KR20230096000A - Reusable hub assembly for abrasive articles - Google Patents

Abstract

A method of reusing a hub in an abrasive assembly is presented comprising removably coupling an abrasive wheel to a reusable hub. The abrasive wheel has an outer circumference and an inner circumference. The abrasive article has an inner circumference and an outer circumference. The method also includes abrading the work surface by contacting the abrasive wheel to the work surface. The reusable hub includes engagement features configured to directly engage an abrasive article. The bonding feature includes an adhesive-free connection between the reusable hub and the abrasive wheel. A direct connection is a removable interlocking between the abrasive wheel and the reusable hub.

Description

Reusable hub assembly for abrasive articles

Bonded abrasive wheels are typically provided with an attachment mechanism for connection to a grinding system. A disk shaped flange extends radially from the middle portion of the bushing and terminates at a peripheral lip. The bushing extends through the central bore of the wheel and is adapted to engage the bearing surface of the wheel proximate the outermost circumference of the center where the lip is recessed. The grinding surface end of the bushing can be flanged radially outward to engage the front grinding surface of the wheel and mechanically capture the wheel between the grinding surface end and the flange. The flange, lip and bearing surface form a cavity within which an epoxy resin is placed to chemically bond the hub to the wheel.

A method of reusing a hub in an abrasive assembly is presented comprising removably coupling an abrasive wheel to a reusable hub. The abrasive wheel has an outer circumference and an inner circumference. The abrasive article has an inner circumference and an outer circumference. The method also includes abrading the work surface by contacting the abrasive wheel to the work surface. The reusable hub includes engagement features configured to directly engage an abrasive article. The bonding feature includes an adhesive-free connection between the reusable hub and the abrasive wheel. A direct connection is a removable interlocking between the abrasive wheel and the reusable hub.

The systems and methods herein provide significant waste reduction compared to modern hubs for abrasive systems. The systems herein allow for savings of more than 30% in the volume of abrasive discs that are often discarded and not available for polishing. Additionally, the systems herein provide a reusable hub for a number of abrasive articles that reduce waste and improve the sustainability of a customer's manufacturing process.

The systems and methods herein also provide improved damping of vibrations caused by abrasive operations. Also, better consistency of material removal is provided using the hub exemplified herein during grinding operations, in part due to improved damping of vibrations caused during grinding operations. Additionally, the creation of a particularly center recessed grinding wheel may be easier since a tapered section for the bonding resin is not required. The bonded configuration is a simple circular washer-like shape.

In the drawings, which are not necessarily to scale, like reference numbers may indicate like elements in different drawings. The drawings generally illustrate the various embodiments discussed herein by way of example and not as limitation.
1A and 1B illustrate a depressed center grinding wheel without and with a metal hub.
2 illustrates an exploded view of a reusable hub assembly according to an embodiment herein.
3A-3C illustrate cutaway views of a reusable hub assembly according to embodiments herein.
4 illustrates a position locking feature for a reusable hub assembly according to an embodiment herein.
5 illustrates a method of using a reusable hub according to an embodiment herein.
6 illustrates a method of abrading a workpiece according to embodiments herein.
7A and 7B illustrate a mating ring design for a reusable hub assembly according to embodiments herein.

A center recessed grinding wheel is an example of an abrasive article that can be used in a grinding operation. Many grinding wheels are used with hubs for mounting to grinding assemblies. 1A illustrates an exemplary center recessed grinding wheel of the prior art, and FIG. 1B illustrates such a wheel to which a metal hub is attached.

US Patent No. 5,895,317, issued on April 20, 1999, describes a prior art hub assembly for an abrasive article, specifically a center recessed grinding wheel as shown in FIGS. 1A and 1B . Typically, the hub is attached to the wheel using adhesive. The hub overlaps a portion of the surface of the abrasive article, at least on the side to which it is bonded. Unfortunately, this means that the user can only grind to the edge of the hub. The outer diameter gets smaller until the wheel becomes too small to be used. As the wheel diameter becomes significantly smaller, the radial speed of the wheel decreases significantly and performance deteriorates. Especially in the case of center recessed grinding wheels, the "centre recessed" portion of the wheel is often discarded by the user. The discarded portion may be a significant fraction of the total material. For example, more than 30% of 4.5" outer diameter depressed center grinding wheels (DCGW) are in the depressed center portion that is discarded. Additionally, because the hub is discarded, it is not reusable.

A particular problem of hub design for center recessed grinding wheels is exemplified in US Pat. No. 6,454,639 issued Sep. 24, 2002. The DCGW, as illustrated in FIG. 1 of U.S. Patent No. 6,454,639, has a face-grinding design with a taper to accommodate the hub so that the hub can be coupled to the DCGW so that the hub can be flush with one side. ) is often used for applications. Alternatively, as illustrated in Figure 2 of U.S. Patent No. 6,454,639, many hubs connected to flat wheels extend on both sides of the wheel, making them unsuitable for face grinding as the hub material contaminates the substrate. There is a need for a reusable hub that can be used with flat wheels for face grinding applications without contaminating the substrate of the abrasive operation. In some embodiments herein, a reusable hub may engage a grinding wheel without extending completely through the wheel, or only extending through the thickness of the wheel, allowing the wheel to be used in face grinding applications.

