Introduction to Japanese grinding technology

Due to its high quality and excellent reliability, Japan's processing machine tools have been highly praised internationally, so they can surpass Europe's old industrial powers and maintain the number one position in the world in 24 years. In particular, the production of cutting machine tools such as vertical and horizontal machining centers is the world's largest in terms of quantity and quality. However, European countries such as Germany and Italy also have advantages in grinding machine production, and they are strong competitors in Japan's leading position in machine tool exports.
In recent years, the processing of electronic products has begun to grow at a high speed, and ultra-precision, high-performance grinding machines are indispensable, especially for high-precision grinding of small products.
This paper mainly looks forward to the high-tech and high value-added grinder products that Japan is proud of, and focuses on the precision mold grinding technology that is indispensable in the production of optical parts. In addition, it also introduces a grinding machining center with good development prospects in the future and a composite machining machine with grinding function at the same time.

Japanese grinding machine position in the international market
As mentioned earlier, the value of Japanese machine tools has been the highest in 24 years, followed by Germany. After entering the 21st century, China's machine tool output has grown rapidly and is now ranked third. In recent years, Italian machine tool production is also on the rise, ranking fourth.
In the statistics of the data on the production value and output of grinding machines in various countries of the world, there is a certain difficulty in obtaining correct data because there is no internationally standardized standard for project classification methods. Some countries have not released relevant output value and production data.
According to relevant data, the top three exporters of surface grinders are Germany, Japan and Italy. The highest import volume is China, and it is on an upward trend year by year. In terms of quantity, China has a high level of both import and export (the number of exports in Taiwan is also quite large). Based on the unit price of the export surface grinder, the price of China (700,000 yen) and Taiwan (1.4 million yen) is higher than the high price of Germany (15.8 million yen) and Japan (13.6 million yen). low. It can be seen that from the perspective of unit price, the origin of the surface grinder presents a polarization trend.
Japan and Germany imported a large number of grinding machines, because their machine tool manufacturers set up overseas factories in Southeast Asia and other places, and then imported low-cost grinding machines not produced in the country from overseas factories, resulting in an increase in the number of imports. In any case, from a global perspective, Germany, Japan and Italy are undoubtedly the main supply base for high-performance surface grinders.
Although China has a large number of grinding machines, it is the number one importing country in terms of amount. Although the United States imports a large number of grinding machines, the amount is relatively low. It can be seen that the United States mainly uses some low-cost grinding machines. In addition, in terms of the amount, the largest export destination of the US grinding machine is Germany; in terms of quantity, it is the Taiwan area.

Grinding processing ultra-precision (1) grinding example of micro spherical lens arrangement
Japan leads the world in digital cameras, mobile phones with camera functions and surveillance cameras. Nowadays, the improvement of pixels and the price reduction are changing with each passing day, which includes the continuous advancement of ultra-precision machining of optical components such as micro spherical lenses.
Prof. Suzuki from the Central University proposed a method for ultra-precision grinding of cemented carbide molds for the production of miniature spherical lenses. Previously, only one lens could be formed in one mold, but now, the array of molds makes it possible to mass-produce lenses, which reduces production costs. The mold processing of the microspherical convex lens is a four-axis linkage ultra-precision grinding device and a shaped diamond grinding wheel, and the creation motion is realized by synchronous control. The workpiece is mounted on the main shaft to rotate at a low speed, and a diamond grinding wheel having a concave (or convex) cross-sectional shape is mounted on the rotating vertical shaft for grinding. First of all, when rotating at low speed, it is necessary to ensure a certain distance between the workpiece and the grinding wheel. The rotation direction and speed of the grinding wheel and the workpiece should be synchronized to achieve precise grinding of the concave (or convex) spherical shape. Then, adjust the workpiece position and repeat the above machining operation.
In order to achieve high-speed, high-precision synchronous control, it is necessary to have advanced numerical control system and mechanical structure. Toshiba Machine's ulg-100d ultra-precision surface grinder uses a combination of linear motor feed drive and vv rotation to achieve 1nm step feed, solves the quadrant protrusion problem, and realizes free-form surface machining with smooth circular interpolation. .
In order to properly shape the diamond grinding wheel, the grinding wheel dressing technology is indispensable. Professor Suzuki uses vanadium alloy bond to make the forming radius of 1500# and 3000# thermosetting resin diamond grinding wheels reach r2.5mm.

