Polished porcelain tile processing application of diamond tools

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1 Introduction
Mid-eighties whole vitrified porcelain tiles first appeared in Italy , so that the further development of the high-quality ceramic tiles , a multi-species direction , appeared shortly thereafter imitation marble , granite, polished porcelain tiles various senior , and further improve the grade ceramic tiles and prices [1] . The mid- line of ceramic tiles imported from Italy after the ceramic tiles industry entered a new phase. Also the beginning of a large-scale diamond tools used in ceramic processing industries. From the beginning to now totally dependent on imports domestically, making consumption cost per unit area of ceramic diamond tools dropped seven or eight times , thus greatly promoted the development of the industry , only a few short years , Guangdong Foshan polishing line has reached hundreds , the output value of billions of dollars . Bright and beautiful , affordable upscale all vitrified ceramic tiles began to decorate every household.
2 , full characterization of vitrified porcelain tiles
Ceramic tile body material using a conventional clay, feldspar , quartz and plasticity [2], white clay , ball milling , granulation , drying, pressing, sintering at 1200 ℃ after about 50 to 60 minutes to prepare . Microstructure body by the crystal phase , grain boundaries, the composition of the glass phase and pores [3] . Crystal phase mullite , α- cristobalite and free quartz. Mullite, clay ( kaolin ) at a high temperature above 1000 ℃ changes made ​​are also generated as part of the α- cristobalite , α- cristobalite another part is converted by the addition of components made ​​of quartz . Glass phase is composed of feldspar as a flux in the form of silicate melts at high temperatures [3] . Glass phase mainly potassium and sodium . The body mainly in the glass phase forms a continuous phase around the crystal phase . Grains during sintering can be bonded together to fill the gap between promote dense green body , the green body sintering temperature to reduce and increase the transparency of [3 ] . How much depends on the porosity content of the composition and sintering conditions blanks are usually distributed pores in the glass phase matrix. Pores significantly affect the physical properties of ceramic materials , significantly reduces the mechanical strength of the gloss after polishing and the body , the content of polished porcelain tiles pores are much lower than the ordinary glazed . How many holes are usually content with the absorption of said holes , said the higher water absorption , the more low- density, ceramic tile water absorption <0.5 %, while 10-20% of the general glazed water absorption [2] . The lower water absorption brick hardness , higher strength, more difficult to process . General porcelain tile flexural strength > 27MPa, 15MPa and glazed [2] .
In addition to a greater absorption performance impact on the ceramic tile , the content of the glass phase , the composition of the crystal phase has a great influence on both the applicability and workability properties of ceramics and diamond tools. Since the crystalline phase as compared to loose glass strength is low expansion coefficient and high temperature easy to soften [3 ] , the ratio of the glass phase , the lower green strength and higher abrasion resistance, increased brittleness . The more crystalline phase α- cristobalite content is higher body rigidity, the stronger the abrasive , diamond tools workability decline , consumption increased.
Porcelain tile varieties are more recipes from different manufacturers , different processes , resulting in some differences in performance. Distinguished by different production processes , the current production of several varieties of large seepage tile ( imitation marble ) , large particles brick ( imitation granite ) , brick powder , etc. [4] . Overall, porcelain tile hardness, strength and abrasive resistance are lower than natural granite slabs , but higher than marble.
3 , polished porcelain tiles analysis tool with diamond processing characteristics
A complete polishing process including pre- milling, Calibrating, rough grinding , polishing, edging after drying , waxing and packaging. Diamond tools are mainly used for coarse milling round on wheels ( front edging ) , hob , octopus ( evenness ) , finely ground side of the wheel , trimming wheel ( after edging ) . And other uses of diamond tools, ceramic processing adaptive problem also exists with diamond tools. Both the ceramic itself to adapt the performance problem with the device is also adapted to the problem of adaptability to different products , but with different sensitivities . The following detailed description of the sub-species .
3.1 Diamond hob
Calibrating machine main drive system driven by high-speed rotation hob clockwise , the feed drive system under pressure and adjust the depth of the knife , ceramic tile body from the bottom bearing , belt drive , through the hob is Calibrating [5] . Configure each line of the drum is generally 6-10 , diamond particle size between 36 mesh -140 mesh, tapering from coarse delivery times and thus make marks Calibrating adobe shallow , easy , after grinding and polishing process .
Dense and hard body porcelain tile , two-way process pressure movement , hob gram micro-cutting mechanism to take the tile surface is " plow into the way " and " crush mode" joint action . So the more coarse granularity hob , the greater the " plow into the " removal , the deeper marks . The greater the pressure of the same size hob " crush " into the chip area and increasing depth , to increase the removal rate , but the marks produced by the more coarse , so sometimes the partial pressure is too large, but also the depth of the fine knife marks . Increasing the number of fine lines hob cutter , thereby reducing cutting surface unit pressure limits the amount of feed , and can improve the flatness of the body of the fine marks .
