The introduction of a new generation of rhinestone grinding wheels and discs has sparked a revolution in the initial grinding of diamonds, marking a new era for Chinese rhinestone processing. Industry professionals are now more excited than ever, witnessing a transformation that promises greater efficiency and quality. Since May 2005, the adoption of these advanced tools has expanded from a single manufacturer to multiple models and specifications across various companies, gaining widespread use in provinces like Zhejiang, Guangdong, and Shanghai. The applications have also evolved, moving beyond just large and small diamond grinding to include small crystal balls, pendants, and other delicate accessories. This shift has even led to increased demand from glass deep-processing companies for custom-shaped discs and drums.
Industry experts believe that this new abrasive wheel series is an ideal replacement for silicon carbide, offering better product quality, cost-effectiveness, and environmental benefits. It also holds potential for increasing production capacity in large-scale armor manufacturing—something traditional methods couldn't match. However, as more companies adopted the technology, some challenges emerged. This article explores the issues encountered during the use of these new grinding tools and offers practical solutions.
**First, the problems in use:**
1. **Slower Grinding Speeds:** Compared to diamond abrasives, the new wheels are not as sharp and perform slightly worse than green silicon carbide.
2. **Groove Formation on Tools:** These wheels tend to develop grooves quickly during grinding.
3. **Overheating and Cracking:** Some beads turn red or even crack due to excessive heat generated during the process.
**Analysis of the Issues:**
1. **Grinding Efficiency:** The new wheels are slower because they rely on alpha quartz (hardness 7) rather than super-hard materials. While this helps protect the workpiece, it results in slower grinding. Traditional diamond grinding can be faster but often leads to chipping and scratching, which complicates polishing. The slow speed of the new wheels is related to their design, which prioritizes protection over speed.
2. **Different Working Principles:** Unlike corundum wheels, which cut through the material with high hardness, the new wheels work by rubbing and wearing down the surface gradually. This requires a different mechanical approach. If machines aren’t designed accordingly, grooves form quickly. Proper machine design is essential to avoid this issue.
3. **Overheating and Cracking:** This problem is most common in domestic roller mills. Beads often turn red during grinding, leading to cracks. This isn’t due to the wheels themselves, but rather the machine’s inability to adapt to the new grinding method. The water supply and feed mechanisms need to be optimized to prevent overheating.
**Second, Solutions to the Problems:**
To address these issues, the focus should be on improving the compatibility between existing machines and the new grinding tools. Most current equipment was designed for traditional diamond grinding and lacks features needed for the new wheels. For example, many machines don’t account for tool wear or provide automatic compensation, leading to groove formation and poor performance.
**Solutions include:**
- **Revising Machine Design:** Machines must be redesigned to accommodate the unique grinding mechanism of the new wheels.
- **Improving Water Supply Systems:** Since the grinding process generates more heat, a more efficient cooling system is necessary.
- **Adding Automatic Feed Compensation:** This helps maintain consistent pressure and reduces tool wear.
- **Including a Trimming Device:** This allows for regular maintenance and ensures optimal performance of the grinding tools.
In conclusion, while the new rhinestone grinding wheels and discs offer significant advantages, their successful implementation depends on proper machine adaptation and user understanding. Many large manufacturers have already made progress, implementing flexible feeding, oscillation, and improved grinding techniques. Their success demonstrates the potential for the industry to evolve. As more companies adopt these innovations, the challenges will be overcome, and Chinese rhinestone producers will be well-positioned to compete globally.
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