ABRASIVE SEGMENT FOR AN ABRASIVE ROLL, GRINDING MACHINE, AND USE

Abstract

An abrasive segment includes a carrier body for attaching the abrasive segment to a lateral surface of an abrasive roll in an interlocking manner; and a substantially planar abrasive layer. The abrasive layer is oriented substantially parallel to the lateral surface of the abrasive roll in a state of the abrasive segment in which it is attached to the abrasive roll, and an elastic intermediate layer is located between the carrier body and the abrasive layer.

Claims

1. An abrasive segment for a grinding roller including at least one carrier body for positively lockingly fixing the abrasive segment to a peripheral surface of the grinding roller and at least one substantially flat abrasive layer, characterized in that the at least one abrasive layer in a state of the abrasive segment of being fixed to the grinding roller is oriented substantially parallel to the peripheral surface of the grinding roller and at least one elastic intermediate layer is arranged between the at least one carrier body and the at least one abrasive layer.

2. The abrasive segment as set forth in claim 1, wherein arranged between the at least one carrier body and the at least one abrasive layer is at least one elastic intermediate layer substantially comprising felt.

3. The abrasive segment as set forth in claim 1, wherein the at least one elastic intermediate layer is such that a grinding fluid, in particular water, can be stored and delivered therein, and/or is of an abrasive-free configuration.

4. The abrasive segment as set forth in claim 1, wherein the at least one carrier body is substantially T-shaped in cross-section and/or is of such a configuration that the carrier body can be positively lockingly fixed to the peripheral surface of the grinding roller by way of a dovetail connection.

5. The abrasive segment as set forth in claim 1, wherein the at least one carrier body includes at least one contact surface at which the at least one elastic intermediate layer is at least region-wise supported, preferably wherein the at least one contact surface is oriented substantially parallel to the at least one flat abrasive layer.

6. The abrasive segment as set forth in claim 1, wherein the at least one elastic intermediate layer is fixed with an adhesive layer to the at least one carrier body and/or to the at least one abrasive layer.

7. The abrasive segment as set forth in claim 1, wherein the at least one elastic intermediate layer is of a thickness, the thickness being at least three times as great as a layer thickness of the at least one abrasive layer.

8. The abrasive segment as set forth in claim 1, wherein the at least one abrasive layer includes at least one abrasive, preferably diamond, cubic boron nitride, sintered corundum and/or an abrasive with zirconium corundum, aluminum oxide and/or silicon carbide, preferably wherein the at least one abrasive is of an abrasive grain size between 50 μm and 745 μm and/or is embedded in at least one bonding agent, preferably a resin bonding agent, preferably wherein the abrasive layer is arranged on a carrier layer.

9. A grinding roller for machining a surface of a workpiece and/or a surface of a negative form for the production of the workpiece, wherein the grinding roller has a substantially cylindrical main body having a peripheral surface, wherein the abrasive segment as set forth in claim 1 is positively lockingly fixed to the peripheral surface.

10. The grinding roller as set forth in claim 9, wherein the peripheral surface is provided with at least one groove for receiving at least one abrasive segment, preferably wherein the at least one groove is of a substantially dovetail-shaped configuration and the at least one abrasive segment is positively lockingly fixed therein.

11. The grinding roller as set forth in claim 10, wherein the at least one groove is arranged inclinedly relative to a longitudinal direction of the grinding roller, preferably at an angle between 1° and 10°, particularly preferably at an angle between 2° and 3.5°.

12. The grinding roller as set forth in claim 1, wherein arranged at at least one end of the substantially cylindrical main body is at least one preferably substantially cylindrical opening for at least one tool receiving means, preferably wherein precisely two openings are arranged at the at least one end.

13. The grinding roller as set forth in claim 9, wherein at least one locking mechanism, at least one cover and at least one opening, wherein the opening is arranged in the at least one cover and the at least one locking mechanism can be introduced into the at least one opening, for arresting the at least one abrasive segment are arranged at at least one of the ends of the substantially cylindrical main body.

