Brown aluminum oxide cutting discs are common abrasive tools, widely used in cutting metal, stone, concrete and other materials. Due to the hardness and wear resistance of brown fused alumina, cutting wheels are usually used for high-intensity cutting operations. The process of making brown corundum cut off discs involves multiple steps, from the selection of raw materials to the quality inspection of the final product.
Detailed process of making brown aluminum oxide cutting disc:
1. Raw material preparation
Brown aluminum oxide grit: The hardness and wear resistance of brown fused alumina make it an ideal abrasive for cutting wheels. The particle size range is usually between F14 and F120.
Substrate: The substrate of the cut off disc is usually made of fiber cloth, wire mesh, metal mesh and other materials to enhance strength and toughness. Common substrates include fiber cloth reinforced substrate and steel sheet reinforced substrate.
Binder: The binder usually uses resin (such as phenolic resin), metal binder or ceramic binder. The main function is to firmly bond the brown aluminum oxide grit and the substrate to ensure that it will not break during use. Resin binder is the most widely used.
Additives: To improve performance, some specific chemical additives may also be added, such as hardeners, antioxidants, anti-wear agents, etc.
2. Screening and mixing of brown aluminum oxide sand
Screening: Screen the brown fused alumina sand to ensure that the particles are uniform and meet the designed particle size requirements. Particles that are too large or too small will affect the effect of the cutting wheel.
Mixing: Mix the brown fused alumina sand, binder and other additives in the specified proportion. When mixing, it is necessary to ensure that the sand and binder are completely and evenly combined to avoid uneven distribution of sand that affects the cutting effect.
3. Coating and pressing
Substrate coating: The mixed sand and binder are applied to the substrate surface of the cutting disc. The substrate is usually made of fiber cloth or metal mesh, and the purpose of coating is to enhance the structural strength.
Pressing: The coated substrate and mixture are placed in a mold for pressing. The material is compacted by high pressure to ensure that the sand is evenly distributed and tightly adheres to the substrate. This process is usually completed using a hydraulic press, and the pressure needs to be properly adjusted to avoid pressing too tightly and causing the substrate to crack.
4. Drying and curing
Drying: After pressing, the cutting wheel needs to be dried to remove excess water and solvent. Drying is usually done at low temperature to avoid damage to the substrate and adhesive caused by high temperature.
Curing: For cut off discs using resin adhesives, curing is required after drying. Curing is to completely harden the adhesive by heating to ensure its durability and structural stability. The curing temperature is usually between 150°C and 180°C, and the curing time varies according to the product specifications and adhesive type.
5. Cooling and demoulding
Cooling: The solidified cutting wheel needs to be cooled naturally to room temperature. During the cooling process, the temperature must be gradually reduced to avoid cracks caused by excessive thermal stress.
Demolding: The cooled cutting disc is removed from the mold. At this time, the appearance and structure need to be carefully checked to ensure that there are no cracks, defects or sand falling off.
6. Trimming and cutting
Trimming: After the cut disc is taken out of the mold, the edge is usually uneven and needs to be trimmed. The trimming process includes grinding its outer edge with a grinder or trimmer to ensure flatness and appearance.
Trimming: Cutting according to the final specifications of the cut disc (such as diameter, thickness, etc.), usually using laser cutting, laser drilling and other precision processing methods to ensure that the size meets the requirements.
7. Quality Inspection
Appearance inspection: Check the appearance of the cutting wheel to ensure that there are no cracks, deformations or sand shedding.
Hardness test: Test the hardness with a hardness tester to ensure that it has sufficient hardness to cope with the cutting task.
Abrasion test: Test the wear resistance through experiments to ensure its durability during use.
Balance check: The cut off disc needs to have good balance to avoid vibration during use. Usually a professional balance test instrument is used to check the balance.
Impact resistance test: Check the impact resistance to ensure that it is not easy to break during high-speed cutting.
8. Packaging and Storage
Packaging: Qualified cutting wheels will be packaged according to customer requirements. Common packaging methods include plastic bags, cartons or wooden boxes to prevent damage during transportation.
Storage: Cutting discs need to be stored in a dry and ventilated place to avoid humidity, high temperature and other environments that affect their quality. Especially for resin binders, they should be avoided from being stored in direct sunlight or humid environments for a long time to avoid affecting the stability of the binder.
Summary
The production process of brown aluminum oxide cutting discs includes multiple links such as raw material selection, mixing, coating, pressing, curing, trimming, quality inspection, etc. Each link is crucial, and negligence in any link may affect the performance and service life of the final cut off disc. Therefore, strict process control and quality inspection are the key to ensure the efficient, stable and safe use of brown fused alumina cutting discs.
