The Difference Between Ordinary Abrasives and Superhard Abrasives

Common Abrasives: Overview

Common abrasives are essential grinding tools used extensively in the machining of metal and non-metal materials. These abrasives play a vital role in various industries such as manufacturing, construction, and automotive where precision and efficiency are critical.

Structure of common abrasives

The structure of common abrasives consists of three main parts: matrix, abrasive grains, and binder. Each element contributes to the overall function and performance of the grinding tool.

1. Matrix

The matrix is the main structural component of the grinding tool. It provides the necessary support and shape for the abrasive. The matrix is ​​usually made of the following materials:

• Metal: Often used in heavy-duty applications due to its strength and durability.
• Ceramic: has good wear resistance and is suitable for high-precision grinding tasks.
• Plastic or Composite: For lighter applications where flexibility and weight are a concern.

The choice of matrix material affects the performance and application of abrasive tools.

2. Abrasive particles

Abrasive is the actual grinding material that performs the cutting action during the grinding process. Common types of abrasives include:

• Aluminum Oxide: Known for its versatility and effectiveness in grinding a variety of materials, including metals and plastics.
• Silicon Carbide: Due to its sharpness and hardness, it is ideal for grinding hard materials such as glass and ceramics.
• Boron Nitride: For specialized applications, especially grinding of superhard materials.

The choice of abrasive is critical as it determines the tool’s cutting ability, efficiency, and suitability for a specific application.

3. Binder

The binder is the substance that holds the abrasive particles together and attaches them to the substrate. Common binder materials include:

• Resins: Provide flexibility and are commonly used in bonded abrasives for general-purpose grinding.
• Rubber: Has good shock absorbing properties and can be used in applications where a softer feel is desired.
• Metal: For high-performance applications where strength and durability are critical.

The properties of the adhesive affect the performance of the tool, including its ability to withstand wear and high temperatures.

Characteristics of common abrasives

• High Processing Efficiency: They can remove material quickly, making them suitable for a variety of grinding applications.
• High Machining Accuracy: Ordinary abrasives can achieve tight tolerances and smooth surfaces, which are critical in many manufacturing processes.

These properties make common abrasives a popular choice for a wide range of applications, from coarse grinding to fine finishing.

Limitations of ordinary abrasives

Although ordinary abrasives have many advantages, they also have certain limitations:

• Abrasion Resistance: Ordinary abrasives may not withstand long-term use in high-stress applications, resulting in faster wear and reduced effectiveness.
• Thermal Stability: They can resist the heat generated during the grinding process, which can cause thermal degradation of the abrasive and binder.
• High-end Machining Needs: For special applications that require extreme precision or the ability to grind ultra-hard materials, ordinary abrasives may not meet the necessary performance standards.

Superhard Abrasives

Superabrasives are advanced grinding tools made from extremely hard materials that are essential in high-end grinding applications. These tools are designed to meet the stringent requirements of industries requiring ultra-precision machining, such as aerospace, automotive, and semiconductor manufacturing.

Superhard abrasives structure

The structure of super abrasive is similar to that of ordinary abrasive, consisting of three main components: matrix, super abrasive, and binder.

1. Matrix

The matrix is the basic structure of the grinding tool. It provides support and shape, ensuring the tool maintains its integrity during the grinding process. The materials used in the base material are generally the same as those found in ordinary abrasives, including:

• Metal: Typically used for its strength and durability, especially in heavy-duty applications.
• Ceramic: Has good wear resistance and is suitable for high-precision grinding tasks.
• Plastic or Composite: For lighter applications where flexibility and weight are a concern.

2. Super abrasive

The distinctive feature of super abrasives is the use of super abrasives, which have extremely high hardness. Common super abrasives include:

• Diamond: Diamonds are known for their unparalleled hardness, making them ideal for grinding hard materials such as ceramics, glass, and concrete. It has excellent cutting efficiency and an excellent finish. Diamond tools include diamond grinding discs, diamond polishing pads, etc.
• Cubic Boron Nitride (CBN): CBN is the second hardest material after diamond and is particularly suitable for grinding ferrous materials. It has excellent thermal stability and wear resistance and is suitable for high-speed applications.
• Silicon Carbide: Although not as hard as a diamond or cubic boron nitride, silicon carbide is still considered a super abrasive and can effectively grind non-ferrous materials and hard ceramics.

3. Binder

The binder in super abrasives does the same job as regular abrasives, binding the super abrasive particles together and attaching them to the substrate. Common adhesive materials include:

• Resin: Provides flexibility and is often used to bond super abrasives for general-purpose grinding.
• Metal: For high-performance applications where strength and durability are critical.

Characteristics of superhard abrasives

• High Hardness: The special hardness of super abrasives enables them to grind difficult-to-machine materials, which makes them invaluable in specialized applications.
• High Grinding Precision: Superabrasives enable tight tolerances and smooth surfaces, which are critical for industries requiring precision engineering.
• Long Tool Life: Due to their durability and wear resistance, super abrasives have a longer service life than regular abrasives, reducing replacement costs over time.