U.S. patent application number 17/574112 was filed with the patent office on 2022-05-05 for abrasive segment for an abrasive roll, grinding machine, and use.
The applicant listed for this patent is Tyrolit-Schleifmittelwerke Swarovski K.G.. Invention is credited to Bent ANKERSEN.
Application Number | 20220134511 17/574112 |
Document ID | / |
Family ID | |
Filed Date | 2022-05-05 |
United States Patent
Application |
20220134511 |
Kind Code |
A1 |
ANKERSEN; Bent |
May 5, 2022 |
ABRASIVE SEGMENT FOR AN ABRASIVE ROLL, GRINDING MACHINE, AND
USE
Abstract
An abrasive segment includes a carrier body for attaching the
abrasive segment to a lateral surface of an abrasive roll in an
interlocking manner; and a substantially planar abrasive layer. The
abrasive layer is oriented substantially parallel to the lateral
surface of the abrasive roll in a state of the abrasive segment in
which it is attached to the abrasive roll, and an elastic
intermediate layer is located between the carrier body and the
abrasive layer.
Inventors: |
ANKERSEN; Bent; (Herning,
DK) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Tyrolit-Schleifmittelwerke Swarovski K.G. |
Schwaz |
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AT |
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Appl. No.: |
17/574112 |
Filed: |
January 12, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/AT2020/060266 |
Jul 9, 2020 |
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17574112 |
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International
Class: |
B24D 5/06 20060101
B24D005/06; B24D 3/28 20060101 B24D003/28; B24D 99/00 20060101
B24D099/00; B24D 13/14 20060101 B24D013/14 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 16, 2019 |
AT |
A 50642/2019 |
Claims
1. An abrasive segment for a grinding roller including at least one
carrier body for positively lockingly fixing the abrasive segment
to a peripheral surface of the grinding roller and at least one
substantially flat abrasive layer, characterized in that the at
least one abrasive layer in a state of the abrasive segment of
being fixed to the grinding roller is oriented substantially
parallel to the peripheral surface of the grinding roller and at
least one elastic intermediate layer is arranged between the at
least one carrier body and the at least one abrasive layer.
2. The abrasive segment as set forth in claim 1, wherein arranged
between the at least one carrier body and the at least one abrasive
layer is at least one elastic intermediate layer substantially
comprising felt.
3. The abrasive segment as set forth in claim 1, wherein the at
least one elastic intermediate layer is such that a grinding fluid,
in particular water, can be stored and delivered therein, and/or is
of an abrasive-free configuration.
4. The abrasive segment as set forth in claim 1, wherein the at
least one carrier body is substantially T-shaped in cross-section
and/or is of such a configuration that the carrier body can be
positively lockingly fixed to the peripheral surface of the
grinding roller by way of a dovetail connection.
5. The abrasive segment as set forth in claim 1, wherein the at
least one carrier body includes at least one contact surface at
which the at least one elastic intermediate layer is at least
region-wise supported, preferably wherein the at least one contact
surface is oriented substantially parallel to the at least one flat
abrasive layer.
6. The abrasive segment as set forth in claim 1, wherein the at
least one elastic intermediate layer is fixed with an adhesive
layer to the at least one carrier body and/or to the at least one
abrasive layer.
7. The abrasive segment as set forth in claim 1, wherein the at
least one elastic intermediate layer is of a thickness, the
thickness being at least three times as great as a layer thickness
of the at least one abrasive layer.
8. The abrasive segment as set forth in claim 1, wherein the at
least one abrasive layer includes at least one abrasive, preferably
diamond, cubic boron nitride, sintered corundum and/or an abrasive
with zirconium corundum, aluminum oxide and/or silicon carbide,
preferably wherein the at least one abrasive is of an abrasive
grain size between 50 .mu.m and 745 .mu.m and/or is embedded in at
least one bonding agent, preferably a resin bonding agent,
preferably wherein the abrasive layer is arranged on a carrier
layer.
9. A grinding roller for machining a surface of a workpiece and/or
a surface of a negative form for the production of the workpiece,
wherein the grinding roller has a substantially cylindrical main
body having a peripheral surface, wherein the abrasive segment as
set forth in claim 1 is positively lockingly fixed to the
peripheral surface.
10. The grinding roller as set forth in claim 9, wherein the
peripheral surface is provided with at least one groove for
receiving at least one abrasive segment, preferably wherein the at
least one groove is of a substantially dovetail-shaped
configuration and the at least one abrasive segment is positively
lockingly fixed therein.
11. The grinding roller as set forth in claim 10, wherein the at
least one groove is arranged inclinedly relative to a longitudinal
direction of the grinding roller, preferably at an angle between
1.degree. and 10.degree., particularly preferably at an angle
between 2.degree. and 3.5.degree..
