CN111971148A

CN111971148A - Method and apparatus for grinding, and product and use of said product

Info

Publication number: CN111971148A
Application number: CN201980019223.3A
Authority: CN
Inventors: 斯特凡·林德瓦尔
Original assignee: Mocha Ltd
Current assignee: Mocha Ltd
Priority date: 2018-03-14
Filing date: 2019-03-11
Publication date: 2020-11-20
Also published as: EP3765241A4; EP3765241A1; WO2019175475A1; MX2020009155A; US20210046613A1

Abstract

A continuous abrasive product includes a predetermined length and number of predetermined types of abrasive regions on an abrasive surface (104). A method for abrading a workpiece (10) comprises arranging an abrasive area of an abrasive product at an abrading zone (105) for abrading the workpiece (10), and after abrading, replacing the abrasive area at the abrading zone (105) with another abrasive area of the abrasive product for abrading the workpiece (10) according to a subsequent abrading stage. The used abrasive region is replaced by a different kind of unused abrasive region. The abrasive product comprises a continuous longitudinal abrasive material (101, 103) comprising at least two longitudinally sequential different abrasive regions having different kinds of abrasive properties.

Description

Method and apparatus for grinding, and product and use of said product

Technical Field

The present application relates to a method and apparatus for grinding. Furthermore, the present application relates to an abrasive product and to the use of the method, the apparatus and the abrasive product.

Background

Lapping refers to a method for abrading abrasive particles on a surface in order to treat or finish the surface. Surface treatments can achieve desired results with respect to, for example, surface smoothness, roughness, structure or design. Finishing may include, for example, providing a surface texture, a polished surface, or a mirror finish. More than one grinding stage is often required to achieve the desired result. The grinding may comprise several different grinding stages. The different grinding stages may include any stage between a coarse grain size enabling removal of a large amount of material and a fine grain size enabling mirror polishing.

Disclosure of Invention

The aim of the application is to simplify the process for grinding workpieces in different grinding stages with different grinding properties.

The continuous abrasive product includes predetermined types of abrasive regions of predetermined lengths and numbers on the abrasive surface. The abrasive product includes at least two abrasive regions having different abrasive characteristics. The different abrasive characteristics enable different surface roughness to be sequentially provided using a single abrasive product. The different abrasive characteristics of a single abrasive product may enable a workpiece of a desired shape, surface pattern, or surface finish to be formed using a single abrasive product at a single processing location, stage, and/or machine.

According to one aspect of the invention, an abrasive product comprises a continuous longitudinal abrasive material comprising at least two longitudinally sequential different abrasive regions having different kinds of abrasive properties. A continuous longitudinal abrasive product can be fed into the grinding zone of the grinding apparatus to sequentially arrange the grinding with a corresponding at least two sequential different kinds of abrasive regions.

According to another aspect of the present invention, an apparatus for abrading a workpiece comprises: an abrasive zone in which the workpiece is arranged to be abraded; and an arrangement configured to feed an abrasive region of an abrasive product to the grinding zone and replace the abrasive region at the abrasive zone with another abrasive region of the abrasive product. The further or unused abrasive region is different from the abrasive region or used abrasive region.

Yet another aspect of the invention includes a method for abrading a workpiece that includes arranging an abrasive region of an abrasive product at an abrading zone for abrading the workpiece, and replacing the abrasive region at the abrading zone with another abrasive region of the abrasive product for abrading the workpiece. The further abrasive region is different from the abrasive region. The abrasive product comprises a continuous longitudinal abrasive product comprising at least two longitudinally sequential different abrasive regions having different kinds of abrasive properties.

According to a further aspect of the invention, the use of an abrasive product in a grinding apparatus comprises a continuous longitudinal abrasive product having a surface of at least two sequential different kinds of abrasive regions along a longitudinal dimension of the abrasive product, wherein the at least two sequential different kinds of regions have different kinds of abrasive properties. A continuous longitudinal abrasive product can be fed to an abrading zone of the abrading device such that the at least two sequential different kinds of abrasive zones can be sequentially fed to the abrading zone.

Drawings

Embodiments of the invention are described in more detail below, together with the accompanying drawings, in which:

FIG. 1 shows an apparatus for grinding according to one embodiment.

FIG. 2 shows a method for grinding according to one embodiment.

FIG. 3a shows an abrasive product according to one embodiment.

FIG. 3b shows an abrasive product according to one embodiment.

FIG. 3c shows an abrasive product according to one embodiment.

Fig. 4 shows an apparatus for grinding according to one embodiment.

FIG. 5 shows a method for grinding according to one embodiment.

FIG. 6 shows an abrasive product according to one embodiment.

The drawings may not be to scale.

Detailed Description

The abrasive product may be a flexible elongated sheet arranged to be rolled up. The abrasive product may be in the form of a roll, belt, or comprise a similar elongated form. An abrasive surface is disposed on the backing. The abrasive surface comprises different kinds of abrasive areas. The abrasive region may be arranged to contact an object or surface to be abraded. The abrasive surface and the surface to be abraded are arranged to move relative to each other. The abrasive surface may be arranged to move, e.g. oscillate, reciprocate, roll-to-roll, while in contact with the object/surface to be abraded. The object/surface to be abraded may be arranged to move, e.g. rotate rapidly or in rotation, while in contact with the abrasive area.

FIG. 1 shows an apparatus for grinding according to one embodiment. The abrasive product includes a roll of abrasive material 101. The abrasive material is arranged from a roll of abrasive material 101 to a used roll of abrasive material 103. The roll of abrasive material 101 refers to a source of abrasive material. The used roll of abrasive material 103 is arranged to collect used abrasive material. Instead of a used roll of abrasive material 103, the abrasive material may be pulled from the grinding zone for disposal. Abrasive material may be moved from the roll of abrasive material 101 to the used roll of abrasive material 103 by the contact roller 102. The abrasive material includes two opposing surfaces, one of which is abrasive surface 104. Abrasive surface 104 is disposed facing workpiece 10. The opposite surface of the abrasive material is disposed against the contact roller 102.

