Ultra-thin cutting wheels are mainly used for precision grooving and cutting, and generally adopt deep-cut slow-feed grinding method. It has the characteristics of large grinding depth, low feed speed, large contact area between grinding wheel and workpiece, narrow cutting gap, high metal removal rate, high grinding accuracy, good processing surface quality and high material utilization rate.
Key points for using ultra-thin cutting wheels:
The integral cutting wheel has thin thickness (mostly below 0.5mm), small outer diameter (20-100mm), fine grain size, high size and shape accuracy, and light weight. It is generally used under high speed conditions. The general speed is 5000-40000 rpm.
The base type cutting wheel is mostly thicker (0.5-2mm), large diameter (100-200mm), coarse grain size, and low precision. It is generally used under low speed and large cutting depth conditions. The general speed is 3000-10000 rpm.
Ultra-thin cutting wheels mostly use fine grains, and generally the thinner the thickness, the finer the abrasive grains will be, and the better the surface quality of the processing. However, the finer the abrasive grains, the lower the corresponding cutting sharpness, and the feed speed should be reduced accordingly to adapt to the machinability of the abrasive grains.
The cutting depth of ultra-thin cutting wheels is generally determined by the user according to the cutting parts, and most of its cutting adopts a slow feed grinding process, and the depth is cut once. In this way, due to the thin cutting wheel and poor cutting conditions (mostly three sides contact the workpiece), it is difficult to dissipate heat, so it is necessary to increase (flow, pressure) to cool the cutting area.
When the cutting wheel cannot cut or the workpiece collapses as soon as it is put into use at the user's place, it is recommended to increase the cutting speed or reduce the feed rate; when it cannot cut or collapses after a period of use, it is recommended to sharpen the grinding wheel surface with an oil stone of appropriate grain size to adjust its sharpness.
The surface quality and cutting performance of the workpiece are mainly related to the abrasive grain size of the ultra-thin cutting wheel. The finer the grain size, the better the surface finish of the processing. It is also related to factors such as workpiece material, hardness, cutting amount, machine tool conditions, and processing requirements.
Ultra-thin cutting wheels are generally shaped and sharpened before leaving the factory, and users can use them directly. If the user needs further shaping, it is recommended to use green silicon carbide or white corundum oilstone, and the particle size should be 1-2 numbers coarser than the cutting wheel particle size; if the user needs further sharpening or sharpening after a period of use, it is recommended to use green silicon carbide or white corundum oilstone, and the particle size should be 1-2 numbers finer than the cutting wheel particle size or the same number.
The cutting amount is generally related to the processed material, hardness, precision, processing requirements, etc. It is recommended to use it under the user's original conditions for the first use, and do not change the cutting amount easily.
User conditions are also the main factors affecting cutting performance, especially the axial stringing, radial runout, flange parallelism, dynamic balance accuracy, etc. of the machine tool spindle, which directly affect the cutting accuracy of the cutting wheel.