12. The grinding roller as set forth in claim 1, wherein arranged
at at least one end of the substantially cylindrical main body is
at least one preferably substantially cylindrical opening for at
least one tool receiving means, preferably wherein precisely two
openings are arranged at the at least one end.
13. The grinding roller as set forth in claim 9, wherein at least
one locking mechanism, at least one cover and at least one opening,
wherein the opening is arranged in the at least one cover and the
at least one locking mechanism can be introduced into the at least
one opening, for arresting the at least one abrasive segment are
arranged at at least one of the ends of the substantially
cylindrical main body.
14. A grinding machine comprising the grinding roller as set forth
in claim 9 and at least one rotary drive with which the grinding
roller can be set in rotation to cause a relative movement of the
at least one abrasive layer relative to the surface to be machined
of the workpiece or the negative form.
15. The grinding machining as set forth in claim 14, wherein there
is provided at least one handle, preferably provided with at least
one grinding fluid feed means, for manual guidance of the grinding
machine.
16. The grinding machine as set forth in claim 14, wherein there is
provided at least one robot arm, arranged at the end of which is at
least one tool receiving means of at least one grinding roller,
preferably wherein the tool receiving means is provided with at
least one grinding fluid feed means.
17. A use of the grinding machine as set forth in claim 14 for
machining a surface of a workpiece, that is preferably provided
with a coating for protection from environmental influences,
wherein it is preferably provided that at least one region of the
workpiece, that adjoins the surface to be machined, comprises a
carbon fiber and/or glass fiber composite material or a surface
that is preferably coated with wax of a negative form for the
production of a workpiece which preferably at least region-wise
comprises a carbon fiber and/or glass fiber composite material.
18. The use as set forth in claim 17, wherein the workpiece is in
the form of an airfoil or fuselage of an aircraft, parts of a ship,
parts of a train or in the form of a rotor blade of a wind
turbine.
19. The use as set forth in claim 17, wherein the use is
implemented with the feed of a grinding fluid, preferably water,
particularly preferably water mixed with soap.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention concerns an abrasive segment for a
grinding roller including at least one carrier body for positively
lockingly fixing the abrasive segment to a peripheral surface of
the grinding roller and at least one substantially flat abrasive
layer. The present invention further concerns a grinding roller for
machining a surface of a workpiece and/or a surface of a negative
form for the production of the workpiece, wherein the grinding
roller has a substantially cylindrical main body having a
peripheral surface. The present invention further concerns a
grinding machine having at least one grinding roller according to
the invention including abrasive segments according to the
invention and at least one rotary drive. The present invention
moreover concerns a use of such an abrasive segment, such a
grinding roller or such a grinding machine.
[0002] Such an abrasive segment is already known from the
specification of DE 20 2005 016 671 U1 in which the abrasive is
fixed on a support means with a hook and loop fastener strip in
such a way that the abrasive layer is oriented in normal
relationship with the peripheral surface of the grinding roller and
upon contact of the abrasive segment with a workpiece the abrasive
segment is elastically deformed in one direction.
[0003] A disadvantage with the state of the art in accordance with
a first aspect is that the orientation of the abrasive layer in
normal relationship with the peripheral surface of the grinding
roller means that during rotation in the grinding process the
removal rate is only limitedly effective as the force on the
workpiece cannot be transmitted to the workpiece in the optimum
fashion by elastic deformation of the abrasive segment.
[0004] Furthermore during the removal process the abrasive segment
follows the contour and therefore does not substantially contribute
to flattening of a surface of the workpiece.
[0005] The abrasive segment described in DE 20 2005 016 671 U1 is
provided with an elastically deformable support means, in which
respect this preferably involves an elastically bendable material
like a brush, a foam or some other suitable material.
[0006] A disadvantage with the state of the art in accordance with
a second aspect is that the elastically bendable materials are
adapted to the deformation during the grinding process but are not
designed for a grinding fluid feed and/or grinding fluid
storage.
[0007] In addition, by virtue of the described support means it is
only very limitedly possible to cater for relevant properties in
the removal process like vibration damping, acoustic insulation,
thermal protection, varying surface geometries and so forth.
[0008] Such a grinding roller is known from the specification of DE
20 2005 016 671 U1 that has mounted abrasive segments that are
provided with an abrasive layer, being oriented in normal
relationship to the peripheral surface.
[0009] A disadvantage with the state of the art is that material
can be removed only in one direction of rotation without conversion
of the fixed abrasive segments.
