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**Abstract**
Superhard material coated abrasives are abrasive tools that use adhesives to attach superhard abrasive particles to a flexible substrate. Among all processing methods, grinding consumes the most abrasives. The increase in the production of diamonds and cubic boron nitride (CBN) has created new opportunities for the development of advanced abrasive tools. The National Twelfth Five-Year Plan emphasizes the need to build a resource-saving and environmentally friendly society, urging industrial production to shift from traditional, extensive processes to more efficient and eco-friendly methods.
Despite the potential, the application of superhard material coated abrasives in China is still limited due to factors such as equipment, raw material costs, and manufacturing levels. However, in developed countries, where environmental protection is prioritized and technology is well-established, these abrasives have found widespread use across various industries. Companies like 3M and Norton offer a wide range of superhard abrasive products, from car body polishing to engine crankshaft and camshaft machining. Figure 1 shows an example of a 3M superhard material coated abrasive.
The 21st century is often called the "century of diamonds," and the application of superhard materials is expected to grow significantly. Superhard material coated abrasives are among the most promising developments in the field. Flexible products such as diamond or CBN abrasive belts, grinding wheels, and discs are gradually replacing traditional corundum and silicon carbide tools in the market.
**1. Introduction**
A superhard material coated abrasive refers to a tool that adheres superhard abrasive grains to a flexible substrate using an adhesive. Grinding remains the largest portion of abrasive consumption in industrial processes. The growing output of diamonds and CBN provides strong material support for the advancement of these tools.
In China, the adoption of superhard material coated abrasives is still limited due to production constraints and high costs. In contrast, industrialized nations have embraced these technologies due to their environmental benefits, mature production techniques, and comprehensive product ranges. Many companies in these countries have already achieved large-scale production.
Leading global manufacturers, such as 3M and Norton, offer numerous superhard abrasive products. These include high-grade sandpapers and polyester film belts used for car body polishing and engine component machining. Figure 1 illustrates a 3M superhard material coated abrasive, with labels indicating different bonding types: M—Metal Plated (electroplated bond), R—Resin Bond (resin bond).
**2. Classification of Coated Abrasives**
Based on abrasive materials, they can be divided into diamond and CBN coated abrasives. According to processing methods, they can be electroplated or resin-bonded. Resin-bonded abrasives are further categorized into coating-type and dispensing-type. Based on usage, they include abrasive belts, abrasive belt rings, flexible grinding wheels, grinding discs, polishing sheets, and soft boring tools.
Diamond abrasives are ideal for hard materials like non-ferrous metals, glass, ceramics, and gemstones. CBN abrasives are mainly used for steel parts, especially in belt grinding applications.
**3. Three Major Elements**
The three main components in the manufacture of coated abrasives are the substrate, abrasive grains, and binder. Any improvement in these elements can significantly enhance the performance of the final product.
The substrate serves as the base for the abrasive and binder. Common types include paper, cloth, composite, and non-woven fabrics. Polyester fiber cloths have become increasingly popular for their strength and versatility in large-area grinding. Non-woven fabrics are formed by heating, pressing, or bonding natural and synthetic fibers. They are often combined with cloth or paper bases to make belts or wheels.
Polyester films are widely used abroad as substrates for superhard abrasive belts, sheets, and polishing papers. They offer advantages in grinding difficult-to-machine materials and are expected to expand the application of superhard coated abrasives into precision and ultra-precision grinding fields.
Abrasives are granular materials used for grinding, cutting, and polishing. They are classified into natural and artificial types. Natural abrasives include garnet and natural diamonds, while artificial ones include corundum, silicon carbide, synthetic diamonds, and CBN.
Binders play a crucial role in holding the abrasive grains to the substrate. Common binders include animal glues and synthetic resins. Phenolic resin is widely used due to its excellent bonding strength and resistance to water, acid, and weathering. Nano-SiOâ‚‚ bisphenol phenolic resin is emerging as a key material in the industry.
**4. Diamond Belt Application**
Diamond abrasive belts are available in metal-bond and resin-bond varieties. In Western countries, several companies produce a wide range of these belts with different particle sizes and working layer colors. For example, a Swiss company offers various patterns and binder types, as shown in Table 1.
**4.1 Automotive Glass Edging**
Glass edging typically uses abrasive belts or grinding wheels. Diamond belts are preferred for their low damage, long service life, and suitability for complex shapes, especially in automotive glass processing. However, due to immature technology in China, many manufacturers still use silicon carbide belts, which have shorter lifespans and lower efficiency.
Table 2 compares the cost of using diamond and silicon carbide belts for automotive glass edging. Although diamond belts are more expensive upfront, their longer lifespan and higher efficiency result in much lower overall costs. This makes them a more cost-effective and environmentally friendly option.
**4.2 Roll Wear Coating Processing**
Corrugated rollers are critical components in corrugated board production. Advanced thermal spraying technology is used to apply WC-Co cermet coatings to improve wear resistance and surface hardness. After coating, the surface is usually ground with diamond belts to achieve the required smoothness.
**4.3 Surface Grinding and Chamfering of Silicon Ingots**
Diamond abrasive belts are ideal for grinding and chamfering silicon ingots. They reduce process steps, improve surface quality, and lower labor costs. Their efficiency and reliability make them a top choice for high-precision semiconductor manufacturing.
**5. CBN Abrasive Belt Application**
CBN abrasive belts offer superior performance and cost-effectiveness. They are particularly effective in precision bearing grinding and CNC belt grinding machines. Compared to ordinary belts, CBN belts last longer, improve productivity, and enhance surface quality.
**6. Other Superhard Material Coated Abrasives**
Other types include diamond abrasive sheets, hand grinding blocks, and abrasive brushes, each tailored for specific applications.
**7. Conclusions and Prospects**
As machining technology advances and new materials emerge, the demand for high-efficiency, high-precision grinding tools continues to rise. Superhard material coated abrasives are becoming essential in specialized applications such as high-precision and automated production lines.
China, as a major producer of superhard materials, has significant advantages in raw materials and variety. However, there is a need to overcome misconceptions about cost and performance. With proper investment and technological progress, the future of superhard material coated abrasives in China looks very promising.
**References**
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