ANGLE GRIND COATING APPARATUS AND A METHOD THEREOF

Abstract

An angle grind coating apparatus and method for providing a coating onto materials is described. The angle grind coating apparatus comprising workpiece holder (102) assembled for holding tool material (104) and is assembled over base (106) provided over a fixture (108). The workpiece holder (102) has a spring assembly (110) to apply an upward thrust force to the tool material (104) and a grinding wheel (114) is mounted perpendicular to the workpiece holder (102) to enable grinding of the tool material (104) fixed in front and just below the grinding wheel (114) to align the fixture (108) with the grinding wheel (114). The angle grind coating apparatus comprises an angle grinder (116) to enable rotation of the grinding wheel (114) over the tool material (104) at a predefined Rotations Per Minute (RPM), such that rotation of the grinding wheel (114) generates a stream of swarf particles (118) from the workpiece/tool material 104 and are deposited over a target surface fixed (120) at a pre-set standoff distance from the angle grind coating apparatus.

Claims

1. An angle grind coating apparatus (100), comprising: a workpiece holder (102) assembled for holding a tool material (104), wherein the workpiece holder (102) is assembled over a base (106) provided over a fixture (108), wherein the workpiece holder (102) has a spring assembly (110) to apply an upward thrust force to the tool material (104); a grinding wheel (114) mounted perpendicular to the workpiece holder (102) for enabling grinding of the tool material (104), wherein the tool material (104) is fixed in front and just below the grinding wheel (114) to align the fixture 108 with the grinding wheel (114); and an angle grinder (116) to enable rotation of the grinding wheel (114) over the tool material (104) at a predefined Rotations Per Minute (RPM), such that rotation of the grinding wheel (114) generates a stream of swarf particles (118) from the tool material (104), wherein the stream of swarf particles (118) is deposited over a target surface fixed (120) at a pre-set standoff distance from the angle grind coating apparatus.

2. The angle grind coating apparatus as claimed in claim 1, wherein the tool material 104 comprises a cylindrical workpiece (104), wherein the cylindrical tool material (104) comprises low carbon steel.

3. The angle grind coating apparatus as claimed in claim 1, comprising: a safety plate (122) located on top of the grinding wheel (114).

4. The angle grind coating apparatus as claimed in claim 1, wherein the stream of swarf particles (118) comprises swarf particles 128 in micrometer size.

5. The angle grind coating apparatus as claimed in claim 1, wherein the target surface comprises a substrate selected as one of a metal substrate, a polymer substrate or a ceramic substrate.

6. The angle grind coating apparatus as claimed in claim 1, wherein the RPM comprises in a range of operation up to 10,000 rpm.

7. The angle grind coating apparatus as claimed in claim 1, wherein the grinding of the tool material (104) is controlled by adjusting at least one of a spring stiffness, alignment of the fixture (108), and rotational speed of the grinding wheel (114).

8. The angle grind coating apparatus as claimed in claim 1, comprising: a handle (124) provided over the angle grinder for holding the apparatus.

9. The angle grind coating apparatus as claimed in claim 1, comprising: links (126) connected to each of the fixture (108) and the angle grinder, the links (126) are provided for the assembly of the cylindrical shaped workpiece holder (102), spring (112) and base plate (106) of fixture (108).

10. The angle grind coating apparatus as claimed in claim 1, wherein the coating of the stream of swarf particles (118) is controlled by adjusting the stand-off distance and impact angle of the stream of swarf particles (118) generated due to grinding.

11. The angle grind coating apparatus as claimed in claim 1, wherein swarf particles (118) of shape comprising spherical, needle or platelet morphology are deposited; and wherein the shape is based on a set of grinding variables.

12. The angle grind coating apparatus as claimed in claim 4, wherein the set of grinding variables comprises stand-off distance between the tool material (104) and the substrate (120), rotational speed of angle grinding disk, spring stiffness of the spring (112) in the infeed holder, feed rate of tool material, flow rate of the swarf particles 128, and trajectory of a swarf particles stream.