The workpiece 10 is disposed at the abrasive zone 105. An abrasive surface 104 of abrasive material is fed over the contact roll 102 such that the abrasive surface 104 is disposed in contact with the workpiece 10 at an abrasive zone 105. The contact roller 102 is arranged to support a region of an abrasive surface 104 of abrasive material and to be arranged in contact with the workpiece 10. The contact roller 102 is arranged to move the abrasive material towards the workpiece 10 such that the abrasive area of the abrasive surface 104 of the abrasive material is arranged to contact the workpiece 10. The contact roller 102 may be pneumatically moved. The contact roller is arranged to move towards and away from the workpiece 10. During the grinding phase, the abrasive surface 104 and the workpiece 10, which are arranged in contact with each other, are arranged to move relative to each other. Abrasive material may be moved from the roll of abrasive material 101 to the roll of waste abrasive material 103 by contact rollers 102. The abrasive material may be arranged to move continuously and/or constantly on the contact roll 102. The abrasive material includes different abrasive regions having different abrasive properties. The continuous movement of abrasive material with different abrasive areas enables the workpiece to be continuously abraded with different kinds of abrasive areas. Different kinds of successive grinding stages are carried out without interruption. The abrasive material can be designed according to the desired end result of the different kinds of grinding stages.

The sequential grinding stages may be arranged to change continuously on-the-fly. Different types of abrasive regions can be introduced into the grinding zone by a roll-to-roll grinding process. The roll of abrasive product may include two, three, or more sequential distinct types of abrasive regions having a predetermined length along the longitudinal dimension of the roll. After all required different grinding stages are completed, the movement is stopped. The contact roller is arranged to move away from the workpiece, thereby releasing contact between the abrasive material and the workpiece.

The grinding zone refers to a portion of the grinding apparatus in which grinding is performed. The abrading zone may at least partially comprise a portion of an abrading apparatus arranged to receive a workpiece to be abraded. The abrasive zone may at least partially comprise a movable support for receiving abrasive material. The abrasive surface of the abrasive product may be arranged to contact the workpiece at the abrading zone. The abrasive surface is arranged to be in contact with the workpiece with the aid of a movable support. The abrading is performed at a contact area of an abrasive surface of the workpiece.

For abrading, a relative movement of the abrasive material and the workpiece is arranged. During abrading, the abrasive material and the workpiece are arranged to move relative to each other. Movement may include unidirectional movement, bidirectional movement, reciprocating movement back and forth, rotation, and/or oscillation. The grinding stage may include a predetermined grinding time. Both the workpiece and the abrasive surface on the contact roll may be arranged to rotate, optionally in different rotational directions. The workpiece may be arranged to move against the abrasive surface. The abrasive surface may be arranged to move against the workpiece. The abrasive surface may be arranged to move with the aid of a support. The workpiece may be arranged to rotate relative to the abrasive surface so as to abrade the surface of the workpiece through the abrasive surface. The workpiece may be arranged to oscillate with or without rotational movement. The abrasive surface may be arranged to reciprocate. The workpiece may be arranged to rotate and/or the abrasive surface may be arranged to oscillate with the support in order to arrange the abrading. The oscillation may comprise an in-plane one-dimensional oscillation, which refers to a reciprocating motion or a back and forth movement in the x-direction. The oscillation may comprise an in-plane two-dimensional oscillation, which refers to a movement or two-dimensional reciprocating motion in x and y directions.

FIG. 2 shows a method for grinding according to one embodiment. The workpiece is arranged to the grinding zone 201. Abrasive material is directed to the grinding zone 202. The abrasive material includes a sequence of different kinds of abrasive regions on its abrasive surface. The abrasive is arranged on a support, for example on a contact roller, which support enables movement of the abrasive material at the grinding zone. An abrasive material is placed in contact 203 with the workpiece. The continuous grind 204 may be arranged by moving the abrasive material from the source roll to the web via contact rollers. Different abrasive areas of abrasive material of a single abrasive product are successively fed into the grinding zone. Different kinds of grinding stages are provided in a continuous manner to the grinding zone, on the support, without damaging or modifying the abrasive product.

The grinding phase may involve a predetermined grinding result and/or involve the sequential use of a certain kind of abrasive area of the abrasive product. The grinding stage can be modified to a different grinding stage by replacing the used abrasive area with another, unused different kind of abrasive surface. The sequential grinding stages involve grinding results of a predetermined kind and/or involve the sequential use of different kinds of abrasive areas. Sequential abrasive regions differ in their abrasive characteristics from adjacent abrasive regions. The sequential grinding stages may be initiated by replacing the used abrasive surface with a different kind of abrasive surface. The different grinding stages in sequence can be achieved by providing the grinding apparatus with successive abrasive products comprising different abrasive areas. In this way, different grinding stages can be achieved without the need to replace the abrasive product or to replace the grinding machine with another grinding machine. With the abrasive product, two, three or more different grinding stages can be achieved without interruption. The plurality of different grinding stages may be completed as a single continuous process.

Fig. 3a shows an abrasive product 300 according to an embodiment. The abrasive product 300 includes an abrasive surface. The abrasive surface comprises at least two or more

abrasive regions

301, 302, 303. The abrasive surface may comprise three or more different sequential abrasive regions.

