The abrasive disc is the main abrasive tool in the grinding process, which is used to polish the product. It is a porous object composed of abrasives and binders. There are many different materials for abrasive disc , and resin abrasive discs are one of the most common.Resin abrasive discs have high strength and certain elasticity, and are widely used in aluminum alloy door and window processing, construction industry, shipbuilding, machining, automobile maintenance, electronic medical industry, metallurgy, DIY & woodworking and other industries. Abrasives, binders, and pores are the three basic components of abrasive disc. With different abrasives, binders, and abrasive disc manufacturing processes, the characteristics of abrasive disc may vary greatly, which affects the accuracy, roughness, and production efficiency of grinding. It has an important influence, therefore, the appropriate abrasive disc must be selected according to the specific conditions.Resin abrasive disc is a abrasive disc whose binder is resin. It has the advantages of small grinding force, low grinding temperature, good self-sharpening, and high grinding efficiency. It is widely used in the grinding of hard and brittle materials such as cemented carbide, ceramics, and glass.
The simple understanding of resin abrasive disc is the disc made of resin. The most primitive production of abrasive disc does not meet the production standards, and excessive waste and difficult-to-decompose raw materials will cause environmental pollution. It is precisely because of this that there is a resin abrasive disc, a more environmentally friendly raw material, which solves all the previous problems.Our factory can produce 400,000 pieces of abrasive discs per day, guaranteeing on-time delivery. So what does the day of a resin abrasive disc production worker look like?
Take a look at the production process of our cutting discs.
Resin abrasive disc production step one: mixing
1.The process of mixing abrasives, binders, wetting agents, and colorants together to make molding materials.
Preparation of formula Select materials according to performance requirements .
Step 1: Select the abrasive according to the material of the work piece, metal: grade A, B, C, abrasive: stone, Silicon carbide, WA.
Step 2: Select resin bond for processing method Cutting .Thin slices are cut by resin 2818/S with large molecular weight and long length.Ordinary sheets are ground with resin 2893-B/ L with medium molecular weight and medium flow length.Grinding disc type Resin M with small molecular weight and long length.
Step 3: choose auxiliary materials, according to the improvement requirements of grinding performance.
Step 4: Choose a Colorant
First step :Mixed ingredients
Mix abrasives, binders, fillers, and colorants according to the formula to form abrasive molding materials that can be pressed .
Equipment: Mixer double pot countercurrent mixer mixing process.
The first step: Mixing The purpose of mixing the abrasive with the resin liquid is to infiltrate the resin liquid into the abrasive (abrasive surface, capillary pores and micropores) to facilitate subsequent abrasive bonding resin powder and other fillers. Free phenol content: phenol A high content increases the dissolving ability of the resin powder, which is beneficial to the bonding of the resin and the abrasive. Every grain of raw sand needs to be coated with iridium on the surface, which greatly improves the performance and quality of the cutting disc, making it more wear-resistant and durable.
Specific operation: 1. Start the upper pot (1# pot) and the lower pot (2# pot) for dry running. After the dry running is normal, stop the dry running, and add the prepared abrasive into the 1# pot. Requirements: low temperature, full and uniform mixing, no dead ends.
2. Start the 1# pot to mix the mixed abrasive evenly in the pot. The time is 2 minutes shorter in summer and 5 minutes longer in winter.
3. Slowly add the accurately weighed resin solution into the pot to mix the abrasive and the resin solution evenly (time 5 minutes). Then add the accurately weighed colorant into the pot and mix evenly (time 2 minutes).
4. Spread the accurately weighed resin powder and filler evenly on the bottom of the 2 # pot.
5. Turn the 1# pot over and pour it into the 2# pot, start the 2# pot to stir and mix.
6. After mixing evenly, turn over the 2 # pot, pour out the mixture and sieve it. Note that the mesh size used for sieving is not thicker than 14#.
7. Send the mixture together with the construction sheet to the sieve room.
Technical points:
1. The ultra-thin flakes (thickness of the abrasive disc ≤ 2mm) should be slightly wet, and must be filled in sealed plastic bags. The weight of each bag should not exceed 20KG.
2. The coarse material of the angle grinder is slightly dry, but there should not be too much powder.
3. The cutting piece is slightly wet.
Second step:Wake up material
Store the mixed molding material according to the technical requirements, which is convenient for molding to improve product performance.
Purpose: The low-temperature cross-linking process of resin liquid and resin powder is to expand the resin liquid and powder in the presence of water; at the same time, the water evaporates to form an ideal state of wet inside and dry outside; the normal time is more than 4 hours- Environmental conditions for 12 hours: the normal temperature is controlled at 15-25°, and the humidity is controlled at 45-55°. Ultra-thin sheet (thickness ≤ 2mm) molding materials should be stored in bags, and the weight of each bag should not exceed 20KG. Time must be within 24-72 hours.
Cutting discs (2mm≤thickness≤4mm) and angle grinding discs (4mm≤thickness≤8mm) molding materials only need to be packed in pots, but in winter if the temperature is too cold (less than 0°), they should also be stored in bags.
The storage time of cutting discs and angle grinding disc molding materials is controlled within 12-24 hours.
