Common problems in the manufacturing process of resin bond diamond grinding wheels

The manufacture of resin bond diamond grinding wheel relates to many craftsmanship, and there are some problems in the processes of mixing, forming, hardening, and processing.

(1) Mixing process: The key to mixing is uniformity. The molding material should achieve the uniform distribution of the ingredients and maintain looseness, but should not appear obvious powder leakage. The material must be evenly mix and have good forming properties.

(2) Forming process: At present, most of the domestic companies use rotating distributing mechanism, but due to the limitations of the rotating distributing mechanism, the mixed material is unevenly distributed. The position tolerance and the static balance are poor.

(3) Hardening process: This is the most critical production process. There are two factors that easily cause quality problems. One is the temperature difference of the curing oven or the firing kiln is too large; the other is the improper way of installing the furnace. The temperature difference of the hardening furnace is too large, causing the hardening of the diamond grinding wheel to deviate from the set hardening specification (hardening curve), so that the curing (hardening) quality of the grinding wheel cannot be fully guaranteed.

(4) Processing procedures (mainly large diameter and high thickness resin bond diamond grinding wheel): resin bond diamond grinding wheel, especially large diameter and high thickness, or grinding wheels with strict dimensional tolerances, must be processed after hardening to ensure the geometric size, shape and balance of the grinding wheel.

(5) The production formula and process parameters are copied mechanically.

Of course, in addition to the manufacturing process issues, there is also equipment tooling issues.

(1) Equipment problems: Production equipment is an important material condition for the production of grinding wheels. Some companies don’t have sufficient equipments, such as lack of good mixing machines, small tonnage specifications, etc.; at the same time, equipment maintenance is poor, and is not easy to guarantee the product quality.

(2) Tooling problem: Some of the smaller enterprises have weak tooling management, and there is no good storage place, and they are piled up and down at the production site.

Inspection equipment problems:

(1) Raw material inspection, process inspection and pre-shipment inspection are important contents for diamond grinding wheel manufacturers to implement effective inspection and control, but there are fewer manufacturers that truly achieve standardized management. The main problems are related to the incomplete systems, unimplemented functions, lax management, short and lack of control of inspection equipment, and poor professional quality of inspection personnel.

(2) Incomplete inspection equipment

The inspection equipment is not complete. There are three major pieces inspection equipments for resin bond diamond grinding wheel: rotary strength testing machine; hardness machine; static balancer (dynamic balancer is also required for diamond grinding wheels). There should also be radial runout tester, bore gauge, vernier caliper, cutting performance tester, etc.