1.Characters of CA made by sol-gel method
CA, produced by sol-gel method, is a kind of sintered abrasive grains. Its crystal dimension is very small, which is only 100--500nm, and it is only less one-percent of common corundum crystal size. A piece of 46# grain contains billions of crystal grains. When grinding, the grains of traditional electrical fused alumina become flat and deactive and easily come off from abrasive tools under the grinding force. Its service life is short. However, for CA made by sol-gel method, the entire wear process is also the self-sharpening process of the grains. During its service life, the new sharp grinding edge exposes constantly when passivating fine crystal grains come off from the grinding tools under the grinding force, which makes the grains always in sharp status. So, the abrasive tools made by CA are of long life band, good self-sharpening ability, high cutting efficiency, as well as not burning workpieces.
Due to its different microstructure, CA shows difference on abrasive grains fracture behavior. CA shows along the crystal fracture damage, while traditional electrical fused alumina shows transgranular fracture damage. Therefore, the toughness of CA is twice than that of the common fused alumina.
CA produced by sol-gel method has similar chemical composition and hardness to WFA (White Fused Alumina). Due to its uniform tiny microcrystalline structure, high toughness and tiny broken performance, CA can be widely used for grinding of difficult-to-process materials like tool steel, tough stainless steel, heat-resistant alloy steel, etc.
2.Features of abrasive tools made by CA
(1) The grains are very sharp, which makes it has strong cutting capacity, high grinding efficiency. It can be used for large deep cutting, roughing feed, heavy duty and high efficiency grinding. According to the experiment, single process feeding can reach 0.3mm or more, metal removal rate is more than twice of common corundum grinding wheels.
(2)Good toughness, small abrasion, and grinding wheels with good shape retention. For precision grinding and form grinding, higher dimensional accuracy and size shape consistency can be easily got.
(3)High durability and long service life. It can reach 5 to10 times of common corundum grinding wheels. Low replacement frequency can reduce auxiliary processing time and downtime, which makes it conducive to the use of numerical control automatic machine, realizing automatic production.
(4)Good self-sharpening performance, not clogging. It can keep steady grinding performance, reduce correction (only about 1/3 of the common corundum grinding wheels) and improve production efficiency.
(5)In grinding performance, CA grinding wheels are far better than common corundum grinding wheels. For price, CA is much lower than CBN and diamond abrasives, while its hardness is similar to that of common fused alumina, which makes it not need special grinding equipments and correcting devices. So it has no special requirements for grinding equipments and no repairing difficulties compared to CBN and diamond abrasives. It also has no special requirements for grinding fluid. So, it is easy to spread the use of it.
1.Chemical Composition (Typical value):
|Al2O3 (%)||Na2O (%)|
2. Physical Index:
|density (g/cm3)||Ball Grinding Toughness||Crystal Size|