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Some manufacturers are troubled by many quality problems in the production of resin grinding wheels. Today, Xiaobian specially found some common problems analysis and solutions. Hope to share and learn with friends!
The following are 20 common quality problems and solutions in the production process of resin grinding wheels for you.
1. The particle size of the material does not match, and the hardness does not match.
The ingredients are calculated strictly according to the ingredient list, and the review is the key procedure.
Before and during the mixing process, clean up the tooling and equipment. Before ingredients, check the various raw materials for impurities.
3. Uneven mixing.
According to the process requirements, the mixing time is mixed. Replace overly worn mixer parts at any time. The powdery resin material should be sieved according to the screen number and times specified by the process.
4. Uneven organization and uneven hardness.
Adjust the dry humidity of the mixture to make it have good formability. Spreading and scraping operations are carried out according to process requirements. According to the process requirements, use the horn first to maintain the precision of the press. When feeding, the spread and scraping are uneven. The mixture is wet, or the material is agglomerated, and the feeding is uneven. The mold is worn and the material leakage is serious, and the mold needs to be replaced.
5. Cracks in the formed blank.
The hot pressing temperature is too high, and the product is rapidly cooled and heated. When the temperature is too low, the core type should be removed in time. The raw material has deteriorated due to moisture, or the compounding material is wrong.
6. End face cracks.
The plasticity of the molding material is poor, and the method of unloading the mold and taking the blank is improper. The bottom plate of the forming mold is not flat or the non-parallelism of the backing plate is too large.
7. Peripheral cracks.
The mold sleeve is seriously worn, and when the mold sleeve is removed, it is too skewed.
8. Aperture cracks.
The strength of the blank is low, and the vibration is too large when unloading the mold. The wear of the mandrel is too large or the taper is too small, and the unloading sequence does not meet the process regulations.
9. Diagonal cracks.
The selected spring bolster has inconsistent elastic force, which causes the mold to be deflected and compressed to produce diagonal lines. The pressing speed of the fine-grained abrasive tool is too fast, the pressure maintenance time is short, and the mold matching gap is too large.
10. The two ends are not parallel.
Maintain the accuracy of the pressing table of the press and operate according to the process regulations.
11. The surface is uneven.
Tooling equipment is maintained within the required accuracy.
12. The molding hardness does not match.
The first pressed piece must be inspected, and no less than 30% of each batch of blanks are sampled. Always check the weighing unit and observe whether the pressure changes.
13. The bridge is uneven.
The cooling needs to be uniform, and the plane where the surface of the workpiece is “warped” without being flat is called a bridge. This is caused by uneven shrinkage of the part due to uneven cooling or uneven backing of the furnace. Mostly from flake grinding wheels and fine-grained thin products. When the cooling speed of the thin-film grinding wheel is too fast, it is very easy to produce bridging waste.
Controlled temperature hardening is carried out according to the hardening curve of the product specification. Strict quality control of the compounding process. The molding temperature is too high or too low, and the temperature needs to be adjusted. The curing temperature is too high, and the curing oven temperature is out of control. Mismatched binder. Superabrasive local surface convex deformation or the entire surface expansion. And was resinous luster, and some appeared tortoise-like cracks.
15. Deformation and collapse.
The furnace is installed and the temperature is controlled according to the process regulations. The ratio of fillers should be strictly controlled and adjusted, and there is an interaction between fillers. Insufficient pressure will deform the cutting discs when they are stacked.
The exhaust system of the hardening furnace needs to be unblocked, and the hardening operation is performed according to the hardening curve of the product specification. Correct control, the blank of liquid resin material, use porous pad or ceramic pad. Redness appears in the center of the super-hard abrasive tool, causing uneven hardness of the grinding wheel and easy cracking.
17. The hardness of hardening does not match with the rotary fracture.
According to the correct temperature control operation of the hardening curve, the hardening of the powder resin blank must be covered or buried. In the process of loading and unloading, avoid the shock of the blank. The superhard abrasive broke during the inspection rotation. This is due to low bond strength or abrasive cracks.
18. The cutting piece is off the net during use.
The quality of resin powder resin liquid and mesh should be qualified, the process formula should be reasonable, and the above problems basically do not exist. In some fractures, the abrasive grains are coarse, the organization is loose, and the binder is missing, and the mesh cloth will be detached after a little pulling. The occurrence of these defects is associated with improper manufacturing process.
19. The hardness and strength of the finished product do not match.
The resin quality is unstable, and the resin powder and urotropine are mixed unevenly. The particle size of the binder is too coarse, and the particle size of the binder should be fine. This is conducive to uniform distribution of the binder and full contact of the hardener.
20. Dropped edges and corners.
Care should be taken after forming until after hardening. Ensure that the edges of the parts are intact and avoid mechanical damage. Dropped edges and corners are mostly caused by careless handling during furnace installation and transportation. Unskilled workers should be trained to improve their skills. Resin abrasive blanks with low wet strength should be transferred or picked and placed by the flip-up method, and the blanks cannot be directly moved by hand.