From both raw material concerns as well as environmental waste concerns, it is desirable to reduce the amount of material wasted. Additionally, it is desirable to have a reusable hub that is releasably connected to the abrasive article and can be reused between grinding operations. In some embodiments, the reusable hub is made of a material that provides sufficient stability. Additionally, it is desirable that the hub can be mated to an appropriate spindle as needed. There is also a further need to manufacture reusable hubs from sustainable materials.

Sustainable materials may include recyclable materials, such as plastics, metals or other materials that can be recaptured and recycled. Additionally, some embodiments herein include reusable hubs having one or more sustainable polymer components, such as bio-based or compostable polymers or mixtures of polymers. Such materials may be desirable in some embodiments because the polymer blends can provide tunable properties, as described in US Provisional Patent Application Serial No. 63/074617, filed on September 4, 2020. 1A and 1B illustrate a center recessed grinding wheel (DCGW) without and with a metal hub. The abrasive layer 110 has a depression 120 to which a hub 140 can be attached. The connecting ring 130 facilitates insertion of the shaft through the abrasive article. The hub 140 is metal and adheres to the surface of the wheel 110 .

As illustrated in FIG. 1B , a portion of abrasive wheel 110 , represented by radius portion 142 , is covered by the surface area of hub 140 . Portion 142 is discarded after use as it is unusably coupled to hub 140 . Preferably, the entire area of the wheel 110, represented by the radius portion 112, can be used during the grinding operation.

DCGW also notes that the product may have poorer performance as it nears the end of its life, due to the reduced outer diameter and linear speed as the wheel 110 grinds down to the edge of the hub 140. . This manifests itself in both the wheel's cutting consistency and rate of degradation. Embodiments herein provide improved cutting consistency as well as reduced waste during manufacturing and use. Embodiments herein also provide the benefit of reducing waste during manufacturing and use as well as limiting the use of cutting and grinding wheels at small wheel diameters.

2 illustrates an exploded view of a reusable hub assembly according to an embodiment herein. The abrasive article 230, in one embodiment, accommodates the reusable hub 210 by using a mating ring 220. The mating ring 220, in the illustrated embodiment, receives the hub 210 by means of a corresponding threaded fit. However, although screwing to mating ring 220 is illustrated as one fastening mechanism, other suitable fasteners may be used to removably couple hub 210 to abrasive article 230 . For example, mating ring 220 may be clamped, screwed, clipped, magnetically coupled, removable screws or rivets, quick-release fasteners, interlocking grooves, or other suitable removable mechanisms such as friction-based contacts. Can be coupled to hubs. In some embodiments, the coupling is toolless coupling, allowing a user to remove the hub 210 from the abrasive article 230 without the use of tools, eg, by hand force only. A removable fastening can be any mechanical fastening system that can be manually or semi-automatically during assembly or installation.

As illustrated in FIG. 2 , the hub 210 has a thickness 212 that is substantially the same as the thickness 232 of the abrasive hub. Thus, hub 210 provides stability throughout the entire thickness 232 of abrasive article 230 .

3A-3C illustrate cutaway views of a reusable hub assembly according to embodiments herein. 3A illustrates a single component hub 300 , while FIG. 3B illustrates a two-component hub 350 coupled to a grinding wheel 370 .

3A illustrates a cutaway view of a hub 300 having a housing 310 and an interior 320 . In one embodiment, interior 320 is the same material as the housing and is designed to reduce vibration during use. In another embodiment, the interior 320 is a different material than the housing 310, but a material designed to reduce vibration. Hub 300 illustrates a threaded connection 340 for coupling to a shaft of a tool. Additionally, a threaded connection 330 is also illustrated for direct coupling to the mating ring, eg, into a corresponding threaded portion of an abrasive article. However, other coupling mechanisms are expressly contemplated, including driving the threads into the inside diameter of the wheel to create a self mating thread system.

3B illustrates a cutaway view of hub assembly 350 . The hub assembly includes two different hub components, a top component 352 and a bottom component 356. The top component 352 can have an interior 354 with a damping material, and the bottom component 356 can also include a damping material 358 . For example, damping material 358 may include an O-ring, rubber washer, lightweight hub material, semi-rigid hub or semi-flexible hub material, and the like. A material may be considered a “damping material” if it has a dissipation factor (tan(delta)) greater than 10 times that of aluminum, as measured by ASTM standard D4065 for dynamic mechanical analysis.

Both top component 352 and bottom component 356 are received by mating ring 360 illustrated in the embodiment of FIG. 3B . However, it is expressly contemplated that in some embodiments, mating ring 360 is not required. For example, registration features may be incorporated into the abrasive layer itself. Alternatively, the mating ring may be applied during or after curing of the bonded wheel.

Several embodiments of damping structures are described herein that may be useful in a single-component hub configuration, such as that of FIG. 3A, or a multi-component hub configuration, such as that of FIG. 3B. Additionally, while a multi-component construction may be the result of an additive manufacturing process, a customer may interact with an assembled hub that behaves like a single-component construction. Both embodiments are designed with registration such that the grinding layer and reusable hub are closely attached and function like a typical cutting or grinding wheel.