13. A method providing coating over a material, the method comprising: applying, through a spring (112), an upward thrust force over a tool material (104), wherein the tool material (104) is fixed in a workpiece holder (102) of an angle grind coating apparatus, wherein the workpiece holder (102) is assembled over a base (106) provided over a fixture (108); enabling, through a grinding wheel (114), grinding of the tool material (104), wherein the grinding wheel (114) is mounted perpendicular to the workpiece holder (102), wherein the tool material (104) is fixed in front and just below of the grinding wheel (114) aligning the fixture (108) with the grinding wheel (114); and enabling, through a tool material (104), a rotation of the grinding wheel (114) over the tool material (104) at a predefined Rotations Per Minute (RPM), such that rotation of the grinding wheel (114) generates a stream of swarf particles (118) from the tool material (104), wherein the stream of swarf particles (118) is to be deposited over a target surface fixed (120) at a pre-set standoff distance from the angle grind coating apparatus.

14. The method as claimed in claim 13, wherein the RPM comprises in a range of operation up to 10,000 rpm.

15. The method as claimed in claim 13, wherein the grinding of the tool material (104) is controlled by adjusting at least one of a spring stiffness, alignment of the fixture (108), and rotational speed of the grinding wheel (114).

16. The method as claimed in claim 10, wherein grinding is controlled by controlling at least one of a stand-off distance and impact angle of the stream of swarf particle (118) is adjusted and varied manually.

17. The method as claimed in claim 11, wherein swarf particles (128) of shape comprising spherical, needle or platelet are deposited; and wherein the shape is based on a set of grinding variables.

18. The method as claimed in claim 13, wherein the set of grinding variables comprises stand-off distance between the work piece used as a tool material (104) and the substrate, rotational speed of angle grinding disc, spring stiffness of the spring (112) in the infeed holder, feed rate of tool material (104), flow rate of swarf particles 128, and trajectory of the swarf particle stream.

Description

BRIEF DESCRIPTION OF DRAWING

[0008] The foregoing detailed description of embodiments is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present subject matter, an example of construction of the present subject matter is provided as figures; however, the present subject matter is not limited to the specific angle grind coating apparatus and method thereof.

[0009] FIG. 1A shows a schematic of an angle grind coating apparatus, in accordance with an embodiment of the present subject matter.

[0010] FIG. 1B and FIG. 1C shows line diagrams of the angle grind coating apparatus, in accordance with an embodiment of the present subject matter.

[0011] FIG. 1D shows top view of the angle grind coating apparatus, in accordance with an embodiment of the present subject matter.

[0012] FIG. 1E shows side view of the angle grind coating apparatus, in accordance with an embodiment of the present subject matter.

[0013] FIG. 1F shows front view of the angle grind coating apparatus, in accordance with an embodiment of the present subject matter.

[0014] FIG. 1G shows 3D view of the angle grind coating apparatus, in accordance with an embodiment of the present subject matter.

[0015] FIG. 2A shows samples coated with low carbon steel swarf (metal) by the angle grind coating technology on glass substrate (1, 3), on an aluminium substrate (2, 4, 6) and on an acrylic substrate (5); in accordance with an embodiment of the present subject matter.

[0016] FIG. 2B shows a Scanning Electron Microscopy (SEM) analysis of micro-sized low carbon steel uncoated swarf produced during the angle grind coating process, in accordance with an embodiment of the present subject.

[0017] FIG. 3 shows a schematic for powder production by means of the angle grind coating apparatus, in accordance with an embodiment of the present subject matter.

[0018] FIG. 4 shows the cross-sectional SEM analysis of the low carbon steel swarf coating on aluminium (A), glass (B) and acrylic (C), in accordance with an embodiment of the present subject matter.

[0019] FIG. 5 shows a method providing coating over a material, in accordance with an embodiment of the present subject matter.

DETAILED DESCRIPTION

[0020] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words “comprising”, “including”, “containing”, “consisting”, and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary angle grind coating apparatus and method thereof is now described. The disclosed angle grind coating apparatus and method thereof are merely examples of the disclosure, which may be embodied in various forms.

