29
May
Troubled by chipping, poor flatness and failure to form mirror finish during grinding 92% alumina ceramic seals? Adopting Speedfam DSM 9B-5FH double disc grinding machine and Moresuperhard 1200mm/200# ceramic diamond double disc grinding plate, this article shares mature mass-production grinding technology. It realizes mirror surface processing with 0.0003mm flatness and 0.001mm parallelism, solving common pain points such as low yield, high consumable cost and insufficient productivity in alumina ceramic grinding.
In high-end manufacturing fields such as fluid sealing, pneumatic & hydraulic systems, new energy and industrial water pumps, 92% high-purity alumina ceramic seals have become core components of precision sealing assemblies. Featuring 1150HV ultra-high hardness, acid and alkali corrosion resistance, high temperature resistance and excellent thermal stability, they are widely recognized as ideal sealing materials. The double-sided flatness, parallelism and surface finish directly determine the sealing performance and service life of finished products.
Nevertheless, the combination of high hardness and high brittleness makes the double-sided precision grinding of alumina ceramics a universal industrial challenge. Most domestic and overseas processors still adopt silicon carbide lapping plates and ordinary resin-bonded diamond grinding plates for processing. This outdated method can hardly meet high-end mirror sealing standards and brings a series of production problems that squeeze corporate profit margins:
To solve the mass-production pain points of 22×17×4.5mm 92% alumina ceramic seals, Moresuperhard, a professional manufacturer of superhard abrasive tools, has developed customized ceramic diamond double disc grinding plates and complete grinding processes matched with Speedfam DSM 9B-5FH double disc grinding machines. It can remove 0.2mm margin on a single side and stably deliver mirror-effect workpieces. The actionable mass-production parameters are shared below.
The test workpiece in this project is a standardized alumina ceramic seal, commonly used in industrial pumps, construction machinery and new energy fluid sealing equipment.
The finished workpieces require intact edges without cracks or chipping and uniform mirror surface to meet the tolerance standards for high-end sealing parts.
The processing equipment adopted is the Speedfam DSM 9B-5FH precision double disc grinding machine, a mainstream model in the industry. It supports independent speed regulation of upper and lower discs and multi-stage pressure control, perfectly suitable for double-sided grinding of thin, brittle special ceramics and cemented carbide workpieces.
The grinding consumable is the Moresuperhard self-developed Φ1200mm 200# ceramic diamond double disc grinding plate. We optimized the formula of ceramic binder and diamond abrasive ratio to realize efficient and precise grinding for high-hardness alumina ceramics and zirconia ceramics.
After multiple rounds of sample debugging, Moresuperhard technical team optimized core parameters including grinding pressure, rotating speed and cycle times based on workpiece brittleness, machine load and cutting characteristics of ceramic diamond grinding plates.
The optimized parameters effectively avoid chipping, thermal deformation and grinding lines, balancing high precision and mass production efficiency. The complete parameters can be directly applied to identical Speedfam DSM 9B-5FH machines:
| Parameter Item | Detailed Specification |
|---|---|
| Workpiece | 92% High-purity Alumina Ceramic Seal (22×17×4.5mm) |
| Workpiece Hardness | 1150HV |
| Loading Quantity Per Batch | 150 Pcs/Disc |
| Single-side Grinding Margin | 0.2mm |
| Applicable Grinding Machine | Speedfam DSM 9B-5FH Double Disc Grinder |
| Supporting Grinding Plate | Moresuperhard Ceramic Diamond Double Disc Grinding Plate, Φ1200mm, 200# |
| Grinding Pressure | 150GMs/CM² |
| Lower Disc Rotating Speed | 70RPM |
| Upper Disc Rotating Speed | 35RPM |
| Sun Gear Rotating Speed | 25RPM |
| Standard Grinding Cycles | 28 Times |
After process debugging, Moresuperhard technical team conducted sampling inspection on finished workpieces together with the customer’s quality department. All indicators meet the acceptance standards for high-end mass-produced ceramic sealing parts, which can perfectly replace imported grinding solutions.
