Tile polishing process over the years what new changes

Polishing is a very important ceramic tile processing procedures, whether it is polished tiles, ceramic tiles, antique tiles or glazed and handmade tiles, all need to be polished and polished in order to be packaged for sale. The advantages and disadvantages of the polishing process will also have a direct impact on the quality of the tiles, even if the tiles in the pressing and firing process are not a problem, to the polishing of this step if there is a mistake will be abandoned.

The polishing process is realized through the polishing machine, the level of polishing process by the polishing machine structure configuration, polishing grinding block and process parameters and other factors. Over the years, many companies are trying to improve the level of polishing process, or improve the structure of the polishing machine configuration, or to enhance the service life of polishing consumables, as well as optimize the process parameters. Companies catch up with you to make the ceramic industry ceramic tile products have a brighter and more varied surface effect, but also to enhance the energy-saving polishing machine to reduce the level of consumption.

Segmentation of the market

Foshan City, Basel Electro-Mechanical Co., Ltd (hereinafter referred to as "Basel Electro-Mechanical") General Manager Huang Huiting introduced to the ceramic tile polishing process is divided into rough casting, vegetal casting, semi-polishing, full casting and soft casting, etc., and ceramic tile polishing machine scraping rough casting machine, rough casting machine and ordinary polishing machines and other classifications. Rough casting is the application of scraping rough casting machine for tile blanks to scrape flat fixed thickness; plain casting is used for porcelain polishing, the use of billet polishing machine; and half-throw is for handmade tiles and antique tiles of the polishing process; full casting is the use of polished tiles and glazed tiles process; soft casting is the use of the process for recent years the more popular soft tiles and inkjet percolated polished tiles.

In addition, polished tiles and glazed tiles, although both are using the full throw process, but in the structure of the polishing machine and motor power, grinding block and grinding head with the grinding block material are distinguished. Glazed brick polishing using elastic grinding block, while polished brick using alloy grinding block, mesh and sintering strength are higher than the elastic grinding block.

Because of the many types of polishing machines, the enterprise's warehousing capacity, software strength and financial strength are very important, so many companies producing polishing machines choose to produce several of these types of products. Moreover, now the consumables market competition, there are hundreds of enterprises in the country, mainly small and medium-sized enterprises, however, the market is shrinking, the enterprise's inventory pressure. Many enterprises producing consumables are trying to find ways to reduce costs, while also focusing on segmentation of the market cultivation, to make the product more professional, otherwise it will be eliminated.

A supervisor working on the tile polishing line for many years, said that if you do not take into account the internal causes of the tiles themselves, the polishing process alone, affecting the polishing of ceramic tile polishing of a few major factors are the polishing fluid, polishing grinding head, polishing grinding block and polishing process parameters.

Water is commonly used polishing fluid, which can play a role in both grinding and cooling, but also as a medium for the physical action of the polishing process; polishing head is equipped with polishing grinding equipment, per square meter of ceramic tile allocated to the number of polishing grinding head will affect the polishing accuracy of the tiles; polished grinding block of the production of a variety of materials, polishing of polished tiles are mostly used to contain the metal material made of polished grinding block, the softer the hardness of the Grinding block is suitable for soft tile or arc type tile polishing, moderate hardness of the grinding block on the full glaze and other tile polishing effect is better.

In addition, the polishing process parameters are the concentration and supply of polishing agent and polishing pressure and line speed. In less than a certain concentration value, the polishing speed with the increase in the concentration of polishing agent and increase, the concentration value of the maximum, if the concentration is increased, the polishing speed is reduced. Similarly, the polishing speed is maximized when the amount of polishing agent is supplied at a certain value, and then the polishing speed decreases when the amount of supply is increased. Appropriate increase in polishing pressure can increase the polishing speed, but the pressure is too large, the grinding effect is strengthened, not conducive to the formation of glossy surface. Polishing speed depends on the rotational speed of the polishing head, but the linear speed is too large, the polishing agent will be thrown out, resulting in waste.

Polishing machine innovation

Huang Huiting revealed that from the early 1990s modern tile polishing machine was introduced into China, polishing machine has become an essential part of the tile production line. And in the entire tile polishing production line, polishing machine is the most important processing equipment, tiles after the polishing process after the surface has a flat and bright characteristics. The quality of ceramic tile polishing mainly depends on the development of polishing machine process parameters, however, the production process is common due to improper setting of process parameters caused by leakage, back to the phenomenon of throwing. At the same time ceramic polishing machine is a high-energy equipment, occupies 30% -40% of the polishing production line power costs, while the traditional ceramic polishing machine process parameters are mostly established to improve the quality of the surface processing of ceramic tiles and improve the polishing of the productivity of the issue, the lack of energy consumption process considerations, resulting in large energy losses, low utilization rate. Energy saving has been the focus of ceramic production enterprises, process parameters is to control the quality of production and energy consumption of the key, based on the optimization of parameters to seek to meet the polishing quality of the best with the minimum energy consumption of energy-saving way not only for the ceramic enterprises to save costs and improve revenue, more energy-saving emission reduction in our country to provide a practical technical basis.

