What is honing?

 Honing is a method of finishing workpiece surface at low cutting speed. It is a special form of grinding and an efficient machining method in finishing. This process can not only remove large machining allowance, but also improve dimensional accuracy. Geometric precision and effective machining methods to reduce surface roughness are widely used in automobile parts manufacturing。

High machining accuracy

Honing can improve the shape accuracy of the workpiece, especially for some small and medium-sized through holes, the cylindricity of which can be up to 0.001mm. For some parts with uneven wall thickness, such as connecting rod, the roundness of which can be up to 0.002mm. If there is no ring groove or radial hole, the straightness of honing is less than 0.01mm/1m, and the precision of honing is higher than that of grinding. During grinding, the bearing supporting the grinding wheel is located outside the grinding hole, which will cause deviation, especially for small hole machining.

Good surface quality

The surface is cross mesh, which is conducive to the storage of lubricating oil and the maintenance of oil film has a high surface support rate (the ratio of the actual contact area between the hole and the shaft and the matching area between the two), so it can bear large load and wear resistance, thus improving the service life of the product. Due to the low honing speed and the surface contact between the honing stone and the hole, The average grinding pressure of each abrasive particle is small, so the heat of the workpiece is small, the temperature of the cutting area can be maintained at 50-150, the surface of the workpiece almost no thermal damage and metamorphism layer, small deformation.

Wide processing range

Main processing of a variety of cylindrical holes: through holes, axial and radial discontinuous holes, such as radial holes or slots, keyway holes, spline holes, blind holes, In addition, the special honing head can also be used to process conical holes, oval holes, etc., but because of the complex structure of the honing head, the cylindrical body can be honed without the outer round honing tool, but the margin removed is far less than that of the inner round honing

Small cutting allowance

Honing is the one that removes the least amount of margin among all machining methods. In honing, the honing tool takes the workpiece as the guide to remove the excess amount of the workpiece and achieve the required precision of the workpiece

Strong ability to correct holes

Shortcomings due to other processing technology, the machining process will appear the following defects: such as round, bell, corrugated hole, small size, drum-shaped, taper, boring cutter, hole deviation and surface roughness, the honing process can remove the minimum machining allowance and greatly improve the hole and the size precision of cylindrical, roundness, Straightness, cylindricity and surface roughness.

Diamond/CBN honing reamer

More Superhard provides precision bore honing finishing solution, the honing tools include
- Diamond honing stone, cbn honing stick
- Single pass diamond honing tools
- Cylinder honing tools
- Diamond honing head
- Diamond cylinder hone
Honing Machine: Sunnen, Nagel, Gehring, Nissin, Engis, Fuji, Mas and other honing machines.

Diamond honing reamer have fixed and adjustable diamond honing honing reamer reamer, and contains ladder diamond honing reamer, from literal meaning can also see, fixed electroplating diamond reamer is a fixed size, guide, before the blade, the guidance as a whole, while the adjustable electroplating diamond reamer is adjustable reamer size, after the reamer body wear, can be in bushing vertebral body The upper trace movement can compensate the wear size, so that the cutter body can be reused, thus extending the service life. The fixed electroplated diamond reamer is more used in the blind hole, and the adjustable diamond honing reamer is more used in the through hole.

  

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The difference between diamond grinding wheel and ordinary grinding wheel and how to dressing diamond grinding wheel?

 How to dress diamond grinding wheel?

In the dressing process, the ordinary abrasive grinding wheel is aligned with the diamond grinding wheel, and the diamond grinding wheel rotates, while the ordinary abrasive grinding wheel carries out feed movement while rotating Under the action of friction, the grinding particles on the surface of the diamond grinding wheel begin to rotate slowly, which produces certain extrusion pressure on the metal adhesive while rotating, leading to cracks in the adhesive. With the continuous action of friction, cracks in the adhesive are further expanded Finally, the adhesive breaks, making the blunt diamond particles fall off the surface of the grinding wheel and exposing the sharp diamond particles for the purpose of repair.