This system is an improvement over previous designs, such as that of US Pat. No. 6,454,639 issued Sep. 24, 2002. The design illustrated here includes two components external to the grinding wheel that are connected to each other by screwing. The mating ring 230 and hub 220 have a depth that extends over the entire abrasive layer 210, which provides a simpler design for manufacture and use, and the use of adhesive to adhere the clamping components together and It provides the stability required by the inventors of US Pat. No. 6,454,639 without requiring an incorporated damping layer. This design also provides a simpler connection between the hub 220 and the shaft of the tool, since the hub 220 is the only part of the assembly 200 that engages the shaft.

Also note that compared to modern designs, the assembled wheel 250 provides sustainability advantages. Although there is some overlap between the hub components 254, 256 and the abrasive layer 270, the design presents a significant improvement in reducing waste of abrasive materials. And, many of the designs herein provide improved damping, as discussed in the embodiments.

3C illustrates another cut away view of a reusable hub 370 with a connection mechanism 380 . As with the configuration of FIGS. 3A and 3B , the hub 370 can engage the abrasive article such that a majority of the attached abrasive article is fully available for the grinding operation, reducing waste. Additionally, FIG. 3C provides a damping system 374 within hub housing 372 . Damping system 374 includes damping structures 376 and 382 joined by connector 378 . Damping structures 376 and 382 are illustrated as rod-like structures that may be curved 376 or straight 382 . In some embodiments, structures 376 and 382 may have the ability to bend. 3C illustrates the damping system 374 suspended within the housing 372. However, it is also expressly contemplated that damping system 374 may be housed within a filler material within housing 372 to provide additional vibration damping.

3C illustrates one possible structured damping system 374. However, it is expressly contemplated that others are possible. For example, US provisional application Ser. No. 63/198,574, filed on October 28, 2020, illustrates several possible damping structures.

4 illustrates a position locking feature for a reusable hub assembly according to an embodiment herein. 4 illustrates a reusable hub assembly 400 having a first hub component 402 and a second hub component 404 . Position locking feature 420 is presented on mating feature 450 coupled to abrasive wheel 460 . While mating ring 450 is illustrated in FIG. 4 , in some embodiments, position locking feature 420 , as well as any additional engagement features (if present) are directly molded or machined into abrasive wheel 460 . It is expressly contemplated that it can be processed. For example, portion 450 may represent a portion of wheel 460 that is free of abrasive grain. It may have grooves, screw joints, protrusions or recesses machined or formed during manufacture.

The reusable hub 400 is illustrated with a tool receiving bore 410 on the inner diameter and a position locking feature 422 on the outer diameter. As the reusable hub 410 moves into place relative to the abrasive article 460 (with component 402 moving in the direction of arrow 440), it either directly or via mating feature 450. Part 404 is coupled. For example, portions 402 and 404 may directly engage each other, and protrusions 422 may engage openings 420.... However, while a separate mating feature 450 is illustrated, in some embodiments, the corresponding portion 450 does not include abrasive particles, but is instead composed of bonding and filler material to reduce abrasive particle waste. It is expressly contemplated that 460 may be formed. In such an embodiment, a locking mechanism such as protrusion 420 may be machined or molded into article 460 .

While protrusion 422 and corresponding opening 420 are illustrated as one example of a suitable position lock, other such as inflatable or spring-loaded features that actuate when the hub is in place relative to abrasive article 460. It is expressly contemplated that a locking mechanism may be suitable. Additionally, lever-based or other suitable position locking mechanisms are also expressly contemplated.

Reusable hub 400 can include damping features 406 , which in some embodiments can be a flexible material different from the material forming hub portions 402 , 404 . As illustrated in Figure 4, O-rings are used as damping features.

5 illustrates a method of using a reusable hub according to an embodiment herein. Method 500 includes center recessed grinding wheels (DCGW), cut-off wheels (COW), cut-and-grind wheels (C&G wheels), flex-wheels, cylindrical grinding wheels (internal grinding wheels, external grinding wheels, centerless grinding wheels). grinding wheel), cam/crank grinding wheel, surface grinding wheel, or gear grinding wheel (single rib grinding wheel, threaded wheel, bevel gear grinding wheel), plunge grinding wheel, edge grinding wheel, finish grinding wheel, ultra-finish grinding wheel , reusable hubs that mate with any number of suitable abrasive wheel designs, including polishing grinding wheels.

At block 510, the first disk is used with the reusable hub. A reusable hub may provide vibration damping, as shown in block 512 . The reusable hub may also allow substantially all of the abrasive wheel volume to be used, as shown in block 514 . Additionally, in embodiments where the wheel includes a non-abrasive portion that interacts with the lip of the hub, at least 90% of the abrasive volume may be used. In some embodiments, the lip protruding from the hub onto the abrasive article covers about 5% of the abrasive article. The reusable hub may also have other features, such as locking features for maintaining relative position with an abrasive wheel, as shown at block 516 .

At block 520, the first disk is replaced with a second disk. The first disk may be replaced when insufficient abrasive article volume remains to continue the abrasive operation. Insufficient abrasive article volume may be indicated, for example, by reaching a lip or protrusion of the hub or by reaching an end-of-life indicator. For example, the mating ring may engage the abrasive article using a spike or other protrusion that reaches the wheel volume. An end-of-life indication may be the exposure of the mating ring protrusion. Ordinarily, an abrasive article reaches the end of its life when there is insufficient volume left to maintain its structural integrity during a grinding operation, as a broken grinding wheel portion can be hazardous.

