How to extend the service life of diamond grinding wheels

Diamond (CBN) grinding wheel is an indispensable "tool" in the grinding process of PCD and CBN cutting tools, but frequent replacement of grinding wheel not only reduces production efficiency, but also increases costs. Many factories have encountered the problem of short lifespan and fast wear of grinding wheels. Why did the grinding wheel retire early? Is it a selection error, improper operation, or equipment problem behind it? Chinadiatool.com reveals the main reasons for rapid wear of grinding wheels and how to extend the service life of diamond grinding wheels.

main reason

1 PCD tool material aspect

• Firstly, in terms of hardness and materials, PCD cutting tools have extremely high hardness, with a relatively small difference in hardness compared to the abrasive grains of the grinding wheel. During the grinding process, the abrasive grains are subjected to a large reaction force, which can easily lead to accelerated wear. PCD material has good wear resistance and toughness, and during grinding, it will cause significant friction and compression on the abrasive grains of the grinding wheel, making them more prone to detachment and breakage.

 

2 In terms of grinding process parameters

• Secondly, different grinding parameters such as grinding speed, feed rate, and grinding depth have varying degrees of wear on the grinding wheel.
• When the grinding speed is too high, the friction between the grinding wheel and the PCD tool intensifies, and the number of contacts between the abrasive particles and the tool increases per unit time. The impact force and friction force on the abrasive particles increase, thereby accelerating the wear and detachment of the abrasive particles.
• Excessive feed rate means that the amount of material removed by the grinding wheel increases each time it cuts, and the cutting and friction forces borne by the abrasive particles also increase accordingly. This will make the abrasive particles more prone to wear and breakage, leading to accelerated wear of the grinding wheel.
• If the grinding depth is too deep, it will significantly increase the grinding force, and the pressure and shear force on the abrasive particles during the cutting process will increase, which can easily cause the abrasive particles to break and fall off, thereby accelerating the wear of the grinding wheel.

 

3 Improper selection of grinding wheel

• Finally, different processing materials and requirements need to be matched with corresponding parameters such as grinding wheel material, particle size, hardness, etc. If the hardness of the grinding wheel is too high, for materials with high toughness, the abrasive particles are not easy to fall off, which will cause the abrasive particles on the surface of the grinding wheel to become dull due to wear and unable to be updated in a timely manner, thereby exacerbating the overall wear of the grinding wheel; On the contrary, if the hardness of the grinding wheel is too low, the abrasive particles are prone to fall off, which can also cause the grinding wheel to wear out too quickly.

 

solution

For workpiece materials with high hardness and toughness, high-performance grinding wheels such as cubic boron nitride (CBN) grinding wheels or diamond grinding wheels can be selected. These grinding wheels have higher hardness and wear resistance, which can better cope with the grinding of difficult to machine materials. Meanwhile, during the grinding process, the grinding parameters can be appropriately reduced to minimize the wear of the grinding wheel.

 

When installing the grinding wheel, it is necessary to strictly follow the operating procedures to ensure that the grinding wheel is firmly installed. Before installation, it is necessary to check the accuracy of the fit between the grinding wheel aperture and the spindle to ensure that the fit clearance is appropriate. After installation, professional balancing equipment should be used to perform static and dynamic balancing debugging on the grinding wheel, so that the grinding wheel is in a balanced state when rotating.

 

At the same time, select the appropriate grinding wheel based on the properties of the processing material (such as hardness, toughness, etc.) and the requirements of the processing technology. For example, when grinding materials with high hardness, grinding wheels with lower hardness and coarser grain size should be selected; When grinding materials with lower hardness, a grinding wheel with higher hardness and finer particle size can be selected.

 

In actual production, these methods should be comprehensively applied according to specific situations, and the processing technology should be continuously optimized