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**Abstract**
1. Diamond Abrasive Belt and Its Grinding Characteristics
High-hardness thermal spray coatings, such as high-temperature alloys and special ceramics, typically have a hardness above 1000 HV0.2, with coating thickness ranging from 0.1 mm to 0.5 mm. These coatings are both hard and thin, making them challenging to process. Traditional diamond grinding wheels are often used due to their high hardness, but they come with several drawbacks. They consume a lot of power, generate high temperatures, and can cause workpiece burning, affecting both surface and internal quality. Additionally, regular wheel dressing is required, which increases downtime.
In contrast, using ordinary abrasive belts or diamond abrasive belts offers better efficiency and lower energy consumption. However, the cutting efficiency of conventional abrasives is low, making them unsuitable for such hard materials. Diamond abrasive belts, on the other hand, offer superior performance. With a Mohs hardness of 10, diamond is the hardest material known. It is ideal for machining hard and brittle non-metallic and non-ferrous materials. The electroplated diamond abrasive belt ensures strong bonding between the diamond particles and the base fabric. This design allows for efficient chip removal and reduced grinding temperatures, ensuring better surface and internal quality of the workpiece. It also improves fatigue strength and extends service life while reducing dust, noise, and energy consumption, aligning with China's environmental policies.
The surface finish achieved by diamond abrasive belt grinding is exceptional, with small surface roughness, favorable residual stress, and no micro-cracks or changes in metallographic structure. In terms of surface roughness, it can reach Ra 0.01, achieving mirror-like finishes. Experiments show that increasing the belt speed from 35 m/s to 100 m/s reduces surface roughness from Ra 2.0 μm to Ra 1.5 μm, which is difficult to achieve with traditional tools. Therefore, diamond abrasive belts are the best option for grinding high-hardness thermal spray coatings.
2. Diamond Sand Belt Grinding Process Plan and Selection of Grinding Parameters
Diamond sand belts are mainly used for processing rolls and shafts. Diamond grinding discs and impellers are used for polishing planes, curved surfaces, and complex shapes.
(1) Thermal Spraying Layer Grinding Scheme Using Diamond Sand Belt
The microhardness of carbide and various abrasives is an important factor in selecting the right tool. For example, in the case of a ceramic piston rod with a diameter of 540 mm and length of 15 m, the grinding plan involves specific parameters. The lathe model used is 61125, with a belt speed of 16 m/s (1500 rpm). The belt specification is 60 mm × 1950 mm, and the contact method is soft contact (non-contact wheel grinding). The workpiece speed is 30 rpm, and the grinding head speed varies depending on whether it's coarse or fine grinding. Coolant is water, and the spray coating thickness is 60 μm.
(II) Selection of Grinding Process Parameters
Based on the diamond belt grinding process (see Table 2), the grinding time for a 540 mm × 15 m ceramic piston rod is only 90 hours. Initially, due to poor process design, the grinding time was as long as one month.
(III) Characteristics of the Diamond Sanding Belt Grinding Plan
Advantages include simple equipment, fast grinding speed, and good efficiency. The orderly arrangement of diamond particles on the belt ensures sharp cutting and good chip removal, eliminating the need for frequent dressing. Disadvantages include slightly lower precision in non-contact wheel grinding, which can be improved by using contact wheel type grinding.
(4) Determining Time and Quality Factors
Factors like coating quality, operator skill, and feed pressure significantly affect the final result. Advanced applications include automotive stamping dies, turbine blades, and aerospace components. Diamond impellers and grinding discs are widely used in these fields due to their flexibility and high efficiency.
With the development of modern technology, the demand for advanced materials has increased. Diamond abrasive belts are essential for processing high-hardness thermal spray coatings, offering superior performance and environmental benefits.
**Conclusion**
Compared to advanced countries, China’s thermal spray coating processing technology still lags behind. Most factories use diamond grinding wheels and vibration polishing, which are inefficient. There is a lack of matching belt machine tools, limiting the adoption of diamond belt grinding. We have developed a belt machine compatible with lathes, and we believe our efforts will contribute to industrial upgrading and innovation in the thermal spray industry.
(Author: Zhengzhou Reiter Diamond Belt Co., Ltd. An Jianmin)
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