Abrasive regions

301, 302, 303 comprise different abrasive characteristics than their adjacent abrasive regions. The abrasive areas are arranged to provide different abrasive results than the abrasive areas next to them. The

abrasive areas

301, 302, 303 are arranged sequentially adjacent to each other along the longitudinal direction of the abrasive surface of the abrasive product 300. The abrasive product may be in the form of a roll or a belt, for example. Different abrasive results can be obtained using only different

abrasive regions

301, 302, 303 of the abrasive product 300. The longitudinal abrasive product 300 includes a length or longitudinal dimension L and a width or transverse dimension W. The length dimension L may be several tens of times greater than the width dimension W, which may be, for example, 50-100 mm.

The

abrasive areas

301, 302, 303 are sequentially arranged adjacent to each other along the longitudinal direction L of the abrasive surface of the abrasive product 300. In fig. 3a, the intersection between two adjacent abrasive areas is in the form of a line. The lines between adjacent abrasive regions may be straight along the width dimension W across the abrasive product 300. This may allow for a sharp transition from an abrasive area to another type of abrasive area. Alternatively, the line may be an angled line across the width dimension W of the abrasive product, as shown in fig. 3 a. Alternative forms of intersection between two adjacent abrasive regions are possible, and some are illustrated in fig. 3b and 3c below.

FIG. 3b shows an abrasive product according to one embodiment. The abrasive product comprises an intersection between two adjacent

abrasive areas

301b, 302b, 303b, 304b arranged in an elliptical form. This may allow for smooth replacement between successive adjacent abrasive regions. For example, an edge portion of the workpiece to be abraded is first exposed in the next sequential abrasive region before a middle portion of the workpiece; or vice versa, depending on the direction of the elliptical line along which the two abrasive areas vary. Abrasive region 303b includes different abrasive properties at longitudinal edge portions and at a middle portion of abrasive region 303 b. The intersection between the different abrasive sections in the abrasive region 302b includes a non-linear form along the longitudinal dimension L of the abrasive product. This makes it possible to provide different grinding results to the middle portion of the workpiece compared to the longitudinal edge portions of the workpiece. In addition, the non-linear intersection enables a smooth transition between grinding results without sharp edges between grinding results. For example, a convex profile of the workpiece may be achieved.

FIG. 3c shows an abrasive product according to one embodiment. The abrasive product comprises an intersection between two adjacent

abrasive regions

301c, 302c, 303c arranged in the form of a letter V. This may allow for a smooth change between adjacent abrasive regions. For example, an edge portion of the workpiece to be abraded is first exposed to the next sequential abrasive region before a middle portion of the workpiece. Abrasive region 303c of fig. 3c includes abrasive particles arranged in a drop-wise fashion, arranged to form circular or elliptical cells or islands of dots on abrasive region 303 c. This enables removal of grinding waste along the regions between the abrasive grains. The abrasive region 301c includes a portion without abrasive particles, which is disposed between lines of abrasive particles.

The portions between the abrasive portions comprising abrasive particles that are free of abrasive particles enable channels to be provided between the abrasive portions of the abrasive area. The channels between the abrasive sections enable removal of abraded material from the abrasive region. By removing material through the channels, clogging or clogging of the abrasive material is reduced or avoided. This may provide an extended service life of the abrasive region. The channels may help provide a flexible abrasive product. If a lubricant (such as an emulsion, water, or oil) is used for milling, the ability to remove the lubricant from the abrasive region may be enhanced by the channels.

The abrasive product 300 may include a plurality of sets of predetermined sequential abrasive regions.

Fig. 3abc shows different abrasive regions of the abrasive product. The abrasive product may comprise two or three or more distinct abrasive regions. One or some of the sequential abrasive regions may include a pattern. One or some of the sequential abrasive regions may comprise point-like abrasive regions. Sequential abrasive regions comprise different abrasive characteristics than their adjacent abrasive regions. The abrasive regions may comprise different types of particles and/or different sizes of particles and/or different densities of particles on the region unit. The abrasive results depend on the abrasive area used. The abrasive region may comprise a pattern. The abrasive region may comprise a fractal form. The fractal may have an congruent shape and the channel portion may comprise a substantially constant width. The form of the fractal repeat unit may vary. The repeating units on the abrasive region may comprise a self-similar shape or an congruent shape. Congruent refers to graphics or objects having the same shape and size. If the geometry is not symmetrical, a mirror image of the shape may be used. The mirror image of the shape is also congruent with the original shape. The two congruent shapes may be adjacent to each other in an alternating sequence, for example as a translation, a rotation and a reflection. Self-similar shape refers to a shape that may be different in size but the same shape. Fractals are self-similar patterns that may be identical at each scale or nearly identical at different scales. A two-dimensional surface of the abrasive region can be created by using repetitions of the geometry without overlaps or gaps.

Fig. 4 shows an apparatus for grinding. The abrasive product may be a continuous sheet of flexible abrasive material that is rolled into a roll 401. The workpiece 40 to be ground is arranged between the clamp shoes 402. Abrasive material is pulled from the roll 401 and disposed between the clamp shoe 402 and the workpiece 40. The abrasive material is disposed between the clamp shoe 402 and the workpiece 40 such that the abrasive surface 404 of the abrasive product faces the workpiece 40. The surface opposite the abrasive surface 404 of the abrasive is arranged to face the clamp shoe 402. The clamp shoe 402 may be used to push the abrasive material 401 into contact with the workpiece 40 and to hold the abrasive material 401 in contact with the workpiece 40. The clamp shoe 402 may conform to the form of the workpiece 40. The clamp shoe 402 may be arranged to move hydraulically or pneumatically. The clamp shoe 402 is movable toward the workpiece 40 and away from the workpiece 40. After the abrasive surface 404 is placed in contact with the workpiece 40, abrading may begin. The workpiece 40 is arranged to rotate in order to grind it. After finishing abrading with the abrasive surface, the clamp shoe 402 is separated from the workpiece 40. This causes the abrasive surface 404 to loose contact with the workpiece 40. After separation, new unused abrasive areas from the continuous abrasive surface 404 of abrasive material of the roll 401 are fed between the clamp shoe 402 and the workpiece 40. This enables the initiation of another grinding stage using unused abrasive areas of the same abrasive product. The new unused abrasive area replaces the used abrasive area at the grinding zone between the jig shoes 402 and directs the used abrasive area to, for example, waste or another roll 403.

