Flap wheel

Abstract: In one embodiment, a support member on an abrasive wheel has (a) an annular surface which fixedly supports (as by epoxy) a plurality of flaps in a partially overlapping relationship between successive flaps and (b) a central hole for receiving a mandrel which rotates the wheel. Each flap has on one of its surfaces abrasive particles facing outwardly from the annular surface. Each flap defines an acute angle with the annular surface and preferably extends at its opposite axial ends beyond the axial positions of support by such support surface to obtain a fixed positioning of the flaps relative to the support surface even at the axial positions beyond the axial ends of such annular surface. In a second embodiment, the flaps are disposed on the annular support surface in a tighter relationship than in the first embodiment so that each flap contacts adjacent flaps along a portion of its length. When the wheel is rotated with the flaps disposed adjacent a workpiece, the inner portions of the flaps provide an abrading action, partly because of their contact with one another, and the outer portions of the flaps provide a polishing action, partly because of their separation from one another. This polishing action is facilitated by the fact that (a) the flaps become separated from one another at their outer ends because of centrifugal action and (b) the grit on the flaps becomes progressively worn with progressive positions toward the outer ends of the flaps.

Description: This invention relates to an abrasive wheel. More particularly, this invention relates to an abrasive wheel in which a plurality of abrasive flaps are axially disposed on the radial periphery of a support member in a radial direction. BACKGROUND OF THE INVENTION Abrasive wheels have been known for some time. In one type of abrasive wheel of the prior art, a plurality of abrasive flaps have been provided. Each flap has been coated on one side with abrasive particles. In certain embodiments of the prior art, the abrasive wheel has included a radially disposed disc for supporting the flaps. In such embodiments of the prior art, the flaps have been attached to one surface of the disc so that each flap is disposed at an acute angle relative to the disc and in partially overlapping relationship to the adjacent flap in the plurality. In this relationship, a peripheral portion of each flap extends in an annular direction beyond the flap on which it is disposed. In this way, the progressive flaps define a complete ring. When the wheel defined by the support disc and the flaps as discussed above rotates while disposed against a workpiece, the exposed portion of each flap abrades the workpiece. The abrasive wheel is advantageous because it is compact and strong and thus provides for a positive and controlled action on the workpiece. The abrasive wheel discussed above is disadvantageous because it can be used only in a limited manner to abrade workpieces. This results from the disposition of the abrasive flaps on the disc such that the flaps are disposed in a substantially planar relationship on the disc. This limits the abrasive action of the abrasive wheel against workpiece surfaces which are exposed. Abrasive wheels have also been known in the prior art where a support member has been provided with an annular surface defined by a constant radius at progressive positions on the surface. Abrasive flaps have been provided on this annular surface to abrade a workpiece surface. However, the abrasive flaps have been loosely disposed relative to one another on this annular surface. This loose relationship has limited the effectiveness of the flaps in abrading the workpiece surface. Furthermore, the axial widths of the flaps in polymers in which abrasive grains are embedded is present at the outer margin of the base plate, which annular layer is firmly connected to the base plate and the abrasive laminae. German Patent Application No. DE-U-22,10,339 discloses a grinding rotor comprising a number of rectangular abrasive sheets consisting of energy cloth, the abrasive grains of which are fixed to a backing of fabric, synthetic resin, or paper. Two retaining rings secure the abrasive sheets by means of a hub ring and a layer of adhesive of their inner edges. The abrasive surfaces are inclined relative to the axial direction of the hub of the grinding rotor. European Patent Application No. 0 446 626 discloses an annular flexible sleeve or collar which carries spaced apart and overlapping abrasive flaps around its periphery, each of the flaps being secured such that the attitude of each relative to the sleeve or collar forms a constant substantially tangential relationship thereto. BRIEF DESCRIPTION OF THE INVENTION The present invention provides a wheel for abrading and polishing a surface of a workpiece in accordance with a rotation of the wheel, including a support member extending in a radial direction and having an outer periphery and having an axially extending rim at its outer periphery, the rim having an annular configuration; a plurality of abrasive flaps having inner and outer end portions, and an intermediate portion between the inner and outer end portions; means for attaching the inner end portions of the flaps to the axially extending rim at