WO2022023848A1 - Procédé d'abrasion d'une pièce à travailler - Google Patents
Procédé d'abrasion d'une pièce à travailler Download PDFInfo
- Publication number
- WO2022023848A1 WO2022023848A1 PCT/IB2021/056159 IB2021056159W WO2022023848A1 WO 2022023848 A1 WO2022023848 A1 WO 2022023848A1 IB 2021056159 W IB2021056159 W IB 2021056159W WO 2022023848 A1 WO2022023848 A1 WO 2022023848A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- bodies
- loose
- workpiece
- vessel
- abrasive bodies
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B31/00—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor
- B24B31/10—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor involving other means for tumbling of work
- B24B31/116—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor involving other means for tumbling of work using plastically deformable grinding compound, moved relatively to the workpiece under the influence of pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B31/00—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor
- B24B31/06—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor involving oscillating or vibrating containers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B31/00—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor
- B24B31/12—Accessories; Protective equipment or safety devices; Installations for exhaustion of dust or for sound absorption specially adapted for machines covered by group B24B31/00
- B24B31/14—Abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls
Definitions
- the present disclosure broadly relates to abrasives and methods of abrading.
- Additive manufacturing of metals, polymers, composites and ceramics for both prototyping and manufacturing has increased in importance in recent years.
- Additive manufacturing methods such as, for example, Direct Metal Laser Sintering (DMLS) often produce parts with unacceptable surface roughness for the parts’ intended function.
- DMLS Direct Metal Laser Sintering
- Most users require post-processing techniques to reduce the roughness of the surface of the part before use. Examples of such post-processing steps include vibratory finishing and abrasive flow machining. In vibratory finishing, abrasive media are agitated and abrade the surface of a workpiece to smooth its surface.
- the present inventor discovered that under certain conditions, adding resilient foam bodies to abrasive particles can substantially increase their efficiency. Moreover, in many cases, the resilient foam bodies, which can originate as manufacturing scrap, can be used with multiple batches of loose abrasive bodies recycled when the abrasive particles wear down.
- the present disclosure provides a method of abrading a surface of a workpiece, the method comprising: providing a vessel containing: loose abrasive bodies, wherein at least most of the loose abrasive bodies have a maximum dimension of 3 centimeters; loose resilient foam bodies wherein at least most of the loose resilient foam bodies have a maximum dimension of 0.1 to 3 centimeters; and at least a portion of the workpiece; and agitating the vessel with sufficient energy such that at least some of the loose abrasive bodies contact and abrade at least a portion of the surface of the workpiece.
- vessel refers to a hollow or concave container used for holding liquids or other contents.
- the method comprises the steps of providing a vessel containing loose abrasive bodies, loose resilient foam bodies, and at least a portion of the workpiece, and then agitating the vessel with sufficient energy such that at least some of the loose abrasive bodies contact and abrade at least a portion of the surface of the workpiece.
- a vibratory system that includes a vessel having an interior processing chamber.
- the vessel can be reclosable and/or have at least one opening through which a portion of a workpiece may extend into the interior processing chamber.
- the system may further include an actuator (e.g., a mechanical actuator) capable of vibrating the sealed vessel.
- an actuator e.g., a mechanical actuator
- a control module controls the actuator such that the sealed vessel vibrates under resonant or near-resonant conditions (e.g., resonant acoustic conditions) throughout the surface modification process.
- resonant or near-resonant conditions e.g., resonant acoustic conditions
- RAM5, and RAM 55 These devices typically operate at resonant vibrational frequencies of from 20 to up to ⁇ 1 kHz, preferably 40 to 100 hertz, more preferably 40 to 80 hertz, and more preferably 55-65 hertz, although this is not a requirement.
- the vessel may be capable of retaining any volume of material, and may be partially or completely filled with loose abrasive bodies and loose resilient foam bodies. In either case, there should be sufficient mobility of the loose abrasive bodies and the and loose resilient foam bodies and/or the workpiece so that there is relative motion between the bodies and workpiece during agitation.
- the loose abrasive bodies and loose resilient foam bodies collectively fill at least 10 volume percent, at least 20 volume percent, at least 30 volume percent, at least 40 volume percent, or even at least 50 volume percent of the maximum retaining capacity (i.e., excluding overflow) of the vessel.
