Abstract: At present, the world's grinding and grinding technology is developing rapidly. The requirements for the performance and quality of abrasive products are greatly improved. The production technology of foreign abrasive tools is developing rapidly. In order to meet the needs of domestic manufacturing development, China has to rely on imports. High-grade ceramic abrasives to meet the needs of high-efficiency, high-precision machining in the automotive, aerospace, machine tool and other industries. Although China's ceramic abrasive technology has developed rapidly and achieved gratifying results, super-hard ceramic abrasives and special ceramic abrasives have reached a new level of technology, but it should be noted that there is still a certain gap with advanced foreign technology. . Ceramic abrasive products still face important tasks of product innovation, improvement of production processes, improvement of product quality, reduction of energy consumption and environmental pollution.
This paper adopts the comparative analysis method, from the international standard, domestic standard, industry standard, the production level of domestic and foreign enterprises, the manufacturing level of ceramic abrasive tools, the types and applications of ceramic abrasive tools, and the technical level of ceramic abrasives at home and abroad. Conduct a comparative analysis to find out the gap between the technical level of China's ceramic abrasive tools and the advanced level of foreign countries.
Key words: ceramic abrasive technology horizontal balance gyroscopic strength comparative analysis
1 Introduction Since the reform and opening up, especially in the past ten years, China's entire abrasives industry has made great progress, can be said to be a leaps and bounds, the output of all major products At the forefront of the world. Ceramic abrasive technology has developed rapidly and achieved gratifying results. Super-hard ceramic abrasives and special ceramic abrasives have also reached new technical levels, but it should be noted that there is still a certain gap with advanced foreign technology.
2 Development of ceramic abrasives In 1877, the United States used clay as a binder to make abrasive cerAmong the total domestic abrasives, the output of ceramic abrasives has been accounting for most of the total. In the past ten to fifteen years, the output of ceramic bond abrasives has increased by two to four times in European countries. The demand for ceramic bond diamonds and cubic boron nitride abrasives is increasing and is considered one of the most promising grinding processes in mass production. In terms of terms defined in the production of superhard materials, the glass binders, glass-ceramic binders, glass-ceramic binders, silicate binders, etc., which are common in the literature, are all ceramic binders. Abrasives made of ceramic binders are called ceramic bond abrasives, referred to as ceramic abrasives. Cubic boron nitride ceramic bond abrasives, the quality of such abrasive products in China is quite different from that of similar foreign products. Domestic users also rely mainly on imports. High-speed ceramic grinding wheels can only reach 65 m/s in China, and 80-100 m/s in foreign countries. Domestic grinding wheels cannot meet the requirements of high-speed grinding machines of 80-100 m/s. Ceramic bond grinding steel ball grinding wheel, the current domestic use of firing shrinkage to achieve super hard hardness, product quality is not easy to control, high scrap rate, the need to use non-shrinkage production technology to improve quality. Superhard material ceramic abrasives and low temperature ceramic bond abrasives have become the main trends in the development of ceramic abrasives. The development of ceramic grinding tools should meet the requirements of high-speed, high-efficiency and high-precision development, and develop high-speed grinding wheels and high-precision grinding tools suitable for CNC grinding machines and automatic production line production requirements.amic wheels, marking the birth of ceramic abrasives. In 1930, ceramic abrasives began to choose the organization number. In 970, ceramic binder cubic nitrogen Boron wheel appeared. After the 1980s, foreign ceramic abrasive tools developed rapidly and the technical level was high. China's ceramic abrasive tools have been developed since the 1950s. From the past to the present, ceramic abrasives have always played a major role in the overall composition of abrasive tools, despite the continuous development of the types of bonding materials and the types of abrasive tools. Increasing, the output of ceramic abrasives is declining in the total output of abrasive tools, but it still accounts for a large proportion in the total amount of abrasive tools, as shown in the table below.
China's ceramic abrasives accounted for the proportion of total abrasives in recent years, the industry, especially the abrasive industry enterprises, such as Henan Luoyang, Hubei Danjiangkou and other places through the relocation and upgrading and product upgrading, and actively improve product grades, indeed achieved Results. Up to now, there are many manufacturers of medium-sized abrasives that have completed the relocation and transformation, eliminated outdated equipment and improved the level of technological equipment. The technical level has been greatly improved, but overall there is still a considerable gap with advanced foreign technology. Here, we mainly do some analysis and comparison with the foreign countries in the manufacture and application of ceramic abrasive tools to find out the gap.
