Apparatus and method for making and using a combined cutting/grinding wheel

A combined cutting/grinding tool comprises a grinding wheel with an exterior circumferential grinding surface for profiling an object surface of a product to be manufactured. The grinding surface includes an abrasive grit. A profile is formed in the grinding surface for grinding a corresponding profile into the object surface. A plurality of inserts are inserted into a plurality of slots formed in the grinding surface. A cutting portion of each insert extends radially and integrally outward from the grinding surface to cut detail into the object surface of the part to be manufactured.

This application is based on Provisional Application No. 60/008,906 filed 
on Dec. 20, 1995. 
TECHNICAL FIELD 
The present invention relates to a combined cutting/grinding tool which can 
impart a profile of any desirable configuration to a part to be 
manufactured. 
BACKGROUND OF THE INVENTION 
Products that can be molded, machined or ground have long had profiles 
(contours) produced by molding, machining or grinding. Without limitation, 
but by way of background only, one such type of part is a belt, made of 
rubber, such as a v-belt. In some instances, such as in the manufacture of 
belts, a desired profile may be molded into the belt as the belt itself is 
molded. 
The profile of the part to be made can be of virtually any configuration 
that can be machined or ground. In many instances, when grinding is used 
to profile a part, the action of the grinding tool imparts surface 
characteristics to the profiled portion of the part that are superior to 
the surface characteristics achieved through machine cutting. Profile 
grinding allows greater control of surface finish on materials that are 
difficult to machine. However, there are limits to the form that a 
grinding tool can take and, therefore, in the shapes that it can profile 
into a product to be manufactured. Molding and machine cutting can, in 
some instances, be more effective in profiling certain shapes than 
grinding. Moreover, the way in which grinding tools form surfaces can 
limit the life of a grinding tool. 
Machining cutters have certain advantages over grinding tools. Typically, 
machining cutters have longer lives and, therefore, offer greater 
production capabilities than grinding tools. Also, machining cutters can 
profile more intricate detail into the part being produced than grinding 
tools. 
In many instances, the drawbacks of machine cutting more than offset such 
advantages. For example, the superior surface characteristics imparted by 
grinding are sacrificed when a cutting tool is used. 
Tools are available that are able to mold, machine cut or grind virtually 
any material into a given profile. However, what is needed is a single 
tool that is able to impart the superior surface characteristics of a 
grinding tool while, at the same time, profiling the intricate cuts of a 
cutting tool. 
SUMMARY OF THE INVENTION 
In accordance with this invention a combination grinding/cutting tool is 
provided that includes a grinding wheel with the cutting portions of a 
plurality of inserts with cutting portions that extend outward from an 
abrasive-lined profiled grinding surface. The grinding surface imparts the 
superior surface characteristics of a grinding tool while the insert 
cutting portions profile the intricate cuts of a cutting tool. 
Unlike prior art cutting and grinding tools, the present invention includes 
both cutting and grinding implements on a single grinding wheel. The 
combination reduces costs and increases production rates by allowing 
cutting and grinding operations to be carried on simultaneously and by a 
single machine. In addition, the cutting and grinding implements of the 
present invention are arranged to take advantage of the superior 
characteristics of each. 
In accordance with another aspect of the present invention, one or more 
slots may be formed in the grinding surface to receive one or more 
inserts. This allows the inserts to be fabricated separately from the 
grinding wheel. 
In accordance with still another aspect of the present invention, one or 
more of the slots may be adapted to receive both an insert and a wedge 
block shaped to exert retaining pressure against the insert as the wedge 
block is fastened into the slot. The use of such a wedge block to install 
inserts allows the inserts to be more easily removed for replacement or 
re-honing. 
In accordance with the present invention a method is provided for making a 
combined cutting/grinding tool. The method includes the steps of forming 
the grinding wheel, forming a slot in the grinding wheel grinding surface, 
profiling an outer surface of the grinding wheel to correspond to a 
desired profile to be formed in an object surface of a manufactured 
object, applying and securing an abrasive to the grinding wheel outer 
surface, forming an insert with a body portion shaped to fit within the 
slot, and inserting and securing the body portion of the insert into the 
slot. 
