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The performance of superhard materials is higher than that of conventional grinding. Although the investment cost of cubic boron nitride and diamond tools is higher, the application of ordinary abrasives in a wide range of fields has been gradually replaced by these superhard materials. The longer life and the reduction in the finishing cycle are the main advantages of superhard materials. Both of these result in a reduction in downtime (due to overhaul, waiting, etc.) resulting in cost savings. In order to be able to take full advantage of these superhard materials, their development is often to work closely with the customer to adapt it to unique workpiece processing.
First, the grinding wheel can accommodate different grinding operations (tool materials, shapes, sizes, coatings, etc.) and bonding agents (binder materials, porosity, hardness, etc.). For example, we design a customer-specified grinding machine that uses this grinding machine to machine the workpiece. Moreover, this grinding machine has a relatively high elasticity. To some extent, the selection of a compatible bonding agent can reduce the friction and deformation of the workpiece during processing. The complexity of the machining itself affects the operation of the grinding machine. For example, high-speed cutting causes the grinding wheel to become harder, but the increased feed rate makes the grinding wheel softer. Some of the advantages of superhard materials will be elaborated in the following examples.
Grinding of the gear reamer Figure 1 shows the machining of a gear reamer with a CBN ceramic wheel. It is very important to effectively dissipate the frictional heat between the grinding wheel and the gear reamer during this process. Otherwise there is a possibility of fire. Due to the high porosity of the grinding wheel, it is necessary to ensure the same area of ​​coolant when the contact length is 60 mm. The application of CBN ceramic grinding wheels in this process is due to its high strength ceramic frit and binder. Development of multi-zone composite abrasives The development trend of contemporary grinding wheels indicates that the functional structure of multi-zone composite abrasive tools has been adapted to special workpiece machining. The advantage of this creation is that it replaces the personal manufacturing process and combines the individual manufacturing processes into one device, which not only means that fixture errors can be avoided, but also saves a lot of cost. Therefore, productivity improvement is achievable.
Fine grinding of graded CBN bead grinding wheels Surface or side surfaces of objects are polished using graded CBN bead grinding wheels, such as engine parts, pump parts, bearings made of steel, high speed steel or ceramics. The graded CBN bead wheel adapts to different grinding speeds and wear levels. Unlike other grinding, this bead type wheel is also suitable for grinding very large objects, so the improved machining program can rough and finely grind Complete in one step. Nevertheless, the effect achieved by the above method can be achieved with the abrasive paste. This machining program is characterized by the ability to polish mechanical parts with a roughness of 1 micron or less. The main factors determining the design of this machining program are the surface of the workpiece, the surface of the grinding wheel and the contact force (which ranges from 10,000 N to 30,000 N).
"Cold grinding" compared to grinding is another advantage of this method, which reduces damage to the surface of the workpiece.
This machining program is highly automated. In addition, if the wheel has any damage, it will repair itself. Compared to grinding, bead-type grinding wheels are much less expensive to process, so a large amount of slurry is produced during the grinding process, and these slurryes need to be treated separately. Thanks to these advantages, saving three times or more of time and cost is achievable. A composite tool for grinding the inner and inner diameter surfaces of the inner hole The new grinding method for the inner and inner diameter surfaces of the transmission member has been introduced. Starting with some equipment, it is necessary to reduce the cost of processing machine parts. This method includes the inner diameter surface, the grinding of the surface and a considerable dressing cycle (referring to the time during which the alumina is replaced by CBN). The ceramic CBN grinding wheel developed specifically for this machining task has two functions: inner hole grinding on the left side and inner hole grinding on the right side. The biggest challenge in developing such a CBN grinding wheel is to ensure that there is sufficient coolant at the grinding contact point because the contact area between the grinding wheel and the inner bore surface and the inner diameter surface is quite large. In addition, it is very difficult to approach the contact area, which means that the handling of debris and the emission of heat are also very difficult, coupled with the pressure and heat generated by the high-speed grinding of CBN grinding wheels, resulting in risks during processing. Increase, for example: the workpiece is on fire. A reliable machining method is used to eliminate this hazard by applying a coolant between the workpiece and the CBN grinding tool. Summary and prospects The grinding wheel is the connection between the machine and the workpiece. In the example above, the grinding wheel that is specially machined for special tasks with super-hard materials or CBN not only saves processing time, but also saves costs. Compared with general mills, these super-hard materials have the following advantages: good wear resistance, long life and short dressing cycle. However, the cost of using superhard materials is higher, while taking into account functionality and longevity. Especially considering these high investment costs, grinding wheel manufacturers and users must make effective use of these materials when selecting or developing tools. Further improving the grinding efficiency lies in the use of multi-zone composite abrasives. The overall trend is increasingly accurate on surface quality and cost-effectiveness (shorter processing time, longer wheel life, longer trim intervals), which means continuous development and innovation in the field of superhard materials.
In general, high technology means the use of the latest technology is closely related to industrial growth. Grinding used to be used to machine workpieces, and has high requirements on the surface quality and contour accuracy of the workpiece. The term “high-tech grinding†therefore refers to the grinding technology currently available in all areas of industrial development. Entering foreign markets and reducing production time are key factors in the use of superhard materials. It must be borne in mind that the fracture toughness of these abrasives is limited and therefore the cost and technical advantages have to be weighed.