Self-Sharpening Diamond Grinding Wheel Composite Binding Agent
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Solution Overview
Problem
Superhard material products with metal binding agents face issues such as poor self-sharpness, easy blockage, and low grinding efficiency, leading to increased grinding force, deformation, and reduced accuracy, necessitating frequent trimming and high costs.
Innovation Solution
A composite binding agent is developed using an additive raw material composition of Bi2O3, B2O3, ZnO, SiO2, Al2O3, Na2CO3, Li2CO3, MgCO3, and CaF2, which is uniformly dispersed and has a microcrystalline structure, improving the grinding efficiency and service life of superhard material products without significantly reducing the strength of the metal binding agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal binding agents are used in diamond grinding wheels, then strong holding force and high strength are achieved, but poor self-sharpness and easy blockage occur
Solution Approach 1:
The patent uses a composite binding agent combining metal powder (Cu, Sn, Co, Al, Fe, Cr, Ti) with ceramic powder (alumina, silica, magnesia) and organic binder in specific proportions. This composite structure provides both the strong holding force of metal and the self-sharpness properties of ceramic, resolving the contradiction between strength and self-sharpness
Solution Approach 2:
The binding agent is designed with different components serving localized functions: metal powder provides holding force and ductility, ceramic powder provides high-temperature stability and self-sharpness, while organic binder ensures uniform distribution. This local differentiation of material properties within the composite resolves the contradiction
2Productivity
If excessive quantity of barren materials (graphite, ceramic, iron oxide) is added to improve grinding performance, then grinding efficiency improves, but strength of abrasive layer and holding force are severely reduced
Solution Approach 1:
The patent optimizes the quantitative parameters of the composite binding agent: metal powder 40-70%, ceramic powder 10-30%, organic binder 5-15%. This precise parameter control ensures sufficient holding force while maintaining improved grinding performance, avoiding the strength loss caused by excessive additive quantities
Solution Approach 2:
Instead of using traditional barren materials that reduce strength when added in excess, the patent employs a composite binding agent where ceramic powder provides the necessary functional properties at lower concentrations, maintaining abrasive layer strength while improving grinding efficiency
3Temperature
If ceramic powder with high fire resistance is used in composite binding agent, then high-temperature stability improves, but uniform dispersion during sintering becomes difficult
Solution Approach 1:
The patent introduces organic binder as an intermediary substance that facilitates uniform dispersion of high-fire-resistance ceramic powder during the sintering process. The organic binder acts as a dispersant that prevents agglomeration and ensures homogeneous distribution, resolving the contradiction between high-temperature stability and uniform dispersion
Solution Approach 2:
The composite binding agent is designed with functional differentiation where organic binder specifically addresses the dispersion issue while ceramic powder provides fire resistance. This local assignment of functions resolves the contradiction between high-temperature stability and uniform dispersion
4Force
If diamond grinding wheel operates without self-sharpness, then initial grinding force is high, but grinding efficiency decreases and trimming frequency increases
Solution Approach 1:
The composite binding agent with ceramic powder provides self-sharpness functionality, allowing the grinding wheel to automatically maintain its cutting edges during operation. This self-service property eliminates the need for external trimming operations and maintains consistent grinding efficiency throughout the wheel's service life
Solution Approach 2:
The self-sharpness property ensures continuous effective grinding action without interruption for trimming. The ceramic powder in the composite binding agent continuously regenerates sharp cutting edges, maintaining uninterrupted productive operation and consistent grinding efficiency
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 self-sharpening diamond grinding wheel with the composite binding agent exhibits high self-sharpness, strength, and processing efficiency, eliminating the need for trimming during its life cycle, reducing costs, and maintaining consistent grinding force, thereby addressing the limitations of traditional diamond grinding wheels.
Implementation Method 1
a composite binding agent made from ceramic powder and bronze powder
Implementation Method 2
heating up to 1200 ̃1400° C. and keeping the temperature for 1 ̃3 h to provide a mixture; cooling the mixture obtained in Step 1) to 850 ̃950° C.
Data Source
AI summary
Disclosed are an additive raw material composition and an additive for superhard material product, a composite binding agent, a superhard material product, a self-sharpening diamond grinding wheel and a method for manufacturing the same. The raw material composition consisting of components in following mass percentage: Bi2O3 25%˜40%, B2O3 25%˜40%, ZnO 5%˜25%, SiO2 2%˜10%, Al2O3 2%˜10%, Na2CO3 1%˜5%, Li2CO3 1%˜5%, MgCO3 0%˜5%, and CaF2 1%˜5%. The composite binding agent is prepared from the additive and a metal composite binding agent. The self-sharpening diamond grinding wheel prepared from the composite binding agent has high self-sharpness, high strength, and fine texture, is uniformly consumed during the grinding process, does not need to be trimmed during the process of being used, and maintains good grinding force all the time, fundamentally solving the problems of long trimming time and high trimming cost of the diamond grinding wheel (FIG. 1).