High-precision disc inserts are widely used in various industries, including the automobile sheet metal sector, water tank belt manufacturing, shearing machine production, high-speed rail component fabrication, electrical equipment factories, steel mills, and specialized copper processing plants. These inserts are primarily designed to cut full sheets of metal or roll them into strips of specific widths as per customer requirements.
Our company specializes in producing φ 250mm × φ 160mm × 5mm high-precision disc inserts for our clients. The specifications require a thickness tolerance of ±0.001mm and parallelism within 0.002mm. After heat treatment, the discs are processed on an M7340 round table grinder. However, one common challenge is poor parallelism due to the thinness of the disc blade. During heat treatment, the disc tends to deform, and even though the thickness meets the required standards after measurement with a dial micrometer, the parallelism often fails when tested on a flat plate, making it unsuitable for the design.
Upon investigation, we found that the deformation occurs because the disc blade is too thin, and the electromagnetic clamping force during processing is not sufficient. Initially, a weak magnet was used to hold the blade, but once the magnetic force was removed after processing, the blade would slightly rebound, causing deformation. To solve this issue, we focused on reducing the electromagnetic attraction force during the process.
We developed a specialized tooling system, as shown in the drawing. The lower part of the tooling has a φ 20mm hole that aligns with the center positioning hole of the machine table. The outer diameter of the tooling is set to match the 250mm outer diameter of the disc blade. The upper step is designed to press against the blade’s outer edge, while the inner hole is sized to fit the 160mm diameter of the disc. A φ 4mm pin is used at the end face, with the center distance matching the inner diameter of the disc blade.
After heat treatment, the disc undergoes rough machining first. Then, the inner hole is processed, and an R2mm slot is electric discharge machined. The disc is then fixed to the tooling using the pin for further processing. The tooling is made from cast iron, which has low magnetic permeability, helping to minimize electromagnetic interference. This setup ensures the disc remains stable and free from deformation caused by magnetic forces.
The tooling is mounted on the workbench, and before processing, the tooling is aligned to ensure it is perfectly parallel to the work surface. The disc blade is placed on the tooling, and a weak magnetic clamping system is used. Since the contact area between the tooling and the workbench is large, and the tooling itself is heavy, the weak magnetic force is sufficient to secure the blade without causing deformation. As a result, the disc maintains its shape and dimensional accuracy throughout the process.
Precision grinding is carried out in three stages: rough grinding, semi-finishing, and finishing. Each stage requires careful stress relief to maintain quality. The process involves repeated turning and careful control of feed rates to avoid any damage to the thin disc.
Through practical application, we have refined this method and established a complete set of processing and testing procedures. We have become one of the few manufacturers capable of achieving ±0.001mm precision in thin disc blades. Our products now meet domestic advanced standards and can effectively replace imported alternatives. The quality has been well received by customers, and we continue to collaborate with local manufacturers to better meet their needs.
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