Diamond cut off wheel for industrial ceramic

1 Brief introduction of industrial ceramics

2Types of diamond cut off wheel for industrial ceramic

2.1 Resin bond diamond cut off wheel for industrial ceramic

2.2 Metal bond diamond cut off wheel for industrial ceramic

2.3Electroplated diamond cut off wheel for industrial ceramic

3 Conclusion

Industrial ceramics are more and more widely used in the field of advanced science and technology. They are brittle, crack easily in processing, affecting the surface quality and performance. Cutting is the first process when machining industrial ceramics, and the quality of cutting has great influence on grinding and polishing efficiency and production cost. Therefore, we need to learn about the types and features of a diamond cut off wheel for industrial ceramic and choose the suitable ones.

1 Brief introduction of industrial ceramics

Industrial ceramic refers to compounds made of metal and non-metallic components such as oxygen, boron, nitrogen and silicon, and raw material made of metal elements compounds by sintering. Industrial ceramic features high hardness, high wear resistance, corrosion resistance, high-temperature resistance, low density, and low expansion coefficient, which make it widely used in chemical industry, machinery, metallurgy, aerospace, and other fields.

It can be used to manufacture corrosion resistant pumps, gas turbine burners, sealing ring pistons, bearings, and other parts. Its application is expanding day by day, and it becomes one of the pillars of modern engineering structural materials, just like composite materials and metal materials.

The surface and the edge of sintered industrial ceramics are prone to defects, so they must be processed. At present, there are main several steps for processing, such as cutting, grinding and polishing. Cutting is usually the first step of industrial ceramics processing and cut the ceramic into the required shape, which takes up about 10.4% of the mechanical processing.

With high hardness and high brittleness of ceramics, there will be cracks, damages, and burns on the surface of the workpiece when cutting, which reduces the quality and efficiency of cutting. And the quality and efficiency of cutting will have a direct impact on the quality and efficiency of grinding and polishing processes.

2Types of diamond cut off wheel for industrial ceramic

At present, there are resin bond diamond cut off wheels, metal bond diamond cut off wheels, electroplated diamond cut off wheels for industrial ceramic cutting.

2.1 Resin bond diamond cut off wheel for industrial ceramic

Features: Resin bond has good self-sharpening. It has high cutting efficiency and small cutting force, is widely used for processing ceramic materials.

At present, resin bond diamond cut off wheels are mostly solidified by organic resin bond by hot pressed. They have good self-sharpening when cutting and can reduce the surface roughness of the workpiece. However, owing to the poor wettability of resin to diamond, it is difficult to achieve chemical bonding between bond and diamond.

The main holding force of bond to diamond is a mechanical bonding force, so the holding force of resin bond to diamond is not strong. If improve this situation, it should improve the mechanical bonding force of resin bond to abrasives.

  Improvement strategies for traditional resin process:

Zhejiang University of Technology (China) and The University of Tokyo(Japan) have done a lot of research on bonded resin cut off wheels. Mainly use ultraviolet bonded resin with short time and fast bonding speed can be completed from a few seconds to a few minutes. In the solidification process, the change from liquid to solid is only the result of the increase of molecular weight, not the volatilization of solvents, which is pollution-free. At the same time, compared with thermally bonded resin, energy saving is 90%.

When solidification technology is used for resin cut off wheels, the wheels need to be manufactured by the ways of layering because of the effect of solidification thickness. Compared with hubless cut off wheels, the bonding strength of light solidification is weaker and adds some magnetic substances in resin to improve the bond agent strength.

S.B. LEE has also improved the structure of resin cut off the wheel. It is sandwich structure, and coarse grit abrasive grains are in the middle to ensure the cutting efficiency of the wheel. While fine grit abrasive grains are on both sides to improve the quality of the workpiece.

2.2 Metal bond diamond cut off wheel for industrial ceramic

Features: high bonding strength, good formability, long service life, widely used for cutting industrial ceramic.

Metal bond diamond cut off wheels are mostly made by bronze bond and powder metallurgy hot pressed and welded. They have high holding strength, high-temperature resistance, good thermal conductivity, good wear resistance, long service life and can withstand big loads. However, there are inevitable shrinkage and deformation in the sintering process of the cut off wheel. Then, there is the problem-dressing difficulty.

  Improvement strategies for metal bond diamond cut off wheel technology:

There are many methods for dressing metal bond diamond cut-off wheel, such as electrolytic in-process dressing( ELID), electrolytic spark discharge dressing(ECDD), laser dressing, ultrasonic dressing, and etc. Among them, the study of electrolytic in-process dressing is the most mature. Improve the problem of dressing and processing workpiece together by electrolytic removal of a bond agent.

Tanaka of Japan introduced the pore structure of porous vitrified bond cut off wheel into the metal bond cut-off wheel from the view of tool manufacture. The abrasive of the cut off wheel is easy to be cut out and dressed, and improve the dressing of metal bond tools.

2.3 Electroplated diamond cut off wheel for industrial ceramic

Features: Simple manufacture method, easy control thickness, high cutting edge, no dressing

There is no strong chemical metallurgical bond on the interface between electroplated metal and matric and abrasives. The abrasives are only mechanically wrapped in the coated metal. The holding force is small and the diamond falls off easily. The diamonds fall off easily which can cause the reduction of processing efficiency of cut off wheels when heavy-duty machining.

  Technology improvements of the electroplated diamond cut-off wheel

Dr.Liu(China) made a composite electroplated diamond circular saw blade by composite electroplating. It improves the bonding strength between the matrix and the composite coating by the method of matrix incision and pre-plating of the nickel-cobalt alloy.

Dr.Guo( China) developed an electroplated cutting blade with the flange. Deposit the diamond powder on the stainless steel base by composite electrodeposition, and then put the cutting blade to stick to the flange.

Conclusion:

There are 3 kinds of diamond cut off wheels with their own advantages and disadvantages. Customers need to choose the suitable diamond cut off wheels in the view of the specific material of industrial ceramic. There is a process of testing and comparison.

In addition to the above 3 kinds of diamond cut off wheel for industrial ceramic, there is also vacuum brazed diamond cut-off wheel, I will release the articles for you in the near future. Maybe it is the cut off wheel with new technology used in cutting industrial ceramic and will become a new choice for ceramic.

If you want to know some about industrial ceramic grinding and polishing, you can look at our article:

Experimental Study of Electroplated Diamond Abrasive Belt for Alumina Ceramic

How to choose the best diamond grinding wheel for industrial ceramics