Application of Diamond Products in Flat Glass Processing

Introduction: Glass products are widely used in our daily life, among which flat glass is the most common glass product, which is widely used in photography, microscopes, radars, home appliances and other fields. With the development of science and technology, the precision and quality requirements of flat glass processing are also constantly improving. Diamond products are mainly used in flat glass processing for milling planes and spherical surfaces in rough processing (flat and disc grinding wheels), edge grinding wheels (parallel or special angled grinding wheels), fine grinding discs and surface grinding (spherical or flat surfaces) in fine processing, super-fine discs and polishing discs, and saw blades for cutting.

Due to the requirements for the processing accuracy of glass products, especially optical glass, the structure and precision requirements of diamond products are constantly improving, and they also need to be improved accordingly. Therefore, this paper analyzes and introduces the application of diamond products in flat glass processing and process parameters of diamond tools.

Application Process of Diamond Products in Flat Glass Processing

Diamond tools are used at all stages of flat glass processing, with each stage designed to increase efficiency and precision.

1. Milling and grinding wheels

The milling process is the initial step in the processing of flat glass and belongs to the rough processing stage. In this stage, the milling and grinding wheels use diamond products to effectively shape the glass.

Types of milling and grinding wheels:

• Surface milling and grinding wheels: These wheels are used for surface machining and are usually larger than 100mm in diameter. They are used for the initial shaping of glass to ensure a smooth and flat surface. The grit size range for these wheels is usually between 60# and 180#, with a diamond grain concentration between 50% and 100%. These wheels usually use bronze as a binder to provide durability and stability during the grinding process.

• Spherical milling and grinding wheels: These wheels are designed for shaping the spherical surfaces of glass products. They enable precise contouring, essential for applications where curvature is required.

The use of diamond milling cutters and grinding wheels can significantly increase the efficiency of glass machining operations, allowing for faster material removal and improved surface quality.

2. Diamond edge grinding wheel

After the flat glass milling is completed, the next step is edge grinding, which is essential to obtain a smooth and safe edge. Diamond edge grinding wheels are designed for this purpose.

• Function: The main function of the diamond edge grinding wheel is to process and grind the outer circle of flat glass. This step is essential to remove sharp edges and ensure the safety of the glass during handling and installation.

• Binders used: There are two common types of binders used in diamond edge grinding wheels:

• Electroplated nickel-based binders: These bonds provide a strong bond between the diamond grains and the grinding wheel, allowing for efficient grinding while maintaining the integrity of the tool.

• Sintered bronze binders: These binders are available in different concentrations and particle sizes and can be selected depending on the optical characteristics of the flat glass to be processed. The choice of binder affects the grinding performance and the final quality of the edge.

Selecting the right edge grinding wheel is crucial as it directly affects the quality of the finished product and the efficiency of the grinding process.

3. Fine grinding and ultra-fine grinding

Fine grinding and super-fine grinding are key steps in the production of ultra-precision optical glass components. These processes are designed to enhance the optical properties of flat glass, ensuring that the final product meets industry standards for clarity, smoothness and overall quality.

Fine grinding:

• Purpose: The main purpose of fine grinding is to refine the glass surface after the roughing stage. This step is essential to obtain a smooth surface that fully demonstrates the optical properties of the glass.

• Binder used: The choice of binder is crucial during the fine grinding process. The fascia sheets commonly used at this stage usually have binders made of bronze, iron, nickel or cobalt-based materials. These binders provide the necessary strength and stability to the grinding tool.

• Diamond grit size and concentration: The particle size of diamond is generally 325400~10E5, with concentrations ranging from 100% to 35%.

This range allows for efficient material removal while maintaining the integrity of the glass surface.

Ultra-fine grinding:

• Purpose: Superfinishing takes the process to the next level, focusing on achieving an even higher surface finish. This stage is particularly important for applications that require ultra-precision machining, such as optical lenses and high-end glass products.

• Binders used: Unlike fine grinding, super-finishing usually uses a resin-based organic material as a binder. These binders are designed to provide a softer touch, allowing for a finer polish without damaging the glass.

• Diamond particle size and concentration: The particle size of diamond in fascia is generally within the range of 14 E8~7 E5, and the concentration is between 50% and 25%. This configuration is ideal for achieving the desired smoothness and optical clarity.

4. Polishing Pad

Polishing is the final process to improve the surface finish and flatness of flat glass after fine grinding and super fine grinding. This process is essential to ensure that the glass has a certain pore size and remove any deteriorated layers on the surface.

• Purpose of polishing: Polishing is to improve the overall surface quality of flat glass to a level comparable to that of gold film polishing pads and ultra-fine abrasive pads. This step is critical for applications where optical clarity is important.

• Polishing pad composition: The primary binder of the polishing pad is a resin, which provides flexibility and conformability during polishing. The abrasive is typically composed of cerium oxide and a small amount of diamond powder. This combination effectively removes material while improving the surface finish of the glass.

In Conclusion

By using diamond tools with the appropriate binder and grit, manufacturers can ensure that their glass meets the stringent requirements of a wide range of industries. As technology continues to advance, the role of diamond products in flat glass processing will become increasingly important, enabling the production of high-quality glass products that meet the highest standards of precision and quality.