Resin Bond Diamond and CBN Wheels

Advantages of Resin Bond Diamond and CBN Wheels

Resin Bond CBN Wheels:

Elasticity and Self-Sharpening: Good flexibility and the ability to adjust cutting angles during grinding ensure efficient grinding and high-quality surfaces.

Cost-Effective: Suitable for small-batch, multi-variety grinding processes due to lower manufacturing costs.

Versatility: Flexible for a variety of tool shapes and sizes.

Resin Bond Diamond Wheels:

Efficient Grinding: The diamond abrasives provide efficient grinding performance, ensuring rapid completion of grinding tasks while minimizing wheel wear, thus saving costs.

Low Heat Generation and Self-Sharpening: These wheels generate minimal heat, reducing the risk of workpiece burns. Their good self-sharpening properties help maintain performance and reduce the need for frequent dressing.

Elasticity and Precision: The flexible nature of resin bonds improves surface roughness and is suitable for precision grinding, semi-precision grinding, tool grinding, and polishing, ensuring high accuracy and quality.

Short Production Cycle: Resin’s low-temperature curing characteristics allow for a shorter production cycle and simpler equipment, enabling quick market response.

Environmental and Cost Benefits: Resin bond wheels typically produce little to no dust, meeting modern industrial environmental standards. Although the initial investment is higher, their efficiency and long life result in lower overall usage costs compared to traditional materials.

Resin Types in Diamond/CBN Grinding Wheels

Phenolic Resin:

Widelyused in resin bond diamond wheels, phenolic resin boasts excellent mechanical properties, thermal stability, and chemical resistance. It firmly binds diamond abrasives, forming a robust wheel capable of withstanding the impacts and vibrations of grinding.

Polyimide Resin:

Known for its high heat resistance, mechanical strength, and storage stability, polyimide resin significantly enhances the performance of diamond wheels. With a higher hot-press temperature (235±5°C) compared to phenolic resin (185±5°C), it improves the wheel’s heat resistance, mechanical strength, and wear resistance, increasing cutting capacity and surface quality.

Extensive Formulation Library

After years of experimentation and testing, we have established a comprehensive formulation library for diamond and CBN wheels. This library contains hundreds of resin bond formulations tailored for various industry needs. These formulations address different abrasives, auxiliary fillers, resin types, molding pressures, curing cycles, and temperatures, ensuring optimal performance across a wide range of grinding applications. We also offer custom formulations based on specific requirements.

Dry Grinding vs. Wet Grinding

Resin bond diamond and CBN grinding wheels can be made for both dry and wet grinding.

Dry Grinding:

In dry grinding, resin bond diamond wheels directly engage with the material without coolant. This method is simple and does not require additional cooling and lubrication systems, suitable for applications where coolant cannot be used.

Wet Grinding:

Wet grinding employs cutting fluids to cool and lubricate during the grinding process, reducing heat accumulation and cleaning the grinding area. This method enhances grinding efficiency, surface quality, and wheel lifespan but requires extra cooling and lubrication systems, increasing equipment cost and complexity.

Whether it’s dry grinding or wet grinding, we have a wide range of formulas and successful case studies. Just clearly communicate your grinding environment and grinding requirements to us, and we can provide you with a more suitable grinding solution and the most appropriate grinding wheels.

Base Materials of Resin Bond Diamond Wheels

Resin bond diamond wheels are made using various base materials to suit specific grinding needs:

Aluminum Base: The most commonly used material, made from forged aluminum alloy, offering high strength and good plasticity for various grinding applications.

Bakelite Base: Made from 11-10 bakelite powder by hot pressing, it features a low specific gravity and good elasticity, suitable for making small-sized grinding wheels.

Other Materials: Steel matrix, ceramic matrix, phenolic resin aluminum powder bases, and phenolic resin aluminum fiber bases, each chosen based on the application and grinding conditions, providing unique benefits and limitations.

Dressing Methods for Resin Bond Diamond Wheels

Maintaining the performance of resin bond diamond wheels involves several dressing methods to ensure the wheel remains sharp and effective:

Grinding Oil Stone Method:

Using silicon carbide oil stones of various grit sizes to dress the wheels, with an abrasive protrusion of 0.01-0.02mm. This simple method requires careful control to avoid over-dressing, which can lead to abrasive breakage and uneven wheel surfaces.

WA Grinding Method:

Easily implemented on cylindrical grinders and can be adapted for surface grinders with additional power heads. The process involves shaping with a profiling dressing wheel followed by sharpening with a dresser wheel.

Dressing Block Assistance:

Using molybdenum blocks as dressing aids, the wheel is dressed by grinding the surface regularly, adjusting grinding parameters to control wheel runout within 0.003mm. The wheel is then balanced and ready for use.

Each dressing method offers advantages and should be chosen based on specific work conditions and wheel characteristics.