1、 Process characteristics of diamond tool grinding
The grinding of diamond tools has its own technological characteristics. The outstanding characteristics are that the Hardness is high, which leads to the rapid loss of the grinding wheel in the grinding process and the dimensional instability; Secondly, most diamond cutting tools are turning tools or Blades, and the position of their grinding parts relative to the machine tool is uncertain (such as changes in blade thickness), causing changes in the grinding points. Thirdly, the high grinding resistance causes significant elastic deformation in the process system composed of grinding wheels, cutting tools, fixtures, and machine tools, resulting in a significant phenomenon of "cutting out".
These three characteristics are the three "roadblocks" that achieve automated grinding, which directly affect the dimensional accuracy of the tool after molding. If not properly addressed, it will inevitably lead to poor consistency in grinding dimensional accuracy and roughness, low grinding efficiency, and unsuitable for mass production. The use of voice control technology in diamond tool grinders can effectively solve these three problems.
2、 Application of Adaptive Control Technology in Rough Grinding
The main task of rough grinding diamond is to improve grinding efficiency, that is, to set as few safe distances as possible and reduce the time for "grinding" air; Remove the grinding allowance as soon as possible within the range of machine tool rigidity; Early detection that the grinding allowance has been removed (indicating that the grinding resistance has been minimized).
The friction between the grinding wheel and the diamond tool generates intense sound waves that propagate on the process equipment. Monitoring the sound waves can accurately reflect the grinding condition, such as whether the tool is in contact with the grinding wheel, and whether the pressure (i.e. grinding resistance) between the tool and the grinding wheel is eliminated. If the control system can collect and analyze this information in real time, making the machine tool control system adapt to it, it is equivalent to installing a sensitive ear on the machine tool, making the machine tool controller a more intelligent adaptive system. In fact, the development of this system was also inspired by on-site workers grinding knives.
During normal grinding, there are two distinct characteristics of sound wave frequency: the moment when the tool and grinding wheel come into contact, and the moment when the grinding reaches the final size (the grinding resistance decreases to the minimum), which is easy to understand. The former can serve as the boundary between the end of rapid feed and the beginning of grinding feed; The latter can serve as a sign of grinding completion.
Even during the process of "close contact" between the cutting tool and the grinding wheel, the change in sound frequency can reflect the resistance between the cutting tool and the grinding wheel. This "information" is fed back to the machine tool controller, and the servo feed speed is adjusted to complete the grinding under a relatively "constant" resistance. This is of great significance for improving grinding efficiency and extending the service life of the machine tool.
III The application of "knife grinding method" in precision grinding
The main task of diamond precision grinding is to accurately and stably control the final dimensional accuracy of grinding. Grinding wheel wear, accurate positioning of blade grinding points, and grinding resistance ultimately affect machining accuracy. These factors are not related to the motion accuracy of the machine tool, but rather to issues such as when to start grinding (i.e. tool point alignment) and to what extent the grinding is completed, and are closely related to monitoring the grinding status.
Although the amount of grinding wheel wear is difficult to measure, and the height of the blade (which affects the position of the grinding point) is also difficult to measure within a certain range, the control system with a sound control device can easily record the accurate position of the contact moment between the tool tip and the grinding wheel surface. Using this as a starting point, relative feed can accurately control dimensional accuracy, which is known as the "tool grinding method". Of course, the prerequisite for the "knife grinding method" is that the previous process has an accurate benchmark or can accurately measure the size before grinding, which can be achieved using the CCD system online measurement system. In the industry, manual machine tools are used to grind PCD tools. The grinding process for the first back corner (also known as the polished edge) of PCD tools is to grind down 0.02-0.03mm on the basis of the rough grinding size to form a 0.05-0.1mm edge band. This also coincides with the "knife sharpening method".
During the grinding process, the grinding wheel is constantly worn, and the system can detect and compensate for this wear in a timely manner, compressing the time of "grinding air" to close to zero, greatly improving the grinding efficiency.
Voice control technology is widely used in the entire grinding industry because it can resolve common contradictions in grinding. This contradiction is particularly prominent in diamond grinding.
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Grinding characteristics of diamond cutting tools
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