progressive positions around the complete periphery of the annular rim; the flaps being disposed on the axially extending rim in a radial direction and the intermediate portion of each individual one of the flaps being disposed in an overlapping relationship to, and contacting relationship with, the adjacent flaps in the radial direction when the wheel is at rest; the inner end portion of each individual one of the flaps not being in an overlapping or contacting relationship with the individual one of the adjacent flaps on one side of said each individual one of the flaps, and the outer end portion of said each individual one of the flaps not being in an overlapping or contacting relationship with the flap adjacent to the individual one of the flaps on the other side of said each individual one of the flaps; the attaching means providing an attachment of the inner end portions of the flaps to the axially extending rim in the overlapping relationship of the intermediate portion of each of the abrasive flaps with the adjacent abrasive flaps when the wheel is at rest. This invention provides an abrading and polishing wheel which has all the advantages of the prior art discussed in the previous paragraphs. The abrading and polishing wheel is able to provide both an abrading action and a polishing action on a workpiece. The abrading and polishing wheel is also able to abrade and polish surfaces not capable of being abraded or polished by the prior art abrasive or polishing. Furthermore, the abrading and polishing wheel is able to provide more positive abrading and polishing actions on such surfaces than the abrading and polishing wheel discussed. The abrading and polishing wheel of the present invention is also advantageous because the flaps in such wheel preferably have a greater width than the member supporting such flaps. This allows the abrading and polishing wheel to abrade and polish workpiece surfaces not capable of being abraded or polished by the abrasive wheels and the abrading discs of the prior art. When the wheel is rotated with the flaps disposed adjacent a workpiece, the inner portions of the flaps provide an abrading action, and the outer portions of the flaps provide a polishing action. This polishing action is facilitated by the fact that the grit on the flaps becomes progressively worn with progressive positions towards the ends of the flaps. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: Figure 1 is a schematic perspective view of an abrasive disc of the prior art and of a tool for rotating the abrasive disc with the disc disposed against a workpiece surface; Figure 2 is an enlarged perspective view of the abrasive disc shown in Figure 1 with the disc removed from the tool; Figure 3 is an enlarged fragmentary sectional view taken substantially on the line 3-3 in Figure 2 and shows on a schematic basis the inter-relationship between successive abrasive flaps on one surface of the disc; Figure 4 is a schematic perspective view, similar to that shown in Figure 1, of an abrasive wheel according to the present invention mounted on a tool for rotating the abrasive wheel; Figure 5 is a perspective view showing a first embodiment of an abrasive wheel according to the present invention and showing a support member provided by an annular flange or rim and abrasive flaps on the support member in such abrasive wheel; Figure 6 is a sectional view taken substantially on the line 6-6 of Figure 5 and shows additional details of the inter-relationship between the support member and the flaps in the abrasive wheel shown in Figure 5; Figure 7 is a fragmentary perspective schematic view of an abrasive wheel according to the invention and shows the relative disposition of successive flaps on the wheel; Figure 8 is an enlarged fragmentary sectional schematic view of a portion of the wheel shown in Figures 5 to7, and shows the wheel rotatably disposed against a surface of a workpiece when the wheel is new and before any use is made of the wheel in abrading or polishing the surface of the workpiece; and Figure 9 is an enlarged fragmentary sectional schematic view of a portion of the wheel shown in Figures 7 and 8, this view being similar to that shown in Figure 7, and shows the wheel rotatably disposed against a workpiece when the flaps in the wheel have become partially worn. DETAIL DESCRIPTION OF THE INVENTION Figures 1-3 illustrate an abrasive wheel, generally indicated at 10, of the prior art. The abrasive wheel 10 includes a support plate 12 which may preferably be made of a suitable material such as steel and which may be provided with an annular configuration. The support plate 12 may have an indented central portion 14 with a centrally disposed hole 16 for receiving a mandrel 18 for rotating the support plate. The support plate 12 also includes a portion 20 disposed radially outwardly from the central portion 14. The portion 20 is preferably inclined at a relatively shallow angle from a planar configuration to facilitate the disposition of the abrasive wheel 10 against a workpiece surface not shown) which is to be polished by the abrasive wheel. A tool 21 rotates the mandrel 18 and the abrasive wheel 10. A plurality of abrasive flaps 22 are disposed on the portion 20 of the support plate 12. Each of the flaps 