 

Q: What material is suitable for grinding artificial diamond wheel?

A: synthetic diamond grinding wheel is suitable for grinding high hardness inorganic materials Cemented carbide materials and high hardness of metal materials Diamond grinding wheel for grinding glass ceramic ferrite and semiconductor materials and other hard brittle materials and metal materials, and carbide materials Synthetic diamond grinding wheel is grinding carbide optical glass ceramic gem stone high hardness The best grinding tool for brittle non-metallic materials.

Q: What material is suitable for grinding artificial diamond wheel?

A: Diamond grinding wheel, with diamond abrasive as raw material, made of metal powder resin powder ceramics and electroplating metal circular through hole consolidation abrasive called diamond grinding wheel (alloy grinding wheel).

Diamond grinding wheel belongs to superhard grinding wheel. Compared with ordinary grinding wheel, diamond grinding wheel has very obvious characteristics and advantages:

1. The hardness of diamond abrasive determines the main characteristics of diamond grinding wheel: it can effectively grind hard alloy glass ceramics and other difficult materials, grinding tools have the longest service life.

2 Diamond has higher wear resistance, the less wear of grinding wheel, the longer the use time. In the grinding process, the size, shape and shape of diamond grinding particles change little, more suitable for high-precision machining, high production efficiency diamond wheel is a kind of tool that can meet the requirements of efficient and precision machining at the same time.

3. The repaired diamond grinding wheel can maintain the micro-blades of particles for a long time, and the good cutting performance ensures the small grinding force in the grinding process, thus reducing the grinding power and saving energy.

4. Diamond has good thermal conductivity, conducive to heat dissipation, avoid the phenomenon of workpiece burns, cracking and falling off, greatly improve the quality of workpiece surface processing.

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High precision gear machining for new energy vehicles

 1. Hard surface gear

The hard tooth surface processing technology is mainly applied to the gear finishing whose tooth surface hardness is higher than 45 HRC after heat treatment. The purpose is to improve the efficiency and quality of the gear finishing and reduce the processing cost. The main processing methods are for the hard tooth surface shaving fine rolling (scraping) tooth grinding and honing, etc. Compared with the traditional processing technology, the hard tooth surface processing method can improve the tool materials and coatings of machine tools tool technology and other higher requirements.

Hard gear surface machining technology is mainly applied to gear finishing whose tooth surface hardness is higher than 45 HRC after heat treatment, aiming to improve the efficiency and quality of gear finishing and reduce the processing cost. The main processing methods are for hard tooth surface shaving, fine rolling (scraping), grinding and honing, etc. Compared with traditional processing technology, The machining method of hard tooth surface puts forward higher requirements for machine tool, tool material and coating, tool technology and so on.

Gear honing and grinding can use electroplating or sintering grinding tools of CBN or diamond superhard abrasive. The forming grinding tools of CBN grinding wheel are shown in Figure 3, and the rough-finishing cutting tools are designed into combined cutting tools during tool design. The number of working procedures can be reduced by using coated HSS or cemented carbide cutting tools for tooth shaving and fine rolling on the hard tooth surface.

Compared with the traditional technology, the superhard tool material grinding wheel can significantly reduce the surface roughness, improve the surface quality, and improve the accuracy of 1~2 degrees. The processing efficiency is more than 25 times of the conventional tooth surface grinding. In order to adapt to the requirements of the hard tooth surface gear processing, the machining machine pays more attention to the CNC technology, high-speed machining and multi-function.

2. Strong precision honing

 

Due to the limitation of the gear hobbing and shaving heat treatment grinding process commonly used in gear processing in high precision automotive transmission gear processing, it is difficult to meet the technical requirements of gear to grind the hard tooth surface after heat treatment, and then adopt the honing method to improve the quality and the processing cost is high However, it is an efficient method for high precision gear machining to use strong gear honing directly on the hard tooth surface.