[0010] A grinding machine having abrasive segments is known from
the specification of DE 20 2005 016 671 U1, in which the abrasive
segments are arranged in the grinding roller in such a way that the
abrasive layer is oriented in normal relationship to the peripheral
surface of the grinding roller and thereby after fitment of the
grinding roller the direction of rotation of the grinding roller is
determined by the function of the abrasive layer.
[0011] A disadvantage there is that the orientation of the abrasive
layer in normal relationship to the peripheral surface of the
grinding roller means that during rotation in the grinding process,
by virtue of the abrasive layer being oriented in normal
relationship to the peripheral surface of the grinding roller, it
is also not possible to generate in the direction of rotation that
is solely possible for the grinding process an automatic advance
which is preferably necessary for large workpieces with manual
machining and in addition this does not permit a high removal
rate.
SUMMARY OF THE INVENTION
[0012] The technical object according to the first aspect of the
present invention is therefore to provide an abrasive segment which
is improved over the state of the art and in which the
disadvantages of the state of the art are at least partially
overcome and which is distinguished in particular by an abrasive
layer which permits an increased material removal and the material
removal by the abrasive segment also contributes to significant
flattening of the workpiece surface.
[0013] The technical object of the second aspect is to provide an
abrasive segment which ensures an effective grinding fluid feed and
grinding fluid storage and which is matched to parameters relevant
for the removal process like vibration, sound, heat, surface shape
and so forth, wherein it is not necessary to dispense with
convenient handling and/or a long service life and the grinding
result is improved.
[0014] A further object according to a third aspect of the present
invention is to provide a grinding roller which is improved over
the state of the art and in which the disadvantages of the state of
the art are at least partially overcome and which is distinguished
in particular in that the grinding roller can be used in both
directions of rotation that are relevant for the removal
process.
[0015] A further object according to a fourth aspect of the present
invention is to provide a grinding machine which is improved over
the state of the art and in which the disadvantages of the state of
the art are at least partially overcome and which is distinguished
both by user-friendly handling in relation to large grinding
rollers (from a roller length and/or a roller diameter of around
300 mm) and also by a high level of possible removal on the
workpiece.
[0016] A further object according to a fifth aspect of the present
invention is to provide a use of the abrasive segment, the grinding
roller or the grinding machine, that is improved over the state of
the art.
[0017] Accordingly, the at least one abrasive layer in a state of
the abrasive segment of being fixed to the grinding roller is
oriented substantially parallel to the peripheral surface of the
grinding roller and at least one elastic intermediate layer is
arranged between the at least one carrier body and the at least one
abrasive layer.
[0018] By virtue thereof, it is possible for the first time for the
contact and thus also the transmission of force between the
abrasive layer and the workpiece surface to be effected
substantially normal to the peripheral surface of the grinding
roller, wherein an increased removal rate on the workpiece (for
example a negative form and the form parts thereof) is guaranteed
as the abrasive segment can apply more pressure to the surface.
[0019] Furthermore, the parallel orientation of the abrasive layer
with respect to the peripheral surface ensures efficient leveling
of the surface to be machined, wherein in particular residues are
effectively dealt with and the surface is locally corrected to the
factors in the surrounding area and flattened.
[0020] In particular, after repair operations in negative forms by
virtue of compensating materials unevenness and residues remain to
an increased extent, and they can be effectively removed by that
abrasive segment.
[0021] The term elastic (synonymous with compressible while
retaining shape) means that the intermediate layer is compressible
under the influence of a force and when a force is no longer
applied the intermediate layer returns to its original shape again.
That property achieves substantially two advantages, namely that
the layer has a pressure-compensating effect and it deploys a
damping action in the grinding process.
[0022] It is accordingly provided that arranged between the at
least one carrier body and the at least one abrasive layer is at
least one elastic intermediate layer which substantially comprises
felt.
[0023] That makes it possible for the first time that, by virtue of
the sponge-like nature, a structure in respect of the elastic
intermediate layer can be afforded, which is suitable both for
receiving and storing fluid and also delivering fluid in the
optimum fashion for the removal process.
[0024] The elastic intermediate layer which substantially comprises
felt means that the abrasive segment can be operated both in a dry
grinding procedure and also using grinding fluid.
[0025] In addition, the elastic properties of felt have a high
compression elasticity and resilience whereby creases and wrinkles
scarcely occur, which would be detrimental for the grinding
process.
[0026] In addition, felt is sound-insulating and provides efficient
insulation in respect of heat, wherein those properties, in
particular in use of the abrasive segment, provide both for more
convenience in operation and also afford a better grinding result.
In addition, the cushioning afforded ensures protection from an
excessively high mechanical loading on all the components involved
like the abrasive layer, carrier body and/or workpiece.