The abrasive product may be wound from a roll 401. The abrasive product may be rolled between the two

rolls

401, 403. The two rolls may be a roll 401 of unused abrasive material and a roll 403 of used abrasive material. The roll 401 of unused abrasive material refers to a source of unused abrasive material. The used abrasive product roll 403 may be arranged to collect used abrasive product. The

rolls

401, 403 enable the abrasive material to move between them. For example, by moving the abrasive product between the rolls, the used abrasive surface at the grinding zone may be replaced with an unused abrasive surface of the same abrasive product.

The or one of the rolls of the roll-to-roll arrangement may be replaced with an arrangement capable of moving abrasive material between the rolls. Instead of a used roll of abrasive material, the abrasive material may be pulled from the grinding zone for disposal. The rolls may be replaced with rolls, a nip between two rolls, or similar arrangements suitable for moving the abrasive material toward and/or away from the abrasive zone. The abrasive product may be in the form of a belt. The belt may be arranged to move by means of rollers and guide rollers.

The shaft, rod or bearing (e.g., connecting rod or drive rod) may be ground in three different stages, with three-stage machining techniques typically being used. Three different machines have been used for the three phases. Alternatively, machines with three separate grinding arms have been used. The use of different machines or arms requires moving the workpiece between different positions of the corresponding grinding stages. According to an inventive aspect, a single machine may be used in place of three different machines, or the use of a separate grinding arm may be avoided. The abrasive area of the abrasive material arranged adjacent to the workpiece to be machined may be replaced by another abrasive area of the abrasive material. When the grinding stage is completed, the used abrasive area is removed from the grinding zone, while a new unused abrasive area of the same abrasive product is fed to the grinding zone for a subsequent grinding stage. The feeding of new different kinds of abrasive areas can be repeated continuously or several times in order to arrange several successive grinding stages. Abrasive products having different abrasive areas can be fed into the grinding arrangement between different grinding stages, either as the start of a grinding stage or continuously without any interruption between the different grinding stages.

The abrasive product may be arranged in the form of a roll, belt or corresponding continuous structure. The abrasive product may be arranged to be pulled or rolled down from the roll. The support is configured to place the abrasive surface in contact with a workpiece to be processed through a plurality of different sequential abrading stages. The support may include a contact, a contact roll, an abrasive support, an abrasive substrate, and the like. The support may comprise any form, for example it may comprise a square or circular flat surface arranged to urge the abrasive surface into contact with the workpiece. A rear surface of the abrasive product opposite the abrasive surface is disposed adjacent the support. There is friction between the rear surface of the abrasive product and the support, so that the abrasive product is arranged to move with or with the help of the support.

Contact between the abrasive material and the round object may be achieved by a clamp shoe or a contact roller. The workpiece and the abrasive surface are arranged to move relative to each other. Both the workpiece and the abrasive surface on the contact roll may be arranged to rotate, optionally in different rotational directions. The abrasive surface on the contact roll may be moved while the abrasive surface is in contact with the workpiece surface. The workpiece may be arranged to move, e.g. rotate or oscillate, in order to grind it.

For example, lapping is applied to planar, contoured, or curved surfaces. Grinding can be performed on cylindrical or circular objects, such as shafts. Flat planar surfaces can be ground in addition to circular surfaces. The square support may press the abrasive product into contact with the workpiece, wherein the support is arranged to move or reciprocate along a plane in the x-direction and/or the y-direction. The contact area between the workpiece and the abrasive surface of the abrasive material may be equal to or smaller than the size of a support surface arranged to press the abrasive surface thereon to contact the workpiece. The size of the support surface refers to the surface area of the support on which the abrasive material is arranged to be placed. The size of the support surface corresponds to the size of the machined or ground surface of the workpiece. For example, the abrasive product may have a width of 50 mm. If a support surface with a diameter of 25mm is used to press the abrasive surface in contact with the workpiece, the workpiece is machined at a contact area with a width of 25mm depending on the size of the support surface. When a clamp shoe is used, the abrasive surface can be pressed around a round workpiece. The clamp shoe can conform to the shape and size of a round workpiece, such as a rod. In addition, the contact area depends on the inner surface area of the clamp shoe. The dimensions of the inner surface of the clamp shoe arrange the contact area of the abrasive surface with the workpiece.

FIG. 5 shows a method for grinding according to one embodiment. A workpiece to be machined is arranged into the grinding zone 501. The workpiece will be processed by the grinder at the grinding zone. A desired end result associated with the machined or finished workpiece may be determined. Thus, a sequence of grinding stages can be planned which enable the desired end result of the workpiece appearance to be achieved. The sequential grinding stages may have a predetermined grinding result that is predetermined to be achieved at a certain grinding stage. The grinding phase is initiated by supplying abrasive material to the grinding zone. Abrasive material 502 is fed at the grinding zone. The abrasive material may be fed on or adjacent to a support, such as an abrasive support or a clamp shoe. The abrasive material includes an abrasive surface and a back surface opposite the abrasive surface. The rear surface of the abrasive material is arranged to face the support. And pressing the support frame towards the workpiece. The support is pressed against the workpiece so that the abrasive surface of the abrasive material is arranged in contact with the workpiece 503. Next, grinding 504 is started. Grinding 504 includes (machining) of the workpiece. Abrading includes relative movement between abrasive surfaces arranged to at least partially contact a workpiece.