As shown at block 524, the hub is removed from the first disk and reused with the second disk. This may involve unlocking the locking feature, unscrewing the threaded connection between the hub and the abrasive article, or otherwise removing the hub. This may also include discarding the mounting ring or flange used in the first polishing operation, and retrieving a new mounting ring for use with the second disk. The second disk is then attached to the reusable hub using, for example, a threaded joint, locking feature, or other suitable temporary or semi-permanent attachment mechanism.

In some embodiments, such as the one illustrated in FIG. 3B , exchanging the first disk for the second disk involves disengaging the first hub component from the second hub component. The first and second hub components may be made of the same material or different materials. For example, one component may be more compliant to provide damping, while a second component is made of a material chosen for its structural integrity.

At block 530, the second disk is used with the reusable hub. The reusable hub can provide vibration damping, as shown at block 532, and can allow substantially all of the abrasive wheel volume to be used, as shown at block 534. The hub may also provide other features, as shown in block 536 . 6 illustrates a method of abrading a workpiece according to embodiments herein. Method 600 includes center recessed grinding wheels (DCGW), cut-off wheels (COW), cut-and-grind wheels (C&G wheels), flex-wheels, cylindrical grinding wheels (internal grinding wheels, external grinding wheels, centerless grinding wheels). grinding wheels), cam/crank grinding wheels, surface grinding wheels, gear grinding wheels (single rib wheels, threaded wheels, bevel gear grinding wheels), plunge grinding wheels, edge grinding wheels, finish grinding wheels, ultra-finish grinding wheels, Any suitable abrasive wheel may be useful including, but not limited to, a polishing grinding wheel.

At block 610, the reusable hub is removably coupled to the abrasive wheel. The engagement may be a mounting ring 612, a threaded connection 614 between the hub and the abrasive wheel, or between the hub and the mounting ring, a locking feature 616 that maintains the relative position between the hub and the abrasive wheel, or another suitable ratio. Permanent connection features may be included. The connection between the reusable hub and the abrasive wheel is, in some embodiments, a mechanical rather than chemical connection. Additionally, in some embodiments, the connection is an adhesive-free connection.

At block 620, the reusable hub is removably coupled to a tool that causes rotation of the hub and associated abrasive wheel. The hub may have an internal bore with, for example, a threaded portion 632, which may facilitate a removable connection. The hub may also have a locking feature 634 to retain the relative position of the hub and tool. As indicated in block 636, other connection features may also be presented.

At block 630, an abrasive operation is performed by contacting the abrasive wheel to the work surface and rotating the operation. The reusable hub may provide vibration damping, as shown in block 632 . The reusable hub may also be sized such that at least 90% of the abrasive article is available for abrasion, as indicated by block 634 . As discussed in the Examples below, this is in contrast to previous versions where up to 30% of the abrasive articles were discarded.

7A and 7B illustrate a mating ring design for a reusable hub assembly according to embodiments herein. As explained, one advantage of the reusable hubs herein is the ability to use them with attached grinding wheels for face grinding applications. 7A and 7B illustrate partial views of one such embodiment of a mating ring 700 coupled to an abrasive wheel 720 . As illustrated, the abrasive wheel 720 has both a first side 722 and a second side 724 that are planar. This differs from traditional center recessed grinding wheels, which generally have a first side 722 and a second side 724 with mating features (e.g., reusable hubs) maintaining a planar grinding surface on face 722. ) has an abrasive layer 720 with a taper that allows it to bond to both. In contrast, the reusable hubs herein may engage the abrasive article 720 substantially only along the inner region covered by, for example, the mating ring 710 .

As illustrated more clearly in FIG. 7A and in FIG. 7B , mating ring 710 does not fully extend from face 722 to face 724 . Instead, there is a gap 728, which ensures that the reusable hub does not engage the work surface during the face grinding operation.

Although the mating ring 710 is illustrated in FIGS. 7A and 7B , it is expressly contemplated that the mating ring 710 could instead be integral with the wheel 720 . For example, the bonded wheel can be molded or machined with threaded joints so that the wheel 720 can directly receive a reusable hub using the corresponding threaded joints. Other mechanical coupling mechanisms other than screwing are also contemplated as being sufficient, such as corresponding protrusions and openings, grooves and ridges, or a close fit where friction alone is sufficient.

Thus, although exemplary embodiments have been disclosed for illustrative purposes, those skilled in the art will recognize that various modifications, additions, and substitutions are possible. Accordingly, the present disclosure is not limited to the foregoing embodiments, but may be modified within the scope of the appended claims, along with the full scope of their equivalents.

A method of reusing a hub in an abrasive assembly is presented comprising removably coupling an abrasive wheel to a reusable hub. The abrasive wheel has an outer circumference and an inner circumference. The abrasive article has an inner circumference and an outer circumference. The method also includes abrading the work surface by contacting the abrasive wheel to the work surface. The reusable hub includes engagement features configured to directly engage an abrasive article. The bonding feature includes an adhesive-free connection between the reusable hub and the abrasive wheel. A direct connection is a removable interlocking between the abrasive wheel and the reusable hub.

The method can be implemented such that the direct connection is a toolless connection.

The method may be implemented such that the direct connection involves the reusable hub interacting with a receiving feature on the inner circumference of the abrasive wheel.

The method may be implemented such that the receiving feature is a screw joint, groove or receiving opening.

