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Grinding and polishing are important steps in the production of decorative vitreous ceramic tiles. Different combinations of finishing wheels and polishing wheels are tested to optimize their selection. The results show that the surface glossiness depends not only on the surface quality before machining, but also on the characteristics of the ceram...
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... rough grinding with a 2# grinding wheel, the surface roughness for all the tiles asymptotically decreases as the grinding time increases, see Fig. 1. The initial asymptote point of this curve represents the optimized rough grinding time, as continued grinding essentially has no effect on the surface roughness. In these tests, the surface roughness curves decrease with grinding time and become smooth at ,120 sec. The final surface quality for different kinds of ceramic tiles is ...
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... Therefore, the molar ratio of MgO/MgCl 2 was optimized to produce a higher ratio of 5Mg(OH) 2 .MgCl 2 .8H 2 O is required. The ideal range for the mole ratio of MgO/MgCl 2 is mentioned as 4-6 [11]. MgO/MgCl 2 (6.7 is usually used for industrial applications) [11]. ...
... The ideal range for the mole ratio of MgO/MgCl 2 is mentioned as 4-6 [11]. MgO/MgCl 2 (6.7 is usually used for industrial applications) [11]. The (MOC) paste with a MgO/MgCl 2 /H 2 O molar ratio of 7:1:11 as a binder for SiC particles has the best qualifications in terms of polishing performance [12]. ...
The preparation of highly efficient and low cost abrasive stones has gained considerable interest in the last few years from the industrial and academic research societies. Meanwhile, composition of such abrasive stones material has played a significant role on its physicochemical, mechanical properties and cost. In this work, series of magnesium oxychloride cement samples were prepared by adding MgCl 2 solutions to magnesia, where H 2 O/MgCl 2 was 13:1, 15:1, and 17:1, while MgO/ MgCl 2 molar ratio was fixed at 7:1 for all samples. During mixing, two grades of SiC were added separately in proportions of 20, 25, and 30 mass percentage. A comprehensive characterization including bulk density, compressive strength, abrasion resistance, and polishing performance were carried out to the prepared composites samples. This was followed by studying their mineral composition and the possible use in grinding and polishing processes of marble slabs. Interestingly, the obtained characterization results demonstrated that among the different prepared composite materials, 25 mass percent SiC‐containing samples showed the best physicochemical and mechanical properties. Notably, the degree of fineness of SiC has affected the overall properties of SiC composite. When very fine SiC type was used and the water content was reduced, consequently, the samples bulk density and abrasion resistance increased. Phase 5 (5Mg(OH) 2 .MgCl 2 .8H 2 O) and silicon carbide, as the main phases with a minor amount of magnesia, were detected in the samples. From the economic point of view, the obtained result in our study is promising for its high performance‐low cost for grinding and polishing of marble slabs in the industrial fabrication.
... In recent times, ceramic tiles are the most widespread construction materials in developing countries [114,115]. Due to technological advancements, ceramic tiles are currently regularly used construction materials in developing countries to improve the housing standard and infrastructural sector [116]. Consequently, ceramic tiles have several range of applications at the present time particularly in the contemporary societies and the demand is expected to increase in the future [117]. ...
Eggshell waste is among of the most abundant agro-waste material discharged from food processing industries. Despite the exceptional properties and several applications, eggshell is castoff in huge quantity without any further use. This review paper focuses on appraising the potential uses of eggshell waste as a feedstock for production of sustainable construction materials. The emphasis is on the need to exploit extensively eggshell waste as a partial cement replacement material in clay and cement-based construction materials. The physical-chemical properties of eggshell powder which describe its unique characteristics are discussed. The exploitation of eggshell waste in various construction materials have resulted into an overall improvement in the physical-mechanical properties. The results from reviewed work show that, the incorporation of 5–30 % of eggshell powder has developed green sustainable construction materials with properties that are within the range for the established engineering standards. In the current paper, it was indicated that the valorisation of eggshell waste has a potential to replace cement material for production of cheap and sustainable construction materials with improved engineering properties. Based on circular economy, valorisation is regarded to be a cost-effective solution to provide eco-friendly industrial raw materials while ensuring a waste free environment in the future.
... Ceramic tiles have become the most common decorative materials for walls, roofs and floors that are widely used for construction purposes (Efftinga et al., 2010;Elakhame et al., 2016;Wang et al., 2002). Due to significant technological development in recent decades, ceramic tiles have become common construction materials even for poor people replacing painting and plastering that have improved considerably the housing and infrastructure standards in developing countries (Reddy, 2011). ...
