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**Abstract**
Superhard material coated abrasives are abrasive tools that use adhesives to attach superhard abrasive particles to a flexible substrate. Grinding is the most significant part of abrasive consumption across all processing methods. The increasing production of diamonds and CBN has provided an opportunity to accelerate the development of these tools. The National Twelfth Five-Year Plan emphasizes the need to build a resource-efficient and environmentally friendly society, pushing industrial production to shift from traditional extensive processing to more efficient and eco-friendly methods.
Despite the potential, the application of superhard material coated abrasives in China remains limited due to factors such as production equipment, raw material costs, and manufacturing capabilities. In contrast, industrialized countries have widely adopted these materials due to environmental concerns, advanced technology, and a full range of products. Companies like 3M and Norton offer a variety of superhard abrasive products, including sandpaper and polyester film belts used for car body polishing and engine component grinding.
The 21st century is considered the "century of diamonds," and the application of superhard materials is expected to expand significantly. Coated abrasives made from diamond or CBN are among the most promising developments, gradually replacing traditional tools like corundum and silicon carbide. These materials are particularly valuable in precision and ultra-precision grinding and polishing.
**1 Introduction**
A superhard material coated abrasive is a type of abrasive tool that uses adhesives to bond superhard grains to a flexible substrate. This method offers high efficiency and durability, making it ideal for challenging applications. Grinding remains the largest consumer of abrasives, and with rising production of diamonds and CBN, there is growing interest in developing advanced coated abrasive technologies.
While China lags behind in the adoption of these materials, many developed nations have already integrated them into various industries. For instance, companies like 3M and Norton have long offered a wide range of superhard abrasive products, from automotive polishing to engine component machining. These products are available in different forms, such as metal-plated (M) and resin-bonded (R) types, as shown in Figure 1.
**2 Classification of Coated Abrasives**
Coated abrasives can be classified based on the abrasive material, processing method, and application. They include diamond and cubic boron nitride (CBN) coated abrasives. Based on the bonding method, they can be electroplated or resin-bonded. Resin-bonded abrasives are further divided into coating and dispensing types. In terms of use, they come in various forms, such as abrasive belts, grinding wheels, and polishing sheets.
Diamond abrasives are ideal for hard materials like glass, ceramics, and precious stones, while CBN abrasives are mainly used for steel parts, especially in belt grinding machines.
**3 Three Major Elements**
The three main elements in the manufacture of coated abrasives are the substrate, abrasive grains, and binder. Each plays a critical role in determining the performance of the final product. The substrate serves as a carrier for the abrasive and binder, and common types include paper, cloth, composite, and non-woven fabrics. Polyester films are increasingly used due to their advantages in grinding difficult-to-machine materials.
Abrasives are granular materials used for grinding and polishing. They can be natural or synthetic, with examples including garnet, corundum, and synthetic diamonds. Binders, such as phenolic resins and nano-SiOâ‚‚-based resins, provide structural integrity and bonding strength.
**4 Diamond Belt Applications**
Diamond abrasive belts are categorized into metal-bond and resin-bond types. They are widely used in industrialized countries for applications like automotive glass edging. Compared to silicon carbide belts, diamond belts offer longer service life, higher efficiency, and better surface quality. Table 2 illustrates the cost comparison between the two, showing that despite higher initial costs, diamond belts provide significant long-term savings.
In addition to glass edging, diamond belts are also used in precision grinding and chamfering of silicon ingots, offering reduced processing time and improved yield.
**5 CBN Abrasive Belt Applications**
CBN abrasive belts are known for their superior performance and cost-effectiveness. They are widely used in precision bearing grinding and CNC belt grinding machines. Unlike conventional abrasives, CBN belts maintain shape and extend service life, improving productivity and reducing downtime.
**6 Other Superhard Material Coated Abrasives**
Other types include diamond abrasive sheets, hand grinding blocks, and abrasive brushes. These are used in specialized applications where high precision and durability are required.
**7 Conclusions and Prospects**
With the continuous advancement of machining technologies and the emergence of new materials, the demand for high-efficiency, high-precision abrasive tools is increasing. Coated abrasives, especially those made from superhard materials, are becoming essential in modern manufacturing. Despite challenges, China's rich resources and growing industry present a promising future for this field.
It’s time to move beyond misconceptions about the cost of superhard materials. Their long service life and high efficiency make them a cost-effective choice in many applications. As technology advances, the use of superhard material coated abrasives will continue to grow, opening up new opportunities in precision manufacturing and sustainable production.
**References**
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