[0027] Adaptation of the properties of the felt to the individual
requirement of the surface to be machined can also be controlled by
way of the density of the basic felt layer.
[0028] Added to that there is the positive property that even
regions which are curved to differing degrees and/or regions of
differing thickness can be simultaneously machined by virtue of the
material-specific properties of felt without having in advance to
influence the form of the curved regions and/or regions of
differing thickness in regard to the configuration of the abrasive
segment and without having to suffer a loss in removal rate. As a
result the removal procedure also acts in particular in producing
leveling of the surface.
[0029] Furthermore, the abrasive segment with the elastic
intermediate layer comprising felt affords the option of
additionally dealing with special and challenging curved regions
like for example convex or concave geometries without major cost or
resources involvement insofar as the elastic intermediate layer of
felt follows the curvature of the workpiece to be machined. The
thickness of the elastic intermediate layer of felt can
additionally vary in a thickness over at least a length of the
abrasive segment.
[0030] The use of felt as the supporting elastic intermediate layer
therefore affords the advantage that both the necessary pressure
for effective removal of material is transmitted from the carrier
element to the workpiece by way of the abrasive layer and also it
is possible to pursue complex surfaces in contour.
[0031] The vibration-insulating property of felt which can be
adapted to the factors involved in the removal process by means of
the specific composition permits user-friendly and convenient
operation of the abrasive segment which due to the low specific
density does not involve any substantial additional weight in terms
of handling.
[0032] Added to this, there is the positive property that the
abrasive segment is exposed to less elastic deformation, and that
results in an increase in service life or minimization of the wear
phenomena. It is thus possible to dispense with frequently changing
the felt layer and also the carrier body.
[0033] Accordingly, at least one such abrasive segment is
positively lockingly fixed to the peripheral surface.
[0034] By virtue of that, it is possible for the first time that
the material-specific properties, that are conducive to the
grinding process, of the elastic intermediate layer which is formed
in particular from felt and can therefore ensure damping, sound
insulation, pressure equalization, heat protection, fluid
reception/storage/delivery and deformability can be utilized to the
optimum extent in both directions of rotation.
[0035] Accordingly, the at least one grinding roller can be set in
rotation with the at least one rotary drive in order to cause a
relative movement of the at least one abrasive layer relative to
the surface of the workpiece to be machined and/or the negative
form.
[0036] As a result, it is possible for the first time that the
abrasive layer is oriented substantially parallel to the peripheral
surface of the grinding roller and both directions of rotation are
provided with an automatic advance during the grinding process.
That permits simple operation of grinding rollers with a length
extent of up to 800 mm.
[0037] The abrasive segments moreover, due to the elastic
intermediate layer, ensure large-area contact and effective removal
by the abrasive layer over the entire longitudinal extent of the
grinding roller.
[0038] According to an advantageous configuration of the invention,
the at least one elastic intermediate layer is such that a grinding
fluid, in particular water, can be stored and delivered therein,
and/or is of an abrasive-free configuration.
[0039] That provides a particularly advantageous cooperation of the
initially abrasive-free workpiece surface and the abrasive layer in
a wet grinding process, more specifically such that a grinding
fluid stored in the elastic intermediate layer can issue during the
removal process and grinding dust which is formed when grinding on
the abrasive layer can be efficiently flushed away.
[0040] In addition, the abrasive prevents increased heat generation
and thus carefully treats both the abrasive layer and also the
surface of the workpiece and/or the negative form.
[0041] In the case of workpieces and/or negative forms in which no
grinding fluid is required in the removal process, it is possible
to eliminate additional cleaning operations for the user of the
abrasive segment by virtue of the abrasive-free elastic
intermediate layer.
[0042] Advantageously, the at least one carrier body is
substantially T-shaped in cross-section and/or is of such a
configuration that the carrier body can be positively lockingly
fixed to the peripheral surface of the grinding roller by way of a
dovetail connection.
[0043] That permits a positively locking connection of the segment
to a corresponding groove on a roller, in which the forces acting
during the removal process are transmitted to a high degree to the
more massive main body of the grinding roller by way of the carrier
body.
[0044] The use of a dovetail connection affords the positively
locking connection to a higher degree as fixing is effected not
only in a direction transversely to the dovetail connection but
also in a perpendicular direction relative to the groove.
[0045] Preferably, in the longitudinal direction of the groove, the
abrasive segment is fixed on the grinding roller by a constructive
termination.
[0046] It has proven to be advantageous if the at least one carrier
body includes at least one contact surface at which the at least
one elastic intermediate layer is at least region-wise supported,
preferably wherein the at least one contact surface is oriented
substantially parallel to the at least one flat abrasive layer.