The method may be implemented such that the direct connection includes engaging the reusable hub to a mating feature that directly engages the abrasive article.

The method may be implemented such that the mating feature includes a mating ring coupled to the abrasive article.

The method may be implemented to engage a reusable hub to a mating ring using screwing, clamping, clipping, grooves, magnetic forces, or frictional forces.

The method may be implemented such that the reusable hub, when coupled to the abrasive wheel, extends partway through the thickness of the abrasive article from the mating surface.

The method may be implemented such that the reusable hub extends through the thickness of the abrasive article and is flush with the opposite side.

The method may be implemented such that the reusable hub extends halfway through the thickness of the abrasive article.

The method may be implemented such that the reusable hub includes damping features.

The method may be implemented such that the damping feature comprises the material composition of the hub. The material composition includes metal, plastic, or reinforced composites.

The method may be implemented such that the damping feature is an internal structure of the reusable hub.

The method may be implemented such that the internal structure is a series of repeating units within a reusable hub.

The method may be implemented such that the internal structure is a second material. The hub includes a housing made of a first material. The second material is different from the first material.

The method may be implemented such that the first material has a first storage modulus and the second material has a second storage modulus. The second storage modulus is smaller than the first storage modulus.

The method may be implemented such that the second e-modulus is at least 10 times smaller than the first storage modulus.

The method can be implemented such that the damping feature is an infiltrated material, a coextruded material, a layer in a reusable hub, or a 3D-printed structure in a reusable hub.

The method can be implemented so that the reusable hub has a radial width extending from the inner edge to the outer edge. The width of the system extending from the inner edge to the outer circumference is less than 10% greater than the sum of the radial width of the reusable hub and the radial distance from the inner to the outer circumference.

The method can be implemented such that the reusable hub further includes a position locking mechanism.

The method may be implemented to include coupling the reusable hub to a mating ring that engages directly the abrasive wheel.

The method may be implemented such that the reusable hub includes a first portion and a second portion. Joining includes joining the first part to the second part such that the abrasive wheel is between the first part and the second part.

The method may be implemented such that the first part comprises metal.

The method may be implemented such that the first part is plastic.

The method may be implemented such that the first portion has a modulus of elasticity greater than 1 GPa.

The method can be implemented such that the damping features include flexible features.

The method may be implemented such that the flexible feature is an o-ring.

In this method, the abrasive wheel is a center recessed grinding wheel, a cut-off wheel, a cut-and-grind wheel, a flex-wheel, an inner grinding wheel, an outer grinding wheel, a centerless grinding wheel, a cam/crank grinding wheel, a surface grinding wheel, It may be implemented to be a gear grinding wheel, a plunge grinding wheel, an edge grinding wheel, a finish grinding wheel, an ultra-finish grinding wheel, or a polishing grinding wheel.

The method may be implemented such that the first material has a first damping factor and the second material has a second damping factor. The second damping coefficient is higher than the first damping coefficient.

The method involves coupling a hub to a flat abrasive wheel that includes a depressed center and such that the bottom surface of the flat abrasive wheel is offset from the reusable hub, such that the hub is spaced from the work surface when the bottom surface contacts the work surface. It can be implemented to be configured.

The method may be implemented such that the removable interlocking is magnetic.

The method may be implemented so that it also includes an o-ring between the first portion and the second portion.

In this method, the reusable hub is made of aluminum, high carbon steel, stainless steel, high nickel alloy, titanium, epoxy, polyamide, polycarbonate, acrylonitrile butadiene styrene, polyethylene terephthalate, polystyrene, polytetrafluoroethylene, poly vinylidene fluoride, polymethyl methacrylate, phenolic resins, vinyl ester resins, and polyetherketones; It may be implemented to include a housing composed of a structural material including a combination thereof, or a combination thereof reinforced with glass fibers, carbon fibers, ceramic fibers, or polyamide fibers.

The method may be implemented such that the damping feature comprises a damping material comprising an elastic and/or rubber material having a modulus of elasticity that is at least 10 times less than the modulus of elasticity of the structural material.

The method may be implemented such that the damping material is polyisoprene, polychloroprene, silicone rubber, nitrile rubber, polyisoprene, polyethylene, fluoroelastomer, styrene-butadiene rubber, polyolefin, polyolefin copolymer, or polyurethane.

The abrasive system is presented comprising an abrasive wheel comprising abrasive particles in a binder matrix. The abrasive wheel includes an outer circumference, an inner circumference, and a wheel width extending from the outer circumference to the inner circumference. The system also includes a reusable hub comprising a mating feature, the mating feature removably coupling the reusable hub to the abrasive wheel.

The system can be implemented such that the mating feature is integral with the abrasive wheel.

The system can be implemented such that the registration features are molded or machined into the abrasive wheel.

The system can be implemented such that the mating feature is integral with the reusable hub.

The system can be implemented such that the mating feature includes a mating ring that mechanically couples to the reusable hub on a first side and to the abrasive wheel on a second side.

The system can be implemented such that the mating feature engages the reusable hub using screwing, clamping, clipping, magnets, grooves or friction.

The system can be implemented such that the reusable hub includes an upper portion and a lower portion. The mating feature joins the upper portion to the lower portion on both sides of the abrasive wheel.