14. A grinding machine comprising the grinding roller as set forth in claim 9 and at least one rotary drive with which the grinding roller can be set in rotation to cause a relative movement of the at least one abrasive layer relative to the surface to be machined of the workpiece or the negative form.

15. The grinding machining as set forth in claim 14, wherein there is provided at least one handle, preferably provided with at least one grinding fluid feed means, for manual guidance of the grinding machine.

16. The grinding machine as set forth in claim 14, wherein there is provided at least one robot arm, arranged at the end of which is at least one tool receiving means of at least one grinding roller, preferably wherein the tool receiving means is provided with at least one grinding fluid feed means.

17. A use of the grinding machine as set forth in claim 14 for machining a surface of a workpiece, that is preferably provided with a coating for protection from environmental influences, wherein it is preferably provided that at least one region of the workpiece, that adjoins the surface to be machined, comprises a carbon fiber and/or glass fiber composite material or a surface that is preferably coated with wax of a negative form for the production of a workpiece which preferably at least region-wise comprises a carbon fiber and/or glass fiber composite material.

18. The use as set forth in claim 17, wherein the workpiece is in the form of an airfoil or fuselage of an aircraft, parts of a ship, parts of a train or in the form of a rotor blade of a wind turbine.

19. The use as set forth in claim 17, wherein the use is implemented with the feed of a grinding fluid, preferably water, particularly preferably water mixed with soap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0081] Further details and advantages of the present invention are described more fully hereinafter by means of the specific description with reference to the embodiments by way of example illustrated in the drawings in which:

[0082] FIG. 1a is an exploded view of an abrasive segment in its individual components according to a first preferred embodiment as a perspective view with a detail view of an abrasive layer,

[0083] FIG. 1b shows an abrasive segment in its entirety according to a second preferred embodiment as a perspective view with a detail view of an elastic intermediate layer of felt,

[0084] FIG. 2 shows a grinding roller in its entirety as a perspective view according to a preferred embodiment with fitted abrasive segments in accordance with the embodiment shown in FIG. 1a or FIG. 1b,

[0085] FIG. 3a shows a grinding machine according to a first preferred embodiment in the form of a manually operable grinding machine with a fitted grinding roller in accordance with the embodiment shown in FIG. 2 and included abrasive segments according to the embodiment shown in FIG. 1a or FIG. 1b as a side view,

[0086] FIG. 3b shows the grinding machine according to a second preferred embodiment in the form of a robot-controlled grinding machine having a fitted grinding roller according to the embodiment shown in FIG. 2 and included abrasive segments according to the embodiment shown in FIG. 1a or FIG. 1b as a side view,

[0087] FIG. 4a shows the use of a grinding roller according to the embodiment shown in FIG. 2 with fitted abrasive segments according to the embodiment shown in FIG. 1a or FIG. 1b during the removal process on a workpiece as a side view,

[0088] FIG. 4b shows the use of a grinding roller according to the embodiment shown in FIG. 2 with fitted abrasive segments according to the embodiment shown in FIG. 1a or FIG. 1b during the removal process on a negative form as a side view, and

[0089] FIG. 5 shows a grinding roller according to a further preferred embodiment without abrasive segments as a view in a radial direction.

DETAILED DESCRIPTION OF THE INVENTION

[0090] FIG. 1a shows an abrasive segment 1 including a carrier body 3 and a flat abrasive layer 6, an elastic intermediate layer 7 being arranged between the abrasive layer 6 and the carrier body 3. For the sake of ease of viewing the drawing those components are separate in the view, but the components are connected together by the formation of the abrasive segment.

[0091] The carrier body 3 is T-shaped, wherein the T-shape includes a dovetail-shaped limb intended for a dovetail connection (see FIG. 2) to provide the positively locking connection. The carrier body 3 in itself can be of any length. Lengths are preferred however which are suitable for the removal process of extensive surface geometries.

[0092] The elastic intermediate layer 7 is of a cuboidal configuration. It can however also differ from that shape and/or can be adapted to specific surface geometries to be treated. By way of example the elastic intermediate layer 7 can be of a trapezoidal configuration.

