diamond wheel

Diamond abrasives have the characteristics of high hardness, good wear resistance, low grinding force and heat, making them very suitable for efficient grinding of ceramic materials. Diamond grinding wheels have significantly different effects from ordinary grinding wheels in grinding: high production efficiency, high machining accuracy, low surface roughness value, low grinding wheel wear, long service life, and improved labor conditions. They can solve many grinding problems of difficult to machine materials.

Diamond grinding wheels are generally composed of three parts: an abrasive layer, a transition layer, and a substrate. At present, most of the research work focuses on the preparation of the abrasive layer, and the matrix material and shape of the diamond wheel will also affect the grinding process of ceramic materials. The design of the matrix should also be an important part of the diamond wheel. The matrix material affects the dynamic characteristics of diamond grinding wheels, further affecting the dynamic characteristics of the contact area between the grinding wheel and the workpiece, thereby affecting the grinding surface quality, grinding force, and grinding wheel wear of ceramics.

1 diamond grit 

The selection and design of diamond grinding wheels usually need to consider a series of factors such as abrasive type and particle size, binder, concentration, and wheel shape and size. The abrasives used for diamond grinding wheels can be divided into two types: natural diamond and artificial diamond.

The particle size of diamond abrasive directly affects the surface quality and processing efficiency of ceramic workpieces. The selection of abrasive particle size should be based on process conditions, processing requirements, and the optimal size range. In general, coarse-grained diamonds can improve the lifespan and material removal rate of grinding wheels, while fine-grained diamonds can achieve better surface quality.

For the grinding of oxide ceramic materials, electroplated diamond grinding wheels with natural abrasive particles can be selected. Natural diamonds have sharp cutting edges, do not contain metal impurities, and have good impact resistance. The sintered metal bonded diamond grinding wheel for grinding oxide ceramic materials often uses artificial diamond abrasive particles with good and complete crystal shape, which have high grain strength, sharp cutting edges, and can obtain longer grinding wheel life and cutting characteristics. Resin bonded grinding wheels using artificial diamond abrasives are more suitable for processing non oxide ceramic materials. Artificial diamond abrasives have irregular grain shapes and a large number of intracrystalline cleavage surfaces, and new cutting edges are continuously obtained through micro crushing of the abrasive. Fragile diamond grinding is most suitable for manufacturing resin bonded diamond grinding wheels, and the elasticity and wear characteristics of resin make the diamond blade exposed and sharpened more ideal.

2 binder 

The bond of diamond grinding wheels can be divided into resin bond, ceramic bond, and metal bond, among which the generalized metal bond includes bronze or cast iron bond, electroplating bond, and brazing bond. The bonding strength of different binders to abrasives varies, and each binder corresponds to its own concentration range of diamond abrasives. The concentration of diamond grinding wheels affects the grinding efficiency and processing cost of ceramic materials.

3 Recycling and Remanufacturing of Diamond

Usually, the abrasive layer of diamond grinding wheels cannot be completely consumed. When the abrasive layer becomes thinner or the diamond wears out, the grinding wheel with expensive diamonds remaining loses its cutting ability and is scrapped. In the face of a large amount of annual total diamond consumption and the demand of developing Low-carbon economy, recycling and remanufacturing diamond grinding wheels is one of the effective means to improve diamond utilization and save manufacturing costs.

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