After polishing is completed, the polishing phase 505 is stopped. Stopping 505 includes stopping the relative movement of the abrasive surface and the workpiece. Lapping may be considered complete when a desired abrasive result is reached in relation to lapping or the final result of the current lapping stage, when a predetermined time of the current lapping stage has expired or when the abrasive surface tends to wear. After grinding is stopped, the support is separated 506 from the workpiece. If the final grinding stage is complete and/or all of the predetermined grinding stages are complete and/or the predetermined end result of the workpiece is reached, the workpiece is considered finished and the grinding and grinding stages are stopped 507. The finished, machined, and/or finished workpiece may be removed. If abrading is to continue to another sequential abrading stage, the method continues from stage 502 by feeding another abrasive surface of abrasive material to the abrasive region. The other abrasive surface that replaces the feed of the previously used abrasive surface in the abrasive zone may have different abrasive characteristics than the previously used abrasive. After an abrasive material having another abrasive surface is fed 502 to the abrading zone, it is placed in contact with the workpiece. The abrasive material is arranged on a support frame that is pressed towards the workpiece. An abrasive material is placed in contact with the workpiece 503. Next, grinding is started 504, and the workpiece is ground. After being ready for abrading, abrading is stopped 505 and the support is separated from the workpiece 506, causing the abrasive surface to loose contact with the workpiece. Thereafter, the preparation of the workpiece is considered again. Thereafter, milling may be stopped or a new milling stage may be started. Thus, depending on the grinding stage, a workpiece may be ground with a single abrasive product, which may include grinding with different types of abrasive surfaces. Stage 502-506 may be repeated two, three, or more times for the same workpiece. This enables two, three or more different kinds of grinding stages to be provided for the workpiece without the need to change tools, machines or grinding positions. This makes it possible to provide a subsequent different grinding stage and/or to switch quickly and efficiently from a grinding stage to another grinding stage. A workpiece may be ground and finished using a single abrasive product and machine.

To provide longer abrading times over a certain type of abrasive area, the abrasive surface may comprise multiple abrasive layers. With multiple abrasive layers, longer abrading times can be achieved. The multiple layers are resistant to abrasion and can be used for a longer period of time. As the abrasive layer wears, a new layer is exposed, allowing continued abrading with the same kind of abrasive surface. Another alternative way to allow certain types of abrasive regions to have longer abrading times is to provide an increased length of abrasive region on the abrasive surface. This enables worn abrasive areas to be replaced by unused abrasive areas of the same kind. Thus, the same kind of abrasive area may subsequently be fed to the grinding zone. This allows two or more subsequent abrasions to be made using the same kind of abrasive region. In the case of continuous grinding, the length of the different kinds of abrasive areas along the longitudinal abrasive product has an effect on the grinding time of the different kinds of abrasive areas, in case abrasive material is fed continuously onto the contact roll at the grinding zone. In addition to the size of the abrasive area, the feed rate of the abrasive material also has an effect on the grinding time of a certain type of abrasive area.

FIG. 6 shows a side view of an abrasive product according to an embodiment. The abrasive product includes a backing 601 and an abrasive surface 602. The backing 601 may include one or more layers. The backing 601 may comprise laminated or coextruded layers. The layers of the backing 601 may include similar or different functions, chemistries, thicknesses, and other properties.

The backing 601 may be flexible. The flexible backing material may comprise a thermoplastic, paper, polymer, fabric, foam, laminate, or wire. The backing 601 may comprise a film, a metal film, a plastic film, a fabric, a woven fabric made of combustible fibers, a sheet comprising vulcanized fibers. The flexible backing material may conform to the surface to be abraded. The backing layer 601 may have a thickness of, for example, 50 to 250 micrometers. This may provide the desired flexibility. The abrasive product may be in or be part of an abrasive sheet, disc, roll, belt, or similar continuous elongated form. The backing 601 comprising a polymeric material may be modified to include desired properties. The backing 601 may be simultaneously flexible to conform to the abrasive surface and durable to withstand use in machine abrading. Durability is related to characteristics such as tensile strength, bending stiffness, and/or elongation strength of the backing 601. The backing 601 comprising a thermoplastic polymer enables processing by extrusion, coextrusion, injection molding or lamination. The thermoplastic polymer can be formed to have a precise composition, can be easily molded and processed, and can provide the backing 601 with a uniform quality. The thermoplastic polymer may be selected to include a combination of elastic and plastic properties suitable for abrasive products.

An abrasive surface 602 or abrasive layer is disposed on the backing 601. The abrasive surface may include abrasive particles adhesively attached to backing 601 by an adhesive. The binder may include at least one of a water-based binder, a solvent-based binder, an acrylic resin, or a formaldehyde resin. The backing 601 may be arranged to operate as an adhesive. The backing may comprise a resin reinforced with fibers. The particles may be partially embedded in the plastic film or in the organic and/or inorganic coating. Two or more abrasive layers may be disposed on the backing 601. The abrasive surface 602 may include several layers of abrasive regions on top of each other. The abrasive layers may be of similar size and/or shape, or the layers may be of different sizes and/or shapes. A fine abrasive layer may be disposed on a predetermined area of the backing 601 and a coarse abrasive layer disposed on top of the fine abrasive layer. The outermost abrasive layer may disintegrate due to mechanical forces such as pressure or shear rate. There may be abrasive regions having multiple abrasive layers on top of each other. Abrasive areas with more abrasive layers are less prone to wear than abrasive articles with a single abrasive layer. For example, abrasive areas having multiple abrasive layers may be provided for a longer period of use than abrasive areas having fewer abrasive layers.