In accordance with the present invention a method is provided for profiling 
a part using a combined cutting/grinding tool. The method includes the 
steps of forming the grinding wheel with the insert cutting portions 
extending outward from the grinding surface, spinning the grinding wheel, 
moving the object surface of a product to be manufactured into contact 
with the grinding surface and inserts until the grinding surface and 
cutting portion have formed a desired profile in the object surface, and 
removing the product from the grinding wheel.

DETAILED DESCRIPTION OF THE DRAWINGS 
A combined cutting/grinding tool made in accordance with the present 
invention is generally shown at 10 in the figures. Generally, the tool 
comprises a grinding wheel 12 having at least one opening or slot 14 for 
receiving a cutting insert generally indicated at 16. 
The grinding wheel 12 has a contoured exterior circumferential grinding 
surface 18 matching the profile of a part to be manufactured by the tool 
10. That is, the exterior grinding surface 18 of the grinding wheel 12 
includes a predetermined profile for making the profile in an object 
surface of the product to be manufactured. As shown in the figures, the 
profile on the exterior grinding surface 18 of the grinding wheel 12 is 
arcuate. It will be appreciated that the grinding surface 18 of the 
grinding wheel 12 can have any desired configuration to make any profile 
in the object surface of the part to be manufactured. 
The exterior circumferential grinding surface 18 of the grinding wheel 12 
includes an abrasive grit 20. The abrasive grit 20 is best shown in FIGS. 
4 and 5. The abrasive grit 20 can comprise any grit well known in the art, 
such as tungsten carbide, diamonds or the like. Thus, the grinding wheel 
12 comprises a substrate to which the abrasive grit 20 is secured. The 
abrasive grit can be applied to the substrate or blank in any matter well 
known in the art. In the preferred embodiment the profile of the abrading 
(grinding) surface closely matches the profile of the object surface of 
the part to be manufactured. 
In other embodiments, the profiled grinding surface 18 may be disposed on 
an exterior surface of the grinding wheel other than a circumferential 
surface. For example, the grinding surface 18 may be disposed on the 
grinding wheel face, shown at 38 in FIG. 1, with the inserts 16 protruding 
at various points on the grinding wheel face 38. 
As best shown in FIG. 1, the tool 10 includes at least one and preferably a 
plurality of slots 14 extending inwardly from the grinding surface 18 and 
spaced circumferentially around the grinding wheel 12. The slots 14 are 
adapted for receiving a cutting insert 16. While the preferred embodiment 
includes a plurality of slots 14, other embodiments may include only a 
single slot 14. 
The slots 14 extend from the exterior surface 18 of the grinding wheel 12 
inwardly toward the center of the grinding wheel 12. The slot 14 generally 
extend in the radial direction. As best shown in FIG. 4, the slots 14 may 
be angled relative to the true radial direction. That is, the slots 14 may 
be disposed on an angle .alpha. relative to perpendicular to the exterior 
surface 18. The slots 14 may be placed at any angle .alpha., depending on 
the part to be manufactured. 
The slots 14 may include one or more side walls to comprise a pocket for 
receiving the insert 16. In one alternative embodiment, each slot is 
enlarged to form a wedge block receptacle, as shown at 14' in FIG. 5. Each 
wedge block receptacle 14' includes first 21 and second 23 opposing 
receptacle sidewalls spaced far enough apart to also accommodate a wedge 
block 26 for mechanically retaining the insert 16. An insert 16 is 
disposed flush against the first receptacle sidewall 21 and is spaced from 
the second receptacle sidewall 23. The first receptacle sidewall 21 is 
slanted outward, as shown in FIG. 5, so that the greatest distance between 
the two walls is measured at the point where the sidewalls 21, 23 meet the 
exterior circumferential grinding surface 18 of the grinding wheel 12. 
A wedge block, or shim 26 is shaped to fit between the insert 16 and the 
second receptacle sidewall 23. The wedge block 26 has the shape of a 
trapezoidical prism having a first non-parallel side 30 angled to lie in a 
generally parallel disposition against an outer surface 32 of the insert 
16 and a second non-parallel side 31 angled to lie in a generally parallel 
disposition against the second sidewall 23. 