When the manufacturing cost is close to the traditional process, higher machining precision and surface quality and machining efficiency can be obtained, showing good economic benefits. The tooth shape and direction correction of strong gear honing can be greater than 0.05 mm, can correct the heat treatment deformation and micro-defects, surface roughness can reach Ra0.2μm below, after heat treatment using strong gear honing process, can reduce the surface wear caused by grinding teeth, avoid the resonance and noise generated in the transmission gear meshing process.

The tooth surface has a large residual compressive stress, which significantly increases the strength, wear resistance and pitting corrosion resistance of gear. In the process of strong gear honing, the tool slides relative to the tooth surface and removes the workpiece material at the same time. The cutting speed is low, which avoids the tooth surface burn caused by high-speed grinding in the process of gear grinding.

Compared with gear grinding, gear honing can process the gear with shoulder. Although the precision is slightly lower than that of gear grinding, the cost and comprehensive efficiency of strong gear honing are obviously better than that of gear grinding process. Gear honing costs about 50% of the shaving cost and 20% of the grinding cost.

Therefore, the application of strong gear honing process in high-precision gear machining of automobile transmission has great advantages, and improves the reliability and stability of transmission operation, extends the overhaul cycle, and reduces the problem of automobile noise. The process route of high-precision gear machining of automobile transmission can be simplified into rolling, shaving, honing, and even the strong gear honing can be carried out directly after hobbing.

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Using diamond band saw blade for high precision dicing

 Diamond band saw blade is a straight line curve cutting tool of brittle materials. It is a composite steel strip with diamond embedded in a high-quality spring steel matrix. It can cut any non-metallic, super hard, brittle materials (such as marble, agate, hard alloy, glass, magnetic alloy) with energy saving, raw materials saving, good cutting quality (smooth and smooth), high cutting efficiency. Good formability, not easy to crack four advantages.

 

When cutting carbide speed can reach 300mm/min, cutting marble can reach 100mm/min, cutting granite can reach 40mm/min, is the traditional reciprocating saw or line cutting efficiency of dozens of times, its narrow incision (only 1.2mm) It can efficiently cut monocrystalline silicon, polysilicon, graphite, jade products, fiberglass, quartz, sapphire, zircon, marble, ceramics and other metallic materials.

Diamond band saw blade blade can efficiently cut monocrystalline silicon, polysilicon, graphite, jade products, fiberglass, quartz, sapphire, zircon, marble, ceramics and other metallic materials.

 Advantage for diamond band saw blade :

1. Diamond sand and coating combined firmly, sand, wear-resistant.

2. The diamond particles on the surface of the band saw have regular crystal shape, sharp edges and moderate chip space.

3. The cutting edge is sharp, the cutting speed is stable, the dimensional precision of the product after cutting is high, the cutting surface is smooth and smooth, and the damage is small.

4. The matrix of the band saw is made of high quality steel, both rigid and flexible, the welding is firm and smooth, not easy to break, and the service life is long.

Process selection of diamond band saw blade 

1. Selection of diamond particle size

When the diamond particle size is coarse and single, the blade head is sharp and the cutting efficiency is high, but the bending strength of diamond agglomeration decreases. When the diamond particle size is fine or mixed, the saw blade head has high durability but low efficiency. Considering the above factors, 50/60 mesh diamond size is selected as the most suitable diamond size. When the diamond particle size is coarse and single, the saw blade head is sharp and the cutting efficiency is high, but the bending strength of diamond agglomeration decreases. When the diamond particle size is fine or mixed, the saw blade head has high durability but low efficiency. Taking the above factors into consideration, 50/60 mesh diamond size is more appropriate.

2. Selection of diamond distribution concentration

In a certain range, when the diamond concentration changes from low to high, the sharpness and cutting efficiency of the saw blade gradually decrease, but the service life is gradually extended. But the concentration is too high, the saw blade will become dull and use low concentration coarse particle size, efficiency will improve the use of the different parts of the tool head in the sawing cutting, using different concentrations (that is, in the three or more layers of the structure of the middle layer can use a lower concentration), the process of the saw head work on the formation of the middle groove, is conducive to prevent the saw blade swing, so as to improve the quality of stone processing.

