This Is How Ultra-thin Diamond Cutting Discs Are Made

The 0.04mm diamond ultra-thin cutting disc is actually made in this way!

 

Ultra-thin diamond cutting discs have gradually gained people's attention because of their advantages such as ultra-thin cutting groove width, smooth cutting fracture, low reject rate and high cutting efficiency. Common blades currently used can be roughly divided into two types: electroplated blades with a thickness of 15-100 μm and resin blades with a thickness of 100-500 μm. Today, the editor found a production method that can achieve 40μm. I hope to share and discuss with grinding friends~

 

 

2. Preparation of a special chemical conversion film;

3. Precisely control blade thickness ≤ 40μm;

4. The surface of the knife body is smooth and no nodules;

5. The blade must have sufficient strength and toughness to ensure that the blade does not hit or deflect at ultra-high speeds, and the width of the blade is ≤50 μm;

 

According to the thickness of the tool, the requirements for use accuracy and the principle of the diamond tool, the diamond used is determined to be a high-quality micro-single crystal. The domestic broken crystal diamond powder with a particle size of 10 μm was used in the test, and the high-grade micro-single crystal with a particle size of 5 μm was used in the practical stage. The selected diamonds are strictly screened by solution sedimentation method.

3.2 Preparation of chemical conversion film

3.2.1 Chemical conversion coating and its requirements

The chemical conversion film is a special conductive film prepared on the cathode substrate before electrodeposition. Its requirements are:

1. It has good electrical conductivity, so that the electrodeposition process can proceed smoothly;

2. Prevent the strong combination of the electrodeposition material and the substrate, and facilitate the stripping of the coating.

After various tests, the results show that the phosphate chemical conversion coating of austenitic stainless steel is the best.

3.2.2 Preparation

Phosphate chemical conversion coating formula (g/L): 5 oxalic acid, 15 phosphoric acid, 4 sodium oxalate, 10 disodium phosphate, 5 sodium chlorate. The operating conditions are: ambient temperature 20°C, working time 5min.

3.3 Blade production method

3.3.1 Body electroplating

The Ni-Co-diamond micropowder flakes were deposited on the stainless steel cathode substrate with the conversion film prepared by the composite electrodeposition method. The formula of the plating solution is (g/L): nickel sulfate 220~240, cobalt sulfate 15~30, boric acid 25~35, sodium chloride 10~20, patent additive No. 1 0.6~0.8, patent additive No. 2 0.08~0.1, Diamond powder 5~10. The operating conditions are: electroplating temperature 45~50°C, pH value 4.1~405, Dk=2A/dm2, air pump stirring, intermittent time 10min.

3.3.2 Thickness control

The thickness of the product is accurately controlled to 35 μm by using a single-board computer thickness controller. The existing problem is to strictly control the "nodulation", and the existing patented process method solves the "nodulation" problem of the deposited layer.

3.3.3 Stripping

Using heat peeling technology, the method has been included in the patent.

3.3.4 Cold stamping

The peeled sheet is punched and formed with a special hard alloy punch on a cold stamping forming machine, and the product is shown in Figure 1.

3.3.5 Bracket installation

The cutting disc is directly clamped on the flange driven by the air bearing. The cutting disc with its own bracket is glued to the aluminum alloy flange with adhesive on a special coating machine, as shown in Figure 2.

The test results meet the cutting requirements, and the cost is reduced, which is welcomed by the manufacturers. Currently, the product is being industrialized.