The abrasive particles disposed on the backing material may be selected for each application, for example, according to composition, particle size, or surface treatment. Typical materials for use as abrasive particles are hard minerals, which may be synthetic or natural. Minerals used as abrasive particles may include cubic boron nitride (c-BN), Boron Carbide (BC), alumina (Al)₂O ₃) Titanium oxide (TiO)₂) Iron oxide (Fe)₂O ₃) Cerium oxide (CeO)₂) Silicon carbide (SiC), zirconia alumina, and diamond, such as synthetic diamond particles. Additionally or alternatively, the abrasive particles may comprise ceramic particles or engineered particles.

The abrasive particles may be sized or not sized. By sized is meant that the particles have a specified average size and/or a specified size distribution. The particles may have an average size of 3-260 microns. The finer the particles, the finer the surface finish can be achieved. So-called rough abrasive surfaces enable a faster removal of material, while in contrast fine abrasive surfaces achieve the end result of polishing, even mirror polishing. The specified size distribution may be relatively narrow. By indefinite size is meant that the particles have not been selected according to size. For example, the particle type may be used as a basis for additional selection or replacement of particle size.

The abrasive product may refer to an abrasive material and/or an abrasive article. Abrasive material may refer to a material that includes abrasive particles on an abrasive surface. The abrasive product may comprise a sequence of abrasive regions in the order: starting with an abrasive region having a particle size of 120 microns, followed by an abrasive region having a particle size of 80 microns, followed by an abrasive region having a particle size of 18-20 microns.

An abrasive surface comprising abrasive particles is formed on the backing. A binder may be provided on the backing, and abrasive particles may be provided on the binder. Alternatively, a mixture of binder and abrasive particles may be provided on the backing. The abrasive regions may be formed on the backing by engraving or printing methods such as calendering, gravure or gravure printing or pressing using a cylindrical roll. Printing allows for stippling manufacturing and smaller tolerances than conventional cutting methods. The different abrasive regions may be provided on the backing by coating with a kiss roll or an engraved roll. The coating method may enable different abrasive regions to be provided along the longitudinal sheet of abrasive material. The roll may enable a certain kind of pattern or density of adhesive/particles to be repeated sequentially along the longitudinal backing. The roll enables, for example, a certain density of adhesive/particles to be provided at certain areas of the backing. The roll may have a density of apertures to provide a quantity of adhesive/particles on the backing.

Printing can be used to provide different types of abrasive surfaces and/or abrasive patterns on the backing. Printing may include screen printing or other known methods. The pattern of at least one abrasive region may comprise a fractal pattern. Printing can be used to provide a surface comprising repeating units. The surface may include at least two or more abrasive regions adjacent to each other in the longitudinal dimension of the abrasive product. The printing method is capable of producing at least two different abrasive areas on the backing layer having different abrasive properties, such that the different abrasive areas are adjacent to each other. When one of the various abrasive regions ends along the longitudinal abrasive sheet, the other abrasive region begins.

Printing methods such as gravure, inkjet, or other digital printing methods may be used to apply the abrasive (e.g., binder and/or particles) to the backing. Printing may be used to match the two different abrasive regions and the possible regions between them in the desired location and shape of the two different abrasive regions. As predetermined, printing may enable the provision of abrasive and non-abrasive areas. Printing may enable two different kinds of abrasive regions to be provided along the longitudinal abrasive sheet. Printing may be used to pre-define the type of abrasive particles at a length along the longitudinal dimension of the backing. Printing may be used to print abrasive particles at a predetermined density at a length along the longitudinal dimension of the backing. Printing may be used to print abrasive particles of a predetermined size at a length along the longitudinal dimension of the backing.

The printing process may comprise two separate printing stations which may be placed adjacent to each other. The two different types of abrasive regions may be printed simultaneously at the same printing station or sequentially at two separate printing stations. The adhesive may be printed on the backing at a first printing station and the particles applied to the adhesive at a second printing station. For example, the adhesive may be printed as areas, lines or dots. The abrasive areas formed correspond to the size, area, line or dot of the binder. The density of the bonded region determines the density of the granular region. The amount of binder may have an effect on the size of the particles to make them adhere/non-adhere. The size of the particles may differ between two different abrasive regions.

Abrasive materials may be used in various manufacturing processes to perform finishing operations to produce a desired surface finish. When used for abrading, the abrasive surface of an abrasive product may last only a few minutes to a few hours, depending on the abrasive surface and the end application. In industrial applications, the life of the abrasive surface of a flexible abrasive product can typically range from a few seconds to several minutes. The efficiency of industrial use can be increased by providing an unused abrasive surface of the same product for continued abrading with the same, similar, or different types of abrasive surfaces. No replacement of the machine, the abrasive arm or the position is required.

The abrasive product may include predetermined abrasive regions of predetermined variety and predetermined length along the longitudinal dimension of the abrasive product. The grinding process is determined according to the desired grinding result. The abrading process may include adjustable parameters such as the type of abrasive area used, the sequential abrading area to be used, the total abrading time, the abrading time with a certain abrasive area, the speed of the machine, the manner and speed of movement of the workpiece and/or the abrading support between the abrading supports, the feed rate of the abrasive material. The specifications of the workpiece to be ground can be used to determine which grinding stage to use and how long to repeat which grinding stages. Finishing may include utilizing an abrasive region comprising a pattern. For example, a raster pattern may be desired on the surface of the workpiece.