[0093] The abrasive layer 6 is of a thickness 16, wherein the abrasive layer 6 includes an abrasive 17, preferably diamond 18, cubic boron nitride 19, sintered corundum 52 and/or an abrasive 17 with zirconium corundum 20, aluminum oxide 21 and/or silicon carbide 22.

[0094] The precise composition of the abrasive 17 and the abrasive grain size 18 however can be any desired composition. Particularly preferably the one abrasive 17 is of an abrasive grain size 18 of between 50 μm and 745 μm. The abrasive 17 is held together by a bonding agent 23. Particularly preferably the abrasive 17 is embedded in a resin bonding agent 24 but can also be embedded in another material as the bonding agent 23.

[0095] The abrasive layer 6 is arranged on a carrier layer 49. The carrier layer 49 can in itself be of any desired material and is also not absolutely necessary. The abrasive layer 6 can also be applied directly to the elastic intermediate layer 7. A carrier layer 49 of textile is however particularly preferred.

[0096] The elastic intermediate layer 7 is fixed with an adhesive layer 14 to the carrier body 3 and/or to the abrasive layer 6. The adhesive layer 14 in that case can be applied over the entire surface area or only region-wise.

[0097] The elastic intermediate layer 7 is of a thickness 15, the thickness 15 being a multiple larger than a layer thickness 16 of the abrasive layer 6. Particularly preferably the thickness 15 is at least three times the layer thickness of the abrasive layer 6.

[0098] The abrasive layer 6 is applied to the carrier layer 49. The abrasive layer 6 can be applied to the carrier layer 49 over the entire surface area or only region-wise.

[0099] FIG. 1b shows an abrasive segment 1 with an elastic intermediate layer 7 comprising felt 8.

[0100] The carrier body 3 includes a contact surface 13 at which the elastic intermediate layer 7 is at least region-wise supported. The contact surface 13 is oriented parallel to the flat abrasive layer 6.

[0101] The elastic intermediate layer 7 is of such a configuration that a grinding fluid, in particular water 10, can be stored therein and can be delivered, and/or it is of an abrasive-free nature.

[0102] The elastic intermediate layer 7, the contact surface 13 and the abrasive layer 6 are oriented substantially parallel and are at an angle of substantially 90° relative to a radial direction of a grinding roller 2 (not shown for the sake of clarity).

[0103] The grinding fluid 9 can be of any desired composition. Particularly preferably a water 10 mixed with soap 48 is present in the grinding fluid 9.

[0104] The grinding fluid 9 is stored in the fibers 50 of the felt 8 and penetrates between the fibers 50 of the felt 8 upon delivery of the grinding fluid 9 to the abrasive layer 6.

[0105] In general the elastic intermediate layer 7 can also be in the form of foams or plastics. In that case the thicknesses of the individual components of the abrasive segment 1 can be different.

[0106] FIG. 2 shows a grinding roller 2 with a cylindrical main body 28 having a peripheral surface 5. Abrasive segments 1 are fixed in positively locking relationship on the peripheral surface 5.

[0107] The peripheral surface 5 is provided with grooves 29 for receiving abrasive segments 1. In this design the grooves 29 are of a dovetail-shaped configuration. The abrasive segments 1 are positively lockingly fixed in the grooves 29.

[0108] A cover 53 is arranged at an end 30 of the cylindrical main body 28 and has two openings 54. Two locking mechanisms 33 engage into those two openings in order to fix the plurality of abrasive segments 1 in an axial direction.

[0109] Two cylindrical openings 31 for a tool receiving means 32 are arranged at an end 30 of the cylindrical main body 28. The cylindrical openings 31 can be arranged at one or at both ends 30 of the grinding roller 2.

[0110] The cylindrical openings 31 in themselves can be present in any desired number. A particularly preferred embodiment is that in which the end 30 includes two eccentric cylindrical openings 31.

[0111] A locking mechanism 33 is arranged at one of the ends 30 of the cylindrical main body 28 for arresting the abrasive segments 1.

