FIELD OF DISCLOSURE
The present disclosure relates to diamond based machine tools.
More particularly, the present disclosure relates to diamond disk dressers for
dressing grinding wheels.
BACKGROUND
Diamond is the hardest known natural material. Industrial use of diamonds has
typically been associated with their hardness as this property makes diamonds an
ideal material for cutting and grinding tools. As the hardest known naturally
occurring material, diamond can be used to polish, cut, or wear away any material,
including other diamonds. Common industrial adaptations of this ability include
diamond-tipped drill bits and saws, and use of diamond powder as an abrasive.
Due to its hardness, diamond can be used to make various tools such as saw
blades, core drill bits, cup wheels, polishing pads, dressers, bore machines and
the like, to cut, grind or polish, hard or abrasive materials, such as stone, concrete,
asphalt, ceramics, bricks, carbide alloy and the like .
Grinding machines are typically used for fine boring of holes, abrasive machining,
surface grinding and the like. Grinding machines typically have a hard rotating
disk referred to as a grinding wheel fitted on the machines. Grinding machines are
used more widely in machine and instrument manufacturing. Grinding machines
use grinding wheels to cut, grind or polish, hard or abrasive materials.
However, the grinding wheel undergoes wear and tear after prolonged use. In order
to be used again, typically the grinding wheel is re-sharpened by means of a
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dresser. A dresser is a tool to dress the surface of the grinding wheel. Dressers are
also used for making different profiles on grinding wheels. The dresser re-sharpens
the grinding wheel in order to return the wheel to its original shape. Various types
of dressers are used for dressing grinding wheels such as diamond dressers, star
dressers, dressing sticks and the like. Diamond dressers have diamonds affixed on
the dressers for effectively sharpening the grinding wheel. Different types of
diamond dressers include rotary dressers generally referred to as diamond disk
dressers, stationary dressers, diamond crush rolls, and the like.
There are many methods employed to affix diamonds onto the diamond disk
dressers. Typically, diamond is brazed on the disk. However, a major drawback of
diamond disk dressers with brazed diamonds is that whenever any diamond
particle gets damaged during operation or due to any other reason, the entire disk
has to be replaced. The replacement procedure is expensive and time consuming
especially if the disk gets damaged while being used on site. Another drawback is
that diamond disk dressers with improperly brazed diamonds can have very low
strength to endure stress while sharpening grinding wheels composed of hard
abrasive materials. As a result these diamond disks are less durable, they wear out
fast and are not cost effective.
Hence there is a need for an alternative method to affix diamonds on the disk
dressers which can also provide means to replace diamonds on site when the disk
is damaged. There is also a need for a diamond disk dresser with high strength to
endure stress while being used for sharpening or polishing grinding wheels made
from hard or abrasive materials besides being cost effective.
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OBJECTS
Some of the objects of the present disclosure aimed to ameliorate one or more
problems of the prior art or to at least provide a useful alternative are listed herein
below.
An object of the present disclosure is to provide a diamond disk dresser with high
strength for dressing grinding wheels.
Another object of the present disclosure is to provide a diamond disk dresser
which is highly durable and does not wear out easily.
Still another object of the present disclosure is to provide a diamond disk dresser
on which diamonds can be replaced on site.
Yet another object of the present disclosure is to provide a diamond disk dresser
which is cost effective.
One more object of the present disclosure is to provide an alternative to brazing
diamonds on a disk dresser.
Other objects and advantages of the present disclosure will be more apparent from
the following description when read in conjunction with the accompanying figures,
which are not intended to limit the scope of the present disclosure.
SUMMARY
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In accordance with the present disclosure, a multi-bit diamond disk dresser
comprising: a plurality of through holes defined concentrically along a Pitch Circle
Diameter (PCD) of the disk; a bit removably fastened within each of the through
holes, each of the bit having an operative top end with at least one diamond affixed
thereon along a plane defining a dressing plane; and a plurality of bores defined
perpendicular to the plurality of through holes and disposed along the periphery of
the disk, each of the bores adapted to receive a screw therein for fastening the bit
within the through hole.
