Vitrified diamond wheel for zirconia ceramic is made of vitrified bond and diamond powder by hot pressed sintering. Compared with resin bond, it has fast grinding speed, long life and good rigidity.
In the grinding process of zirconia ceramic, vitrified bond diamond grinding wheel has become an indispensable tools with unique advantages.
What is Zirconia Ceramic?
Zirconia usually refers to stabilized zirconia( Y-PSZ) in the yttriz and stabilized zirconia( Mg-PSZ) in magnesium. Its unique ability to resist crack propagation and high thermal expansion make it an excellent material for connecting ceramic with metal such as steel. With the unique properties, zirconia is sometimes referred to as ceramic steel.
Processing Technology Of Zirconia Ceramic
Zirconia ceramic is a very firm industrial ceramic with excellent performance in hardness, fracture toughness, and corrosion resistance. It almost does not exhibit plastic deformation at room temperature, and the processed surface cracks, and the corners collapse. These residual cracks on the surface will lead to a decrease in the physical performance
At the same time, due to its hard and brittle material, diamond grinding wheel is severely worn during grinding, and the material removal rate is low, affecting the processing efficiency. Therefore, it is difficult to process zirconia ceramic into accuracy geometric shapes, high dimensional accuracy, positional accuracy, and low surface roughness with common methods. So, what are the processing technologies for zirconia ceramic?
---Zirconia Ceramic Blank Cutting
In the past, the cutting of zirconia ceramic blank mainly used bonded grinding tools( such as diamond cutting off wheel or band saw), In the actual selection of cutting blades, it is recommended to choose the custom-formulated Diamond Blade For Cutting Zirconia，ultrasonic flow abrasives and other machining methods, as well as electrical discharge cutting. In recent years, high-energy density lasers are gradually being used as cutting tools for cutting, that is, laser cutting, which has achieved satisfactory results.
---Zirconia Ceramic Grinding Process: Metal Bond, Resin Bond or Vitrified Bond?
Zirconia ceramic belongs to high hardness and difficult to machine material, and diamond grinding wheels are used for zirconia ceramic. At present, there are resin bond, vitrified bond, metal bond and electroplated bond diamond wheels. However, each bond diamond wheel has different feature and is theoretically feasible, but there are many limitations in the actual machining process.
----Resin Diamond Wheel For Zirconia Ceramic
Resin bond diamond grinding wheel has simple manufacturing process, high sharpness and good self sharpening. In practical using, the grinding efficiency is high, but the holding diamond for resin bonding agent is poor due to the hardness of zirconia, resulting in the falling off diamond abrasive grains from diamond grinding wheel, which cannot meet the requirement of life.
Moreover, resin bond diamond grinding wheel has not good rigidity and deformated easily. It needs frequent shaping during the grinding process, which has a significant impact on grinding efficiency. However, resin bond diamond grinding wheel plays a good role in the precision grinding stage. The resin bonding agent is elastic, and the surface roughness of workpiece is good after grinding, which can meet the customers’ requirements and standards.
----Metal Diamond Wheel For Zirconia Ceramic
Metal bond diamond grinding wheel has good rigidity and good bonding between diamond and bonding agents, but they also bring a problem of frequent block during the grinding process, requiring frequent dressing of the wheels. For example, the following is a kind of grinding process: electrolytic grinding of diamond grinding wheel.
Under the action of electrolysis, first sharpen the metal bond diamond grinding wheel, and add the electrolytic grinding fluid between the electrode and the grinding wheel during the grinding process, and add the pulse current. During the entire zirconia ceramic processing, the sharpness of the grinding wheel is maintained. It solves the dressing difficulty of grinding wheel for this processing method and achieves stable high-precision grinding.
Metal bond diamond grinding wheel has good rigidity and good bonding between diamond and bonding agents, but they also bring a problem of frequent block during the grinding process, requiring frequent dressing of the wheels. For example, the following is a kind of grinding process: electrolytic grinding of diamond grinding wheel.
----Vitrified Diamond Wheel For Zirconia Ceramic
Vitrified bond diamond grinding wheel has high strength, hardness, and processing accuracy, which is suitable for high-speed and high-precision grinding machine. It is an ideal tool for zirconia ceramic processing.
Compared with resin bond diamond grinding wheel, vitrified bond wheel has good rigidity and does not deform when grinding high hardness zirconia. It also has good self sharpening and high sharpness. It is rarely dressed during the grinding process, which overall improves grinding efficiency. So, in the current grinding process, vitrified bond diamond grinding wheel is the first choice, while resin bond wheel is a necessary supplement.
----Electroplated Diamond Wheel For Zirconia Ceramic
Electroplated bond diamond grinding wheel for zirconia ceramic has fast grinding speed and good rigidity, but it has a fatal disadvantage of short life and rich cost.However, electroplated diamond grinding wheels can be made into various shaped grinding tools, which can be used in complex grinding scenarios.
There are various grinding modes for zirconia, including cylindrical grinding and surface grinding, which require different shapes of diamond grinding wheels to match them. As for the choice of bonding agents, there are many options available. Vitrified bond diamond grinding wheels for zirconia is used in the vast majority of grinding scenarios, and sometimes diamond abrasive belt is also a kind of good grinding tool.
Grinding parameters and drawings of a vitrified grinding wheel for zirconia surface grinding.
- Product name: Zirconia ceramic grinding wheel
- Abrasive: Diamond
- Shape: 1A1 parallel, 14A1 double-sided reinforced
- Binder: Vitrified
- Matrix: Aluminum alloy
- Concentration: 75%/100%/125%/150%
- Grit: Roughing 150#/Fine processing 400# (can be customized according to product margin and RA requirements)
- Application: Zirconia ceramic, aluminum oxide ceramic, iron oxide ceramic small plane large water grinding roughing, fine grinding, etc.
- The following are the common sizes of this type of special grinding wheel:
Diameter (D): 125/150/180/200/250/300/350/400mm
Thickness (T): 10/12/15/20/30/40mm
Center hole (H): 12.7/31.75/50.8/127mm
