fill the void
between the plurality of abrasive grains; and curing the bond.
2. The method of claim 1, further comprising wrapping the film to
form at least one of a cylinder and a cone.
3. The method of claim 2, further comprising firing the at least
one of the cylinder and the cone to form a grinding wheel.
4. The method of claim 2, further comprising sizing the at least
one of the cylinder and the cone.
5. The method of claim 1, wherein each of the plurality of abrasive
grains comprises a first portion having first charge and a second
portion having a second charge.
6. The method of claim 5, wherein each of the plurality of abrasive
grains includes at least one of a coating and an inclusion
material, wherein the at least one of the coating and the inclusion
material having at least one of a paramagnetic characteristic and a
ferromagnetic characteristic.
7. The method of claim 5, wherein each of the plurality of abrasive
grains have a cutting orientation.
8. The method of claim 7, wherein a grinding wheel formed by the
method has an increased material removal rate based on the cutting
orientation of each of the plurality of abrasive grains.
9. The method of claim 5, wherein the aligning the abrasive grains
includes applying at least one of an electrical current and a
magnetic field.
10. The method of claim 1, wherein the bond comprises filler.
11. A grinding wheel made from a process comprising: distributing a
plurality of abrasive grains on a film; aligning the abrasive
grains on the film with at least one of a magnetic field and an
electrical current; wrapping the film into a about a hub; and
firing the wrapped film to form the grinding wheel.
12. The grinding wheel of claim 11, wherein each of the plurality
of abrasive grains has a cutting orientation.
13. The grinding wheel of claim 12, wherein the cutting orientation
is associated with at least one of the type of grinding wheel and
the direction of rotation of the grinding wheel.
14. The grinding wheel of claim 11, wherein each of the plurality
of abrasive grains has a first end and a second end.
15. The grinding wheel of claim 14, and wherein each of the
plurality of abrasive grains has a polarity between the first end
and the second end.
16. The grinding wheel of claim 15, wherein each of the plurality
of abrasive grains is alignable in response to the application of
an electrical current.
17. The grinding wheel of claim 11, wherein a bond is disposed on
the film and the bond fills the voids between each of the abrasive
grains.
18. The grinding wheel of claim 11, wherein the bond is at least
partially cured prior to the wrapping.
19. A grinding wheel comprising: a plurality of layers, each of the
plurality of layers comprising a film, wherein each of the
plurality of layers is bonded together by a firing process, and
wherein the film comprises a plurality of abrasive grains, each of
the plurality of grains positioned in a cutting orientation in
response to application of a magnetic field prior to the firing
process.
20. The grinding wheel of claim 19, wherein the each of the
abrasive grains comprises at least one of a coating and an
inclusion material.
21. The grinding wheel of claim 19, wherein the at least one of the
coating and the inclusion material having at least one of a
paramagnetic characteristic and a ferromagnetic characteristic.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of, claims priority to
and the benefit of, PCT/US2015/011178 filed on Jan. 13, 2015 and
entitled "APPARATUSES, SYSTEMS AND METHODS FOR ALIGNED ABRASIVE
GRAINS," which claims priority from U.S. Provisional Application
No. 61/930,222 filed on Jan. 22, 2014 and entitled "APPARATUSES,
SYSTEMS AND METHODS FOR ALIGNED ABRASIVE GRAINS." Both of the
aforementioned applications are incorporated herein by reference in
their entirety.
FIELD
[0002] The present disclosure generally relates to apparatuses,
systems, and methods for grinding wheels, and more specifically, to
grinding wheels with aligned abrasive grains.
BACKGROUND
[0003] Traditional grinding is often used for precision finishing.
Grinding operations typically have lower material removal rates
than turning (e.g., lathe operations) and/or milling processes.
Abrasive grinding wheels typically include abrasive particles that
are added to a retention medium in a random fashion. In this
regard, the abrasive particles are not oriented with respect to one
another and/or the direction of rotation of the grinding wheel.
SUMMARY
[0004] A method may comprise depositing a plurality of abrasive
grains on a film, aligning the abrasive grains on the film,
depositing a bond on the film (wherein the bond is configured to
fill the void between the each of the plurality of abrasive grains)
and curing the bond.
[0005] A grinding wheel is provided. The grinding wheel may be made
from a process comprising: distributing a plurality of abrasive
grains on a film; aligning the abrasive grains on the film with at
least one of a magnetic field and an electrical current; wrapping
the film into a about a hub; and firing the wrapped film to form
the grinding wheel.
[0006] A grinding wheel is provided. The grinding wheel may
comprise a plurality of layers. Each of the plurality of layers may
comprise a film. Each of the plurality of layers may be bonded
together by a firing process. The film may comprise a plurality of
abrasive grains, each of the plurality of grains positioned in a
cutting orientation in response to application of a magnetic field
prior to the firing process.
[0007] The forgoing features and elements may be combined in
various combinations without exclusivity, unless expressly
indicated herein otherwise. These features and elements as well as
the operation of the disclosed embodiments will become more
apparent in light of the following description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The subject matter of the present disclosure is particularly
pointed out and distinctly claimed in the concluding portion of the
specification. A more complete understanding of the present
disclosure, however, may best be obtained by referring to the
detailed description and claims when considered in connection with
the drawing figures, wherein like numerals denote like
elements.