22 is formed from a thin strip of a backing material. Abrasive particles 24 are suitably secured to one surface of each of the flaps 22. The flaps 22 are disposed on one another in a partially overlapping relationship and are secured at their inner ends to the portion 20 of the support plate 12 as by a suitable material such as an epoxy resin adhesive material 124. As shown in Figure 3, the flaps 22 are separated from adjacent flaps along the lengths of the flaps. Furthermore, the epoxy 124 for securing the different flaps to the portion 20 of the support plate 12 is in a common plane. Because of the partially overlapping relationship, the outer portion of each of the flaps 22 extends outwardly for a particular distance. This extension is essentially in an axial direction. Furthermore, because of this partially overlapping relationship, each of the flaps is disposed at an acute angle relative to the portion 20 of the support member 12. The flaps 22 have a rigid disposition relative to the portion 20 of the support member 12 even when the abrasive wheel 10 is rotated against a workpiece surface to be polished. The abrasive wheel 10 has certain advantages but also has significant disadvantages. The rigid relationship between the different flaps 22 causes the flaps to be effective in abrading a surface of a workpiece when the portion 20 of the. support plate 12 is disposed against the surface. However, the support plate 12 cannot be disposed against all surfaces because of the disposition of the support plate in the form of a disc. Another disadvantage is that the flaps 22 provide either an abrading action or a polishing action on a workpiece depending upon the characteristics of the abrasive particles 24 on the flaps 22 but do not provide a combination of an abrading action and a polishing action on the workpiece. An abrading action may be considered to constitute a coarse removal of material from the surface of a workpiece. A polishing action may be considered to constitute a fine removal of material from the surface of the workpiece so that the surface of the workpiece becomes smooth. Figures 4 to 9 show an abrasive wheel, generally indicated at 58, constituting a preferred embodiment of the present invention; Figures 5-9 show the abrasive wheel 58 in more detail. A support plate 60 having a disc-like configuration is provided with a central hole 62 for receiving a mandrel (not shown) and has an annular flange or rim 64 at the radially outward end of the support plate. Flaps 66 are attached as by an epoxy resin adhesive material 68 (Fig. 6) to the flange 64 at the inner ends of the flaps. Successive ones of the flaps 66 may have a partially overlapping relationship with respect to the adjacent flaps. The flaps 66 extend axially beyond the flange 64 at the opposite axial ends of the flaps. Each flap 66 has abrasive particles 67 suitably attached to one surface (i.e. the outer surface when so attached)of the flap and the flaps are disposed on the flange or rim in overlapping relationship so that the particles face outwardly and form a continuous abrasive surface around the rim when the wheel is new. The embodiment shown in Figures 5-9 has certain important advantages. It is able to abrade or polish surfaces not capable of being abraded or polished by the abrasive wheels of the prior art. This results from the preferably extension of the abrasive flaps in the axial direction beyond the axial periphery of the support plate at the opposite axial ends of the support plate. The effective abrading or polishing action of the abrasive wheel 58 additionally results from the firm and solid relationship between the adjacent flaps 66 around the annulus defined by the flaps even at the axial positions of the flaps beyond the support plate 58. Because of this firm and solid relationship, the flaps 66 are able to provide an effective abrading or polishing action on the workpiece surface when such workpiece surface is contacted by such flaps. The embodiment shown in Figures 5-9 is also advantageous in that the flange 64. on the support plate 60 provides a firm support for the flaps 66. Figures 7-9 illustrate greater detail still of the embodiment shown in Figures 4 and 5. The embodiment shown in Figures 4-9 has one hundred and twenty (120) flaps 66 illustratively spaced at three degree (3°) intervals around the annular periphery of the flange 64. Not all of these flaps are shown. Each of the flaps 66 is attached to the annular periphery of the support member 64 as by the epoxy 68. Each individual one of the flaps 66 does not overlap the adjacent flaps at the inner end of such individual one of the flaps or at the outer end of such individual one of the flaps. It is only in the middle portion of each individual one of the flaps 66 that such flap overlays or overlaps adjacent flaps. The overlapping of the intermediate portion of each individual one of the flaps 66 with the adjacent flaps involves a physical contact between such individual one of the flaps and the adjacent flaps in the overlapping region. This is illustratively shown in Figures 8 and 9. When a new wheel generally indicated at 58 as shown in Figure 9 is disposed against a workpiece 102 and the wheel is rotated, the outer end of each flap 66 is disposed against the