Additionally, the disk further comprises at least five concentric circular regions
defined thereon, the circular regions including: a first circular region defining a
central through hole adapted to receive a shaft therethrough; a second circular
region radially spaced apart from the first circular region and defining a counter
bore to the first circular region; a third circular region having a pre-determined
depth adapted to receive a nut therein for firmly clamping the disk on the shaft; a
fourth circular region containing the plurality of through holes; and a fifth circular
region having a pre-determined thickness, the fifth circular region adapted to
contain the plurality of bores.
Additionally, the disk further comprises a segment defined at the base of the disk
for mounting the disk on a shaft.
Typically, each of the plurality of through holes is associated with a corresponding
counter bore.
Typically, each of the plurality of through holes is tapped.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
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The dresser of the present disclosure will now be described with the help of the
accompanying drawings, in which:
Figure 1a illustrates a schematic representation of a multi-bit diamond disk dresser
in accordance with the present disclosure;
Figure 1 b illustrates a schematic representation of a sectional side view of the disk
dresser of Figure 1a in accordance with the present disclosure;
Figure 1 c illustrates a schematic representation of a cross-sectional view of the
disk dresser of Figure 1 a with diamonds affixed on the disk, in accordance with the
present disclosure;
Figure 2 illustrates a schematic representation of a completely assembled multi-bit
diamond disk dresser in accordance with an embodiment the present disclosure;
and
Figure 3 illustrates a schematic representation of a diamond bit being replaced in a
diamond disk dresser of the present disclosure.
DETAILED DESCRIPTION
Grinding machines are typically used for fine boring of holes, abrasive machining,
surface grinding and the like. Grinding machines are used more widely in machine
and instrument manufacturing. Grinding machines typically have a hard rotating
disk referred to as a grinding wheel fitted on the machines. Grinding machines use
grinding wheels to cut, grind or polish, hard or abrasive materials. A grinding
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wheel is an expendable wheel that is composed of an abrasive compound used for
various grinding, abrasive cutting and abrasive machining operations. Grinding
wheels are used to smoothen flat surfaces of metallic/non-metallic materials to give
them a more refined look or to attain a desired surface for a functional purpose.
The grinding wheel covered in rough particles cuts chips of metallic/non-metallic
substance from a workpiece, making the desired faces flat or smooth. Bore of
metallic/non-metallic components is ground typically with the help of a Cubic
Boron Nitride (CBN) grinding wheel.
However, the grinding wheel undergoes wear and tear after prolonged use.
Eventually the grinding wheel gets blunt after grinding a certain quantity of
components. In order to be used again, the grinding wheel is typically re-sharpened
by means of a dresser. Dressers are also used for making different profiles on
grinding wheels. The dresser re-sharpens the grinding wheel in order to return the
wheel to its original shape.
Diamond disk dressers known in the art, for sharpening grinding wheels
implements diamonds brazed on the disk. A major drawback of conventional
diamond disk dressers is that whenever any diamond particle gets damaged during
operation or worn out after prolonged use, the entire disk has to be replaced. The
replacement procedure is expensive and time consuming especially if the disk gets
damaged while being used on site. Life of a dresser is calculated in terms of
number of components ground on the machine. Typically conventional dressers get
worn out after re-sharpening of about 8000 CBN grinding wheels or after
approximately grinding 200,000 components.
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Thus to overcome these aforementioned limitations, the present disclosure
envisages a multi-bit diamond disk dresser with a convenient method to affix and
replace diamonds on the disk.
The diamond disk dresser of the present disclosure will now be described with
reference to the embodiments shown in the accompanying drawings. The
embodiments do not limit the scope and ambit of the disclosure. The description
relates purely to the examples and preferred embodiments of the disclosed tool and
its suggested applications.
The dresser herein and the various features and advantageous details thereof are
explained with reference to the non-limiting embodiments in the following
description. Descriptions of well-known components and processing techniques are
omitted so as to not unnecessarily obscure the embodiments herein. The examples
used herein are intended merely to facilitate an understanding of ways in which the
embodiments herein may be practiced and to further enable those of skill in the art
to practice the embodiments herein. Accordingly, the examples should not be
construed as limiting the scope of the embodiments herein.