The detailed testing data is as follows:
Compared with ordinary resin diamond grinding plates, silicon carbide lapping plates and metal-bonded grinding plates on the market, Moresuperhard ceramic diamond double disc grinding plates are specially customized for brittle special ceramics.
We control every link from binder formula R&D to abrasive proportioning to solve core grinding pain points, helping processing factories reduce costs and increase efficiency:
Adopting a controlled-pore ceramic binder structure, passivated diamond abrasives can fall off automatically to keep the grinding plate sharp continuously and reduce dressing frequency. The flexible cutting mode effectively avoids edge chipping and micro-cracks of brittle alumina ceramics.
The grinding plate features high rigidity and ultra-low thermal expansion coefficient, which resists thermal deformation during long-term high-speed grinding and slows down flatness attenuation, ensuring consistent accuracy of batch workpieces.
Adopting high-purity high-strength diamond abrasives, the 200# specification is ideal for 0.2mm medium margin removal. Its cutting capacity far exceeds traditional abrasive tools, boosting production efficiency by more than 35% compared with conventional processes.
The service life is 2-3 times longer than ordinary resin grinding plates, cutting the cost of abrasive procurement and frequent machine downtime. Cooperated with Moresuperhard exclusive process, the defective rate can be controlled within 0.5%, saving 15%-25% comprehensive production cost for long-term mass production.
Fully compatible with mainstream double disc grinding machines worldwide, including Speedfam, Lapmaster and Yujing. It is applicable to grinding and mirror polishing of 90%-99% alumina ceramics, zirconia ceramics, silicon nitride ceramics and other structural ceramics.
Three main reasons lead to chipping:
Alumina ceramics have poor shear resistance and are easy to be torn by passivated traditional grinding plates. The optimal solution is to replace with Moresuperhard ceramic diamond double disc grinding plate, optimize pressure and speed parameters, and adopt segmented processing with light pressure for rough grinding and stable pressure for finish grinding.
Three essential elements for low-cost mirror processing:
It is recommended to use Moresuperhard 200# ceramic diamond grinding plate for margin removal and fine grit plate for secondary polishing to obtain mirror finish without extra polishing equipment.
This small and medium-sized precision double disc grinder is designed for thin brittle precision parts. It is suitable for various alumina ceramic seals, ceramic substrates, insulating ceramic parts, zirconia structural parts and ceramic plungers, supporting both small-batch sample testing and large-scale automatic mass production.
200# ceramic diamond grinding plate is the priority choice for 0.2mm single-side margin, balancing cutting efficiency and perfect workpiece appearance.
For ultra-high precision mirror polishing requirements, a two-stage process of 200# rough grinding + 600# finish polishing is recommended. Moresuperhard provides full-spec grinding plates to meet your diversified demands.
The rough grinding mode has been phased out in modern alumina ceramic processing. High-quality abrasive tools plus customized grinding parameters are indispensable to balance high precision, mirror finish, high productivity and low cost.
Specialized in superhard abrasive tools, Moresuperhard provides integrated double-sided grinding solutions for special ceramic processing enterprises, covering water pump sealing, hydraulic & pneumatic equipment, new energy energy storage, semiconductor parts, medical devices and other industries.
Different from ordinary abrasive suppliers that only sell products, Moresuperhard provides one-stop technical services including:
In addition to high-quality ceramic diamond double disc grinding plates, we help customers completely solve processing problems such as workpiece chipping, substandard accuracy, insufficient productivity and high consumable cost.
If you are processing alumina ceramic seals and other structural ceramics, or looking for cost-effective and long-life diamond grinding plates to upgrade your processing technology, feel free to contact the Moresuperhard technical team to get a customized grinding solution and free workpiece testing service!
