Diamond Electrostatic Sand-Planting Process for Anti-Clogging Abrasive Belts
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Solution Overview
Problem
Diamond electrostatic sand-planting is challenging due to diamond's difficulty in forming dipoles in electric fields, leading to poor polarization and adsorption, resulting in low grinding force and clogging issues, especially when applied to high-hardness materials like tungsten carbide coatings.
Innovation Solution
A diamond electrostatic sand-planting process involving soaking diamond micropowder in aluminium sol, surface modification with KH560, gradual electric field reduction, and specific coating steps to enhance bonding with glues, ensuring effective polarization and adhesion, including primer and compound glue application to prevent clogging and improve cutting force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If diamond abrasive is used for high-hardness material processing, then cutting force is improved, but polarization effect in electrostatic field deteriorates
Solution Approach 1:
The patent introduces an aluminium sol treatment as an intermediary process between the diamond abrasive and the electrostatic field. The aluminium sol modifies the surface properties of diamond particles, enabling them to be effectively polarized in the electrostatic field while maintaining their high cutting force characteristics. This intermediary treatment resolves the contradiction by bridging the gap between diamond's inherent non-polarizable nature and the requirements of electrostatic sand-planting.
2Strength
If diamond abrasive is coated with glue layer, then adhesion is improved, but grinding force is lost due to passivation or clogging
Solution Approach 1:
The patent employs a multi-stage glue application process with controlled parameters. The primer layer is applied first to provide initial adhesion, followed by the base glue in a second stage. This staged approach with controlled timing and composition allows optimal bonding while preventing excessive glue buildup that would cause clogging and loss of grinding force. The parameter control includes timing, composition, and thickness of each glue layer.
3Productivity
If electrostatic sand-planting is applied to diamond, then production efficiency is improved, but particle size control deteriorates for particles larger than 240#
Solution Approach 1:
The patent segments the electrostatic sand-planting process into distinct stages: aluminium sol treatment, primer application, base glue application, and compound glue application. This segmentation allows each stage to be optimized independently, particularly for particle size control. Larger diamond particles (above 240#) can be handled effectively by adjusting parameters in each segment, maintaining both high productivity and precise particle size control throughout the process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process results in an anti-clogging, high-cutting diamond abrasive belt with enhanced grinding force and extended life, effectively treating high-hardness tungsten carbide coatings with improved uniformity and adhesive properties.
Implementation Method 1
S1. soaking diamond micropowder with an aluminium sol under stirring; S3. modifying a surface of the diamond micropowder with a surface modifier
Implementation Method 2
The principle is to use a high-voltage electrostatic field to make the abrasive become a charged body and be adsorbed on the substrate coated with a binder by virtue of the electrical properties of the abrasive
Implementation Method 3
gradually decreasing strength of an electric field by placing the diamond micropowder into the electric field, so that the diamond micropowder with a poor polarization effect sheds off under own gravity, and then separating the diamond micropowder with the poor polarization effect from the diamond micropowder
Implementation Method 4
S5. coating a surface of a substrate with a primer to increase a binding force with a base glue and the diamond micropowder
Data Source
AI summary
The present disclosure relates to a diamond electrostatic sand-planting process, including the following steps: modifying a surface of diamond micropowder to polarize an electric field of the diamond micropowder; screening the diamond micropowder to remove the diamond micropowder with a poor polarization effect; coating a surface of a substrate with a primer to increase a binding force with a base glue and the diamond micropowder; continuing to coat a portion of the substrate coated with the primer with the base glue; sand-planting the diamond micropowder into the substrate in an electrostatic field; continuing to coat one surface of the substrate on which sand-planting is completed with a compound glue; and drying and curing one surface of the substrate coated with the compound glue.