Introduction of Abrasive Tool Manufacturing Process

Grinding materials of different materials have different production processes. Consolidated super-abrasive abrasive tools are mainly abrasive tools made of diamond, cubic boron nitride, etc. and a bonding agent. Due to the high price of diamond and cubic boron nitride and good wear resistance, the consolidated abrasive tools manufactured by them are different from ordinary abrasive consolidated abrasive tools. In addition to the super-hard abrasive layer, there is a transition layer and a matrix. The super-hard abrasive layer is the part that plays a cutting role and is composed of super-hard abrasive and a bonding agent.

The substrate is used as a support in the grinding process, and is composed of metal, bakelite or ceramics. The transition layer is used to connect the substrate and the super-hard abrasive layer, and is composed of a bonding agent, which can sometimes be omitted. Commonly used bonding agents are resins, metals, electroplated metals and ceramics. The manufacturing process of fixed abrasive tools includes: distribution, mixing, forming, heat treatment, processing and inspection, etc. Depending on the bonding agent, the manufacturing process is also different. The ceramic bond abrasive tool mainly adopts the profiling method. After weighing the abrasive and the bonding agent according to the weight ratio of the formula, they are placed in a blender and mixed evenly, put into the metal mold, and the abrasive tool blank is formed on the press. The blanks are dried and then loaded into the kiln for roasting. The firing temperature is generally about 1300°C. (Guide: Small Collection of Steel Knowledge)

When using low melting point sintering bonding agent, the sintering temperature is lower than 1000℃. Then it is processed accurately according to the specified size and shape, and finally the product is checked. Resin bond abrasive tools are generally molded on a press at room temperature, and there is also a hot pressing process in which heating and pressure are applied under heating conditions. After molding, it is hardened in a hardening furnace. When phenolic resin is used as the binder, the curing temperature is 180-200°C. Rubber bond abrasives are mainly mixed with a roller machine, rolled into thin sheets, and then punched out with a punching knife; some loose materials are put into a metal mold and formed on a press. After molding, it is vulcanized in a vulcanizing tank at a temperature of 165-180°C.

The manufacturing process of metal bond abrasive tools includes powder metallurgy method and electroplating method, which are mainly used for super-hard abrasive cemented abrasive tools. The powder metallurgy method uses bronze etc. as the binder, after mixing the materials, it is formed by hot pressing or pressurization at room temperature, and then sintered. The electroplating method uses nickel or nickel-cobalt alloy as the electroplating metal, and the abrasive is fixed on the substrate according to the electroplating process to make abrasive tools. Special types of mills include sintered corundum abrasive tools and fiber abrasive tools. Sintered corundum abrasive tools are made by mixing and molding alumina micropowder and appropriate amount of chromium oxide, and sintering at about 1800°C. This kind of abrasive has a compact structure and high strength, and is mainly used for processing parts such as clocks and meters. Fiber abrasives are made of fiber filaments (such as nylon filaments) that contain or adhere abrasives as raw materials. They have good elasticity and are mainly used for polishing metal materials and their products.

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