3 Comparative analysis of technical level of ceramic abrasives at home and abroad In order to understand the gap between the technical level of ceramic abrasives at home and abroad, we use comparative analysis and comparison methods, from international standards, domestic standards, industry standards, production levels of domestic and foreign enterprises, ceramic grinding With regard to the manufacturing level, the types and applications of ceramic abrasives, the technical level of ceramic abrasives at home and abroad is compared and analyzed. We have selected ceramic grinding tools from some large companies at home and abroad to compare and analyze the corresponding representative ceramic grinding tools in China. For comparative analysis, there should be a common benchmark. This benchmark is the utilization rate of ceramic abrasive tools. This benchmark is different for different countries and different ceramic abrasive products. Therefore, when comparing the technical level of ceramic abrasives, the difference in the intensity of application should be considered. 3.1 Domestic and foreign ceramic abrasives manufacturers Compared with foreign representative abrasive manufacturers, NORTON in the United States, TAROHT in Austria, WINTER in Germany, and Unicon in the United Kingdom. Vincent (VINCENT), USA's Bayden (BAYSTATE), Switzerland's WINTERTHUR, etc., Saint-Gobain Group is headquartered in France, with more than 1,000 financial consolidation subsidiaries in 45 countries. There are production companies with a total of 171,000 employees. Saint-Gobain Abrasives (Shanghai) Co., Ltd. is a wholly-owned enterprise of Saint-Gobain Group in China, located in the Minhang Economic Development Zone of Shanghai. Production and sales of precision ceramic grinding wheels using advanced production techniques and modern management methods. Saint-Gobain Abrasives products include bonded abrasives, including grinding wheels, oilstones and grinding heads; coated abrasives, abrasive belts for sanding, polishing, sanding, sanding and sanding. Superhard materials, diamond and CBN wheels, diamond saw blades and diamond dressing pens, as well as cutting and drilling tools designed to cut, grind and polish silicon carbide, concrete, masonry, metal and other superhard materials.
Saint-Gobain Abrasives has NORTON, FLEX0. VIT, CORA, WINTER, UNICON and other world-renowned abrasive tools brands. The company has developed a range of common ceramic bond abrasives and superhard materials (CBN, diamond) abrasives and other tools for the automotive industry. Saint-Gobain Abrasives (Shanghai) Co., Ltd. is a wholly-owned enterprise of Saint-Gobain Group in China. It has strong technical force and high technical content. It develops and owns patented ultra-fine crystal sintered corundum abrasive, which is produced by crystallizing gel sintering process. It has a grain size of several times that of ordinary white corundum d, Jt, high abrasive grain strength, micro-crushing performance, excellent grinding efficiency and high precision in terms of grinding difficult-to-grind materials, and has excellent characteristics. At the same time, the dressing amount of the grinding wheel can be greatly reduced, and the service life of the grinding wheel can be prolonged. Due to the relatively high price of SG abrasives, they are mixed with corundum abrasives according to different requirements during use, forming different grades. In order to give full play to its performance, a special ceramic bond was developed, one is a high-efficiency low-temperature bond, and the other is a ceramic CBN wheel with a high-temperature and low-temperature combined camshaft at an atmospheric hole, with a speed of 125 m/s. The company also recommends grinding wheels of various price points for coarse grinding and fine grinding according to different workpieces and different grinding requirements, and gives a comparison of their grinding effects to facilitate user selection. Conventional abrasive wheels for the grinding of car engines and gearbox parts typically use speeds of 45 to 63 m/s.
Austria's TYROLIT was founded in 1919. In l952, the first batch of glass fiber reinforced cutting blades and finishing wheels were created. In 1974, the first batch of ceramic bond CBN grinding wheels was produced. Since the 1990s, with the United States DIAMOND PRODUCTS company and Switzerland's HYDR0. STRESS's partnership has successively taken over a number of internationally renowned abrasives manufacturers such as VINCENT in Italy and BAY STATE in the United States. It has become a powerful and influential supplier of abrasive tools in the world, with 18 branches distributed throughout the world. The network covers more than 60 countries and regions.
WINTHERTHUR (Switzerland) is a well-known company producing precision grinding wheels. It mainly produces ceramic binders, air hole slow feed wheels, microcrystalline sintered ceramic abrasive wheels and ceramic bond CBN grinding wheels. The ceramic bond agent is used for the grinding of turbine blades by the grinding hole, the barrel grinding method, the barrel rolling method and the partial grinding method, and it is said that it is one of the few manufacturers that can produce such a grinding wheel. . Its ceramic bond single or double thread forming grinding wheel can be used to cut precision ball screws, threads and worms by cutting or tangential feed grinding. The company has a CNC machine tool for forming complex faces of machined grinding wheels. It can supply pre-formed grinding wheels of profiled surface to ensure the geometrical accuracy of various grinding wheel profiles and reduce the user's on-site installation dressing time and dressing tool consumption.
