How can double disc grinding machines solve the problem of machining high hardness materials?

In terms of technical principle, the double disc grinding machine adopts a symmetrical layout of two grinding wheels, which can grind both end faces of the workpiece at the same time. This design not only reduces the number of clamping times and avoids repetitive positioning errors, but more importantly, through the simultaneous application of pressure by both grinding wheels, the workpiece is subjected to a balanced force during the machining process, which significantly reduces the risk of brittle chipping of high-hardness materials caused by excessive grinding force from one side.

The innovation of grinding wheel technology is the key for double disc grinding machine to overcome the high hardness material. For the characteristics of different materials, super-hard abrasive grinding wheels are widely used. The choice of bond for the grinding wheel is also crucial - metal bond grinding wheels are suitable for high-precision profile grinding, while resin bond grinding wheels can absorb vibration through elastic deformation, reducing surface vibration in the machining of high hardness materials.

The optimisation of the cooling and lubrication system should also not be overlooked. The grinding process of high hardness materials will generate a lot of heat, if the heat dissipation is insufficient, it is very easy to lead to thermal cracks on the surface of the workpiece or changes in metallurgical organisation. Double disc grinding machines are usually equipped with a high-pressure jet cooling system, which delivers the grinding fluid precisely to the contact area between the grinding wheel and the workpiece, and removes the heat through the forced convection of the fluid. For materials sensitive to thermal shock, such as ceramics, the use of low-temperature cold air or micro quantity lubrication (MQL) technology can reduce the effects of thermal stress.

Precise regulation of process parameters is the core of ensuring processing quality. The double disc grinder dynamically matches the grinding wheel speed, feed and grinding pressure through the CNC system. For highly brittle materials, the heat build-up from continuous grinding can also be reduced by ‘intermittent grinding’ (i.e. the grinding wheel is periodically removed from the workpiece for a short period of time).

In practice, double disc grinding machines have achieved significant results in the field of high hardness material processing. In the future, with the integration of intelligent technology (such as AI real-time monitoring of grinding status and adaptive parameter adjustment), the potential of the machine in the processing of high hardness materials will be further released to provide more efficient and precise solutions for high-end manufacturing.