The shape of the wedge block 26 allows it to be inserted into the wedge 
block receptacle 14' to retain or jam the insert 26 against the first 
receptacle sidewall 21, retaining the insert 16 in the installed position 
in the slot 14'. 
A fastener in the form of a bolt 28 passes through a cylindrical aperture 
34 formed vertically through the wedge block 26 with the head of the bolt 
28 engaging an upper surface 29 of the wedge block 26. A threaded shaft 
portion 33 of the bolt 28 threads into a threaded hole 34 extending 
radially inward from a floor 36 of the receptacle 14' toward a central 
rotational axis 25 of the grinding wheel 12. The bolt 28 is therefore 
adjustably connected to the grinding wheel 12 to allow an installer to 
draw the wedge block 26 into the receptacle 14' or to back the wedge block 
26 out of the receptacle 14' by threading the bolt 28 into or out of the 
threaded hole 34. 
As is best shown in FIGS. 3-5, each cutting insert 16 includes a cutting 
portion 24 that extends integrally and radially outward from the grinding 
surface 18. In the present embodiment, the inserts 16 are fabricated 
separately from the grinding wheel 12. However, in other embodiments, the 
"inserts" may be integrally formed with the grinding wheel 12 as a single 
unitary piece by casting or machining or like processes known in the art. 
As shown in FIGS. 4 and 5, in the present embodiment, each cutting insert 
16 also includes a body portion 22 that is insertable and retainable 
within any one of the slots 14. The body portion 22 integrally extends 
from the cutting portion 24. Preferably, the body portion 22 and the 
cutting portion 24 are integrally formed as a unitary member. It will be 
appreciated, however, that the body portion 22 and the cutting portion 24 
of each slot 14 may be separately formed and secured together in any 
suitable manner. 
The cutting surface of each insert 16 is disposed such that it extends 
radially outwardly from the outer circumferential grinding surface 18 of 
the wheel 12. In this manner, the cutting surface of each insert 16 cuts 
the part to be manufactured. As is best shown in FIG. 3, a cutting portion 
24 of each insert 16 includes a peaked cutting surface. This peaked 
cutting surface has no abrasive grit and does not grind the part to be 
profiled. Rather, the cutting portion 24 comprises a cutting tool. In the 
preferred embodiment, each of the inserts 16 have cutting portions 24 that 
are identical in configuration. The insert cutting portions 24 extend 
outward from around the grinding wheel 12 grinding surface 18 in a 
co-planar spaced-apart disposition. In other words, the inserts 16 of the 
preferred embodiment are all circumferentially aligned in a single ring 
around the circumferential grinding surface 18 of the grinding wheel 12 to 
cut the identical profile in the part to be manufactured. 
In other embodiments, the cutting portion 24 of each insert 16 may have any 
configuration and may be fixed to any portion of the grinding surface 18, 
depending on the part to be manufactured. In other words, the 
configuration and/or placement of one or more insert cutting portions 24 
may differ from the others on a grinding wheel 12. By using inserts 16 
having cutting portions 24 with different configurations and placements, 
different cutting configurations may be effected in the object surface of 
a product to be manufactured. 
The body portion 22 of the cutting insert 16 is disposed in the slot 14. 
The cutting insert 16 can be held in the slot 14 in any mechanical or 
bonded fashion, such as by induction brazing or welding or by the use of a 
strong adhesive. In other embodiments, the insert 16 may comprise only a 
cutting portion 24 projecting outwardly from the exterior circumferential 
surface 18 of the grinding wheel 12. In such embodiments, the cutting 
portion 24 may be bonded to the exterior circumferential surface 18 in any 
mechanical or bonded fashion, such as by induction brazing or welding; or 
may be formed with the grinding wheel 12 by machining or casting. 