- the loose abrasive bodies and the loose resilient foam bodies may collectively fill less than 90 volume percent, less than 80 volume percent, or less than 70 volume percent of the maximum retaining capacity of the vessel. Lesser and greater amounts of the loose abrasive bodies may also be used. Typically, the greater the mass of each loose abrasive body, the less important the percentage fill of the vessel, although this is not a requirement.
- the loose abrasive bodies may collectively constitute up to 20, 30, 40, 50, 60,
- the vessel may further contain additional items, if desired. In other embodiments, the vessel may be free of such additional items.
- Any suitable means to agitate the vessel and hence also the loose abrasive bodies and loose resilient foam bodies may be used, including, for example, shaking, vibrating, and/or tumbling.
- Motion of the vessel may comprise linear, arcuate, elliptical, or random oscillations, for example. In some preferred embodiments, the motion comprises linear reciprocating motion.
- the process of abrading the workpiece may be batch-wise or continuous.
- the loose abrasive bodies, the loose resilient foam bodies, and the workpiece(s) are disposed within the vessel.
- the workpiece(s) may be loose within the vessel or fixed in a given position relative to the vessel (e.g., mounted to a wall of the vessel or extending into the interior processing chamber).
- the latter configurations may be desirable in instances where selective modification of a portion of the workpiece surface is desired.
- the latter configuration may also be desirable if the workpiece has a large mass and/or is delicate, so that collisions between the workpiece and the vessel walls are prevented.
- the loose abrasive bodies may be smooth or rough, regular in shape or irregularly shaped so that sharp-edged particles can cut away brittle surface deposits; however, this is not a requirement.
- the loose abrasive bodies may be spherical.
- Loose abrasive bodies useful for the methods of the present disclosure may include any abrasive bodies that are useful for abrasive blasting (commonly termed "sandblasting") or vibratory tumbling. There are several variants of the process using various media. Some are highly abrasive, whereas others are milder.
- the abrasive bodies may comprise crashed abrasive bodies and/or shaped abrasive bodies.
- the abrasive bodies can comprise a ceramic abrasive material.
- Useful abrasive materials include, for example, fused aluminum oxide, heat treated aluminum oxide, white fused aluminum oxide, ceramic aluminum oxide materials such as those commercially available as 3M CERAMIC ABRASIVE GRAIN from 3M Company of St.
- sol-gel derived ceramics e.g., alumina ceramics doped with chromia, ceria, zirconia, titania, silica, and/or tin oxide
- silica e.g., quartz, glass beads, glass bubbles and glass fibers
- feldspar or flint.
- sol-gel derived crashed ceramic particles can be found in U.S. Pat. Nos.
- the abrasive bodies may be shaped (e.g., precisely-shaped) or random (e.g., crashed and/or platey). Shaped abrasive bodies and precisely-shaped abrasive bodies may be prepared by a molding process using sol-gel technology as described, for example, in U.S. Pat. Nos. 5,201,916 (Berg), 5,366,523 (Rowenhorst (Re 35,570)), 5,984,988 (Berg), 8,142,531 (Adefris et al.), and U.S. Patent No. 8,764,865 (Boden et al.).
- Exemplary shapes of abrasive bodies include crushed, pyramids (e.g., 3-, 4-, 5-, or 6-sided pyramids), truncated pyramids (e.g., 3-, 4-, 5-, or 6-sided truncated pyramids), cones, truncated cones, rods (e.g., cylindrical, vermiform), spheres, and prisms (e.g., 3-, 4-, 5-, or 6-sided prisms).
- the ceramic particles respectively comprise platelets having two opposed major facets connected to each other by a plurality of side facets.
- the ceramic particles preferably comprise crushed abrasive particles having an aspect ratio of at least 1.73, at least 2, at least 3, at least 5, or even at least 10.
- ceramic particles used in practice of the present disclosure have a core hardness of at least 6, at least 7, at least 8, or at least 15 GPa.
- the abrasive bodies range in diameter from 0.01 millimeter (mm) to as large as 3 cm, preferably from 0.05 mm to 1 cm, more preferably 0.05 to 500 mm; however, this is not a requirement.