3. Selection of diamond strength

The strength of diamond is an important index to ensure the cutting performance. If the strength is too high, the crystal will not be broken easily, and the abrasive particles will be polished during use, and the sharpness will decrease, leading to the deterioration of tool performance. When the strength of diamond is not enough, it is easy to break after impact, and it is difficult to bear the cutting load. Therefore, the strength of diamond should be selected in the range of 130~140N.

4. Selection of bond 

The performance of the saw blade is not only dependent on diamond, but depends on the diamond and binder properly matched to the tool head of the overall performance of this composite material for marble and other soft stone, the mechanical properties of the tool head is relatively low, can choose copper based binder but copper based binder sintering temperature is low, strength hardness is low, toughness is high, and diamond combination strength is low When WC is added, WC or W2C is used as the skeleton metal, and appropriate amount of cobalt is added to improve the strength and hardness and bonding characteristics. A small amount of Cu, Sn, Zn and other metals with low melting point and hardness are added as the bonding phase. The particle size of the main additive component should be finer than 200 mesh, and the particle size of the additive component should be finer than 300 mesh 5. Choice of sintering process

With the increase of temperature, the densification degree of the tire body increases, so does the bending strength. With the extension of holding time, the bending strength of the blank tire body and diamond caked first increases and then decreases. The sintering process of 120s at 800 ℃ can be selected to meet the performance requirements

The diamond particles on the surface of the band saw have regular crystal shape, sharp edges and corners, moderate chip space, sharp cutting edge, stable cutting speed, high dimensional accuracy of the product after cutting, smooth and smooth cutting surface, and small damage. The matrix of the band saw is made of high quality steel, both rigid and flexible, the welding is firm and smooth, not easy to break, and the service life is long.

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How does diamond grinding wheel wear?

 Under the condition of low grinding force and grinding speed, after the operation of diamond grinding wheel, the surface of the diamond abrasive is scattered with many edges clearly reflecting the small wear plane of diamond abrasive. This is because the mechanical wear caused by the mechanical conflict between diamond abrasive particles and superhard data is gradually carried out, and the wear amount of abrasive particles is directly proportional to the grinding stroke length.

According to the properties of diamond, the degree of graphitization depends on the crystal integrity of diamond abrasives, and the degree of graphitization is related to the crystal orientation. Diamond abrasives with good crystal integrity have a low degree of graphitization loss.

On the surface of diamond grinding wheel, some diamond abrasive grains crack and break, causing the whole grain to fall off. Because crystal cleavage is the plane rupture caused by the type strength and distribution of chemical bond of crystal structure element 7, it often occurs along the directional plane at the end of the strength of chemical bond.

The fracture formed by the breakage is that in the irregular grinding process, the abrasive rises to high temperature instantaneously, and then cools rapidly under the effect of grinding fluid, which is repeated repeatedly, forming a great thermal stress on the surface of the abrasive, which makes the surface of the abrasive crack, the thermal stress, the fracture wear and the defect distribution and oxidation of the diamond abrasive Graphitization has a close contact, so, first of all, some thermal stress occurs at the surface shortcomings of the abrasive crystal, causing multiple cracks to occur and expand under the effect of grinding force, some of the weakest strength of the crushing and falling abrasive is the result of grinding force and grinding heat together.