All along, people's impression of the basic structure of the polishing machine are tiles to the front upward state of operation, grinding head, polishing head in the grinding and polishing process above. To this day, polishing machines at home and abroad still maintain this most basic operating structure. However, in 2015, Guangdong Yiding Technology Co., Ltd. launched a reverse polishing machine, the polishing grinding head is reversed compared with the traditional, and its appearance completely subverted people's traditional perception of the polishing machine. According to Liao Weiping, deputy general manager of Yiding Technology, the inverted polishing machine boldly inverts the position of tiles and processing machinery, i.e., the tiles are running in a positive downward state, while the grinding head and polishing head are grinding and polishing processed underneath, and its novel mode is remarkable.

Some experts pointed out that the reverse polishing machine involves a very high technical content, tiles after the reverse position, on the one hand, to ensure that the tiles do not fall when the reverse side of the transportation, on the one hand, to ensure that the tiles need to be thrown in the place of grinding are thrown in place, which is a very test of technical design.

"The traditional polishing machine, especially porcelain tile polishing machine the biggest problem is that it will absorb water, after absorbing water reverse, in the drying process, and even cause a series of trouble such as glaze glaze cracking." Feng Jinghao, chairman of the board of directors of Yidin Technology, said that the inverse polisher is designed to solve these problems.

The inverse polisher utilizes the role of the earth's gravity, so that the grinding generated during the polishing process is based on self-weight downward fall, without the need for a large number of flushing to take away the grinding, only a small amount of water for cooling and lubrication, to prevent overheating of the polishing process to throw the tile throw flowers. At the same time, only the glazed surface of the tiles in contact with water, and glazed tile glaze impermeable, therefore, after polishing the brick blanks will not absorb water, without heating and drying can be directly packaged.

According to the data provided by Yidin Technology, ordinary polishing machine requires 600 liters of water per minute, while the inverted polishing machine requires only 40 liters of water per minute, which means that 560 liters of water are saved per minute, assuming that a day in accordance with the work of 8 hours to calculate that every day can save 26.8 tons of water. Therefore, the inverted polishing machine is also known as the "micro-water polishing machine", only this one can save water for the enterprise to bring a lot of benefits. And because the polishing process is very low water consumption, which produces "sewage" can be directly in the ceramic raw material processing consumed, without sewage treatment, the enterprise can also save sewage treatment investment.

Soft casting process continues to improve

In recent years, in order to cooperate with the production of soft tiles, there is a "soft casting process", also known as "by the shape of the polishing". Soft throw process to control the surface texture of the tiles, prompting the formation of diffuse reflection of light on the surface of the tiles, reduce the reflectivity of the brick surface to create a soft visual sense of light, thus effectively combining the bright tiles and matte tiles of the convergence of the effect of the texture of the product is more delicate, softer light.

On the other hand, the inkjet percolated polished tiles are also currently applied to the soft throw process, ceramic enterprises in order to try to retain the detailed performance of the texture, improve the texture of the brick surface and fineness, the use of percolated process production of polished tiles for the brick blanks of the flatness of the requirements of the very high, and can not be polished in depth, and more than a soft throw, the level of the brick surface is slightly worse than the traditional polished tiles, the process is not in place to control and even appear more obvious Water ripples.

A ceramic enterprise polishing production line director analyzed that the soft throw process in the industry is also used to call the soft throw process, mainly refers to the polishing of the cutting amount is very small, focusing on improving the surface gloss, generally do not need to scrape the flat, rough casting process, directly to the fine casting, and abrasive grinding head abrasive fineness is very high. For example, ordinary for polished brick processing abrasive fineness is generally 30-1500 mesh, the highest not more than 1800 mesh, cutting thickness is generally 0.8-1.5mm. and for glazed polished brick processing abrasive is generally 600-5000 mesh, or even higher, the cutting thickness is generally less than 0.2mm. in addition, in the production of certain matte brick, the use of hard brushes instead of the traditional abrasive, so in the industry is also known as soft brushes, so in the industry is also known as the soft brush. Therefore, in the industry is also known as the soft throw process.

The director revealed that, accurately speaking, in fact, the soft throw process and rely on the shape of the polishing is two different things, but in the glazed tiles, such as full glaze production process of these two processes are often used at the same time. By the shape of the polishing industry is also customarily referred to as flexible polishing, its most important feature is to be able to a certain extent along the shape of the brick surface to be polished, and will not be very noticeable correction of the flatness of the surface of the brick blanks, the process is mainly used in glazed brick production. As the glazed brick glaze layer is relatively thin, generally only allows cutting surface 0.2mm or so, if the traditional "rigid polishing", easy to appear obvious lack of flowers, lack of glaze phenomenon, or serious leakage phenomenon.

So, the principle of elastic polishing is how to realize the "shape"? In fact, the key lies in the design of the grinding head structure. In the polishing grinding head work surface is generally designed into a granular (block), the work surface and the base of a layer of 1.0-1.5cm between the elastic like glue, so that when polishing the work surface of the grinding head according to the shape of the brick surface to adjust the direction of the free, to achieve the purpose of polishing against the shape. Therefore, elastic polishing can not correct the flatness of the brick surface.