[0112] The abrasive segments 1 are arranged radially outwardly on the peripheral surface 5. The abrasive segments can be spaced at any desired spacing as indicated at 51. An equidistant arrangement of the abrasive segments 1 is particularly preferred. The spacing 51 between the abrasive segments 1 should not be selected to be so large that the result of the removal process is adversely affected.

[0113] The grinding roller 2 can be of a roller diameter in the range of between 80 mm and 400 mm. The grinding roller 2 can be of a roller length in the range of between 50 mm and 800 mm.

[0114] FIG. 3a shows a grinding machine 34 having a grinding roller and a rotary drive 35a with which the one grinding roller 2 can be set in rotation in order to produce a relative movement 36a of the one abrasive layer 6 relative to the surface 25 to be machined on the workpiece 26 and/or the negative form 27.

[0115] There is a handle 35b for manual guidance of the grinding machine 34. The handle 35b is provided with a grinding fluid feed means 36b , wherein the grinding fluid feed means 36b is fixed on and/or in the handle 35b in such a way that the operator is not impeded in handling the grinding machine 34.

[0116] The handle 35b can be designed for one-arm or two-arm operation.

[0117] FIG. 3b shows a robot arm 37, at the end 38 of which there is provided a tool receiving means 32 of a grinding roller 2.

[0118] The tool receiving means 32 is provided with a grinding fluid feed means 36b . In a further embodiment however that can also be mounted to the robot arm 37 or another component of the grinding machine 34. If no grinding fluid feed means 36b is needed for the removal process it can also be entirely eliminated.

[0119] The grinding fluid 9 is passed further to the grinding roller 2 by way of the grinding fluid feed means 36b.

[0120] FIG. 4a shows the use of abrasive segments 1, a grinding roller 2 or a grinding machine 34 for machining a surface 25 of a workpiece 26, that is coated with a coating 39 to give protection from environmental influences.

[0121] The workpiece 26 can in itself be of any nature. Use of the abrasive segments 1, grinding roller 2 or the grinding machine 3 for the abrasive procedure on airfoils or fuselages 44 of an aircraft, rotor blades 45 of a wind turbine, parts of a ship or parts of a train is however particularly preferred. The workpiece 26 however can also be formed from other extensive geometries 46 comprising composite materials 47.

[0122] A region 40 of the workpiece 26, that adjoins the surface 25 to be machined, at least partially comprises a carbon fiber composite material 41 and/or a glass fiber composite material 42.

[0123] FIG. 4b shows a surface 25, coated with wax 43, of a negative form 27 for the production of a workpiece 26 (shown in FIG. 4a).

[0124] The use is effected with the feed of a grinding fluid 9. It is optionally also possible however to dispense with the feed of the grinding fluid 9.

[0125] FIG. 5 shows a grinding roller 2 before being fitted with abrasive segments 1.

[0126] The grooves 29 in which the abrasive segments 1 are fixed in positively locking relationship are at an angle in the range of between 1° and 10°, particularly preferably between 2° and 3.5°, relative to a longitudinal direction of the grinding roller 2, but can also be arranged parallel to the longitudinal direction of the grinding roller 2.

[0127] The longitudinal direction of the grinding roller 2 is defined by the axial direction (axis of rotation) of the grinding roller 2 and is thus normal to the direction of rotation or a radial direction of the grinding roller 2.

[0128] Two locking mechanisms 33 can be seen at the end 30 at the left. The grooves 29 are continuous as far as that facing side and terminate before an opposite side in order to permit a positively locking connection of the abrasive segments 1 (not shown for the sake of clarity) in the grinding roller 2 by a termination of the grooves 29.

[0129] In order to fix the abrasive segments 1 to the grinding roller 2 the cover 53 over the openings 54 is released by the locking mechanism 33 (for example by rotation). That removal has already occurred in FIG. 5.

[0130] Then the abrasive segments 1 are introduced into the grooves 29 as far as the end thereof in order subsequently to again fix the cover 53 on the grinding roller 2 and to secure the abrasive segments 1 in the longitudinal direction.

[0131] It is however also possible in accordance with the invention to use two covers 53 for fixing the abrasive segments 1 and to dispense with the termination configuration of the grooves 29.