[0009] FIG. 1 illustrates an abrasive grain, in accordance with
various embodiments;
[0010] FIG. 2A illustrates a top view of a plurality of abrasive
grains disposed on a film, in accordance with various
embodiments;
[0011] FIG. 2B illustrates a side view of a plurality of abrasive
grains disposed on a film, in accordance with various
embodiments;
[0012] FIG. 3 illustrates a side view of a grinding wheel, in
accordance with various embodiments; and
[0013] FIG. 4 illustrates a process flow to create a grinding
wheel, in accordance with various embodiments.
DETAILED DESCRIPTION
[0014] The detailed description of exemplary embodiments herein
makes reference to the accompanying drawings, which show exemplary
embodiments by way of illustration. While these exemplary
embodiments are described in sufficient detail to enable those
skilled in the art to practice the inventions, it should be
understood that other embodiments may be realized and that logical,
chemical and mechanical changes may be made without departing from
the spirit and scope of the inventions. Thus, the detailed
description herein is presented for purposes of illustration only
and not of limitation. For example, the steps recited in any of the
method or process descriptions may be executed in any order and are
not necessarily limited to the order presented. Furthermore, any
reference to singular includes plural embodiments, and any
reference to more than one component or step may include a singular
embodiment or step. Also, any reference to attached, fixed,
connected or the like may include permanent, removable, temporary,
partial, full and/or any other possible attachment option.
Additionally, any reference to without contact (or similar phrases)
may also include reduced contact or minimal contact.
[0015] In various embodiments, multi-layer grinding wheels may have
improved abrasive and/or material removal rates, where the grinding
wheels comprise precision-shaped abrasive grains. These abrasive
grains may be alignable during the manufacturing process. In this
regard, the abrasive grains may be aligned such that they have
material removal rates that are similar to milling and/or turning
(e.g., lathe) processes. The abrasive grains may comprise
particular cutting surfaces and/or particular shapes that improve
material removal rates.
[0016] In various embodiments, and with reference to FIG. 1, an
abrasive grain 110 may comprise a first portion 102 (e.g., a first
end), a second portion 104 (e.g., a second end), and a cutting
portion 106. Abrasive grain 110 may be of any suitable size,
including, for example, between approximately 220 grit (e.g.,
having an average particle diameter of 68 micrometers) and
approximately 60 grit (e.g., having an average particle diameter of
265 micrometers). Abrasive grain 110 may be used in the
manufacturing of an abrasive wheel. Abrasive grain 110 may also
have a magnetic polarity between first portion 102 and second
portion 104. In this regard, first portion 102 and/or second
portion 104 may be magnetic poles. The polarity may allow abrasive
grain 110 to be oriented in response to be subjected to an
electrical current and/or a magnetic field. In this regard,
abrasive grain 110 may be created with and/or include a
ferromagnetic characteristic and/or material (e.g., iron). Abrasive
grain 110 may also comprise and/or be coated with a paramagnetic
coating. The magnetic field may be created and/or applied by any
suitable method. In this regard, abrasive grain 110 may comprise an
inclusion material and/or a coating containing a ferromagnetic
material and/or a paramagnetic material, giving abrasive grain 110
ferromagnetic characteristics and/or paramagnetic
characteristics.
[0017] In various embodiments, and with reference to FIGS. 2A and
2B and FIG. 4, a plurality of abrasive grains 210 (shown as
abrasive grain 210-1, abrasive grain 210-2, abrasive grain 210-3,
abrasive grain 210-4, abrasive grain 210-5, abrasive grain 210-6 in
FIG. 2A) may be deposited and/or distributed on a film 222 (Step
410) as part of a method of manufacture for grinding wheels. The
plurality of abrasive grains 210 may be aligned and/or positioned
on film 222 (Step 420). More specifically, the plurality of
abrasive grains 210 may be oriented by application of an electrical
charge and/or a magnetic field to at least one of the film 222
and/or to the plurality of abrasive grains 210. In this regard,
each of the plurality of abrasive grains 210 may have a polarity
such that each of the plurality of abrasive grains 210 may move
and/or reorient in response to the electrical charge and/or
magnetic field.
[0018] In various embodiments, the aligning may orient the
plurality of abrasive grains 210 in a known and/or designed
fashion. For example, the aligning may orient the plurality of
abrasive grains 210 into a cutting orientation. Each of the cutting
portions of the plurality of abrasive grains 210 may be aligned
and/or oriented in a similar fashion. Moreover, the aligning may be
accomplished by creating a conductive pattern in film 222. In this
regard, the conductive pattern may be designed and applied to film
222 to organize and/or position abrasive grains 210 in a desired
configuration. The cutting portions may be aligned based on the
rotation of a grinding wheel, the type of grinding wheel being
manufactured, the type of grinding and/or processing being done,
and/or the like.
[0019] In various embodiments, abrasive grains 210 may be placed
and/or positioned in film 222 by any suitable method. For example,
abrasive grains 210 may be individually positioned on film 222.