[0021] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure for a process of an angle grind coating apparatus and method thereof is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.

[0022] The existing surface coating technologies such as thermal spray technologies may not be effective for coating ceramic surfaces such as glass, ceramics and acrylic. These surfaces are difficult to roughen effectively. The present subject matter overcomes a problem of an efficient method for surface coating of such materials.

[0023] Referring now to FIGS. 1A-1G in combination, an angle grind coating apparatus 100, in accordance with an embodiment of the present subject matter may be described. The angle grind coating apparatus 100 comprises a workpiece holder 102 assembled for holding a tool material 104. The tool material (workpiece) 104 may be a cylindrical tool material (workpiece) 104 containing a low carbon steel. The work piece holder 102 may further be assembled over a base 106 provided over a fixture (108) and comprises a spring assembly 110 to apply an upward thrust force to the tool material (workpiece) 104. The spring (112) may have a spring constant in the range 0.45 N/mm to 0.55 N/mm.

[0024] In an embodiment, the angle grind coating apparatus 100 comprises a grinding wheel 114 mounted perpendicular to the workpiece holder 102 for enabling grinding of the tool material (workpiece) 104. The tool material (workpiece) 104 may be fixed in front of the grinding wheel 114 and just below the grinding wheel 114 to align the fixture 108 with the grinding wheel 114. Further, the grinding of the tool material (workpiece) 104 may be controlled by adjusting at least one of a spring stiffness, alignment of the fixture 108, and rotational speed of the grinding wheel 114. Further, a safety plate 122 may be located on top of the grinding wheel 114.

[0025] In an embodiment, the angle grind coating apparatus 100 further comprises an angle grinder 116 that may enable rotation of the grinding wheel 114 over the tool material (workpiece) 104 at a predefined Rotations Per Minute (rpm). The RPM of the grinding wheel 114 may be in a range of operation up to 10,000 RPM.

[0026] In an embodiment rotation of the grinding wheel 114 may generate a micrometre sized stream of swarf particles 118 from the tool material (workpiece) 104. The generated stream of swarf particles 118 may be deposited over the target surface fixed 120 at a pre-set stand-off distance from the angle grind coating apparatus 100. The target surface may be selected from one of a metal substrate, a polymer substrate or a ceramic substrate. The coating of the stream of swarf particles 118 may be controlled by adjusting the stand-off distance and impact angle of the stream of swarf particles 118 generated due to grinding. The swarf particles deposited 130 may have shape comprising spherical, needle or platelet morphology. The shape of swarf particles deposited 130 may depend on a set of grinding variables.

[0027] In an embodiment the set of grinding variables comprises stand-off distance between the work piece 104 and the substrate, rotational speed of angle grinding disk, spring stiffness of the spring in the infeed holder, feed rate of tool material (workpiece) 104, flow rate of the swarf particles 128, and trajectory of a swarf particles stream.

[0028] In an embodiment, the angle grind coating apparatus 100 further comprises a handle 124 provided over the angle grinder for holding the apparatus. The angle grind coating apparatus further comprises a links 126 connected to each of the fixture 108 and the angle grinder. The links 126 are provided for the assembly of the cylindrical shaped workpiece holder 102, spring 110 and the base plate 106 to fixture 108. The links 126 may hold the assembly together and position at a proper location.

[0029] FIG. 1B shows photographs of the angle grind coating apparatus 100. Top view, side view and front view of the angle grind coating apparatus 100 may be seen from FIG. 1.

TABLE-US-00001 Grinding variables for different substrates Sr. No. Type of deposited material Tool material (Workpiece) Substrate material Stand-off distance range (mm) Abrasive cutter speed (rpm) 1 Metal Low carbon steel swarf Aluminium 70-320 10,000 2 Metal Low carbon steel swarf Acrylic 100-350 10,000 3 Metal Low carbon steel swarf Glass 100-300 10,000

[0030] Now referring to Table 1, a set of grinding variables for different substrates such as aluminium, acrylic and glass is shown. As observed from the table 1, the stand-off distance is lower for aluminium and the stand-off distance is higher for glass. However, the rotation of the speed for these examples is maintained constant for all the substrates, although the RPM can also be a variable. The swarf particles 128 are deposited onto the substrate surface at a high impact speed and elevated temperature. In the process of coating, the temperature of the substrate at the start of the process is maintained at room temperature and the temperature of the substrate increases due to the impact of the swarf particles 128 that may be removed from the tool material (workpiece) 104. The increase in temperature during the coating process is proportional to the grinding time and the process variables.

