How can we solve these processing difficulties of zirconia ceramic rings?
Summary: Zirconia ceramic rings are a new type of high-tech ceramic. In addition to having the high strength, hardness, high temperature resistance, acid and alkali corrosion resistance, and high chemical stability that precision ceramics should possess, they also have a toughness that is higher than that of general ceramics.
Zirconia ceramic rings are a new type of high-tech ceramics. In addition to having the high strength, hardness, high temperature resistance, acid and alkali corrosion resistance, and high chemical stability typical of precision ceramics, they also possess greater toughness than ordinary ceramics. They can be used in various industries, such as shaft seals, bearings, cutting components, molds, automotive parts, and even in the human body. In the consumer electronics field, zirconia ceramics are favored for fingerprint recognition modules and mobile phone back panels due to their hardness being close to sapphire, but with a total cost of less than 1/4 of sapphire, and their bending resistance being higher than that of glass and sapphire, non-conductive, and not shielding signals.
Preparation of zirconia ceramic rings
Zirconia ceramic rings are inorganic non-metallic materials formed by high-temperature sintering, with advantages such as high temperature resistance, corrosion resistance, wear resistance, and thermal shock resistance. They are generally formed using graded pressing or dry pressing methods, followed by high-temperature sintering to create ceramic rod blanks, which are then polished, chamfered, and finely ground.
Difficulties in processing and solutions
Due to their characteristics, zirconia ceramic rings encounter many challenges during processing. Below, the editor will introduce how to solve these issues:
① The thickness of the ceramic ring is small, and during processing, it is easy to experience cracking and edge collapse due to the grinding equipment's cutting force, which affects the qualification rate of the finished zirconia ceramic rings.
② The inherent issues with zirconia material. Because the structure of zirconia ceramics changes correspondingly in different temperature environments, we must ensure proper cooling during the grinding process to avoid changes in material due to temperature, which could lead to imperfect polishing results.
▶ Solutions:
① Before rough grinding, conduct a preliminary screening of the materials, mainly to filter out visibly problematic materials, such as those with incorrect colors or containing impurities. This avoids unnecessary losses due to material issues.
② During the grinding and polishing process, we use a process of rough polishing, semi-fine polishing, and fine polishing, utilizing an appropriate amount of copper or iron plates, and using ceramic plates as polishing paper, processed with a ceramic mirror polishing machine.
③ In response to the thin characteristics of the ceramic ring itself, targeted testing is conducted, employing new fixing methods to determine the critical point of the combination between the pressing method and the fixing method, thereby achieving an ideal fit between the zirconia ceramic ring workpiece and the grinding disc.
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