sanding Belt grinding, as a new efficient and energy-saving cutting process method, is a dynamic and constantly developing technical field, just like other mechanical manufacturing technologies. Since the United States first applied abrasive belt grinding to metal materials in the weapons manufacturing industry during World War II, abrasive belt grinding began to develop rapidly around the world. According to relevant statistics, by the 1990s, the ratio of abrasive belt and grinding wheel use in the United States is 49 :51, in West Germany is 45 :55, Japan reached 1 :1, its use is also throughout all walks of life. From the 1980s of the 20th century, China also began to carry out experimental research and application of abrasive belt grinding, but in the actual mechanical processing, China should use abrasive belt grinding for cutting processing is very little, and the development of its technology is also extremely slow. The reason is that we do not understand the characteristics of the process, and we fail to promote the advantages and avoid the disadvantages in practical application. In this paper, the characteristics and application of abrasive belt grinding are described briefly by comparing abrasive belt grinding with grinding wheel grinding in several aspects.
1. Processing mechanism
Like the grinding wheel, the abrasive sanding belt is a multi-tool cutting tool, and its cutting function is completed by the abrasive particles stuck to the matrix. According to the analysis of the structure of the grinding wheel and the abrasive belt, when the grinding wheel grinds the workpiece, because the distribution of abrasive particles on the surface of the grinding wheel is random, uneven and different shapes, some abrasive particles can cut the metal chips, and some cannot cut the chips. When grinding the workpiece, because the abrasive particles are single-layer coated on the abrasive belt matrix, the particles are uniform, the contour of the blade is good, and the orientation is arranged, almost all the abrasive particles can participate in cutting, so the cutting performance is good.
2. Comparison of grinding characteristics
2. 1, the production efficiency of belt grinding is high
Due to the inherent characteristics of the abrasive belt, more and sharp abrasive particles can be put into the contact area between the abrasive belt and the workpiece at the same time for cutting, so the metal removal rate of abrasive belt grinding is much higher than that of grinding wheel (the production efficiency is about 5 to 10 times that of ordinary grinding wheel). When necessary, multiple grinding heads can also be used for grinding, and coarse grinding, semi-fine grinding, fine grinding, high-precision grinding and polishing can be completed in one time. Compared with the grinding wheel, the processing time can be shortened by tens to hundreds of times, which greatly improves the productivity. Therefore, in terms of its principle and application, the abrasive belt is the abrasive with the highest grinding efficiency in coated abrasive tools.
2. 2, high machine utilization rate of abrasive belt grinding
The power of the machine tool main motor consists of the following three parts: N main = N cut + N empty + N attached
Where: N cut - effective power for cutting
N Empty - consumes the no-load power lost by various frictions in the transmission
N - Power consumed by the mechanical friction at which the cutting is increased
※ N is generally expressed in the form of machine efficiency, as early as the 1960s, it was reported that the efficiency of the abrasive belt grinder is higher than other machine tools. In recent years, the utilization rate of abrasive belt grinding machine is still improving. According to the experimental data, when the metal removal rate is equal on the same surface grinder, the power consumption of the abrasive belt grinder is 3 times less than that of the grinding wheel grinder, and the power utilization rate of the abrasive belt grinder is as high as 96%.
2. 3, the cost of belt grinding is low
With the development of science and technology, the technology of sand belt manufacturing is also higher, the service life of sand belt has been increased to 812 hours, and the price is getting cheaper and cheaper. The machine tool required for abrasive belt grinding can be an ordinary machine tool, which has simple structure and low price. Because of the high grinding productivity and short processing time of the abrasive belt, the abrasive belt can process more workpieces when the grinding wheel and the abrasive belt are purchased at the same cost.
4, belt grinding for "cold" grinding and elastic grinding
Whether it is the grinding wheel or the belt, heat will be generated during grinding, resulting in an increase in the temperature of the grinding surface, and the temperature is rising with the increase of the grinding depth. Due to the special structure of the abrasive belt, the grinding heat generated is less, the distribution gap between the abrasive particles is large, the abrasive particles in the space and air contact time is long, easy to dissipate the grinding heat, so the abrasive belt grinding temperature change is relatively gentle, so that it shows the characteristics of "cold grinding". The abrasive belt grinding temperature is low, and the grinding burn on the workpiece surface is reduced. The temperature of grinding wheel increases obviously with the increase of grinding depth or the extension of grinding time. Compared with the grinding wheel, the softness of the sand belt is very good, the grinding speed is stable, and the elastic rubber contact wheel is not sensitive to vibration response, and it is easy to achieve high stability grinding.
3, application range The application range of abrasive belt grinding is characterized by strong adaptability, as follows:
3.1, suitable for the processing of various shapes of parts
In the grinding process, the general shape of the parts of the belt and grinding wheel can be added, but for special shape of the parts, it is difficult to get the requirements with grinding wheel.
(1) Plate processing: sheet parts, especially when the width is large, it is difficult to process with grinding wheel. The maximum width of abrasive belt grinding can reach 4.9 meters.
(2) Special-shaped surface grinding: In the grinding of special-shaped parts with smooth transitions (such as curved surfaces, tanks and large journal, etc.), belt grinding is an efficient and high-precision processing method. As a kind of flexible abrasive tool, the abrasive belt can automatically adjust the position with the change of the shape of the workpiece and the contact wheel and the grinding plate, so as to obtain better processing effect.
(3) Ball processing: For the ball with a certain roundness and surface roughness, only the flexible grinding of sand belt can obtain good processing requirements.
(4) Processing of complex non-clamping base parts: such as the motorcycle gasoline box cover, not only the irregular clamping base, but also the wall is thin, and the mechanical clamping is easy to deformation and fracture when the grinding wheel is used, which is easy to lead to oil leakage during the use of the gasoline box. For this reason, only abrasive belt grinding can be used.
3. 2, suitable for the grinding of various materials
It is not only suitable for the processing of cast iron and steel parts, but also for the grinding of aluminum, copper, silver and other alloy parts with greater viscosity. If the grinding wheel is used, the chips of these materials are very easy to block the gap of the grinding wheel, making the grinding wheel ineffective.
3. 3. Use abrasive sanding belt to grind and cut burrs
Using sanding belt grinding to punch burrs can easily remove burrs and ensure that its surface is not scratched. It can be seen that compared with grinding wheel grinding, abrasive belt grinding is indeed a processing method with excellent quality, high efficiency, low consumption and wide use. However, in China, due to the low technology, resulting in the production of sand belt service life is short, specifications and varieties are not uniform; The relatively low processing precision of belt grinding and not enough research on the theory of belt grinding mechanism restrict the further application and popularization of belt grinding in our country. At present, with the rapid development of abrasive belt grinding technology abroad, abrasive belt grinding has begun to develop in the direction of strong abrasive belt grinding. It can be predicted that driven by the international trend, China's abrasive belt grinding will be further developed and widely used in the machining industry.
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