[0047] As the parallel orientation both of the abrasive layer and
also the carrier body on the peripheral surface of the grinding
roller is guaranteed by that arrangement the forces which are
required for the removal process and occur during the removal
process act to a high degree in the radial direction of the
grinding roller. That is advantageous for an effective and careful
removal process.
[0048] According to an advantageous embodiment of the invention,
the at least one elastic intermediate layer is fixed with an
adhesive layer to the at least one carrier body and/or to the at
least one abrasive layer.
[0049] The adhesive layer as a bonding agent is on the one hand
cost-effective and is adequate in function for demanding removal
processes.
[0050] After the end of the service life of the carrier body, the
elastic intermediate layer or the abrasive layer the worn parts can
be quickly changed by the adhesive layer without requiring a large
amount of material.
[0051] It has proven to be advantageous if the at least one elastic
intermediate layer is of a thickness, the thickness being at least
three times as great as a layer thickness of the at least one
abrasive layer.
[0052] Particularly preferably, the abrasive layer is of a layer
thickness in the range of between 0.6 mm and 1.5 mm.
[0053] Preferably, the elastic intermediate layer has a thickness
in the range of between 5 mm and 12 mm, particularly preferably in
the range between 8 mm and 10 mm.
[0054] That prevents contact occurring between the carrier bodies
and the surface of the workpiece or the negative form when there
are more severe surface unevennesses of the workpiece or the
negative form.
[0055] In addition, the elastic intermediate layer deploys the full
extent of its positive material-specific aspects for the removal
process, only as from a certain thickness.
[0056] An advantageous variant for the machining of surfaces of a
workpiece or a negative form comprising composite material provides
that the at least one abrasive layer includes at least one
abrasive, preferably diamond, cubic boron nitride, sintered
corundum and/or an abrasive with zirconium corundum, aluminum oxide
and/or silicon carbide, preferably wherein the at least one
abrasive is of an abrasive grain size between 50 .mu.m and 745
.mu.m and/or is embedded in at least one bonding agent, preferably
a resin bonding agent, preferably wherein the abrasive layer is
arranged on a carrier layer.
[0057] It is particularly preferred if the peripheral surface is
provided with at least one groove for receiving at least one
abrasive segment, preferably wherein the at least one groove is of
a substantially dovetail-shaped configuration and the at least one
abrasive segment is positively lockingly fixed therein.
[0058] In an embodiment, the at least one groove is arranged
inclinedly relative to a longitudinal direction of the grinding
roller, preferably at an angle between 1.degree. and 10.degree.,
particularly preferably at an angle between 2.degree. and
3.5.degree..
[0059] That ensures a particularly harmonic grinding process as
both upon a first contact of the grinding roller with the workpiece
and also during the grinding process preferential transmission of
force of the at least one abrasive segment to the workpiece is
effected and lower impact forces are generated.
[0060] In addition, the angle of the at least one groove makes it
possible that in a final phase of the grinding contact of a first
abrasive segment a subsequent abrasive segment already comes into
contact with the workpiece and that thereby affords a reduction in
the times in which the workpiece is not in contact with the at
least one grinding segment.
[0061] Therefore, the grinding result is improved by an inclined
positioning of the at least one groove relative to the longitudinal
direction of the grinding roller and the abrasive segments
therein.
[0062] As the carrier bodies of the abrasive segments are of a
substantially T-shaped configuration the at least one corresponding
groove affords a force-locking connection for the abrasive segments
at the peripheral surface of the grinding roller. A dovetail-shaped
connection in that respect affords a secure and force-locking
connection of the abrasive segment to the grinding roller in
particular under high levels of stress in the removal process.
[0063] An embodiment of the invention provides that arranged at at
least one end of the substantially cylindrical main body is at
least one preferably substantially cylindrical opening for at least
one tool receiving means, preferably wherein precisely two openings
are arranged at the at least one end.
[0064] That achieves the effect that the grinding roller can be
used as a tool for the most widely varying grinding machines or
grinding robots.
[0065] This further permits a rapid change of grinding roller,
grinding machine or grinding robot.
[0066] That is a relevant factor, in particular for reasons of time
and cost, in the machining of large surfaces of the workpieces
and/or negative forms.
[0067] Arranging the openings at the end makes it possible for the
abrasive segments to be able to extend over the full lateral extent
of the grinding roller.
[0068] If precisely two openings are arranged at the end, that
takes account of commercially usual tool receiving means.