Reasonable selection of diamond abrasive and bond:

Selection of abrasive particle size

The selection of abrasive particle size of diamond grinding wheel directly affects the surface quality and processing power of superhard data grinding. On the premise that the processing quality requirements can be satisfied, the coarser particle size should be selected as far as possible to improve the processing power Abrasive with 120-150# particle size can be selected for coarse grinding, abrasive with 180-240# particle size can be selected for fine grinding, and micro-powder abrasive with W40-W7 particle size can be selected for superfine grinding

Selection of abrasive concentration

The concentration of abrasive in diamond grinding wheel has certain influence on the grinding effect of superhard data, too high or too low concentration will cause the premature drop of abrasive, so that the grinding wheel loss cost addition test results show that in coarse grinding, a higher concentration can be selected to add the number of useful abrasive particles per unit area, and in improving the processing power + fine grinding, a lower concentration should be selected Under normal conditions, abrasive concentration can be selected 100-150% when coarse grinding, abrasive concentration can be selected 75-100% when fine grinding.

Selection of binding agent

Metal bonds with excellent thermal conductivity (mainly bronze grinding wheels) have a larger binding force on abrasive grains, which is suitable for diamond abrasives with intact crystal shape and relatively high grinding ratio. Resin bond is suitable for diamond abrasives with high brittleness and low strength because of its weak adhesion to abrasive particles. The function of ceramic bond is between the above two. The binding force of cast iron short fiber bond on abrasive particles is as high as 50-100kg/mm2, and the tensile strength is as high as 15-30kg/mm2, which is much superior to the function of common metal bonds. The grinding ratio of the diamond grinding wheel made of the diamond grinding wheel is about 4-5 times that of the resin bond grinding wheel, which is suitable for the manufacture of diamond grinding wheel with intact crystal shape.

Under the condition of low grinding force and grinding speed, mechanical conflict wear occurs mainly in diamond abrasive particles. Under the condition of high temperature in the grinding zone, the diamond particles oxidize and graphitize. The cleavage and crushing of abrasive particles are the result of the combined effect of grinding force and grinding heat. When the mechanical force on the grinding grains exceeds the binding force of the grinding wheel bond, the whole grains fall off.

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The importance of the joint of the sanding belt

 The sanding belt is connected together by a joint, forming a ring belt, suitable for various belt grinding machines.

The most critical part is that joint, because it is an artificial intersection and must be done in the most careful and efficient way, ensuring high resistance and promoting smooth motion without vibration.

Type of joint
There are two main distinguishable joints: overlap and butt.

Overlapping

This type of joint was most common during the first few years of industrial use of the belt. Although it is still in use today, the overlaid back base that must be dealt with can cause all kinds of inconvenience during rolling.

This joint method is most suitable for paper bases because of its very small thickness and because it does not have the wire weaving that occurs in textile supports, it can be mitered without the risk of compromising its resistance. In addition, the paper itself has excellent bonding ability, forming a stable and strong bonding.

This overlap joint is also the main reason for the arrowhead printed on the back of the flexible abrasive indicating the direction of movement in which the sand belt must be mounted on the machine.

Because, if the belt is used in the opposite direction, the overlap of the abrasive portion may be elevated by the constant friction it exerts on the workpiece to be polished, thus breaking the joint and with it the belt.

The fabrication of overlapping joints requires extensive experience and expertise, as the flexible nature of the bracket does not help to make its behavior stable during the bewel process and can be easily automated. If done precisely, overlapping joints are likely to be most effective.

Butt

Butt splicing is done by connecting the ends of the sanding belt face to face, without overlapping, and securing the connection with tape specially designed for this purpose, which sticks to the backs of the ends and joins them very effectively.

This type of joint and its variants are the most widely used today because it does not require such a precise miter operation, its automation is simple and versatile, and the connecting tape or film has very low thickness and strong tensile strength.

Another great advantage is its symmetry. There is no overlap in this oriented structure, so the belt can cycle the joint dip Angle in both directions without problem.

 

Angle of joint

Whether overlapping or butt splicing, joints rarely form right angles. If this is the case, the joint area will strike the workpiece uniformly across the entire workpiece surface, resulting in continuous strikes that produce noise and high vibration, which can rapidly impair the strength of the joint.

