The introduction of a new generation of rhinestone grinding wheels and discs has sparked a revolution in the initial grinding of diamonds, ushering in a new era for Chinese rhinestone processing. Industry professionals are now more excited and optimistic than ever before. Since May 2005, these innovative tools have transitioned from being used by a single manufacturer to being adopted across multiple models and specifications by various companies throughout provinces like Zhejiang, Guangdong, and Shanghai. Their applications have expanded beyond just large and small diamond grinding to include the processing of small crystal balls, pendants, and other delicate accessories. This shift has even led to increased demand from glass deep-processing companies seeking custom-shaped discs and drums.
Industry experts believe that this new abrasive wheel series is ideal for replacing silicon carbide, offering better quality control, cost efficiency, and environmental benefits. It also presents an opportunity to boost production capacity for large-scale diamond manufacturing. However, as more companies adopt these new tools, some challenges have emerged. This article explores the issues encountered during the use of these new wheels and discusses potential solutions.
**First, the problems in use:**
**(a) Common issues with the new round (disc):**
1. The grinding process tends to be slower compared to diamond abrasives and slightly less efficient than green silicon carbide.
2. Grooves often appear on the grinding surface due to uneven wear.
3. Overheating can occur, causing some beads to turn red or even crack.
**(b) Root causes of the problems:**
The slow grinding speed is partly due to the nature of the new wheels. Unlike super-hard abrasives, they rely on alpha quartz, which has a hardness close to that of crystals and glass (Mohs 7 vs. 6.5). This similarity in hardness leads to mutual wear, which may slow down the process but helps protect the workpiece. In contrast, traditional diamond grinding methods are faster but risk chipping or scratching the rhinestones, making polishing more difficult later on.
The working principle of the new disc differs significantly from that of corundum plating wheels. While the latter cuts through the material based on a significant hardness difference, the new disc relies on friction and gradual wear. This method is more gentle and suitable for the delicate nature of rhinestone grinding. However, many machines were not designed with this principle in mind, leading to groove formation and reduced efficiency.
Overheating and cracking are common issues in small roller mills. These problems arise not from the wheels themselves, but from the machine’s water supply and feed mechanism, which are not optimized for the new tool’s requirements. Without proper adaptation, even the best wheels cannot perform effectively.
**Second, solutions to the problem:**
To address these issues, it's crucial to improve the adaptability of existing machines. Current equipment was originally designed for larger crystals, not for the finer, more delicate work required by rhinestones. Many machines lack features such as automatic feed compensation, self-repair mechanisms, and proper water supply systems, which are essential for optimal performance with the new wheels.
Solutions include redesigning the mechanical action to account for abrasive wear, improving the water supply system to manage heat, and adding trimming devices to maintain wheel integrity. These changes will help ensure the new wheels function as intended and maximize their benefits.
**Third, enhance feed control.**
**Fourth, implement a trimming device on the same machine.**
In summary, the emergence of these new grinding wheels has brought significant improvements to the quality of Chinese rhinestones. The challenges faced are primarily due to machine mismatches and improper usage, not the wheels themselves. Some major manufacturers have already made the necessary upgrades, achieving smoother feeding, oscillating grinding, and better results. As more companies follow suit, the current limitations will be overcome, and Chinese diamond producers will be well-prepared for international competition.
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