The apparatus for abrading a workpiece may include a predetermined abrading stage. The milling stage may be programmed into the apparatus. The grinding stage may include feeding sequential abrasive regions onto a support and placing the sequential abrasive regions in contact with the workpiece. The abrading may begin with an abrasive stage, wherein the workpiece is abraded by abrasive regions comprising abrasive particles having an average size of 40 μm. After the grinding stage is completed, grinding may continue from a subsequent abrasive stage, in which the workpiece is ground by abrasive regions of the same abrasive product comprising abrasive grains with an average size of 20 μm. After the grinding stage is completed, grinding may proceed from a subsequent abrasive stage, in which the workpiece is ground by abrasive areas of the same abrasive product comprising abrasive grains with an average size of 9 μm. The predetermined end result of abrading a workpiece may include abrading in three different stages, including finishing with an abrasive region containing abrasive grains having an average size of 9 μm. Alternatively, the predetermined end result of grinding the workpiece may include a further finish or a mirror finish. In this case, grinding may continue from one or two subsequent abrasive stages, wherein the workpiece is further ground by abrasive regions of the same abrasive product comprising abrasive particles having an average size of 5 μm and/or 3 μm.

The abrasive product may include subsequent abrasive regions of different kinds having predetermined lengths, depending on the desired subsequent grinding stage, the desired result of the stage, and the desired end result. The grinding times for different kinds of abrasive surfaces can be adjusted for the successive grinding stages. The sequential grinding stages may include the use of different abrasive surfaces, different grinding times, different kinds of relative movement of the abrasive surface and the workpiece, different pressures of the support towards the workpiece. The oscillating grinding is achieved by arranging the support to the oscillation. PendulumThe movement may be arranged in one or two directions. The contact roller may be arranged to oscillate so as to arrange the abrading by oscillating the workpiece via an abrasive surface on the contact roller. The oscillating movement has an influence on the grinding effect. The pressure between the abrasive surface and the workpiece has an effect on the result of the abrasion. The pressure may be arranged pneumatically. The pressure at the contact surface may be 0.04-2N/mm²Or 0.03-1N/mm². In the case of an at least partially arranged grinding by rotating the workpiece, the rotational speed of the workpiece has an influence on the grinding result. For example, the rotational speed of the workpiece may be 50-200 rpm. The diameter of the workpiece and the rotational speed of the workpiece have an effect on the rotational speed of the workpiece. The rotational speed of the workpiece may be, for example, 40-200 m/s. In the case of continuous feeding of abrasive material, the speed at which the abrasive material is fed has an effect on the grinding result. The feed rate of the abrasive material may be 40-70mm/min or 60-70 mm/min. In addition, the result of the grinding is achieved by means of grinding, for example dry grinding or wet grinding, wherein in the latter oil, water or emulsions can be used. The hardness of the contact area, the support and/or the hardness of the workpiece may have an effect on the grinding results. Before starting the grinding, the grinding phase is predetermined and programmed onto the grinding machine. Even if two or more different grinding stages are required, the intended grinding stage and the used abrasive product having different abrasive areas can achieve automated grinding to achieve the desired end result.

The abrading stage may include abrading with one or more rough abrasive surfaces to effectively remove material from the surface of the workpiece. The grinding stage may be continued by a fine abrasive surface in order to continue towards a smoother abrasive surface. The grinding phase may further continue through a fine (st) abrasive surface in order to provide a finished surface (for the workpiece) as a final result. Alternatively or in addition, the surface of the workpiece may be provided with a surface pattern. In addition to selecting different kinds of abrasive surfaces, the total grinding time and the time of each grinding stage are also predetermined. The grinding is realized by adjusting the relative movement mode and the movement speed of the abrasive surface and the workpiece.

The use of an abrasive product comprising different abrasive areas with different abrasive characteristics enables different kinds of grinding stages to be achieved with another kind of abrasive area of the same abrasive product. Replacement changes an abrasive product (e.g., a roll of abrasive) to a different kind of abrasive product; or alternatively move the workpiece to another machine; or alternatively to changing the grinding position, the grinding stage can be changed to the next grinding stage by feeding a different sequence of abrasive areas of the same abrasive product to the abrasive zone. The abrasive area is pressed into contact with the workpiece at the abrasive zone and the next grinding stage can begin. The different grinding stages may be repeated sequentially.

Claims

1. A method for abrading a workpiece, comprising:

-arranging an abrasive area of an abrasive product at an abrading zone for abrading the workpiece, wherein the abrasive area and the workpiece can be arranged to be in contact at the abrading zone,

-replacing the abrasive area at the grinding zone with another abrasive area of the abrasive product for grinding the workpiece,

wherein the further abrasive region is different from the abrasive region,

wherein the abrasive product comprises a continuous longitudinal abrasive product comprising at least two longitudinally sequential different abrasive regions having different kinds of abrasive properties.

2. The method for abrading a workpiece according to claim 1, comprising constantly feeding the different abrasive regions of the continuous longitudinal abrasive product to the abrading zone in a continuous manner.

3. The method for abrading a workpiece according to any of claims 1-2, comprising feeding the abrasive product comprising three or at least three different abrasive zones to the abrading zone.

4. A method for abrading a workpiece according to any of claims 1-3, characterized in that the method is repeated one or more times by replacing the abrasive area at the abrading zone, i.e. used abrasive area, with a different kind of abrasive area of the abrasive product, i.e. unused abrasive area.

5. The method for abrading a workpiece according to any of claims 1-4, comprising replacing the abrasive region at the abrading zone by feeding unused abrasive region to the abrading zone and simultaneously removing the used abrasive region of the abrasive product from the abrading zone.

6. The method for abrading a workpiece according to any of claims 1-5, comprising abrading the workpiece, including arranging relative movement between the workpiece and the abrasive region of the abrasive product.

7. The method for abrading a workpiece according to any of claims 1-6, comprising continuously abrading the workpiece during feeding of the abrasive material replacing the abrasive area at the abrading zone.