[0069] In addition, the force arm between the opening and the
center point of the end makes it possible for tangentially acting
forces in the removal process, caused by the rotation of the
grinding roller and the relative movement between the abrasive
segment and the surface, to be transmitted by way of the tool
receiving means to the grinding machine or grinding robot and
compensated, to a higher degree.
[0070] According to a preferred embodiment of the invention, at
least one locking mechanism, at least one cover, and at least one
opening are provided. The opening is arranged in the at least one
cover, and the at least one locking mechanism can be introduced
into the at least one opening, for arresting the at least one
abrasive segment are arranged at at least one of the ends of the
substantially cylindrical main body.
[0071] That ensures a more effective positively locking and
force-locking relationship between the abrasive segment and the
grinding roller.
[0072] In addition, the arrangement at the end of the main body
means that the arresting effect can already be effected in a
user-friendly fashion after fitment has been effected to a grinding
roller or a grinding robot.
[0073] Alternatively, it is possible to provide at least one
handle, preferably having at least one grinding fluid feed means,
for manual guidance of the grinding machine.
[0074] The handle ensures convenient handling even for large heavy
grinding rollers.
[0075] The abrasive layer is supplied with grinding fluid by means
of the grinding fluid feed means, without a grinding fluid feed
that has to be externally operated. That saves on unnecessary
working steps in the removal process and also affords more
convenient handling with the grinding machine or the grinding
robot.
[0076] Further preferably, there is at least one robot arm,
arranged at the end of which is at least one tool receiving means
of at least one grinding roller, preferably wherein the tool
receiving means is provided with at least one grinding fluid feed
means.
[0077] That makes it possible for the grinding roller to be used
even on surfaces which are difficult to access of the workpiece or
the negative form while in addition the abrasive layer is supplied
with grinding fluid.
[0078] According to the invention there is provided the use of an
above-described abrasive segment and/or an above-described grinding
roller for machining a surface of a workpiece, that is preferably
provided with a coating for protection from environmental
influences, wherein it is preferably provided that at least one
region of the workpiece, that adjoins the surface to be machined,
comprises a carbon fiber and/or glass fiber composite material or a
surface that is preferably coated with wax of a negative form for
the production of a workpiece which preferably at least region-wise
comprises a carbon fiber and/or glass fiber composite material.
[0079] The uses referred to are effected in a particularly
advantageous form for application to the workpiece which is in the
form of an airfoil or fuselage of an aircraft, parts of ship, parts
of a train or in the form of a rotor blade of a wind turbine.
[0080] The uses referred to are effected in a further particularly
advantageous form with the feed of a grinding fluid, preferably
water, particularly preferably water mixed with soap.
BRIEF DESCRIPTION OF THE DRAWINGS
[0081] Further details and advantages of the present invention are
described more fully hereinafter by means of the specific
description with reference to the embodiments by way of example
illustrated in the drawings in which:
[0082] FIG. 1a is an exploded view of an abrasive segment in its
individual components according to a first preferred embodiment as
a perspective view with a detail view of an abrasive layer,
[0083] FIG. 1b shows an abrasive segment in its entirety according
to a second preferred embodiment as a perspective view with a
detail view of an elastic intermediate layer of felt,
[0084] FIG. 2 shows a grinding roller in its entirety as a
perspective view according to a preferred embodiment with fitted
abrasive segments in accordance with the embodiment shown in FIG.
1a or FIG. 1b,
[0085] FIG. 3a shows a grinding machine according to a first
preferred embodiment in the form of a manually operable grinding
machine with a fitted grinding roller in accordance with the
embodiment shown in FIG. 2 and included abrasive segments according
to the embodiment shown in FIG. 1a or FIG. 1b as a side view,
[0086] FIG. 3b shows the grinding machine according to a second
preferred embodiment in the form of a robot-controlled grinding
machine having a fitted grinding roller according to the embodiment
shown in FIG. 2 and included abrasive segments according to the
embodiment shown in FIG. 1a or FIG. 1b as a side view,
[0087] FIG. 4a shows the use of a grinding roller according to the
embodiment shown in FIG. 2 with fitted abrasive segments according
to the embodiment shown in FIG. 1a or FIG. 1b during the removal
process on a workpiece as a side view,
[0088] FIG. 4b shows the use of a grinding roller according to the
embodiment shown in FIG. 2 with fitted abrasive segments according
to the embodiment shown in FIG. 1a or FIG. 1b during the removal
process on a negative form as a side view, and
[0089] FIG. 5 shows a grinding roller according to a further
preferred embodiment without abrasive segments as a view in a
radial direction.
DETAILED DESCRIPTION OF THE INVENTION
[0090] FIG. 1a shows an abrasive segment 1 including a carrier body
3 and a flat abrasive layer 6, an elastic intermediate layer 7
being arranged between the abrasive layer 6 and the carrier body 3.