[0031] In an example embodiment, heated swarf particle from low carbon steel, formed by the angle grind coating apparatus 100 may be achieved by controlling the operating parameters as mentioned in Table 1. The substrate used for coating may comprise one of a metal or a non-metal. The coating thickness may be achieved by repeated passing of the swarf particles 128 across the substrate. The angle grind coating apparatus 100, which may also be operated in a manual or robot-controlled fashion, deposits coating on contoured materials since it can be angled in many directions due to high versatility derived from a small equipment profile.

[0032] Now referring to FIG. 2A, coating of low carbon steel swarf on glass (1, 3), aluminium (2, 4 and 6) and acrylic (5) is illustrated. FIG. 2B illustrates cross-sectional Scanning Electron Microscope (SEM) analysis of the low carbon steel swarf coating on aluminium (A), glass (B) and acrylic (C). Coating on different surfaces may be achieved by placing the substrate at different standoff distances. Coating of low carbon steel on the aluminium substrate may be achieved at the standoff distance in the range of 70 mm to 320 mm. Metal coating on the glass substrate may be achieved using angle grind coating apparatus 100. The coating on the glass substrate may be achieved at the standoff distance of 190 mm. Further, metal coating on an acrylic polymer substrate at is achieved at the standoff distance in the range of 100 mm to 350 mm.

[0033] Referring to FIG. 3 and FIG. 4, in another exemplary embodiment, the angle grind coating apparatus 100 may be used for powder generation by segregation and separation swarf particles 128 from the stream of swarf particles during angle grind coating process when the stand-off distance is greater than 400 mm. For powder generation, a container 302 may be placed in front of the stream of swarf 118. The swarf particles 128 formed may have varying shape and size. The swarf particles 128 may have spherical 304 or non-spherical shapes 306. The shape and size of swarf scrap may be segregated by magnetic and mechanical scrap separators 308. The segregated swarf particles 128 are cleaned 314. Spherical 304 and non-spherical 306 swarf particles 128 are detected during SEM analysis as shown in FIG. 4. Further, the process parameters of the angle grind coating apparatus 100 may control the shape and size of the swarf particle. The segregated and cleaned spherical swarf particles 304 may be used as a feedstock 316 for material coating technique such as thermal spray, cold spray, plasma spray, additive manufacturing, powder metallurgy and technology that require bespoke powder.

[0034] Referring now to FIG. 5, a method 500 providing coating over the material is illustrated in accordance with the present embodiment. The method may be executed through the angle grind coating apparatus 100.

[0035] At block 502, the upward thrust force over the tool material (workpiece) 104 fixed in the workpiece holder 102 of the angle grid coating apparatus 100 may be applied through the spring assembled 110.

[0036] At block 504, the grinding of the tool material (workpiece) 104 may be enabled through the grinding wheel 114 mounted perpendicular to the workpiece holder 102.

[0037] At block 506, the rotation of the grinding wheel 114 over the tool material (workpiece) 104 at the predefined Rotation Per Minute (RPM) may be enabled though the angle grinder.

[0038] Details of the method 500 are similar to details of the angle grind coating apparatus 100 and hence are not repeated for the sake of brevity.

[0039] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include those provided by the following features.

[0040] Some embodiments of angle grind coating apparatus 100 may provide the cost-effective method 500 for substrate coating.

[0041] Some embodiments of angle grind coating apparatus 100 may enable coating on to metal, polymer, and ceramic surfaces; or a surface that is a combination of these materials.

[0042] Some embodiments of the angle grind coating apparatus 100 may provide a portable equipment that may be lightweight and compact in size.