How does white corundum powder extend the service life of tools?
What is the most painful thing in the dry cutting and grinding industry? It is not the increase in electricity bills or the difficulty of work, but the tools that die too quickly! Grinding wheels, sanding belts, oilstones, grinding discs… these guys who make a living will “break down” in a few days, and replacing them with new ones is like cutting meat. Especially when processing those hard bone materials-stainless steel, high-temperature alloys, and hardened steel, the tools wear out so quickly that you doubt your life.
Hey, old friends, today let’s talk about how this inconspicuous little thing, white corundum powder, has become a panacea for “extending the life” of tools? I’m not exaggerating. If you use it well, it’s not uncommon to double the life of tools, and the savings are all real money!
“Blunt? I’ll fix it for you!”–The magical “self-sharpening” enhancer
Imagine: a layer of abrasive grains on the surface of the grinding wheel is blunted, and the efficiency decreases. At this time, if the grinding wheel structure is evenly distributed with fine white corundum powder, they are like a lurking “reserve team”.
When the binder is properly worn under the action of grinding force and friction heat, these micro-powder particles have the opportunity to “show their heads” and replace those blunt large particles to re-form a sharp cutting edge!
This greatly slows down the speed of the entire grinding wheel surface being “ground flat”, allowing the grinding wheel to remain sharp for a period of time, the cutting force does not decay, and the processing efficiency is stable. Our workshop grinds a batch of high-strength alloy shafts, using ceramic grinding wheels mixed with W10 micro-powder. Compared with ordinary grinding wheels, it takes nearly 30% more work to grind before it needs to be trimmed. The boss is very happy.
The key to using micro-powder to extend life lies in “matching” and “use”
Micro-powder is a good thing, but it is not a panacea, and it is not something that can be used just by sprinkling it randomly. If you want it to really play a magical effect of extending life, you have to pay attention to:
Choose the right “partner” (particle size matching): The particle size of the micro powder (W number) must match the particle size of the main abrasive (coarse particles)! If it is too coarse, the filling and sharpening effect will be poor; if it is too fine, it may be completely wrapped by the binder and “suffocated” and will not work. Rule of thumb: It is ideal for the particle size of the micro powder to be about 1/5 to 1/3 of the particle size of the main abrasive. For example, if you use 46# coarse particles, it is more appropriate to match W20-W14 micro powder.
Master the “dosage” (addition ratio): How much micro powder to add? Too little effect is not obvious, and too much may be counterproductive, affecting the strength of the binder or making the grinding wheel too hard. This ratio depends on experiments and experience, and is generally adjusted within the range of 10%-30% of the total abrasive weight. Resin grinding wheels can be added to 20%-30%, and ceramic grinding wheels are generally 10%-20% is enough. Don’t go heavy for the sake of strong materials!
Choose the “battlefield” (applicable tools):
Consolidated abrasives (grinding wheels, oilstones, grinding heads): This is the main battlefield for micropowder life extension! Especially suitable for grinding wheels with resin bonds and vitrified bonds. The formula and mixing process are the key to ensure that the micropowder is evenly dispersed.
Coated abrasives (sand belts, sandpaper): When making sand belts and sandpaper, adding a small amount of micropowder (such as 5%-15% of the total abrasive) to the base glue and the over-glue can significantly improve the holding force of the abrasive particles, prevent the abrasive particles from falling off prematurely, and also assist in anti-clogging. It is very effective for making precision grinding belts.
Grinding and polishing liquid/paste: Directly use white corundum micropowder to prepare grinding liquid or polishing paste for super finishing. The extremely fine particles and high consistency of micropowder can obtain extremely uniform and low-damage surfaces, and the tool (polishing pad/wheel) itself wears very slowly.
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