The system can be implemented such that the reusable hub has a hub circumference on the outer edge, a bore circumference on the inner edge, and a hub height extending between the hub circumference and the bore circumference. The abrasive system has a system height that includes the distance from the bore circumference to the outer circumference. The system height is less than 10% greater than the sum of the hub height and wheel height.

The system can be implemented such that the reusable hub comprises metal, plastic or fiber-reinforced composites.

The system can be implemented such that the reusable hub includes a housing and an interior. The interior includes damping features.

The system can be implemented such that the damping feature is a material filling the interior.

The system can be implemented such that the damping feature is a plurality of repeating units within the interior.

The system may also be implemented to include a locking mechanism that secures the relative position of the reusable hub to the abrasive wheel.

The system can be implemented such that the locking mechanism includes a protrusion extending from the reusable hub.

The system can be implemented such that the protrusion is received by a corresponding recess in the mating feature.

The system may be implemented such that the mating feature is a mating ring.

In this system, the abrasive wheel is a center recessed grinding wheel, cut-off wheel, cut-and-grind wheel, flex-wheel, internal grinding wheel, external grinding wheel, centerless grinding wheel, cam/crank grinding wheel, surface grinding wheel, It may be implemented to be a gear grinding wheel, a plunge grinding wheel, an edge grinding wheel, a finish grinding wheel, an ultra-finish grinding wheel, or a polishing grinding wheel.

The system can be implemented such that a portion of the wheel width comprises an abrasive particle-free area.

The system can be implemented such that the abrasive particle-free region includes a threaded portion, groove, or opening that receives a corresponding threaded portion or protrusion of the mating feature.

The system can be implemented such that the reusable hub provides a substantially flat grinding surface when coupled to an abrasive wheel.

The system can be implemented such that the reusable hub is spaced from the substrate when the substantially flat grinding surface is in contact with the substrate.

The system can be implemented such that the abrasive wheel is substantially planar along the width of the wheel.

A reusable hub for an abrasive article is presented comprising an abrasive connection mechanism for removably coupling to the abrasive article. The bond between the reusable hub and the abrasive article is a mechanical connection. The reusable hub also includes a connection mechanism for removably coupling the reusable hub to the tool driveshaft. The reusable hub has a thickness along the connection mechanism sized to receive the abrasive article, allowing the reusable hub to engage along an inner edge of the abrasive article.

The reusable hub can be implemented such that the reusable hub has a lip configured to extend over the surface of one side of the abrasive article, such that it covers 10% or less of the area of the abrasive article.

The reusable hub may be implemented such that the reusable hub includes metal, plastic or reinforced composites.

The reusable hub may be implemented such that the reusable hub couples via an abrasive connection mechanism to a mounting ring that couples to an abrasive article.

The reusable hub may be implemented such that the engagement between the reusable hub and the mounting ring includes screwing, grooves, clamping, clipping or friction.

The reusable hub may be implemented such that the engagement between the reusable hub and the abrasive article is toolless.

The reusable hub may be implemented such that the abrasive connection mechanism is integral with the abrasive article.

The reusable hub may be implemented such that the abrasive connection mechanism includes a threaded portion, groove or opening.

A reusable hub may be implemented so that it includes a first part and a second part. The first and second portions are configured to removably engage each other around the abrasive article.

The reusable hub may be implemented such that the vibration damping mechanism is a material construction of the reusable hub. The material is metal, plastic or reinforced composite.

The reusable hub may be implemented such that the vibration damping mechanism is a material inside the reusable hub. This material is different from the hub housing material.

A method of exchanging an abrasive article for a reusable hub is presented that includes disengaging a first abrasive article from the reusable hub and coupling a second abrasive article to the reusable hub. Reusable hubs engage and disengage using mechanical features of the hub. The method also includes contacting a second abrasive article to the work surface.

The method may be implemented such that the mechanical feature includes a threaded portion, groove, clipping, clamping, or protrusion.

The method may be implemented such that the mechanical feature directly bonds to a corresponding feature integral with the second abrasive article.

The method may be implemented such that the mechanical feature directly engages a mating ring that engages an abrasive article.

The method can be implemented such that contacting the second abrasive article to the work surface further comprises providing vibration damping.

The method may be implemented such that the vibration damping is provided by the material of the reusable hub, and the reusable hub includes metal, plastic, or reinforced composites.

The method may be implemented such that vibration damping is provided by flexible features.

The method may be implemented so that it also includes disengaging the second abrasive article from the reusable hub, and coupling the third abrasive article to the reusable hub. Reusable hubs engage and disengage using mechanical features. The method may also include contacting a third abrasive article to the work surface and providing vibration damping.

The method may be implemented such that vibration damping is provided by a material inside the hub housing.

The method may be implemented such that the material is different from the hub housing.

The method may be implemented so that it further comprises the step of positionally locking the reusable hub in place relative to the second abrasive article.

The method may be implemented so that it also includes releasing a position lock between the reusable hub and the first abrasive article.