When hob processing pressure , high speed ( typically 1700-2400 rev / min ) , require a higher diamond grade (MBD8) above , in particular crude granularity ; carcass to support , package inserts securely ; in order to obtain the desired efficiency and lifetime. Calibrating hob outside with a larger effect in addition to the quality of their relationship , but also by brick hardness , deformation of the size , Calibrating machine condition , affecting tone machine operator level . Hob life itself, in addition to the quality of the decision outside the head , mainly related to the amount of brick milling about .
3.2 diamond edging wheel and wheel trim
Line diamond polishing tools , milling round performance for the most sensitive blank porcelain tiles . At the same close relationship with grinding amount , equipment status , conditioners level. Therefore, the carcass must be adjusted properly depending on the recipe and diamond polishing lines and brick varieties, in order to achieve the desired results. Porcelain tile more hard, brittle , edging margin smaller , more easily collapse surface , edging more difficult in this case to adjust the hardness of the milling round the reasonable control of the diamond blade height , can achieve satisfactory results . Another problem associated with the edging wheel is chipping , chipping and sharpness main milling round about , there chipping or diamond adjustment formula should improve sharpness . Chipping is also concerned with the amount of single-head milling , the first single easy edging excessive chipping , grinding it to a reasonable allocation of the amount of each milling round , not too concentrated . If the total edging excessive, should be added before milling, milling or increased head count . Chipping and chipping surface but also with yaw and vibration milling round about , so you must ensure concentricity milling round and balance. Other issues, such as flanging edging , diagonal bias adjustment problems and other issues mainly milling machine , so ominous state .
After trimming wheel mounted milling round , mainly to milling round left jagged marks polished, tile corners to make more regular. Trimming the grinding wheel is not the amount of the general requirements , the use of fine-grained diamond , based on the actual amount of grinding and trimming effect, 80 / 100 mesh -120/140 mesh adjustment . The advantages of metal binding agent trim wheel is long life, low cost trimming ; disadvantage is uneven grinding , grinding inner and easy protrusions, or uneven deformation affecting trimming effect, require frequent grinding. Trimming resin grinding wheel may not have regular , superior smoothness and trimming metal trim wheel, but the drawback is the low life, only the metal binding agent 1/4-1/3 , trimming costs are too high , and because of its grinding is very small, less milling head when using a limited number .
3.3 pairs of wheels and octopus
Both products are still in the old polish line , due to the presence of high cost, difficulty adjusting machine and maintenance issues , gradually replaced the hob and milling round .
The grinding wheel is opposite to the relative rotation by a pair of rotary heads on both sides to complete the grinding of the tile name . Because of the regularity of the grinding wheel milling poor , it is generally with the former edging , has been rarely used .
Octopus is because the planetary host named diamond grinding wheel mounted eight . Host revolution led eight wheels , while wheels were still spinning motion , to complete the brick scraping . Its advantages are: scraping roughness, fine marks ; wheel does not deform due to deformation of brick , can be completely consumed without replacing renovated. Disadvantages : high cost, manufacturing cost is equivalent to a set of octopus 3-4 to drum up the number of brick processed much less ; due bulls installation, commissioning difficult, hosts frequent maintenance . Octopus impact is large, there is a certain deformation of brick , easily broken when scraping , it can not be used alone . A polishing line octopus from coarse to fine install 2-4 group , behind 4-2 coarse rollers. Octopus requirements for higher sharpness , while poor sharpness , cracked tiles or knife to eat a high amount is not enough. Should use a sharp -type diamond and general wear formula.
4, on the diamond
Diamond machining of ceramic tools used to the maximum amount 60/70-100/120 size range , with improved gelling photometric requirements of 120 / 140 also increases the amount of fine-grained diamond . It avoids the consumption peak particle size range saw blades, drill bits and other products, and the production of fine-grained diamond is the advantage of cubic press in China. A rough estimate is currently only used in ceramic processing market in Foshan, Guangdong 's annual consumption of 40 million diamond carats , the growth trend is obvious. This is a considerable potential diamond consumer market.
Transparency, angular development , long single-crystal diamond adapt to high levels of manufacturing ceramic processing tools. MBD8 more quality fine-grained ( 100/ 120 fine ) diamond consumption is increasing , the market supply shortage , the higher the price , hope to attract the attention of diamond manufacturers .
5 , Application Analysis
Compared with natural stone, polished porcelain tiles with a light weight , non-radioactive , no color , free design colors, varieties, more humane , clear price advantage , etc., suitable for all kinds of interior decoration . Compared with ordinary glazed tiles , more beautiful, wearable. Can assert , with the improvement of people's quality requirements and improvements in environmental awareness , ceramic tiles will be used more , the market outlook is very good. Diamond tools as ceramic processing irreplaceable tool , the market capacity will continue to increase along with the competition more intense, and improve the quality requirements . Various types of binding agents or configuration of new products will gradually be developed , applied to fill the gaps in some applications , and deep processing of porcelain tiles and shaped to meet the processing requirements.