Resin grinding wheel (hereinafter referred to as grinding wheel), as a subsidiary product of metal processing and power tools, belongs to a small industry in the industrial industry. Although the grinding wheel industry is relatively small, it is an indispensable industry. The grinding wheel industry is a labor-intensive industry and consumes energy including mineral resources and electric power resources.
The waste produced by grinding wheel manufacturing is difficult to treat, and the mixed material at the source produces waste material. The garbage recycling plant is difficult to process. It requires a specific manufacturer’s specific process for incineration. The incineration process generates a huge amount of waste gas and washing produces a large amount of waste water. The adhesive used in the grinding wheel is phenolic resin, using phenol and formaldehyde as raw materials. The chemical reaction is not complete and the reaction is complete, with certain small molecular free substances. During the mixing process, it volatilizes and produces irritating gas. The odor of phenol is relatively heavy, which is permeated in the air and the smell is relatively unpleasant. The mixing process produces dust, phenolic resin dust, filler dust, pigment dust, sieving dust, etc., which causes more dust in the air and affects the production environment.
The labor-intensive production of grinding wheel products is the current status of most grinding wheel factories, and the production environment is relatively poor. With the changes in modern production labor, grinding wheel factories are facing huge challenges. The first step in the grinding wheel industry is automation, reducing manpower input and labor intensity. The good news is that so far, many grinding wheel factories have gradually realized the automation of each process instead of manual production. The degree of automation has increased and the production capacity has been further increased, making the already surplus production capacity even more surplus, and the market competition is fiercely fierce.
Market competition also brings a leap in the manufacturing process of grinding wheel products. Regardless of the quality of raw materials, in each process, the detailed research is more and more thorough. In the mixing room, with the automatic mixing system, all kinds of abrasives are fed by cranes, forklifts, and powders are fed by forklifts. In a closed environment, dust output is reduced. Under negative pressure, dust is not allowed to rise into the air. Then feed the material through the mixing line, and load the material into the mixing pot. The mixing pot system is also designed as a negative pressure system. There is no large amount of dust in the whole environment. In the mixing workshop, constant temperature and humidity, low-viscosity resin is used to extend the mixing time. The mixture is slightly moist. Set up a sieving machine under the mixing pot to screen the first material. Pack them in tray containers, place them crosswise, and push them into the constant temperature and humidity storage room for full storage.
The temperature and humidity in the mixing workshop are the key to directly affecting the quality of the molding materials. The weather in the north is cold and the humidity is high, and the molding materials are not easy to agglomerate during the mixing process. Like in the south, the weather is relatively hot all year round and the humidity is high. Therefore, we adopt the central air-conditioning to control the temperature and humidity of the workshop within a certain range to prevent the molding material from affecting the product due to changes in temperature and humidity.
The storage process has two advantages. The first is to fully infiltrate the binder, reduce free dust, and make the molding material more stable. The second is to allow small molecules to evaporate fully and have less odor. The mixing workshop and the screening workshop are separated. After the material has been stored for enough time, the screening can be carried out to make the uneven material after full infiltration more uniform. Source mixing is a particularly important process. If the mixing process is well controlled, the quality of the grinding wheel can be guaranteed by more than 60%. The management and control of the mixing workshop is the top priority of the grinding wheel production. The spirit of the grinding wheel craftsman also starts from the mixing process.
Many manufacturers now know the effect of the environment on their products, and the industry is different, and they cannot be applied to the grinding wheel industry based on the standards of a certain industry. Absorption and digestion must exist. Fact-based decision-making methods in the eight principles of quality management: logical analysis or intuitive judgment of data and information is the basis for effective decision-making. Making decisions based on facts can prevent mistakes in decision-making. Statistical techniques are one of the most important tools for scientific analysis of information and data. Statistical techniques can be used to measure, analyze, and illustrate the variability of products and processes. Statistical techniques can provide a basis for continuous improvement decisions. The grinding wheel factory uses actual equipment, analyzes the actual situation, carries out rational control and improvement, so that the product reaches the ideal production conditions, and realizes that each piece is produced according to the standard of small samples. Effectively improve product quality and meet customer needs.
