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The Mystery of Surface Grinding: How to Make Metal Mirror-Smooth?
Surface grinding is a widely used machining process designed to produce a smooth surface for metallic or non-metallic materials. The process involves using a rotating grinding wheel coated with coarse grains to remove metal chips from the surface of a workpiece, ultimately making it flat or smooth.
Surface grinding not only provides an aesthetically pleasing appearance, but also improves the functionality of the material.
Processing
The working principle of surface grinding is to remove the oxide layer and impurities on the surface of the material through the rotating grinding wheel, creating a more refined appearance for the workpiece. Furthermore, this process enables the achievement of functional surfaces of specific standards. Surface grinding machines consist of a grinding wheel, a work fixture (commonly known as a fixture), and a reciprocating or rotating table. For ferromagnetic materials, magnetic clamps can be used for fixation, while for non-ferromagnetic and non-metallic materials, vacuum or mechanical means can be used for fixation.
When grinding a surface, the material of the grinding wheel and the material of the workpiece must be considered. Common workpiece materials include cast iron and mild steel, which are not prone to clogging the grinding wheel during machining. Materials such as aluminum, stainless steel, and brass often weaken and corrode when processed at high temperatures.
The shape of the grinding wheel will be transferred to the object being processed like an inverted image, so the type of grinding wheel must be carefully selected before grinding.
Device Overview
A surface grinder is a specialized machine tool that is capable of providing precision surface finishing. Surface grinding machines can typically achieve an accuracy of ±0.002 mm, depending on the type and application.
Traditional surface grinding machines consist of a table that moves along the surface of the grinding wheel and are usually CNC or manually driven, depending on the work requirements. Modern surface grinding machines are mostly semi-automatic and require minimal operator intervention when used.
Types of surface grinding
Horizontal spindle (peripheral) surface grinding machine
This type of equipment has a grinding wheel edge in contact with the workpiece and is mainly used for simple flat surface high-precision processes. It can realize processing requirements such as grooves, steps and curved surfaces.
Vertical spindle (wheel surface) grinding machine
The face of the vertical spindle grinding wheel is in contact with the flat surface. This type of grinding is often used for rapid material removal and is suitable for various surface finish requirements.
Circular disc grinder and double disc grinder
The circular disc grinder has a larger contact area and can complete the grinding work efficiently, while the double disc grinder can process both sides of the workpiece at the same time, with higher production efficiency.
Grinding wheels and lubrication
The material of the grinding wheel is crucial to the grinding quality. Commonly used materials include aluminum oxide, silicon carbide and diamond.
Common lubricants include water-soluble oils and synthetic oils. These fluids help with cooling, lubrication of interfaces, and removal of debris. The choice of each lubricant must be determined according to the material of the workpiece.
Influence of material properties
The high temperatures generated during the grinding process can have an impact on the material's properties and may lead to the formation of residual stresses or the creation of thin layers of martensite, which can have a negative impact on the fatigue strength of the metal.
With the advancement of metal processing technology, today's surface grinding technology can more efficiently produce mirror-smooth metal surfaces. But how exactly is this technology continuing to evolve in modern industry?