workpiece. An abrading action is accordingly provided by the abrasive particles 67 against the workpiece. This action causes the abrasive particles 67 to become partially worn. The wearing of the abrasive particles 67 increases progressively toward the outer ends of the flaps 66. This progressive wearing of the abrasive particles 67 toward the outer ends of the flaps 66 is schematically illustrated at 104 in Figure 9. With continued rotation of the wheel 58 against the workpiece 102, the outer ends of the flaps 66 become worn so that no abrasive particles exist at the outer ends of the flaps. This is illustrated schematically at 106 in Figure 9. However, as the outer ends of the flaps 66 become worn, the abrasive particles 67 adjacent the worn ends 106 become progressively worn. This is illustrated schematically at 108 in Figure 9. As the outer ends of the abrasive flaps 44 become progressively worn, progressive portions of the flaps inwardly from the outer ends of the flaps become exposed. These progressive portions of the flaps 66 inwardly from the outer ends of the flaps have particles 67 which have not been previously disposed against the workpiece 102. These particles 67 are thus able to provide a full abrading action. It will accordingly be seen that the exposed inner ends of the flaps 66 provide an abrading action because the particles at these inner ends are newly exposed and are at full strength. This abrading action is enhanced because the intermediate portion of each individual one of the flaps 66 engages the adjacent flaps so that the action of the intermediate portion of each individual one of the flaps is fortified or solidified by the engaging portions of the adjacent flaps. The abrading action provided by the flaps 66 progressively decreases in intensity with progressive positions on the flaps toward the outer ends of the flaps. As the abrading action progressively decreases in intensity towards the outer ends of the flaps 66, the polishing action of the flaps progressively increases. As will be appreciated, this polishing action is more gentle than an abrading action. The increase in the polishing action at the progressive positions towards the outer ends of the flaps 66 result sin part from the fact that the amount of material on the abrasive particles 67 progressively decreases with progressive positions towards the outer ends of the flaps because the abrasive particles have become progressively worn towards the outer ends of the flaps. The increase in the polishing action at the progressive position towards the outer ends of the flaps 66 also results in part from the fact that the flaps 66 become progressively separated from one another at their outer ends during the wheel rotation because of the centrifugal forces exerted on the flaps. The increase separation of the flaps 66 at the outer ends of the flaps causes a softened action to be provided by the abrasive particles 67 on the outer ends of the flaps 66 against the workpiece. In this way, most of the area in each flap 66 can be used to provide a combination of an abrading action and a polishing action. The provision of the combination of an abrading action and a polishing action by the abrasive flaps 66 in the wheel 58 constitutes an important advantage of the present invention. Since each flap 66 in the wheel 58 abrades and polishes the workpiece 102, the wheel provides no chatter marks on the surface of the workpiece 102. In view of the combined action of abrading and polishing by each of the flaps 66 on the workpiece 102, the abrasive particles 67 can be provided with a coarsened grain without affecting the fineness of the polishing action. This shortens the time required to abrade the surface of the workpiece 102. Because of the relatively soft abrading and polishing actions provided by each of the flaps 44, the wheel 100 experiences no bounce when the flaps contact the workpiece. Actually, the wheel 100 has a resilience in contacting the surface of the workpiece 102. This resilience causes the wheel 100 to be forgiving when used by a novice and causes the wheel to have flexible properties when used by a skilled workman. These flexible properties allow the skilled workman to provide abrading and polishing actions with a high precision on the surface of the workpiece 102. The wheel 100 also operates on a relatively cool basis because of the separation between the flaps 44 during the rotation of the wheel against the workpiece 102 and because of the polishing action at the outer tips of the flaps. The wheel 100 also operates on a quieter basis than the wheels of the prior art because of the relatively soft abrading action and because of the polishing action at the outer ends of the flaps 44. The axial overhangs provided at the opposite axial ends of the flaps 44 also allow the wheel 100 to grind the surface of a workpiece in tight corners such as corners having angles of 90°. Such corners illustratively occur at the bottoms of tanks and cylinders. The abrasive wheel 100 is also able to provide edge grinding. Although this invention has been disclosed and illustrated with reference to particular embodiments, the principles involved are susceptible for use in numerous other embodiments which will be apparent to persons of ordinary skill in the art.