- the abrasive bodies e.g., abrasive particles
- the abrasive bodies may be sized according to an abrasives industry specified nominal grade.
- Abrasive particles graded according to abrasive industry accepted grading standards specify the particle size distribution for each nominal grade within numerical limits.
- Such industry accepted grading standards i.e., abrasives industry specified nominal grade
- ANSI American National Standards Institute, Inc.
- FEPA Federation of European Producers of Abrasive Products
- JIS Japanese Industrial Standard
- ANSI grade designations may include: ANSI 4, ANSI 6, ANSI 8, ANSI 16, ANSI 24, ANSI 36, ANSI 40, ANSI 50, ANSI 60, ANSI 80, ANSI 100, ANSI 120, ANSI 150, ANSI 180, ANSI 220, ANSI 240, ANSI 280, ANSI 320, ANSI 360, ANSI 400, and ANSI 600.
- FEPA grade designations include P8, P12, P16, P24, P36, P40, P50, P60, P80, P100, P120, P150, P180, P220, P320, P400, P500, P600, P800, P1000, and P1200.
- JIS grade designations include JIS8, JIS12, JIS16, JIS24, JIS36, JIS 46, JIS 54, JIS 60, JIS 80, JIS 100, JIS 150, JIS 180, JIS 220, JIS 240, JIS 280, JIS 320, JIS 360, JIS 400, JIS 600, JIS 800, JIS 1000, JIS 1500, JIS 2500, JIS 4000, JIS 6000, JIS8000, JIS 10000, JIS 20000, and JIS 30000.
- abrasive bodies can be graded to a nominal screened grade using U.S. A. Standard Test Sieves conforming to ASTM E-l 1 "Standard Specification for Wire Cloth and Sieves for Testing Purposes."
- ASTM E-l 1 proscribes the requirements for the design and construction of testing sieves using a medium of woven wire cloth mounted in a frame for the classification of materials according to a designated particle size.
- a typical designation may be represented as -18+20 meaning that the abrasive particles through a test sieve meeting ASTM E-l 1 specifications for the number 18 sieve and are retained on a test sieve meeting ASTM E-l 1 specifications for the number 20 sieve.
- the abrasive bodies have a particle size such that most of the particles pass through an 18 mesh test sieve and can be retained on a 20, 25, 30, 35, 40, 45, or 50 mesh test sieve.
- the abrasive bodies can have a nominal screened grade comprising: -18+20, -20+25, -25+30, -30+35, -35+40, -40+45, -45+50, -50+60, -60+70, -70+80, -80+100, -100+120, -120+140, -140+170, -170+200, -200+230, -230+270, -270+325, -325+400, -400+450, -450+500, or -500+635.
- the loose abrasive bodies may be desirable to provide the loose abrasive bodies according to a predetermined specific size distribution (e.g., monomodal or polymodal) and/or compositional specifications. It may also be desirable to provide the loose abrasive bodies as random shapes or specified shapes.
- a predetermined specific size distribution e.g., monomodal or polymodal
- compositional specifications e.g., compositional specifications
- the vessel may contain a fluid such as, for example, water.
- the fluid may contain optional additives such as, for example, surfactant, defoamer, or in the case of abrasive bodies an etchant (e.g., an alkali metal hydroxide).
- the loose resilient foam bodies may have any shape and size which may be the same as, or different from, one another. For example, they may be randomly shaped, shaped as prisms (e.g., square prisms, rectangular prisms, trigonal prisms, hexagonal prisms). In some embodiments, the loose resilient foam bodies have a maximum dimension of 0.25 to 3 centimeters (cm) preferably 0.5 to 1.5 cm; although this is not a requirement.
- cm centimeters
- the resilient foam may have lesser or greater resilience.
- Exemplary types of foams include silicone foams, polyurethane foams, and latex foams.
- Useful foams may have open or closed cell structure. Resilient foams are widely available from commercial sources. It is also possible to use recycled and/or scrap foam in the method of the present disclosure.
- Mixtures of two or more types, compositions, shapes, and/or sizes of the loose abrasive bodies and/or the loose resilient foam bodies may be used.