Domestic abrasives manufacturers include Baige Group, Shanghai Grinding Wheel Factory, Suzhou Grinding Wheel Factory, Sixth Grinding Wheel Factory, Subei Grinding Wheel Factory Shandong Luxin High-tech Industrial Co., Ltd., Zhengzhou Abrasives Grinding Research Institute.
These domestic companies actively improve the manufacturing level of abrasive tools and attach importance to technological innovation and the development of new products. In 2005, Shandong Luxin invested 100 million yuan to build a series of wear-resistant sand and high-grade abrasive tools in the new park, seriously researching and adopting new technologies, new equipment, new technologies and new materials, and this is in the forefront of domestic counterparts, Taishan brand grinding wheel The static balance performance is better than domestic similar products by more than 30%.
The Dove Group uses a unique process to manufacture a grooved, sandwiched, multi-form combination of grinding crankshaft and camshaft ceramic grinding wheels with a maximum speed of 60m/s. The threaded ceramic flat and double beveled wheels have a maximum diameter of 500mm and the highest speed. Up to 60m/s; the newly developed grinding railway rail grinding wheel, the speed of use is up to 50m / s, installed in groups on the grinding machine, rail surface grinding on the railway line, the amount of grinding is not low At 0.16mm.
Zhengzhou Abrasives Grinding Research Institute's speed of l20m / s ceramic bond CBN grinding wheel, has been successfully used in the grinding of the camshaft of the car in the imported CNC grinding machine manufactured by SCHAUDT MIKROSA. The grinding efficiency and grinding effect have reached the level of similar foreign products.
From the above comparison, we can draw conclusions. In recent years, in order to adapt to the opportunities and challenges brought by China's accession to WT0 and the expansion of domestic demand, as well as modern ceramic abrasives enterprises in high-quality production processes and equipment, modern marketing strategies, modern integrated manufacturing technology The socialization needs of corporate culture construction, information construction environmental protection and labor safety are increasing. China's ceramic abrasives production enterprises have accelerated the pace of restructuring, restructuring, reform, transformation and product structure adjustment. Foreign and private enterprises are also gradually The rise and growth has greatly improved the overall level of China's ceramic abrasives enterprises, but there are still some gaps compared with foreign advanced enterprises. 3.2 Comparison of technical level of ceramic abrasives firing kiln at home and abroad At present, China's large and medium-sized ceramic abrasives production backbone enterprises mainly use the first-level kiln, or are gradually transforming the first-level kiln, these enterprises Including the original state-owned large and medium-sized backbone enterprises, the restructuring of joint-stock enterprises, foreign-funded enterprises and joint ventures, and some private enterprises developed this year, the number of enterprises more than ten. Mainly located in coastal areas, Jiangsu and Zhejiang and domestic large and medium cities. Its annual production capacity is generally above 1000-3000 tons, its product varieties have certain characteristics, can produce high-end products, and the quality of some products has reached the level of similar foreign high-quality products. This type of enterprise is the mainstream enterprise in the production of ceramic abrasives in China. The remaining small and medium-sized enterprises use the third-level kiln, and some of them are gradually being transformed into the second-level kiln. Among them, there are many small-injection direct-fired drawer kiln. These enterprises are numerous and distributed throughout the country.
In the past ten years, China's ceramic abrasives have been burned into kiln, especially in the past three to five years. This is mainly due to the improvement of the overall quality of the enterprise, the increasing competition in the market, and the strengthening of national environmental protection. China's modern ceramic abrasive kiln is compared with foreign advanced level. In the aspect of drawer kiln, China's self-designed and built modern large and medium-sized high-speed thermostat burner new energy-saving and environmentally-friendly computer automatic control drawer kiln adopts international leading The horizontally synchronized development of computer systems, control valves, control components, refractory materials, etc., coupled with the optimization of the design of the times, the overall level of kiln construction has reached the advanced level of foreign countries, and some of the main performance is better than the recent foreign level. For example, the Sixth Design and Research Institute of Machinery Industry has designed and built more than ten large and medium-sized high-speed temperature-regulating burners in China. The energy-saving and environmentally-friendly drawer kiln has better operating indexes than the similar kiln imported from abroad, among which the fieldbus technology controls the drawer. The kiln and computer distributed control system drawer kiln also won the National Machinery Ministry's Science and Technology Progress Award and Excellent Engineering Design Award. In terms of tunnel kiln, the gap between China and foreign countries is nearly 30 years. At present, except for a foreign-funded enterprise using advanced tunnel kiln, China's ceramic abrasive-fired tunnel kiln is basically the technology of the 1960s and 1980s. In terms of kiln technology, kiln materials, kiln structure and the orientation and adaptability to ceramic grinding tools, there is a big gap between modern ceramic grinding tools and tunnel kiln firing. Although the Sixth Design and Research Institute of the Machinery Industry completed the research project of the new ceramic abrasives tunnel kiln in the former Ministry of Machinery in 994, the enterprises in order to adapt to the ceramic abrasives market, many varieties, small batches, fast pace Demand, more flexibility and adaptability of the drawer kiln, coupled with the production of various enterprises is not large enough, so the new ceramic abrasives firing tunnel kiln has not been implemented in the enterprise.