Referring to figure 1 a, a schematic representation of a diamond disk dresser in
accordance with the present disclosure is illustrated. The disk dresser comprises
circular regions radially located from the centre of the disk. In accordance with one
embodiment, the disk comprises five concentric circular regions (101, 102, 103,
104, 1 05) radially located around the centre of the disk. The fourth circular region
( 104) around the center of the disk comprises a plurality of through holes (1 06).
Each through hole (106) is associated with a counter bore (107). The through holes
(106) with counter bores (107) are positioned on the disk, in an orientation along a
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pitch circle diameter (PCD) in the fourth circular region (104). In accordance with
one embodiment, the fourth circular region ( 1 04) from the center of the disk
comprises twenty tapped through holes ( 1 06). The fifth circular region comprises a
plurality of bores (108) with each bore (108) perpendicularly oriented with
reference to each through hole (106).
Referring to figure 1 b, a schematic representation of a sectional side view of the
disk of figure 1 a is illustrated. In accordance with the foregoing description, the
disk comprises five concentric circular regions (101, 102, 103, 104, 105) radially
located around the centre of the disk. The first circular region ( 1 0 1) is a through
hole for mounting the disk on the bore machine. The first circular region typically
receives a shaft therethrough. The first circular region ( 1 0 1) and the second counter
circular region (102) are radially spaced from each other. The third circular region
has a pre-determined depth to receive a nut therein for firmly clamping the disk on
the shaft of the bore machine. The PCD is located along the centre of the fourth
circular region ( 104 ). The through holes ( 1 06) with counter bores ( 1 07) are defined
concentrically along the PCD. The fifth circular region (105) of pre-determined
thickness along the periphery of the disk and at a pre-determined distance from the
top of the disk, includes the plurality of bores (108) perpendicular to the through
holes (1 06) along the periphery of the region (1 05). The disk includes a segment
(112) defined at the base of the disk for mounting the disk on the shaft.
In accordance with one embodiment, the disk has a thickness ( t) of 22 mm. the first
circular region ( 1 01) and the second counter circular region ( 1 02) are spaced apart
radially from each other at an angle of 11 degrees {a1) and the second circular
region (102) has a diameter (d2) of 15 millimeters (mm). The third circular region
(103) has a diameter {d3) of28 mm and a depth (dp) of 12 mm. The fourth circular
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region (104) has a diameter (d4) of 40 mm. The fifth circular region (105) has a
diameter (d5) of 50 mm, thickness (t5) of 6 mm and is at a distance (di) of 10 mm
from the top ofthe disk. The PCD is 34 mm. The segment (111) has a diameter (ds)
of24 mm and a thickness (ts) of3 mm.
Referring to Figure 1 c, a schematic representation of a cross-sectional view of the
disk of figure 1a with the diamonds affixed is illustrated. Each through hole (106)
accommodates a bit (1 09) with an operative top end and a bottom end. The bit is
fastened with a screw (111) at a location proximate the bottom end to enable
positioning of the bit within the through hole (106). The bores (108) defined
perpendicular to the through holes ( 1 06) along the periphery of the fifth circular
region (105) each receive a screw (111) therein for fastening/holding each bit (109)
within each through hole (106). A diamond (110) is affixed at the operative top end
of each bit (109). The bits (109) are aligned and positioned in the through holes
(106) such that all the diamonds (110) are oriented along a common plane over the
disk and are at the same level thereby defining a dressing plane.
Referring to figure 3, a schematic representation of a fully assembled multi-bit
diamond disk dresser in accordance with an embodiment of the present disclosure
is illustrated. The disk dresser comprises twenty diamond bits (109). Each bit (109)
can be replaced after it is worn out by unscrewing of the screw ( 111) threadably
inserted in the bore (108) for fastening the bit (109). In accordance with an
exemplary embodiment, the dresser of figure 3 is capable of re-sharpening at least
12000 CBN grinding wheels or after approximately grinding at least 300,000
components.