8. The method for abrading a workpiece as defined in any one of claims 1 to 6, comprising

-after arranging the abrasive area of the abrasive product at the grinding zone, and

-abrading the workpiece after replacing the abrasive area at the abrading zone with the further abrasive area of the abrasive product.

9. The method of abrading a workpiece according to any of claims 1-8, wherein the abrasive product comprises two or more different abrasive regions comprising abrasive particles of different types, sizes, orders and/or densities.

10. The method for abrading a workpiece according to any of claims 1-9, comprising receiving abrasive material on a support at the abrasive region; and moving the abrasive region toward and away from the workpiece so as to place the abrasive region in contact with the workpiece.

11. A method for abrading a workpiece according to claim 10, wherein the support comprises an abrasive support, a roller, a clamp shoe, a contact element, an abrasive base, or a contact roller.

12. A method for abrading a workpiece according to any of claims 1-11, comprising

-feeding an abrasive area of abrasive product between the workpiece and a support at the grinding zone,

-arranging the support towards the workpiece so as to arrange the abrasive area of the abrasive product in contact with the workpiece,

-after grinding, arranging the support away from the workpiece in order to separate the abrasive area of the abrasive product, i.e. the used abrasive area, from the workpiece,

-feeding another, unused abrasive region of the abrasive product between the workpiece and the support at the grinding zone in order to replace the used abrasive region of the abrasive product,

-prior to lapping, arranging the support towards the workpiece so as to arrange the further abrasive region in contact with the workpiece.

13. An apparatus for abrading a workpiece comprising

-an arrangement configured to feed an abrasive area of an abrasive product to an abrading zone and to replace the abrasive area at the abrasive zone with another abrasive area of the abrasive product,

-wherein the further abrasive area is different from the abrasive area,

-wherein the abrasive area of the abrasive product and the workpiece can be arranged to be in contact in the grinding zone, and

-wherein the abrasive product comprises a continuous longitudinal abrasive product comprising at least two longitudinally sequential different abrasive zones having different kinds of abrasive properties.

14. An apparatus for abrading a workpiece according to claim 13, comprising an arrangement configured to feed abrasive areas constantly to the abrading zone in a continuous manner.

15. An apparatus for abrading a workpiece according to any of claims 13-14, wherein the abrasive product comprises three or at least three different abrasive zones.

16. An apparatus for abrading a workpiece according to any of claims 13-15, wherein the arrangement configured to replace the abrasive area at the abrading zone, i.e. used abrasive area, is configured to replace the abrasive area one or more times with a different kind of abrasive area of the abrasive product, i.e. unused abrasive area.

17. An apparatus for abrading a workpiece according to any of claims 13-16, wherein the arrangement configured to replace the abrasive area at the abrasive zone is configured to feed another unused abrasive area of the abrasive product and to simultaneously remove the abrasive area, i.e. the used abrasive area of the abrasive product, from the abrading zone.

18. An apparatus for abrading a workpiece according to any of claims 13-17, comprising an arrangement configured to abrade the workpiece, the arrangement being arranged to cause relative movement of the workpiece and the abrasive region of the abrasive product, optionally constantly or as follows: after disposing the abrasive region of the abrasive product at the grinding zone; and/or after replacing the abrasive region at the grinding zone with the other abrasive region of the abrasive product.

19. The apparatus for abrading a workpiece according to any of claims 13-18, wherein the abrasive product comprises two or more different abrasive regions comprising abrasive particles of different types, sizes, orders and/or densities.

20. The apparatus for abrading a workpiece according to any of claims 13-19, comprising a support at the abrasive zone, wherein the support optionally comprises an abrasive support, a roller, a clamp shoe, a contact, an abrading base, or a contact roller.

21. An apparatus for abrading a workpiece according to any of claims 13-20, comprising a support at the abrasive region, wherein the support is arranged to be movable towards and away from the workpiece so as to arrange the abrasive surface towards and into contact with and away from the workpiece.

22. The apparatus for abrading a workpiece according to any of claims 13-21, wherein the abrading comprises a sequential abrasive stage comprising at least one of: a predetermined kind of abrasive surface, a predetermined time of different grinding phases, a predetermined time of total grinding, a predetermined movement between the abrasive surface and the workpiece, a speed of relative movement, a speed of feeding the abrasive material.

23. The apparatus for abrading a workpiece according to any of claims 13-22, wherein the abrading comprises a sequential abrasive stage comprising at least one of: a predetermined oscillation of the support, a predetermined pressure between the workpiece and the contact area of the abrasive surface, a predetermined rotational speed (rpm) of the workpiece, a predetermined speed for feeding the abrasive material to the abrasive area, a predetermined grinding pattern of dry grinding or wet grinding.

24. Abrasive product comprising a continuous longitudinal abrasive product and at least two sequential different kinds of abrasive zones along a longitudinal dimension of the abrasive product, the at least two sequential different kinds of zones having different kinds of abrasive characteristics, wherein the continuous longitudinal abrasive product is feedable into a grinding zone of a grinding apparatus for sequential grinding with the corresponding at least two sequential different kinds of abrasive zones.

25. Use of an abrasive product in a grinding apparatus, the abrasive product comprising a continuous longitudinal abrasive product having a surface of at least two sequential different kinds of abrasive zones along a longitudinal dimension of the abrasive product, wherein the at least two sequential different kinds of zones have different kinds of abrasive characteristics, wherein the continuous longitudinal abrasive product is feedable to a grinding zone of the grinding apparatus such that the at least two sequential different kinds of abrasive zones are feedable sequentially to the grinding zone.

26. Use of an abrasive product according to claim 25, wherein the abrasive device is an abrasive device according to any one of claims 13-23.