In heavy industrial scenarios such as stone cutting and wind power equipment flange processing, large-diameter saw blades (usually with a diameter exceeding 1 meter) are the core cutting tools. Due to their large size, high substrate rigidity requirements, and complex blade profile, traditional standardized grinding equipment is difficult to meet the requirements of forming processing. Customized grinding machines, through structural adaptation and parameter optimization, have become key equipment for the manufacturing of large-diameter saw blades. At the same time, a multidimensional accuracy guarantee system needs to be constructed to ensure stable cutting performance of the saw blade.
The core difficulty of forming large diameter saw blades lies in the processing constraints caused by their size characteristics - the large diameter of the saw blade leads to significant centrifugal force during rotation. If the rigidity of the grinding machine fixture is insufficient, it is easy to cause saw blade vibration and contour deviation; And the large diameter saw blade has a large number of cutting edges and a wide distribution range, requiring the grinder to have a wide range and high-precision motion coverage capability. To address these issues, customized grinding machines start with structural design: using high-strength cast iron bed and reinforced spindle to enhance the overall rigidity of the equipment and reduce vibration transmission during high-speed rotation; Simultaneously customizing a large stroke motion module, coupled with adjustable fixtures, to meet the clamping requirements of different diameter saw blades, ensuring that the saw blades remain in a stable processing posture during the grinding process.
At the level of functional customization, the grinding machine needs to optimize its core modules based on the forming requirements of large-diameter saw blades. For example, large diameter saw blades used for stone cutting need to produce serrated edges and chip grooves. Customized grinding machines can be equipped with multiple sets of dedicated grinding wheel sets, and the CNC system can preset trajectories to complete edge grinding and chip groove formation in one go, avoiding accuracy errors caused by multiple clamping; For large diameter saw blades used in metal cutting, the grinding machine can be customized with a low-temperature cooling system to control the grinding temperature and prevent blade height differences due to thermal deformation of the saw blade substrate. In addition, some customized grinding machines also integrate the saw blade dynamic balance pre-processing function, which directly detects and corrects the dynamic balance of the saw blade after forming grinding, reducing the vibration risk during subsequent use.
Accuracy assurance is the core goal of large-diameter saw blade forming processing, and a control system needs to be constructed from the entire processing flow. Before processing, calibrate the saw blade clamping position through a laser positioning system to ensure that the center of the saw blade is coaxial with the grinding machine spindle; Real time monitoring of grinding wheel wear status during processing, combined with automatic compensation of grinding amount by CNC system, to avoid the decrease of cutting edge accuracy caused by grinding wheel wear; After processing, high-precision image measuring instruments are used to detect the blade edge angle, contour size, and flatness of the saw blade, forming a closed-loop control of "pre calibration real-time compensation post detection". At the same time, customized grinding machines also optimize grinding parameters, such as reducing feed rate, controlling grinding depth in stages, reducing stress accumulation during large-diameter saw blade processing, further ensuring forming accuracy and saw blade service life, and providing reliable tool support for efficient cutting in heavy-duty industrial scenarios.