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Referring to figure 4, a schematic representation of a replacing diamond bits in a
diamond disk dresser of the present disclosure is illustrated. A diamond bit (1 09)
with a pre-mounted diamond (11 0) is pushed in the through hole (1 06) in the disk
dresser. Typically a height setting ring (113) is placed around the dresser to enable
the bit ( 1 09) to be positioned at a pre-determined height within the ring in the
fourth circular region (104), whereby all the bits (109) are oriented along the
common plane over the disk and are at the same level to define a dressing plane for
dressing a surface plate (114) of a grinding wheel. After the height of all the bits is
set, each bit is fastened by the screw ( 111 ).
The diamond disk dresser of the present disclosure provides an alternative and
convenient method to affix as well as replace diamonds. When any diamond gets
damaged on site or worn out after prolonged use, each bit can be replaced
individually, aligned and leveled with the plurality of bits instead of replacing the
entire disk as is the case in conventional diamond disks, thus making the disk
highly durable and cost-effective. Furthermore, this configuration provides high
strength to the diamond disk dresser to endure stress while being used for
sharpening or polishing grinding wheels made from hard or abrasive materials.
TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE
The technical advancements offered by the diamond disk of the present disclosure
include the realization of:
• high strength for dressing grinding wheels;
• high durability and does not wear out easily;
• facility to replace diamonds on site;
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• an alternative to brazing diamonds on a disk and
• cost effectiveness.
Throughout this specification the word "comprise", or variations such as
"comprises" or "comprising", will be understood to imply the inclusion of a stated
element, integer or step, or group of elements, integers or steps, but not the
exclusion of any other element, integer or step, or group of elements, integers or
steps.
The use of the expression "at least" or "at least one" suggests the use of one or
more elements or ingredients or quantities, as the use may be in the embodiment of
the invention to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has
been included in this specification is solely for the purpose of providing a context
for the invention. It is not to be taken as an admission that any or all of these
matters form part of the prior art base or were common general knowledge in the
field relevant to the invention as it existed anywhere before the priority date of this
application.
The numerical values mentioned for the various physical parameters, dimensions
or quantities are only approximations and it is envisaged that the values
higher/lower than the numerical values assigned to the parameters, dimensions or
quantities fall within the scope of the invention, unless there is a statement in the
specification specific to the contrary.
The foregoing description of the specific embodiments will so fully reveal the
general nature of the embodiments herein that others can, by applying current
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knowledge, readily modify and/or adapt for various applications such specific
embodiments without departing from the generic concept, and, therefore, such
adaptations and modifications should and are intended to be comprehended within
the meaning and range of equivalents of the disclosed embodiments. It is to be
understood that the phraseology or terminology employed herein is for the purpose
of description and not of limitation. Therefore, while the embodiments herein have
been described in terms of preferred embodiments, those skilled in the art will
recognize that the embodiments herein can be practiced with modification within
the spirit and scope of the embodiments as described herein.

We Claim:
1) A multi-bit diamond disk dresser comprising: ,
• a plurality of through holes defined concentrically along a Pitch Circle
Diameter (PCD) of said disk;
• a bit removably fastened within each of said through holes, each of said bit
having an operative top end with at least one diamond affixed thereon along
a plane defining a dressing plane; and
• a plurality of bores defined perpendicular to said plurality of through holes
and disposed along the periphery of said disk, each of said bores adapted to
receive a screw therein for fastening said bit within said through hole.
2) The disk as claimed in claim 1, further comprising at least five concentric
circular regions defined thereon, said circular regions including:
• a first circular region defining a central through hole adapted to receive a
shaft therethrough;
• a second circular region radially spaced apart from said first circular region
and defining a counter bore to said first circular region;
• a third circular region having a pre-determined depth adapted to receive a
nut therein for firmly clamping said disk on the shaft ;
• a fourth circular region containing said plurality of through holes; and
• a fifth circular region having a pre-determined thickness, said fifth circular
region adapted to contain said plurality of bores.
3) The disk as claimed in claim 1, further comprising a segment defined at the
base of said disk for mounting said disk on a shaft.
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4) The disk as claimed in claim 1, wherein each of said plurality of through holes
is associated with a corresponding counter bore.
5) The disk as claimed in claim 1, wherein each of said plurality of through holes
is tapped.