For the sake of ease of viewing the drawing those components are
separate in the view, but the components are connected together by
the formation of the abrasive segment.
[0091] The carrier body 3 is T-shaped, wherein the T-shape includes
a dovetail-shaped limb intended for a dovetail connection (see FIG.
2) to provide the positively locking connection. The carrier body 3
in itself can be of any length. Lengths are preferred however which
are suitable for the removal process of extensive surface
geometries.
[0092] The elastic intermediate layer 7 is of a cuboidal
configuration. It can however also differ from that shape and/or
can be adapted to specific surface geometries to be treated. By way
of example the elastic intermediate layer 7 can be of a trapezoidal
configuration.
[0093] The abrasive layer 6 is of a thickness 16, wherein the
abrasive layer 6 includes an abrasive 17, preferably diamond 18,
cubic boron nitride 19, sintered corundum 52 and/or an abrasive 17
with zirconium corundum 20, aluminum oxide 21 and/or silicon
carbide 22.
[0094] The precise composition of the abrasive 17 and the abrasive
grain size 18 however can be any desired composition. Particularly
preferably the one abrasive 17 is of an abrasive grain size 18 of
between 50 .mu.m and 745 .mu.m. The abrasive 17 is held together by
a bonding agent 23. Particularly preferably the abrasive 17 is
embedded in a resin bonding agent 24 but can also be embedded in
another material as the bonding agent 23.
[0095] The abrasive layer 6 is arranged on a carrier layer 49. The
carrier layer 49 can in itself be of any desired material and is
also not absolutely necessary. The abrasive layer 6 can also be
applied directly to the elastic intermediate layer 7. A carrier
layer 49 of textile is however particularly preferred.
[0096] The elastic intermediate layer 7 is fixed with an adhesive
layer 14 to the carrier body 3 and/or to the abrasive layer 6. The
adhesive layer 14 in that case can be applied over the entire
surface area or only region-wise.
[0097] The elastic intermediate layer 7 is of a thickness 15, the
thickness 15 being a multiple larger than a layer thickness 16 of
the abrasive layer 6. Particularly preferably the thickness 15 is
at least three times the layer thickness of the abrasive layer
6.
[0098] The abrasive layer 6 is applied to the carrier layer 49. The
abrasive layer 6 can be applied to the carrier layer 49 over the
entire surface area or only region-wise.
[0099] FIG. 1b shows an abrasive segment 1 with an elastic
intermediate layer 7 comprising felt 8.
[0100] The carrier body 3 includes a contact surface 13 at which
the elastic intermediate layer 7 is at least region-wise supported.
The contact surface 13 is oriented parallel to the flat abrasive
layer 6.
[0101] The elastic intermediate layer 7 is of such a configuration
that a grinding fluid, in particular water 10, can be stored
therein and can be delivered, and/or it is of an abrasive-free
nature.
[0102] The elastic intermediate layer 7, the contact surface 13 and
the abrasive layer 6 are oriented substantially parallel and are at
an angle of substantially 90.degree. relative to a radial direction
of a grinding roller 2 (not shown for the sake of clarity).
[0103] The grinding fluid 9 can be of any desired composition.
Particularly preferably a water 10 mixed with soap 48 is present in
the grinding fluid 9.
[0104] The grinding fluid 9 is stored in the fibers 50 of the felt
8 and penetrates between the fibers 50 of the felt 8 upon delivery
of the grinding fluid 9 to the abrasive layer 6.
[0105] In general the elastic intermediate layer 7 can also be in
the form of foams or plastics. In that case the thicknesses of the
individual components of the abrasive segment 1 can be
different.
[0106] FIG. 2 shows a grinding roller 2 with a cylindrical main
body 28 having a peripheral surface 5. Abrasive segments 1 are
fixed in positively locking relationship on the peripheral surface
5.
[0107] The peripheral surface 5 is provided with grooves 29 for
receiving abrasive segments 1. In this design the grooves 29 are of
a dovetail-shaped configuration. The abrasive segments 1 are
positively lockingly fixed in the grooves 29.
[0108] A cover 53 is arranged at an end 30 of the cylindrical main
body 28 and has two openings 54. Two locking mechanisms 33 engage
into those two openings in order to fix the plurality of abrasive
segments 1 in an axial direction.
[0109] Two cylindrical openings 31 for a tool receiving means 32
are arranged at an end 30 of the cylindrical main body 28. The
cylindrical openings 31 can be arranged at one or at both ends 30
of the grinding roller 2.