After being stored for enough time, after secondary screening, a small amount of material is sent to the machine. To ensure that the molding material is loose, the production of the grinding wheel is mainly carried out by rotating the material. There is no suitable and mature flat scraping equipment in China for the flat scraping. The difference between rotary spreader and flat scraper is the difference in centrifugal force. Rotary spreader can easily spread coarse-grained particles to the edge of the product. There is a difference in tissue density, thick on the side and thin on the inside. Flat scraping is to drive the material on the surface, the material particles in the volume are uniform, and the thickness is uniform. During the use of the product, the particles of the product can be uniformly stressed, cutting experience, and the effect is normal. Many manufacturers have begun to recognize this point. To solve this problem, the method of secondary mixing is improved. After storage, the material is sieved, and then the secondary mixing is carried out. The purpose of the secondary mixing is to make the storage adsorbed. Re-mix the materials uniformly to make the molding material system more uniform, and to fundamentally ensure the uniformity of the product system, which has a good effect on improving the quality of the product.
solves the material problem, you can breathe a sigh of relief when it comes to the middle link, the forming link. The molding environment requirements are not very high, and the temperature and humidity control is lower than the mixing process. In recent years, the automation of presses has been gradually improved, and manual auxiliary tools have been continuously improved. There are mature methods to reduce labor and reduce labor. With the development of information technology, the molding equipment has been upgraded and absorbed European, Japanese and Taiwanese technology, and it has qualitatively overstepped. Equipment stability and operational stability have been greatly improved. If the equipment is updated, everyone’s production equipment is basically the same, and it will be used for more than ten years.
The molding process pays special attention to the molding density. The molding density directly affects the quality of the product. The air and water vapor are absorbed by the grinding wheel to form a solution system, which absorbs the water-soluble substances in the grinding wheel and separates into ionic forms, which are easy to occur between ions and ions. The reaction becomes other substances. If these substances can make the phenolic resin ineffective, the effect will accelerate the qualitative change of the grinding wheel from the inside, and there will be phenomena such as product film, cutting edge oblique, cutting edge chipping, cutting dust, and flying sand. After the grinding wheel is attenuated, the abrasive will fail if it does not work. On the other hand, it is a waste of mineral resources in disguise.
molding is a piece of abrasive material pressed into a block after a certain pressure. The adjustment of pressure and holding time can produce a variety of molding densities. The molding process is divided into cold pressing and hot pressing. The temperature of the cold forming mold is normal temperature, no temperature, and the quality of the product is controlled by pressure and holding time alone. Often the pressure of cold press molding is relatively large, and the pressure tonnage of the molding machine required is very large. The holding time of cold press molding also needs to be appropriately lengthened, and the matching resin flow length needs to be longer. In hot press molding, the mold has temperature, which can be divided into high or low temperature. The temperature also affects the level of molding pressure and the level of holding time. There is no quantification of these factors for molding, so it is generally controlled based on the weight and thickness of the product. The weight of the product is calculated by designing a density and thickness. As long as the weight of the material is so large, the pressure and holding time are adjusted to suppress With the corresponding thickness, it can be determined that the ideal molding density has been achieved. Hot press molding is suitable for China, Southeast Asia, Japan, and Taiwan. The press tonnage required by the hot pressing process is not so high, the pressure is too small, and lower quality abrasives can be used. The resin flow length can also be appropriately shorter.
The molding process, the control of molding materials, the effect of spreading, and the thickness and weight of the product greatly affect the appearance of the product after firing. Some key molding processes are controlled. The grinding wheel blank product is attached to the corresponding tooling and transported to the next firing process.
The grinding wheel is hardened and fired, which is a key quality control point. There are box furnaces for firing and rail tunnel kilns for firing. Box furnace, flexible to adapt to small-capacity manufacturers. The tunnel kiln is steadily adapted to large-capacity manufacturers. Regardless of the type of equipment firing in the grinding wheel firing process, the most important thing is the firing curve. There are many differences between resin and abrasive materials, geographical location, year-round climate temperature and humidity differences, product thickness and density, and application areas. There are many differences in the corresponding firing curves. Of course, the phenolic resin used in the resin grinding wheel itself is used as the bonding agent, and the chemical properties are basically similar, but because of the influence of external factors, the firing curve is adapted to local conditions. The grinding wheel manufacturer understands its own differences and adjusts it to be able to adjust the firing curve suitable for its own use.
Grinding wheel is a fusion of physical and chemical theoretical knowledge points. The properties of chemical materials, including abrasives, resins, fillers and the connections between them, can all affect the quality of the grinding wheel. The external climate, daily temperature and humidity, artificial proficiency, tooling and equipment. These can affect the product quality of the boiled grinding wheel. Therefore, to be able to make a piece of grinding wheel, it needs to be calm and settled.
Developing new products and improving old products is the fundamental way for an enterprise to continue to grow and grow, and it is also an important means for an enterprise to improve economic efficiency and competitiveness. Although grinding wheel products do not have a certain market life cycle like other products, the problem of homogenization has become more and more obvious. Therefore, we have established a technical process department. In addition to perfecting and standardizing our existing production processes to correctly guide production, ensuring that products are produced in accordance with standardization, and stably improving product quality, we must also continue to introduce new ones to meet customer needs and strengthen our company’s Core competitiveness in the industry.