Example

Example 1:

A center recessed grinding wheel (DCGW) was assembled with the components illustrated in FIG. 2 . A reusable hub was machined from tool steel with an inside diameter of 0.875 inches and an outside diameter of about 2.5 inches, with a depression angle of approximately 25 degrees. The hub was threaded according to the ANSI standard 2.5"-20-UN threading. A separate mating ring was machined from aluminum using an internal threading of 2.5"-20-UN. A mating ring, a typical resin-bonded abrasive mixture (phenolic resin, abrasive grains and grinding aids), and three layers of glass fiber scrim are loaded into a mold and pressed into a flat grinding element at 50 tons of pressure for 5 seconds. did The glass fiber scrim was a typical scrim for the center recessed grinding wheel, except that the inside and outside diameters were cut to 2.5 inches and 4.5 inches, respectively. The pressed configuration was cured at a maximum temperature of 190°C. After curing, the grinding component could be screwed onto the reusable hub to assemble the center recessed grinding wheel.

The thickness of the reusable hub as well as the abrasive layer was approximately 0.25 inches. The outer diameter of the grinding wheel was 4.5 inches. The relative volumes of the abrasive layer and reusable hub were calculated using Autodesk Inventor software and tabulated in Table I below. A reusable hub corresponds to a portion of a wheel that is often discarded. Thus, as a result of this design, approximately 30% of raw materials and waste were avoided.

[Table I]

Example 2:

A DCGW was produced with the same design as described in Example 1, except that the material used was an epoxy resin. A reusable hub and mating ring were 3D-printed using stereolithography (SLA), where the resin was a UV-cured epoxy.

Example 3:

A DCGW having the structure shown in FIG. 4 was formed by a process similar to that described in Example 3. Example 3 consisted of a two-part reusable hub, where the top component could be screwed onto the spindle. The second hub component includes a structure for screwing onto the spindle as well as a structure for attaching without threading to the mating ring so that the mating components can be moved in axial and radial motions of the hub, mating ring and grinding layer. You would have combined relative motion. Additionally, a rubber damping element was incorporated into the top hub component in the form of an AS568-038 silicone rubber o-ring with a nominal diameter of 2.625 inches.

Comparative Example 1:

Commercially available DCGW was purchased from Grainger as manufacturer's model number 87453 (3M Co.). The nominal thickness (0.25 inch), inner diameter (0.875 inch) and outer diameter (4.5 inch) were the same as in Example 1.

Comparative Example 2:

A DCGW with the same nominal geometry as Comparative Example 1 was formed in the laboratory. The abrasive mixture (abrasive particles, phenolic resin and grinding aid) was the same as described in Example 1. A flat wheel was fabricated by loading the abrasive mixture and three glass fiber scrims into a mold having an outer diameter of 4.5 inches and pressing with a pressure of 50 tons. The wheel was then further shaped to add a depressed center by pressing between two plates having a "T27" shape at 5 tons of pressure. The pressed wheel was then cured at a maximum temperature of 190°C.

test

Safety Test: Burst rate and side load tests were performed on select samples (see Table II) using equipment from Davide Maternini S.p.a. (Italy). Burst tests were performed using a model MDM PVM 030/040 instrument. The rotational speed at burst was measured using a photodetector to record the speed at which the sample failed and no longer blocked the light source from the detector, in terms of RPM and linear tangential velocity (m/s).

The side load test was performed in a pass/fail mode using a model MDM PVM UNI EN 12413-2011 side load tester from Davide Maternini, S.p.a., Italy. Side loading was tested with a single-point loading at a force of 290 N. A pass/fail value was indicated by whether or not the sample failed/damaged after the load was applied. The results are illustrated in Table II below.

[Table II]

Vibration Analysis: Tool vibration was measured for selected examples using a Larson Davis Model SEN041F accelerometer and a Larson Davis Model HVM200 vibrometer. Average acceleration was used as a proxy for tool vibration. The accelerometer was glued to an angle grinder (Bosch model 1375A) near the mounting of the grinding wheel. Accelerations were averaged over 30 seconds for a free-spinning DCGW. Average acceleration values for select embodiments are listed in Table III. Wheel imbalance measurements are also listed in Table III. Wheel imbalance was measured by placing the wheel on a freely rotating spindle and causing the heaviest part to rotate downward due to gravity. A weight was then added to the top end of the wheel until gravity no longer had the preferred orientation of the sample on the freely rotating spindle.

[Table III]

Claims (47)