Abrasive grains 210 may also be dropped and/or propelled at high
velocity (e.g., sprayed) to be positioned on film 222.
[0020] In various embodiments, a bond 224 may be deposited on film
222 (Step 430). An assembly 200 may be formed in response to the
depositing of the bond 224. Assembly 200 may include film 222, the
plurality of abrasive grains 210 and bond 224. Bond 224 may include
filler 226. Bond 224 may coat and/or fill voids between each of the
plurality of abrasive grains 210 on a first surface of film 222. In
various embodiments, the plurality of abrasive grains 210 may be
aligned in bond 224. In response to abrasive grains 210 and bond
224 being disposed on film 222 and the plurality of abrasive grains
210 being aligned, assembly 200 may be cured (Step 440).
[0021] In various embodiments, assembly 200 and/or film 222 may be
wrapped (Step 450). For example, film 222 of assembly 200 may be
rolled around a hub, rod or other suitable device for forming an
axis of a grinding wheel. Wrapped film 222 may have any suitable
shape including, for example, a cylindrical shape, a conical shape,
and/or the like. Wrapped film 222 may be sized, shaped, cut and/or
the like (Step 455).
[0022] In various embodiments and with reference to FIGS. 2A-2B, 3,
and 4 assembly 200 may be fired to create grinding wheel 300 (Step
460). A grinding wheel may have abrasive grains 310 in engineered
alignment.
[0023] In various embodiments, film 222 may be porous. The porous
nature of film 222 may allow contact between a first layer of film
222 and a second layer of film 222. Moreover, film 222 may comprise
and/or include a surface texture and/or bonding structure. The
surface texture and/or bonding structure may promote bonding
between a first layer of film 222 and a second layer of film 222,
during the wrapping and/or firing processes.
[0024] In various embodiments and with reference to FIG. 3,
grinding wheel 300 may be cut and/or shaped in any suitable fashion
after firing. Grinding wheel 300 may comprise a plurality of
abrasive grains 310 (shown as abrasive grain 310-1, abrasive grain
310-2, abrasive grain 310-3 in FIG. 3). Moreover, grinding wheel
300 may comprise an outer surface or an outer diameter 332 and an
axis or hub 334. A first plurality of abrasive grains 310 may be
disposed along the outer diameter to form a cutting and/or
processing surface. Grinding wheel 300 may be configured to rotate
about hub 334. Moreover, the plurality of abrasive grains 310 may
be aligned in a cutting orientation based on the rotational
configuration of the grinding wheel.
[0025] In various embodiments, the systems and methods described
herein may provide for increased tool life, improved surface
finishing quality, improved machine part quality and/or reduced
cost. In various embodiments, the systems and methods described
herein may enable process changes from traditional turning and/or
machining to grinding.
[0026] Benefits, other advantages, and solutions to problems have
been described herein with regard to specific embodiments.
Furthermore, the connecting lines shown in the various figures
contained herein are intended to represent exemplary functional
relationships and/or physical couplings between the various
elements. It should be noted that many alternative or additional
functional relationships or physical connections may be present in
a practical system. However, the benefits, advantages, solutions to
problems, and any elements that may cause any benefit, advantage,
or solution to occur or become more pronounced are not to be
construed as critical, required, or essential features or elements
of the inventions. The scope of the inventions is accordingly to be
limited by nothing other than the appended claims, in which
reference to an element in the singular is not intended to mean
"one and only one" unless explicitly so stated, but rather "one or
more." Moreover, where a phrase similar to "at least one of A, B,
or C" is used in the claims, it is intended that the phrase be
interpreted to mean that A alone may be present in an embodiment, B
alone may be present in an embodiment, C alone may be present in an
embodiment, or that any combination of the elements A, B and C may
be present in a single embodiment; for example, A and B, A and C, B
and C, or A and B and C.
[0027] Systems, methods and apparatus are provided herein. In the
detailed description herein, references to "one embodiment", "an
embodiment", "various embodiments", etc., indicate that the
embodiment described may include a particular feature, structure,
or characteristic, but every embodiment may not necessarily include
the particular feature, structure, or characteristic. Moreover,
such phrases are not necessarily referring to the same embodiment.
Further, when a particular feature, structure, or characteristic is
described in connection with an embodiment, it is submitted that it
is within the knowledge of one skilled in the art to affect such
feature, structure, or characteristic in connection with other
embodiments whether or not explicitly described. After reading the
description, it will be apparent to one skilled in the relevant
art(s) how to implement the disclosure in alternative
embodiments.
[0028] Furthermore, no element, component, or method step in the
present disclosure is intended to be dedicated to the public
regardless of whether the element, component, or method step is
explicitly recited in the claims. No claim element herein is to be
construed under the provisions of 35 U.S.C. 112(f), unless the
element is expressly recited using the phrase "means for." As used
herein, the terms "comprises", "comprising", or any other variation
thereof, are intended to cover a non-exclusive inclusion, such that
a process, method, article, or apparatus that comprises a list of
elements does not include only those elements but may include other
elements not expressly listed or inherent to such process, method,
article, or apparatus.
* * * * *