**Abstract**
High-precision and digital abrasive belt grinding technology has become increasingly essential as technological advancements drive higher demands for the quality of key structural components in major engineering projects across energy, transportation, and national defense sectors. The efficiency, machining accuracy, and surface roughness of these components significantly impact the performance and reliability of energy conversion systems. Traditionally, such parts have been finished manually through sanding and grinding, which is labor-intensive, environmentally harmful, and results in low precision, poor quality, and high costs. This gap between domestic capabilities and the requirements of high-reliability applications like nuclear power and aerospace blades has hindered the development of critical national infrastructure.
**High-Precision, Digital Belt Grinding Technology**
With continuous progress in science and technology, China has raised its standards for the quality of key components used in large-scale engineering projects. These components must meet strict requirements in terms of profile manufacturing efficiency, machining precision, and surface finish, all of which are crucial to the overall performance and longevity of energy and power systems. However, current manual methods fall short in meeting these demands, leading to inefficiencies and quality issues that limit industrial growth.
**Typical Applications**
This advanced technology is widely applied in various industries, including:
- Aero-engine blade grinding
- Turbine blade grinding
- Propeller blade grinding
- Whole turbine disc polishing
- High-grade shaped sink efficient edge grinding
- Titanium alloy tube polishing
**Key Features of High-Precision, Digital Grinding Equipment**
1. Complex curved surfaces require multi-axis CNC machining for accurate control.
2. A constant-pressure grinding head mechanism ensures consistent pressure during processing, especially for blade polishing.
3. High-precision machine tools are essential to maintain accuracy.
4. Integration of online detection with CNC technology improves real-time monitoring and adjustment.
5. Machine size varies depending on the dimensions of the workpiece.
**1. High-Grade Shaped Water Tank High-Efficiency Edge Processing**
By combining advanced numerical control with abrasive belt grinding, this technology addresses the challenges of automatic edge finishing for high-grade water tanks, filling a technical gap in China's industry. In 2006, the company successfully produced over 100,000 sets of star basin products for Guangdong FRANKE (Switzerland), passing factory inspections and exporting 30,000 units abroad, saving approximately 120,000 euros in imported equipment costs.
**2. Zirconium Alloy Pipe Abrasive Belt Grinding**
Zirconium alloy cladding tubes are vital in nuclear reactors, protecting fuel pellets from corrosion and mechanical damage while providing structural support. To meet stringent requirements, these tubes undergo multiple processes, including wall thickness grinding. Ensuring uniform wall thickness and surface finish is critical for cold processing and vacuum annealing. The inner and outer surfaces must be cleaned and treated to remove defects before entering the production line.
**3. Marine Propeller Pitching Paddle Surface High-Efficiency Precision Belt Grinding**
Marine propellers are often milled using five-axis CNC machines, but the resulting surface quality is often poor, affecting propulsion efficiency and fatigue strength. Manual polishing is still commonly used, but it lacks consistency due to operator skill levels. Through collaboration with Chongqing Sanma Haida, a 2ML5560m-4NC CNC strong belt grinding machine was developed, achieving a maximum grinding deviation of ≤0.05mm and a surface roughness of Ra ≤ 0.11–0.29 μm. It was officially used in Chongqing Hengshan Machinery Factory in April 2010.
**4. Turbine Blade Seven-Axis Six-Link High-Efficiency Precision Belt Grinding**
Turbine blades are complex components made from high-temperature alloys or titanium, requiring precise shaping and surface finishing. Advanced seven-axis grinding systems enable efficient and accurate processing, improving both quality and productivity.
**5. High-Precision Precision Belt Grinding of Compressor Blades**
Compressor blades are another critical component that benefits from high-precision abrasive belt grinding, ensuring tight surface integrity and dimensional accuracy, which directly affects engine performance and reliability.
**6. Aeronautical Blade Seven-Axis Six-Link High-Efficiency Precision Belt Grinding**
Aero-engine blades are among the most challenging components to process due to their complex geometry, high operating temperatures, and strict tolerances. Traditional methods, such as manual grinding, result in inconsistencies and high scrap rates. Modern CNC-based belt grinding systems provide more reliable and repeatable results, enhancing both performance and safety.
**Belt and Abrasive Selection**
Abrasive belts come in various types, with the 3M pyramid-grinding belt being one of the most advanced. Its structured abrasive grains allow for efficient cutting, reducing heat generation and thermal stress. Additionally, new types of abrasive belts, such as triangular ceramic alumina belts, offer improved sharpness and longer life, making them ideal for difficult-to-machine materials.
**Superhard Materials**
Synthetic diamond and cubic boron nitride (CBN) are superior to traditional abrasives like corundum and silicon carbide. They offer higher hardness, better wear resistance, and excellent thermal conductivity, enabling efficient machining of hard and brittle materials while maintaining shape and sharpness over time. This not only enhances precision but also boosts productivity and reduces material waste.
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