In addition to providing a larger anchoring surface, which will enhance its drag, the slight Angle will always help the belt cycle smoothly, avoiding premature wear the smaller the Angle relative to the direction of movement of the sand belt, or the further away it is from the right Angle, the better its drag and dynamic performance.

However, very small angles can create very sharp edges at the ends and become weak areas that are very easy to break or separate, especially when using small pulleys or curvatures.

 The most common Angle is usually 45° to 70°

Special joint

Most applications can fit perfectly with the above criteria, whether overlapping or butt splicing, with dimensional tolerances low enough to allow traditional sanding processes to be used without marks or scratches, and with high enough tensile strength.

However, there are some particularly demanding applications where special joints must be used for high resistance flexibility or smoothness.

There are many types of tape used to make joints, and their width, thickness, resistance and flexibility may be large or small, depending on the resistance of the process to the sensitivity of the trace support or the size of the abrasive particles used.

These adhesive strips or films can resist working stresses greater than 60Kg/cm. If greater resistance is required, special tapes of greater thickness and width can be used, or other thinner strips More flexible tape for very flexible straps or very fine grits.

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Hydraulic industry hole honing solution

 In order to solve the problems of low precision and short life of hole processing in hydraulic industry,Moresuperhard diamond honing reamer, with honing machine, machining center and drilling press for grinding, the superhard energy of diamond abrasive can ensure the high precision and high efficiency of hydraulic parts aperture.

(1) Electroplating process

Diamond reamer construction

(1) fixed: good rigidity of the tool body, easy to grind, the size of the machining hole is stable, the tool life is slightly lower

(2) Adjustable: processing size adjustable, long life

Diamond/CBN honing reamer advantage

(1) Coating adhesion, diamond bond fastness, uniform diamond particle distribution, high appearance quality.

(2) The external roundness and cylindricity of the front and rear guides of the diamond reamer are 0.005mm and 0.005mm, respectively. The external circular roughness of the front guide and the rear guide are RA0.63um and Ra0.16um, respectively. The coaxiality between the tool handle and the front and rear guides is 0.015mm.

(3) The cylindricity of the reamed workpiece is less than 0.003, and the roughness can reach Ra0.4-0.2, with high precision, high efficiency and long service life.

(4) Tailored service, standardized process, create value for customer service beyond contract.

Diamond honing reamer application pass
(1) Through hole, blind hole, step hole, etc.

Instructions for diamond honing reamer

(1) Correct selection of reamer
Diamond reamer is suitable for reaming cast iron, steel, aluminum and other non-ferrous and non-metallic materials.
In the reamer structure selection, there are two kinds of fixed diamond reamer and adjustable diamond reamer. In use, in order to prolong the life of the reamer, the reamer of the above two structures can be combined, coarse hinge, half fine hinge with adjustable diamond reamer, fine hinge with fixed diamond reamer.
(2) Select a reasonable processing allowance
Generally should not exceed the abrasive itself particle size of 1/3- 1/4, otherwise it will be too much chip and diamond reamer stuck in the workpiece hole, will reduce the life of the tool.
Particle size 80/100-100/120 diamond reamer, processing allowance is controlled in 0.02mm-0.04mm.
Particle size 170/200-230/270 diamond reamer, processing allowance is controlled in 0.015mm-0.025mm.
Fine-grained 325/400 diamond reamer, machining allowance is controlled in 0.005mm-0.01mm.
(3) Reamer in the hole reciprocating times should not be too much
In general, the next reciprocating stroke can be. At present, many operators use this diamond reamer as grinding rod, because increasing the reciprocating times too much, will reduce the life of diamond reamer.
(4) Select a reasonable cutting fluid

For hinged cast iron holes, a mixture of 80% kerosene and 20% vulcanized or mechanical oil can be used as cutting fluid, or all kerosene can also be used.
When processing steel parts, 70% kerosene and 30% vulcanized oil can be used.
(5) Fair use
In order to improve the life of diamond reamer, the new reamer can be used for rough hinge, generally 5000 ~ 6000 reams.

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