- the workpiece may be any object, typically fabricated, where abrading of the workpiece surface is desired. Examples include camshafts, crankshafts, and turbine blades. Exemplary workpieces include metal components (e.g., which may be sintered metal parts manufactured by rapid prototyping/3 -D printing). Examples of workpiece materials include metal and metal alloys (e.g., aluminum and mild steel), exotic metal alloys, ceramics, glass, wood, wood-like materials, composites, painted surfaces, plastics, reinforced plastics, stone, and/or combinations thereof. The workpiece may be flat or have a shape or contour associated with it.
- a LabRAM Resonant Acoustic mixer from Resodyn Corporation, Butte, Montana was used.
- the machine which was equipped with a sealed mixing vessel, was ran at 100% intensity in the auto frequency mode for 15 mins (2 x 7.5 min segments).
- the mass of the workpiece was measured before processing.
- the workpiece was placed in a polypropylene container with 55 mm internal height and 80 mm internal diameter along with the loose abrasive grains and foam pieces (if present), and the container was sealed with a lid.
- Alumina regular tetrahedrons (100 grams, 0.20 millimeters edge length, prepared as described in U.S. Pat. Appl. Publ. No. 2020/0199425 A1 (Rodriguez et al.), paragraph [0110]) were placed in the mixing vessel with a machined aluminum alloy (Grade BS EN 755 6082-T6) 16 mm x 3 mm x 50 mm workpiece. After running the LabRAM acoustic mixer for 7.5 minutes, a mass loss of 0.001 grams from the workpiece was observed, which increased to 0.002 grams after an additional 7.5 minutes (15 minutes total).
- Comparative Example A The procedure of Comparative Example A was repeated, except that 5 grams of polyurethane foam corresponding to the foam backing found in 3M Flexible Foam Abrasive Discs marketed by 3M Company, cut into 50 mm x 1 cm x 1 cm pieces, was also added to the mixing vessel with the workpiece and abrasive particles. After running the LabRam acoustic mixer for 7.5 minutes, a mass loss of 0.012 g from the workpiece was observed, which increased to 0.018 grams after and additional 7.5 minutes (15 minutes total). It can be seen that an increase in mass loss of more than 8 times resulted from addition of minor amounts of foam to the mixing vessel.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
Abstract
L'invention concerne un procédé d'abrasion d'une surface d'une pièce à travailler qui comprend la mise à disposition d'un récipient contenant des corps abrasifs en vrac, des corps en mousse élastique en vrac, et au moins une partie de la pièce à travailler. Au moins la plupart des corps abrasifs en vrac ont une dimension maximale de 3 centimètres. Au moins la plupart des corps abrasifs en vrac ont une dimension maximale de 0,1 à 3 centimètres. Le récipient est ensuite agité avec une énergie suffisante de telle sorte qu'au moins certains des corps abrasifs en vrac entrent en contact et usent par frottement au moins une partie de la surface de la pièce à travailler.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US202063058818P | 2020-07-30 | 2020-07-30 | |
US63/058,818 | 2020-07-30 |
Publications (1)
Publication Number | Publication Date |
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WO2022023848A1 true WO2022023848A1 (fr) | 2022-02-03 |
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ID=76921056
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Application Number | Title | Priority Date | Filing Date |
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PCT/IB2021/056159 WO2022023848A1 (fr) | 2020-07-30 | 2021-07-08 | Procédé d'abrasion d'une pièce à travailler |
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Citations (29)
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US20200199425A1 (en) | 2017-05-12 | 2020-06-25 | 3M Innovative Properties Company | Tetrahedral abrasive particles in abrasive articles |
US20200391339A1 (en) * | 2019-06-15 | 2020-12-17 | Idea Vault Holdings Inc. | Rock tumbling method and apparatus |
-
2021
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US8764865B2 (en) | 2008-12-17 | 2014-07-01 | 3M Innovative Properties Company | Shaped abrasive particles with grooves |
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US20130125477A1 (en) | 2010-08-04 | 2013-05-23 | 3M Innovative Properties Company | Intersecting plate shaped abrasive particles |
US9808778B2 (en) | 2012-05-31 | 2017-11-07 | Resodyn Corporation | Mechanical system that continuously processes a combination of materials |
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US20200391339A1 (en) * | 2019-06-15 | 2020-12-17 | Idea Vault Holdings Inc. | Rock tumbling method and apparatus |
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