To make a combined cutting/grinding tool 10 according to the present 
invention, a blank wheel 12 is machined to the desired configuration. In 
other embodiments, the wheel 12 may formed into the desired configuration 
by other well-known methods such as casting. A plurality of slots 14 are 
placed circumferentially around the wheel 12. Each of the slots 14 extend 
inwardly from the exterior surface 18 of the wheel 12. After the slots 14 
have been placed in the wheel 12, the exterior surface 18 of the wheel 12 
is profiled to the desired configuration. Next, an abrasive grit 20 is 
applied and secured about the exterior profile configuration of the wheel 
12. The wheel 12 having the grit 20 thereon is then dressed to its final 
configuration. Next, the cutting inserts 16 are formed. Preferably, the 
outside shape of the body portion 22 closely matches the profile of 
exterior surface 18 of the grinding wheel 12 but does not extend to or 
beyond the exterior surface 18, as shown in FIG. 3. In other words, the 
body portion 22 should be shaped to lie flush with, rather than to 
protrude from, the grinding surface 18. Each of the cutting tools, i.e., 
the inserts 16, are then inserted into the slots 14 and secured either 
mechanically or bonded such as by brazing or welding. 
As representatively shown in FIG. 5, other embodiments may include larger 
slots 14' formed to receive wedge blocks 26 for mechanically retaining the 
inserts 16. The wedge blocks 26 are fabricated to fit within these wedge 
block receptacles 14' along with threaded fasteners 28 to engage and draw 
the wedge blocks 26 into the receptacles 14' to clamp the inserts 16 into 
their installed positions. 
To profile a part using a combined cutting/grinding tool 10 constructed 
according to the present invention the grinding wheel 12 is first formed 
with insert cutting portions 24 extending outward from the grinding 
surface 18 as described above. The grinding wheel 12 is then rotatably 
mounted and spun about the central rotational axis 25 by a driving 
mechanism such as an electric motor or by other means known in the art. 
The wheel 12 is spun to cause the circumferential grinding surface 18 to 
spin and the cutting portions 24 to orbit about the central rotational 
axis 25. The object surface of a product to be manufactured is then moved 
into a position contacting the spinning grinding surface 18 of the wheel 
12 and the orbiting insert cutting portions 24. The object surface of the 
product continues to be moved toward the spinning grinding surface 18 and 
the orbiting insert cutting portions 24 until the grinding surface 18 and 
cutting portions 24 have formed a desired profile in the object surface. 
The product is then removed from contact with the grinding wheel 12. 
In this manner, the object surface of a part to be manufactured is 
simultaneously ground and cut by the combination grinding and cutting tool 
10. The grinding is done by the abrasive grit 20 about the exterior 
surface 18 of the grinding wheel 12. The detail is cut into the object 
surface of the part to be manufactured by the cutting portion 24 of the 
insert 16 which extends outwardly of the exterior grinding surface 18, 
i.e., the abrading surface, of the grinding wheel 12. The bulk of the work 
done by the tool 10 in forming the part to be manufactured is done by the 
abrasive grit 20 about the exterior surface 18 of the grinding wheel 12. 
This provides the part to be manufactured with the superior 
characteristics of a ground profile. Furthermore, the detail is cut into 
the part to be manufactured by the cutting portion 24 of the insert 16. 
This provides the benefit of the intricate cuts which were not heretofore 
available by grinding alone. Thus, the combination tool 10 combines the 
benefits of producing a ground part with that of producing a machine cut 
part. 
It will be appreciated that because the configuration of the profile of the 
abrading and cutting tool 10 can take any shape, any part, or number of 
parts can be made simultaneously by one combined grinding and cutting tool 
10. While the present invention could be used to form a wide variety of 
profiles in the surfaces of items made of virtually any material, it is 
particularly useful for forming items such as rubber, plastic or urethane 
belts. The present invention may be used to form either circumferential or 
lateral profiles in the interior or exterior circumferential surfaces of 
such belts merely by altering the mounting arrangement and orientation of 
the grinding wheel 12 in relation to a given belt. 
This is an illustrative description of the invention using words of 
description rather than of limitation. Obviously, many modifications and 
variations of this invention are possible in light of the above teachings. 
Within the scope of the claims one may practice the invention other than 
as described.