Claims: A wheel (58) for abrading and polishing a surface of a workpiece in accordance with a rotation of the wheel (58), including: a support member (60) extending in a radial direction and having an outer periphery and having an axially extending rim (64) at its outer periphery, the rim (64) having an annular configuration; a plurality of abrasive flaps (66) having inner and outer end portions, and an intermediate portion between the inner and outer end portions; means (68) for attaching the inner end portions of the flaps (66) to the axially extending rim (64) at progressive positions around the complete periphery of the annular rim; the flaps (66) being disposed on the axially extending rim (64) in a radial direction and the intermediate portion of each individual one of the flaps (66) being disposed in an overlapping relationship to, and contacting relationship with, the adjacent flaps (66) in the radial direction when the wheel (58) is at rest; the inner end portion of each individual one of the flaps (66) not being in an overlapping or contacting relationship with the individual one of the adjacent flaps (66) on one side of said each individual one of the flaps (66), and the outer end portion of said each individual one of the flaps (66) not being in an overlapping or contacting relationship with the flap (66) adjacent to the individual one of the flaps (66) on the other side of said each individual one of the flaps (66); the attaching means (68) providing an attachment of the inner end portions of the flaps (66) to the axially extending rim (64) in the overlapping relationship of the intermediate portion of each of the abrasive flaps (66) with the adjacent abrasive flaps (66) before any rotation of the wheel (58). A wheel (58) as claimed in claim 1, wherein the flaps (66) are disposed relative to one another to provide for an abrading action against the workpiece by the intermediate portion of each flap (66) during the rotation of the wheel (58) and to provide for a polishing action against the workpiece by the outer end portion of each of the flaps (66) during the rotation of the wheel (58). A wheel (58) as claimed in either preceding claim, wherein the contact between the intermediate portion of each individual one of the flaps (66) and the flaps (66) adjacent the individual one of the flaps (66) provides for an abrasive action on the surface of the workpiece when the intermediate portion of each individual one of the flaps(66) contacts the workpiece surface. A wheel (58) as claimed in any preceding claim, wherein each individual one of the flaps (66) becomes separated from the adjacent flaps (66) at the outer end portion of the individual one of the flaps (66) during the rotation of the wheel (58) and wherein the separation between the individual one of the flaps (66) and the adjacent flaps (66) at the outer end portion of the individual one of the flaps (66) provides for a polishing action on the surface of the workpiece when the outer end portion of the individual one of the flaps (66) contacts the workpiece surface. A wheel (58) as claimed in any preceding claim, wherein the flaps (66) are disposed relative to one another to provide for contact between the intermediate portion of each individual one of the flaps (66) and the inner end portion of the flap (66) adjacent to the individual one of the flaps (66) on the one side of the individual one of the flaps (66) before any rotation of the wheel (58) and to provide for a contact between the intermediate portion of each individual one of the flaps (66) and the outer end portion of the flap (66) adjacent to the individual one of the flaps (66) on the other side of the individual one of the flaps (66) when the wheel (58) is at rest. A wheel (58) as claimed in any preceding claim, wherein the abrasive particles (24) on the outer end portion of each of the flaps (66) become partially worn to facilitate the polishing action against the workpiece at the outer end portion of the flap (66). A wheel (58) as claimed in any preceding claim wherein the flaps (66) extend axially beyond the annular rim (64) at the opposite axial ends of the annular rim (64) and extend at the positions beyond the annular rim (64) in a direction having a component extending radially outwardly from the annular rim (64). A wheel (58) as claimed in any preceding claim wherein the overlapping and contacting relationship in the radial direction between the intermediate portion of each flap (66) and the adjacent flaps (66), when the wheel (58) is at rest, causes the disposition of the flaps (66) to be rigid even at the axial disposition of the flaps (66) beyond the opposite axial ends of the axially extending rim (64). A wheel (58) as claimed in any preceding claim wherein the angle between the inner end portion of each flap (66) and the annular rim (64) provides for the overlapping relationship between the flap (66) and the adjacent flaps (66) in the intermediate portion of the flap (66). A wheel (58) as claimed in any preceding claim wherein the attaching means constitutes an epoxy (68) attached to the inner end portions of the abrasive flaps (66) at the positions-at which the abrasive flaps (66) abut the annular rim (64). A wheel (58) as claimed in any preceding claim wherein each of the flaps (66) is provided with abrasive particles (24) on its outwardly facing surface. A wheel (58) as claimed in any preceding claim wherein the support member (60) is provided with a centrally disposed hole (62) to receive a mandrel for rotating the support member (60), the abrasive flaps (66) and the attaching means (68).

Inventors: EMERSON GRAHAME W, EMERSON, GRAHAME W.
Applicants: MERIT ABRASIVE PROD, MERIT ABRASIVE PRODUCTS, INC.
Application year: 1997
Main classification: B24D13
IPC codes: B24D13