A method of reusing a hub in an abrasive assembly comprising:
removably coupling an abrasive wheel to a reusable hub, the abrasive wheel having an outer circumference and an inner circumference, and the abrasive article having an inner circumference and an outer circumference; and
abrading the work surface by contacting the abrasive wheel to the work surface;
The reusable hub,
an engagement feature configured to directly engage the abrasive article;
wherein the engagement feature comprises an adhesive-free connection between the reusable hub and the abrasive wheel, wherein the direct connection is a removable interlocking between the abrasive wheel and the reusable hub. The method of claim 1 wherein the direct connection is a toolless connection. 3. The method of claim 1 or 2, wherein the direct connection comprises the reusable hub interacting with a receiving feature on the inner circumference of the abrasive wheel. 4. The method of claim 3, wherein the receiving features are screw joints, grooves, magnets, or receiving apertures. 5. The method of any preceding claim, wherein the direct connection comprises engaging the reusable hub to a mating feature that directly engages the abrasive article. 6. The method of claim 5, wherein the mating feature comprises a mating ring coupled to the abrasive article. 7. The method of any one of claims 1 to 6, wherein the reusable hub, when coupled to the abrasive wheel, extends partway through the thickness of the abrasive article from the mating surface. 8. The method of any one of claims 1-7, wherein the reusable hub includes a damping feature. 9. The method of claim 8, wherein the damping feature is an impregnated material, a coextruded material, a layer within the reusable hub, or a printed structure within the reusable hub. 10. The method of any preceding claim, wherein the reusable hub further comprises a position locking mechanism. 11. The method of any one of claims 1 to 10, wherein coupling comprises coupling the reusable hub to a mating ring that directly engages the abrasive wheel. 12. The method of any one of claims 1 to 11, wherein the reusable hub includes a first portion and a second portion, wherein the engagement is such that the abrasive wheel is between the first portion and the second portion. bonding one part to the second part. 13. The method of any one of claims 8-12, wherein the damping feature comprises a flexible feature. As a polishing system,
An abrasive wheel comprising abrasive particles in a binder matrix, the abrasive wheel comprising
outer circumference;
inner circumference; and
including a wheel width extending from the outer circumference to the inner circumference; and
A system comprising a reusable hub comprising a mating feature, the mating feature removably coupling the reusable hub to the abrasive wheel. 15. The system of claim 14, wherein the mating feature is integral with the abrasive wheel. 16. The system of claim 15, wherein the mating feature is molded or machined into the abrasive wheel. 17. The system of any of claims 14-16, wherein the mating feature is integral with the reusable hub. 18. The system of any of claims 14-17, wherein the mating feature comprises a mating ring that mechanically couples to the reusable hub on a first side and to the abrasive wheel on a second surface. 19. The system of any one of claims 14 to 18, wherein the mating feature engages the reusable hub using screwing, clamping, clipping, grooves or friction. 20. The system of any one of claims 14-19, wherein the reusable hub includes a housing and an interior, the interior including a damping feature. 21. The system of any one of claims 14-20, further comprising a locking mechanism to secure the relative position of the reusable hub to the abrasive wheel. 22. The system of claim 21, wherein the locking mechanism includes protrusions extending from the reusable hub. 23. The system of claim 22, wherein the protrusions are received by corresponding recesses in the mating feature. 24. The system of claim 23, wherein the mating feature is a mating ring. 25. The method of any one of claims 14 to 24, wherein a portion of the wheel width comprises an abrasive particle-free region, the abrasive particle-free region forming a corresponding screw joint or protrusion of the mating feature. A system comprising receiving screw joints, grooves or openings. As a reusable hub for abrasive articles,
an abrasive connection mechanism for removably coupling to an abrasive article, wherein the coupling between the reusable hub and the abrasive article is a mechanical connection; and
a connection mechanism for removably coupling the reusable hub to a tool driveshaft;
wherein the reusable hub has a thickness along the connection mechanism sized to receive the abrasive article, such that the reusable hub engages along an inner edge of the abrasive article. 27. The reusable hub of claim 26, wherein the reusable hub has a lip configured to extend over a surface of one side of the abrasive article such that it covers 10% or less of an area of the abrasive article. 28. The reusable hub of claim 26 or 27, wherein the reusable hub engages via the abrasive connection mechanism to a mounting ring that engages the abrasive article. 29. The reusable hub of any one of claims 26 to 28, wherein the coupling between the reusable hub and the abrasive article is a toolless coupling. 30. The reusable hub of any one of claims 26 to 29, wherein the abrasive connection mechanism is integral with the abrasive article. 31. The reusable hub of claim 30, wherein the abrasive connection mechanism comprises threaded portions, grooves or openings. A method of exchanging an abrasive article for a reusable hub, comprising:
disengaging the first abrasive article from the reusable hub;
coupling a second abrasive article to the reusable hub, the reusable hub engaging and disengaging using mechanical features of the hub; and
contacting the second abrasive article to a work surface. 33. The method of claim 32, wherein contacting the second abrasive article to the work surface further comprises providing vibration damping. The method of claim 32 or 33,
disengaging the second abrasive article from the reusable hub;
coupling a third abrasive article to the reusable hub, the reusable hub engaging and disengaging using the mechanical feature; and
and contacting the third abrasive article to the work surface and providing vibration damping. The method of any one of claims 32 to 34,
and positionally locking the reusable hub in place relative to the second abrasive article. The method of any one of claims 32 to 35,
further comprising releasing a position lock between the reusable hub and the first abrasive article. 9. The method of claim 8, wherein the damping feature is located between a first component of the reusable hub and a second component of the reusable hub, the first and second components comprising the abrasive wheel in the first component. coupled to be between the component and the second component. 38. The method of claim 37, wherein the damping feature is a compressible material bonded to the first or second component. 20. The polishing system of claim 19, wherein the mating feature is a mating surface bonded to the first or second component. 32. The reusable hub of claim 31 further comprising a polymeric element between the first component and the second component. 41. The reusable hub of claim 40, wherein the polymeric element is bonded to the first or second component. 41. The reusable hub of claim 40, wherein the polymeric element provides vibration damping. 41. The reusable hub of claim 40, wherein the polymeric material has a loss factor greater than 10 times that of aluminum. 33. The method of claim 32, wherein disengaging comprises removing the first component from a spindle of the tool and removing the first abrasive article from the spindle, and engaging the second abrasive article from the spindle. and mounting the first component to the spindle. 45. The method of claim 44, wherein the first or second component comprises a damping component. 46. The method of claim 45, wherein the damping component is external to the first or second component. 47. The method of claim 46, wherein the damping component comprises a layer of damping material bonded to the first or second component.

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