In addition, there is still a certain gap between China and foreign advanced technology in optimizing the product firing process system and charging system. Generally speaking, China's firing technology system is relatively thick, and the work done on optimizing the firing system for different types, specifications, grain sizes, hardness and scope of use still needs to be deepened. 3.3 Comparison of technical level of domestic and international ceramic abrasive products The German Krebs & Riedel company, which is famous for producing special grinding wheels in the world, is an example. Its super-hard abrasive-CBN/diamond ceramic grinding wheel has a speed of 20% per year in recent years, especially 40% in 2005. Growth is enough to see that the development trend of abrasives is to develop in the direction of superhard abrasive-CBN/diamond ceramic grinding wheels. The reason is that the thermal stability, non-iron affinity, high hardness and wear resistance of CBN abrasives are good. The grinding wheel used for it has high grinding efficiency and good surface quality, especially for hard workpieces. There are a wider range of applications.
The domestic super-hard abrasives enterprises have introduced advanced foreign production technology, and the product performance and quality have also been rapidly improved. The ceramic bond diamond and CBN grinding wheel production technology has been greatly improved. CBN's ceramic bond grinding wheel will be more widely used than resin grinding wheels. Ceramic CBN grinding wheel can be modified according to human needs, and it is not easy to generate heat during work. This is an indispensable condition for high-volume, high-precision production. It can also produce grinding wheels with different hardness according to the requirements of machining workpieces to adapt to processing. need.
For the development and correct selection of binders and fillers, the grinding wheel for the production of atmospheric holes should have good wear resistance. Atmospheric hole grinding wheels are essential for deep grinding and strong grinding processes. They carry the chips and transport the cutting fluid to the contact area to avoid burning the workpiece, especially for forming and precision grinding to ensure the formability of the grinding wheel. .
High-speed grinding wheel, working speed of 60-80m/s, working speed of CBN grinding wheel is more than 100m/s. It has been widely used in Europe, especially some special grinding machines, such as Junker's crankshaft and camshaft grinding machine with Krebs&Riedel grinding wheel. Its working speed reaches 125m / s, which is characterized by more abrasive grains, high efficiency and good surface quality per unit time, which prolongs the life of the grinding wheel.
In the production of new ceramic abrasive tools, some companies have introduced advanced foreign technology and actively developed new technologies, and the performance and quality of the products have also been rapidly improved. For example, Suzhou Industrial Park Saili Technology Co., Ltd. established a joint venture with American Diamond Tools Co., Ltd. in 2004 to establish the Fuzhou Free Trade Zone Meida Meng Superhard Materials Co., Ltd., using the full set of technology and equipment of the US company to produce diamond and CBN grinding wheels. The company's abrasive manufacturing technology has reached a new level, its grinding camshaft grinding wheel speed of more than 80m / s, reaching the advanced level of similar foreign products. But on the whole, there is still a certain gap between China's ceramic grinding wheel and foreign advanced level.
