How to produce cutting disc

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Manufacturing Method and Procedure of Resin Cutting Discs

1. Core Raw Materials (General Formula)

• Abrasive: Brown fused alumina, white fused alumina, silicon carbide (conventional); Diamond/CBN (superabrasive)
• Binder: Powder phenolic resin (main binder) + Liquid phenolic resin (wetting & adhesion)
• Reinforcing Mesh: Fiberglass mesh cloth (double-layer/single-layer for flexural strength)
• Filler: Iron oxide, iron sulfide, cryolite, gypsum, calcium carbonate (adjust hardness, heat dissipation and self-sharpening performance)
• Auxiliaries: Hexamine (curing agent), stearic acid, coupling agent, pigment powder

• Abrasive: 100
• Powder phenolic resin: 12～18
• Liquid phenolic resin: 3～6
• Filler: 5～15
• Fiberglass mesh: 2 layers (Φ100～400mm)

2. Detailed Production Procedures (Industrial Hot Press / Semi-Hot Press Process)

2.1 Raw Material Preprocessing & Weighing

• Dry and screen abrasives to remove impurities and control particle size
• Keep resin and fillers dry and moisture-proof
• Precisely proportion raw materials with electronic scale (allowable error ≤±0.5%)

2.2 Material Mixing (Key for Uniformity, No Agglomeration)

1. Dry Mixing: Mix abrasive, resin powder and filler in a 3D mixer for 10～15 minutes
2. Wet Mixing: Add liquid phenolic resin / wetting agent, continue mixing for 15～25 minutes
3. Maturing: Seal and stand the mixed material for 4～8 hours to fully wet abrasives with resin
4. Sieving: Sift through 16～24 mesh to break up lumps for standby use

2.3 Compression Molding (Mainstream: Semi-Hot Press / Hot Press)

• Temperature: 50～70℃ (semi-hot press) / 80～100℃ (hot press)
• Pressure: 150～300kg/cm²
• Pressure holding time: 15～40 seconds (depends on thickness)

1. Preheat the mold and spray release agent
2. Spread bottom material → place the first layer of fiberglass mesh
3. Spread middle material → place the second layer of fiberglass mesh
4. Spread top material → install center ring / steel ring
5. Mold closing & hot pressing → pressure holding and pressure relief → green disc demolding

2.4 Curing (Hardening / Heat Setting)

• Equipment: Oven / curing furnace with step heating curing
• Standard 24-hour curing curve:
  • Room temperature to 80℃: 2h
  • Constant temperature at 80℃: 4h
  • 80℃ to 150℃: 3h
  • Constant temperature at 150℃: 8h
  • 150℃ to 180℃: 2h
  • Constant temperature at 180℃: 4h
  • Cool naturally to room temperature
• Function: Realize resin cross-linking and curing to meet strength and hardness standards

2.5 Post-Processing

• Surface grinding & thickness trimming: Control thickness tolerance ±0.05～0.1mm
• Chamfering: Inner and outer circle chamfering to prevent edge chipping and reduce vibration
• Dynamic balancing: Weight removal correction (essential for high-speed cutting)
• Printing: Mark specifications, safety lines and brand logo

2.6 Inspection & Packaging

• Appearance inspection: No cracks, missing corners or exposed mesh
• Dimensional inspection: Outer diameter, inner diameter and thickness
• Performance test: Rotation test & bending strength test
• Hardness and sharpness: Sampling cutting verification
• Qualified products → moisture-proof packaging → warehousing

3. Comparison of Three Molding Processes

4. Safety & Quality Key Points

• Double-layer mesh reinforcement: Conventional cutting discs must adopt double fiberglass mesh
• Sufficient curing: Insufficient curing causes cracking and grit falling off; over-curing leads to brittleness
• Uniform mixing: Uneven resin distribution results in inconsistent hardness and burst risk
• Raw material drying: Excessive moisture causes air holes and reduced structural strength