(2) Grinder with linear motor
The feed of the surface grinder was previously driven by a cylinder. Later, hydraulic servo system technology was applied to the cylinder drive control to achieve high-speed reversal in a short stroke for fast grinding. In recent years, linear motor drives have replaced conventional cylinder drives, achieving high efficiency while improving energy efficiency, and contributing to the maintenance of the working environment and the protection of the global environment.
The upg310li grinding machine produced by Okamoto machine is driven by a linear motor, achieving a high-speed round trip of 20 mm stroke and 500 times/min, which greatly shortens the grinding time of small parts such as punching machines. In addition, the grinder table is equipped with a variable sliding system that reduces the friction coefficient while ensuring high rigidity and achieves high energy efficiency and high precision machining of the micro mold.

Grinding composite (1) Grinding machining center
The v milling machine has evolved from a CNC milling machine to a milling center, and the lathe has been upgraded to a turning center via a CNC lathe. As far as the grinding machine is concerned, the numerical control grinding machine has been put into practical use, but the grinding processing center has not yet been popularized, and its future development is worthy of expectation.
In the grinding center, two systems developed from the grinding machine and machining center are included. In general, there are automatic wheel changer (atc), automatic measuring device and workpiece exchange device for managing various grinding wheels. The difficulty of grinding centers relative to milling and turning centers is:
1 tool wear;
2 It is difficult to maintain the high precision of the machined parts;
3 requires higher precision;
4 The debris is very small and can easily fall into the moving parts of the machine. .
The igv-1 nt grinding center based on the vertical internal grinding machine of the sun machine uses the hexagonal grinding wheel to realize the automatic exchange of the grinding wheel; the automatic device ensures the machining accuracy. The machine can be precisely ground on the outer circumference, inner diameter and end surface, and is suitable for grinding various gears and flanges.
The gc620 grinding center developed by Osaka mechanics based on the milling center not only retains the performance advantages of the machining center, but also optimizes the coolant and wear debris handling functions. The use of water-soluble cutting oil is beneficial to the rust prevention of machine tools. The workbench is equipped with a grinding wheel automatic dressing device, which can timely repair the diameter and length and width of the grinding wheel, and can be continuously ground for a long time.

(2) Compound machining machine with grinding function
Further development of the grinding and machining center is a multi-functional composite machining machine. In addition to grinding, the compound machining machine can also perform cutting, laser machining, and electric discharge machining. Machine tool builders have combined various processing capabilities to develop a variety of new machine tools, which are found everywhere at the Japan Machine Tool Show (jimtof).
For example, Professor Sin Boh of Fukuoka Institute of Technology developed a multi-tasking machine that combines laser processing and grinding. Laser is used for roughing and grinding is used for finishing. The interior of the compounding machine is equipped with a laser concentrating system for processing and an optical system for observing the machined surface. Further, the oxygen concentration of the assist gas can be adjusted by incorporating nitrogen into the compressed air. The grinding process uses 3000# electroplated grinding wheel, while the dressing grinding wheel uses 8000# electrified dressing tool. The system can complete the composite processing of the smooth surface of the glassy carbon workpiece below 80 nm in a short time.
The cnj2-e multi-tasking machine developed by Makino Seiki combines electric discharge machining and grinding processing to perform energy-efficient rough machining by electric discharge machining, and then finish the final shape machining by grinding.
Grinding machining centers and multi-tasking machines use workpieces in one clamping process, so the impact of installation errors can be minimized, and the requirements for high precision, energy efficiency, space saving, etc. can be effectively adapted. The development prospects are very worth looking forward to.

Silicon
Carbide is the only chemical compound of carbon and silicon. It was originally
produced by a high temperature electro-chemical reaction of sand and carbon.
Silicon Carbide is an excellent abrasive and has been produced and made into
grinding wheels and other abrasive products for over one hundred years. Today
the material has been developed into a high quality technical grade ceramic
with very good mechanical properties. It is used in abrasives, refractories,
ceramics, and numerous high-performance applications. The material can also be
made an electrical conductor and has applications in resistance heating, flame
igniters and electronic components. Structural and wear applications are
constantly developing.

Silicon Carbide Block

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