4 Comparison of the performance of ceramic abrasive tools at home and abroad The performance of abrasive products is an important indicator for testing the quality of abrasive tools. The quality standards of abrasive products can be divided into four levels: international standards, national standards, industry standards and enterprise standards. The quality standards of abrasive tools include basic standards and technical standards. The basic standards include terms, symbols, code numbers, and so on. Technical standards include dimensional tolerances, row tolerances, appearance defects, static balance of the abrasive tools, strength, hardness, etc. Technical regulations and inspection methods, as well as abrasive safety rules, marking and packaging of abrasive tools, acceptance and storage of abrasive tools Wait. 4.1 Hardness of ceramic abrasives Hardness of abrasive tools is one of the main properties of abrasive tools. The hardness measurement methods of abrasive tools include hand cone detection method and hardness tester. Hardness testers include sandblasting hardness testers, Rockwell hardness testers, mechanical cones, and audio hardness testers. China's national standard GB/T2490—1 984 and GB/T2491-1984 stipulate that for ceramic bond abrasives with particle size F36～Fl50, the hardness is measured by sandblasting hardness tester; for ceramic bond abrasives with particle size Fl80～Fl200, hardness Determined by a Rockwell hardness tester. For F30, coarse and small grinding wheels, small grinding heads and other grinding tools that cannot be measured with sandblasting hardness tester or Rockwell hardness tester can be measured by hand cone method or other methods, but must be compared with standard grinding wheel module. 4.2 Balance of the grinding wheel The International Organization for Standardization (ISO) defines the static imbalance of the grinding wheel as follows: the axis of rotation of the grinding wheel does not coincide with its axis of inertia, and only the equilibrium deviation state. China's national standard GB/Q2492-1984 specifies that ceramic bond ordinary grinding wheels with an outer diameter of 150mm and larger are subjected to static unbalance inspection. The inspection quality of the grinding wheel ranges from 0.2 to 300 kg. If the international standard stipulates that the outer diameter is more than 100mm, static imbalance check is required. However, for the cylindrical, cylindrical grooved, grinding needle, grinding brick, cup shape, bowl shape, cut ore, empty groove, screw fastening and centerless guide wheel, the balance wheel is not checked. 4.3 Rotational Strength of Grinding Wheels The State (GB/T2493-1995) stipulates that ceramic bond grinding wheels with a diameter of 150mm and larger, in addition to cylindrical, cylindrical grooved, grinding needles, grinding bricks, holes, bolts, Excavation ore grinding wheel and centerless grinding wheel are not checked for strength, and the rest are inspected according to the highest working line speed of the grinding wheel.
The rotary strength inspection device is a rotary test machine. At present, the domestic generally adopts stepless speed regulation and digital display devices.
5 Conclusion In recent years, foreign ceramic abrasive technology has made new progress. China's ceramic abrasive industry has developed rapidly. Domestic enterprises have paid great attention to research and development of new technologies, and have also made great achievements. Some technologies have reached the international advanced level. The ceramic bond super-abrasive grinding wheel has also developed rapidly, and the growth momentum is strong. The ceramic bond CBN grinding wheel has been widely used in the processing of automobile camshaft and crankshaft. At present, the processing of superhard material tools and silicon wafers such as PCD and PVB has been adopted. Ceramic bond diamond grinding wheel, some special-shaped tools need to be shaped and ground, and this type of grinding is performed on the CNC machine tool with ceramic bond diamond grinding wheel.
However, from the perspective of the entire ceramic industry, there is indeed a certain gap compared with the level of advanced foreign technology. This requires us to work together to achieve the leap-forward development of ceramic abrasive technology, and accelerate the country through further technology introduction, digestion and absorption. The pace of development of ceramic abrasive products to meet the needs of the domestic market and occupy a place in the international ceramic abrasives market.
BRIEF INTRODUCTION
Henan Yuteng Grinding Material Co., Ltd. is located in Kaifeng City, Henan Province. Is a set of production, research and development, service as one of the grinding agent, grinding, polishing products professional company, specializing in the production and sales of coated grinding tools derived ancillary products: flocking sand disc, blade, all kinds of special-shaped grinding disc, sponge grinding block, steel paper disk, ring sand belt, sand ring and automotive polishing products.
Our main products are Velcro Disc,Abrasive Paper,Fiber Disc,Flap Disc,Abrasive Cloth,Abrasive Belt.
Relying on the advantages of the industrial base, the company has advanced production equipment and strong technical force, complete testing equipment to ensure that the products are sharp, wear-resistant and high strength, and the product quality reaches the advanced level of similar international products.
Our products can be used for all kinds of metal watches and stainless steel, alloy steel, non-alloy steel, non-ferrous metals, titanium alloy and other grinding and wire drawing, polishing and so on; Wood, high-medium fiberboard, flower board, composite board, glass, rubber and other table grinding and polishing. Widely used in automobile, steel, building materials, shipping, aviation, wood, plastic, leather and other industries.
We provide customers with the best surface treatment program, according to the actual needs of customers "tailored" a variety of specifications of sand pan, sand belt, sand carbon and emery cloth ring polishing products.
The company's flexible operating mechanism and all customer-centric concept, we in addition to provide you standardized, serialized products, but also according to your special requirements, for you to manufacture high-quality, personalized non-standard coated with abrasive products.
