Grinding wheel wearing too fast? Find out the "culprit", easily extend life!
Release time:
2025-03-21
Grinding wheel is an indispensable "sharp tool" in the grinding process of PCD and CBN tools, but frequent replacement of grinding wheel not only reduces production efficiency, but also increases costs. Many factories have encountered the problem of "short life and fast wear" of grinding wheels. Why will the grinding wheel "retire" in advance? Behind the selection error, improper operation, or equipment problems? Decarte reveals the main reasons why grinding wheels wear too fast, and provides targeted solutions to help you save time and money!
The main reason
PCD tool material
The first is the hardness and material, the PCD tool hardness is very high, and the hardness difference with the grinding wheel is relatively small, in the grinding process, the grinding particle is subjected to the reaction force is large, which is easy to lead to accelerated wear. The wear resistance and toughness of PCD material are better, and the grinding wheel will have a greater friction and extrusion effect on the grinding wheel, so that the grinding particles are easier to fall off and break.
Grinding process parameters
Secondly, the grinding speed, feed rate, grinding depth and other grinding parameters have different wear degrees to the grinding wheel.
When the grinding speed is too high, the friction between the grinding wheel and the PCD tool is intensified, the contact number of the abrasive particle and the tool increases within the unit time, and the impact force and friction force of the abrasive particle increase, thus accelerating the wear and fall off of the abrasive particle.
Excessive feed means that the grinding wheel removes more material each time it cuts, and the cutting force and friction borne by the grinding particles also increase correspondingly, which makes the grinding particles more prone to wear and break, resulting in accelerated grinding wheel wear.
If the grinding depth is too deep, the grinding force will be greatly increased, and the pressure and shear force of the grinding particles will be increased during the cutting process, which will easily cause the grinding particles to break and fall off, and then accelerate the wear of the grinding wheel.
Improper selection of grinding wheel
Finally, different processing materials and processing requirements need to match the corresponding parameters of grinding wheel material, particle size, hardness and so on. If the hardness of the grinding wheel is too high, the abrasive particles are not easy to fall off for materials with greater toughness, which will lead to the abrasive particles on the surface of the grinding wheel becoming dull due to wear and cannot be updated in time, thus aggravating the overall wear of the grinding wheel. On the contrary, if the hardness of the grinding wheel is too low, the abrasive particles are easy to fall off, and the grinding wheel will wear too fast.
solution
For workpiece materials with high hardness and toughness, high-performance grinding wheels such as cubic boron nitride (CBN) grinding wheel or diamond grinding wheel can be selected. These wheels have higher hardness and wear resistance, and are better able to cope with the grinding of difficult materials. At the same time, during the grinding process, the grinding parameters can be appropriately reduced to reduce 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, check the matching accuracy of the aperture of the grinding wheel and the spindle to ensure that the matching clearance is appropriate. After installation, professional balancing equipment should be used to debug the static balance and dynamic balance of the grinding wheel, so that the grinding wheel is in a balanced state when rotating.
At the same time, according to the nature of the processing material (such as hardness, toughness, etc.) and processing requirements, choose the appropriate grinding wheel. For example, when grinding materials with higher hardness, a grinding wheel with lower hardness and coarser grain size should be selected; When grinding materials with lower hardness, grinding wheels with higher hardness and finer granularity can be used.
In actual production, these methods should be integrated according to the specific situation to optimize the processing technology.