Step Three: Crushing and Screening
After waking up, the surface becomes hard. The waking up molding material must be crushed and sieved to make a molding material equipment feeder suitable for the molding process. If the material is dry, a little liquid paraffin can be added to the broken molding material. Stir by hand (or stir with a mixing pot) to form an oil film between the particles and then sieve, and finally pass the dust through a 60-mesh sieve. If the material is wet, you can add silica powder and then sieve. Add white carbon black (SiO2) and liquid paraffin to reduce the surface friction coefficient. During the mixing process, production workers are required to continuously stir to prevent agglomeration.The key to mixing is to evenly stir the resin, filler, colorant, and corundum. The molding material should meet the following requirements: each component is evenly distributed and adhered to the surface of the abrasive, maintaining looseness. However, powder leakage should not occur, and it is necessary to ensure that the material is spread evenly and has good molding performance. After completing this process, in order to adsorb the resin on the surface of the abrasive, we need to wake up the material next. It is to put the mixed material in a room with constant temperature. The temperature selection of the mixed material is very strict. Too high or too low temperature will cause the mixed material to fail to form. Pay attention to control in a constant temperature and humidity environment, the workshop temperature is controlled at 20-30 degrees, and the humidity is controlled at 40-50 degrees, so as to ensure the stability of the wake-up and molding of the product. In this process, workers also need to check from time to time.

Resin abrasive disc production step two: molding
The molding material is pressed into a abrasive disc blank of a certain shape and performance through a mold and a molding press.
Including feeding, net release, trademark release, grommet release, pre-pressing, mold turning, demoulding and other processes.
1. Equipment Hydraulic Press/Automatic Forming Press.
2. Mold: The mold is composed of mold sets, templates, and mandrels. It is divided into iron molds and rubber molds.
3. The scraper rotates counterclockwise.
4. Molding parameters (the purpose is to spread the molding material evenly in the mold)
Turntable speed.
Minor frequency frequency converter adjustment.
Minor extraction time is less than scraping time.
scraping time.
Molding pressure According to density requirements.
Density: cut sheet 2.3
Ultra-thin sheet 2.45
Grinding disc 2.2
5. Inspection items for semi-finished products.
Hole diameter — tool, plug gauge (stop gauge) H<= 30 +0, +0.16; 30<H<=50 +0,+0.25 Weight — tools, electronic scales Allowable error is less than 2% Thickness — tool, caliper 0.2mm Static balance D>=150mm — Tool Balancer Static unbalance value / gram weight = square root of coefficient * mass
Appearance — visual inspection
Forming should be the easiest item in the production process of resin abrasive discs. At present, most of the materials in China are rotary spreading mechanisms, but due to the limitations of rotary spreading mechanisms, some employees in large manufacturing companies cannot operate, the mixture is unevenly distributed, and the row position tolerance and static balance are out of tolerance.
Damon abrasive disc adopts fully automatic and semi-automatic production machines. On the one hand, it reduces the labor force, and on the other hand, it also makes the produced resin abrasive disc more accurate. Molding material, mesh, trademark and grommet are placed according to the steps.According to the product requirements, they are pressed together, and then the semi-finished products are separated by accessories. We have dozens of fully automated production lines, which can meet the production needs of different types of abrasive discs. At the same time, the workshop has constant temperature and humidity to ensure the quality of the abrasive disc. Our cutting sheets are beautiful in shape and meet the needs of different markets.
Resin abrasive disc production step three: hardening
Hardening is the most important and critical production process in the entire production process. The formed abrasive disc blank is made into a abrasive disc with a certain strength and hardness in a hardening furnace according to a certain hardening specification.
1. Equipment abrasive disc forming and hardening furnace Fixed furnace/tunnel furnace.
2. Furnace loading requirements: Ventilated ultra-thin sheets must be packed with high-temperature cloth or Teflon cloth with good air permeability, and 2 pieces must be placed between the abrasive disc sheets to ensure the air permeability of the abrasive disc during the hardening process, 355 2 sheets of nets can be used for such large films. An aluminum plate is placed between every 5 abrasive discs of the ultra-thin sheet to maintain rigidity. 250-400 per piece of steel, every 5 pieces of aluminum.
3. Hardening curve
Whether the hardening is good or not can tell whether the quality of your product is good or not. There are two factors that are likely to cause quality problems. One is that the temperature difference in the curing oven or firing kiln is too large; the other is the improper way of loading the furnace. The semi-finished product is soft, and it is cured by heating the resin at high temperature. The curing temperature is different for different products. In principle, the higher the resin content, the higher the curing temperature. It is also very important to adjust the temperature during the hardening process. To put it simply; the burning temperature of the black chip should be higher than that of the green chip. We have the most advanced tunnel kiln. After 72 hours of temperature test, the perfect cutting pieces are released.
Resin abrasive disc production step four: out of the warehouse
When the abrasive disc comes out of the oven, manual inspection is required, and defective products such as damaged trademarks or gaps in the abrasive disc must be removed. For example, phenomena such as sand leaks, no trademarks, non-porous rings, and surface cracks will all be discarded as waste products. The labor cost required in this link is relatively high, but manual inspection ensures the quality of the finished product and the reputation of the product. So it is also one of the essential links. Damon abrasive disc has been vacuum-packed since its inception. Although the cost increases, it can make the shelf life of the resin abrasive disc longer.
The above is a day for workers in the production of resin abrasive discs. Although the production process is simple and transparent, it needs to deal with the problem in detail. Although it is very tiring, I will still be satisfied with my labor when I see the fruits of my labor.