Solutions for the grinding process of abrasive materials

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To achieve optimal grinding results with abrasive materials requires a detailed and systemic approach. This includes using the appropriate abrasive grain, the selection of a grinding wheel with the correct characteristics, the use of suitable grinding fluids, and implementation of effective grinding techniques. Below we will look into each of these aspects.

Part One: Selection of the Grinding Wheel

1. Choosing the Right Abrasive

Selecting the appropriate abrasive is paramount in achieving efficient grinding processes. Materials like white corundum (WA), zirconia alumina (ZA), single crystal corundum (SA), micro-crystalline corundum (MA), green silicon carbide (GC), and cubic boron nitride (CBN) are commonly employed abrasives. For instance, using zirconia alumina for grinding stainless steel not only boosts grinding efficiency but also reduces the risk of burn marks. Single crystal corundum is highly effective for machining high-hardness, high-toughness materials like ordinary high-speed steel, vanadium high-speed steel, stainless steel, and high-temperature alloys. In some cases, combining multiple abrasives in varying proportions to create a composite grinding wheel can yield superior results compared to using a single abrasive.

2. Employing Different Grit Sizes

Incorporating two abrasives with different particle sizes in a grinding wheel, in a specific ratio, enhances its durability, ultimately extending its service life.

3. Selecting Appropriate Hardness and Structure

When grinding abrasive materials, opt for wheels with relatively lower hardness and a more porous structure. Lower-hardness wheels tend to shed abrasive particles during grinding, which rejuvenates the cutting edge and results in lower grinding temperatures and forces. This minimizes the risk of workpiece surface burns and reduces chip adhesion to the wheel.

Part Two:  Selection of Grinding Fluids

Choosing the right grinding fluid is crucial in improving the machinability of abrasive materials. For instance, when grinding high-temperature alloys, as well as titanium alloy, using light-colored sulfurized cutting oil as a grinding fluid significantly increases metal removal rates and grinding ratios. Similarly, when grinding steel-based hard alloys with diamond abrasives, utilizing boron sand and triethanolamine water solution as a grinding fluid can alleviate chip adhesion on the wheel's working surface, leading to improved grinding ratios and reduced workpiece surface roughness.

Part Three: Rational Selection of Grinding Parameters

1. Workpiece Speed

Opt for higher workpiece speeds to mitigate or prevent workpiece burns. However, when utilizing deep creep-feed grinding, lower workpiece speeds are advisable to avoid overheating.

2. Wheel Speed

In most cases, grinding wheel speeds should be kept below 35 m/s. However, for specific abrasive materials, higher wheel speeds can sometimes yield favorable results.

3. Grinding Depth

Given the challenging machinability of abrasive materials, it is generally advisable to employ smaller grinding depths. For instance, when grinding titanium alloy with green silicon carbide wheels, using smaller grinding depths can lead to higher grinding ratios and greater metal removal rates.

Implementing the right grinding strategies for abrasive materials is a critical aspect of ensuring high-quality finished products. By carefully selecting grinding wheels, fluids, and parameters, manufacturers can optimize their grinding processes, leading to enhanced productivity and superior product quality.