EN
Diamond and CBN wheels are major investments in high accuracy grinding. They perform outstandingly on hard and abrasive materials until they do not. Wheel chipping is one of the most irritating and expensive problems that users have to deal with. Such damage does not only harm the usefulness of the wheel, but also results in bad surface finishes, inaccurate tolerances, and unnecessary cost. Zhengzhou Ruizuan Diamond Tool Co., Ltd. is aware of this difficulty. Over the decades of experience in the manufacturing and application support, we have found the usual offenders that cause chipping and what is more important, the effective measures implemented to stop it.
Perception of the Source of Wheel Chipping
Hardly ever does chipping have no cause. Frequently, it is a side effect of the stress or influence that the wheel structure is not able to absorb. A major reason is that it is not handled or mounted properly. The slightest impact on a hard surface can cause a microscopic crack that spreads in the course of operation. Another critical factor is mechanical shock in the grinding itself. This may either be as a result of an unbalanced feed rate, sudden introduction of a hard piece into the work piece, or through extreme vibrations of an unbalanced spindle or machine tool. In addition to that, specification of the wheel which is not appropriate to the application at hand (i.e. bond hardness, grit size or concentration) may result in overly strong grinding forces which will localize fracture and chipping at the working end.
Best Practices of Prevention and Longevity
It is always cheaper to prevent than to cure. The initial and most important process is the initial right installation. The wheel must always be mounted on a clean and true flange and tightened to the correct and specified torque by the manufacturer. When a wheel is placed on a spindle, it must fit freely. When you are operating it is important to optimize your grinding parameters. Do not have aggressive and single-pass depths of cut. Rather, apply lighter and steady passes to control heat and stress. Sufficient and proper use of coolants is a must. It will not only suppress thermal shock but also swarf will be washed away and the particles will not be able to damage the cut and create impact. The basic requirement to achieve a stable environment of your high quality wheel is a well-maintained machine with a rigid spindle and minimal runout.
The Significance of Selecting the appropriate Wheel to the task
A wheel can never be everything to everything. This mismatch may often be related to a basic mismatch. A wheel whose bond is too hard to be used in the way proposed, will not sharpen itself, and only by undue pressure at the end will it cut. On the other extreme, a bond that is excessively soft can also wear out too fast, but also result in unbalanced loading and unstable breakdown. Here is where the advice of a seasoned manufacturer comes in more than handy. We do not only sell wheels at Zhengzhou Ruizuan Diamond Tool Co., Ltd. as we sell grinding solutions. Our technical staff makes attempts to know your unique material, machine situations, and preferred result to suggest the best wheel specification, a combination of grit, bond, and concentration, to provide a good performance and durability, which in effect prevent the chances of chipping.
Adopting a Routine Preventive Maintenance and Inspection
Lastly, the best defense is being on the offensive. Have a wheel inspection routine prior to and after use. Search in any nicks, chips and dulled spots. Vitrified bond wheels need simple ring test before mounting. Wheels of stores should be stored in containers where they were originally found in a controlled dry place to avoid moisture damage and physical contact. Record specific data on the performance of every wheel on various jobs; this information is invaluable in trouble-shooting and optimizing future process parameters.
To sum up, diamond and CBN wheel chipping is a significant issue, and it can be avoided to a great extent. With a cautious approach to handling, optimized machine procedures, and, most importantly, a selection of the properly designed wheel of a reliable partner, such as Zhengzhou Ruizuan Diamond Tool Co., Ltd. you will be able to get maximum tool life, attain the best possible grinding effect, and secure your productivity. Get in touch with our team and get to know how we can assist you in creating a more robust and efficient grinding process.