[0110] The cylindrical openings 31 in themselves can be present in
any desired number. A particularly preferred embodiment is that in
which the end 30 includes two eccentric cylindrical openings
31.
[0111] A locking mechanism 33 is arranged at one of the ends 30 of
the cylindrical main body 28 for arresting the abrasive segments
1.
[0112] The abrasive segments 1 are arranged radially outwardly on
the peripheral surface 5. The abrasive segments can be spaced at
any desired spacing as indicated at 51. An equidistant arrangement
of the abrasive segments 1 is particularly preferred. The spacing
51 between the abrasive segments 1 should not be selected to be so
large that the result of the removal process is adversely
affected.
[0113] The grinding roller 2 can be of a roller diameter in the
range of between 80 mm and 400 mm. The grinding roller 2 can be of
a roller length in the range of between 50 mm and 800 mm.
[0114] FIG. 3a shows a grinding machine 34 having a grinding roller
and a rotary drive 35a with which the one grinding roller 2 can be
set in rotation in order to produce a relative movement 36a of the
one abrasive layer 6 relative to the surface 25 to be machined on
the workpiece 26 and/or the negative form 27.
[0115] There is a handle 35b for manual guidance of the grinding
machine 34. The handle 35b is provided with a grinding fluid feed
means 36b , wherein the grinding fluid feed means 36b is fixed on
and/or in the handle 35b in such a way that the operator is not
impeded in handling the grinding machine 34.
[0116] The handle 35b can be designed for one-arm or two-arm
operation.
[0117] FIG. 3b shows a robot arm 37, at the end 38 of which there
is provided a tool receiving means 32 of a grinding roller 2.
[0118] The tool receiving means 32 is provided with a grinding
fluid feed means 36b . In a further embodiment however that can
also be mounted to the robot arm 37 or another component of the
grinding machine 34. If no grinding fluid feed means 36b is needed
for the removal process it can also be entirely eliminated.
[0119] The grinding fluid 9 is passed further to the grinding
roller 2 by way of the grinding fluid feed means 36b.
[0120] FIG. 4a shows the use of abrasive segments 1, a grinding
roller 2 or a grinding machine 34 for machining a surface 25 of a
workpiece 26, that is coated with a coating 39 to give protection
from environmental influences.
[0121] The workpiece 26 can in itself be of any nature. Use of the
abrasive segments 1, grinding roller 2 or the grinding machine 3
for the abrasive procedure on airfoils or fuselages 44 of an
aircraft, rotor blades 45 of a wind turbine, parts of a ship or
parts of a train is however particularly preferred. The workpiece
26 however can also be formed from other extensive geometries 46
comprising composite materials 47.
[0122] A region 40 of the workpiece 26, that adjoins the surface 25
to be machined, at least partially comprises a carbon fiber
composite material 41 and/or a glass fiber composite material
42.
[0123] FIG. 4b shows a surface 25, coated with wax 43, of a
negative form 27 for the production of a workpiece 26 (shown in
FIG. 4a).
[0124] The use is effected with the feed of a grinding fluid 9. It
is optionally also possible however to dispense with the feed of
the grinding fluid 9.
[0125] FIG. 5 shows a grinding roller 2 before being fitted with
abrasive segments 1.
[0126] The grooves 29 in which the abrasive segments 1 are fixed in
positively locking relationship are at an angle in the range of
between 1.degree. and 10.degree., particularly preferably between
2.degree. and 3.5.degree., relative to a longitudinal direction of
the grinding roller 2, but can also be arranged parallel to the
longitudinal direction of the grinding roller 2.
[0127] The longitudinal direction of the grinding roller 2 is
defined by the axial direction (axis of rotation) of the grinding
roller 2 and is thus normal to the direction of rotation or a
radial direction of the grinding roller 2.
[0128] Two locking mechanisms 33 can be seen at the end 30 at the
left. The grooves 29 are continuous as far as that facing side and
terminate before an opposite side in order to permit a positively
locking connection of the abrasive segments 1 (not shown for the
sake of clarity) in the grinding roller 2 by a termination of the
grooves 29.
[0129] In order to fix the abrasive segments 1 to the grinding
roller 2 the cover 53 over the openings 54 is released by the
locking mechanism 33 (for example by rotation). That removal has
already occurred in FIG. 5.
[0130] Then the abrasive segments 1 are introduced into the grooves
29 as far as the end thereof in order subsequently to again fix the
cover 53 on the grinding roller 2 and to secure the abrasive
segments 1 in the longitudinal direction.
[0131] It is however also possible in accordance with the invention
to use two covers 53 for fixing the abrasive segments 1 and to
dispense with the termination configuration of the grooves 29.
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