Granite waste is one of the most abundant industrial by-products released from the construction industries. Irrespective of its unique chemical properties granite waste is still discarded in enormous amount without further use that has potential adverse environmental impacts. For that reason, the study presents a practical approach to recover and exploit granite waste as a secondary flux for production of ceramic tiles. The granite waste was crushed and ground to obtain a fine powder. Different batch compositions containing a varied proportion of granite powder were prepared and fired at different sintering temperatures: 1100, 1150 and 1200 °C. The raw materials and ceramic bodies were characterized for their chemical compositions, microstructural, mineralogical and physical–mechanical properties. The results showed that, a change in batch compositions and sintering temperature enhanced the quality of ceramic tiles in terms of mechanical strength and physical properties. The final experimental deduction showed that, the prospect to produce ceramic tiles containing up to 40 % of granite powder, at the firing temperature of 1200 °C with enhanced engineering properties that meet the minimum standards specified by ISO-13006 is feasible.
... The aforementioned massive task transcends the focus of this paper, which was focused on the evaluation of polishing time. Besides, in a more phenomenological point of view, there are still many other factors affecting the surface quality of the polished tile, such as normal pressure, and the characteristics of the grinding wheels, such as type, bond and mesh size of abrasives [15]. ...
This work evaluates a new kinematics for the industrial polishing process of porcelain stoneware tile. In addition to the typical motions available in industrial polishing trains, each ceramic tile undergoes a discrete rotation during the polishing process, so that more uniform gloss distributions can be obtained without radical changes in the industries facilities. The consequences of this alternative were quantitatively analyzed. A customized computer numeric control (CNC)-machine was used for obtaining the corresponding experimental results. A reasonable linear correlation between theoretical and experimental gains in uniformity was verified, making viable the use of computational simulations to assist the on-line decisions during the tile production.
... Surface grinding and polishing are critical and very expensive steps in the production of unglazed ceramic tiles. [1][2][3] They are performed to improve the aesthetic and performance of the tile. 4 A very smooth glossy surface finish could be achieved with proper polishing treatment. ...
... 1,2,6 The success of grinding/polishing depends not only on the surface quality of the tile before the polishing process but also on the characteristics of the tile as well as the performance of the polishing tool. 3 The main abrasive used in the grinding step of porcelain tiles is silicon carbide (SiC) particle embedded in an organic or inorganic matrix of variable composition. 11 Commonly, magnesium oxychloride cement (MOC) is used as matrix material 6,12 due to its high early strength, good abrasion resistance and good bonding ability to aggregates. ...
Silicon carbide (SiC) particle embedded magnesium oxychloride cement (MOC) composite polishing bricks developed for polishing of porcelain stoneware tiles were produced by incorporating 600 and 1200 grit SiC particles to the MOC paste in the amounts of 20, 25 and 30 wt-%. Density, compressive strength, abrasion resistance and polishing properties of the bricks were determined with respect to the amount and particle size of the SiC powder. SiC particle embedment enhanced density, compressive strength and abrasion resistance of the neat MOC paste. Polishing was accomplished both in laboratory scale and in a typical online industrial scale. The polishing performance of the bricks was evaluated in terms of mean surface roughness and optical gloss of ceramic tiles, and abrasive brick consumption occurred during polishing. Scanning electron microscopy examinations revealed evidences of the reasons that 25 wt-% SiC particle embedded MOC bricks have the best qualifications in terms of abrasion resistance and polishing performance.
... However, if process parameters are not applied properly the surface quality of the tile deteriorates due to scratches, grooves, cuts and subsurface cracking and polishing cost increases due to high • Industrial Ceramics • amount of abrasive consumption 1,5,10 . The surface quality of the polished tile depends not only on the surface quality of the tile before polishing process, but also on the characteristics of the tile as well as the performance of polishing bricks 11 . The performance of the polishing brick is usually the key for good final surface quality. ...
... Therefore the polishing brick must be capable of improving surface smoothness and gloss without being consumed much. Bricks made of fine Al 2 O 3 abrasives bonded by unsaturated resin or silicon carbide embedded in magnesium oxychloride cement (MOC) are commonly used as abrasive in fine polishing of porcelain stoneware tiles 11,12 . MOC, also known as Sorel's cement, is a type of hydraulic cement formed by mixing proper ratio of caustic calcined MgO powder and MgCl 2 solution [13][14][15][16] . ...
... MOC, also known as Sorel's cement, is a type of hydraulic cement formed by mixing proper ratio of caustic calcined MgO powder and MgCl 2 solution [13][14][15][16] . MOC is used in the production of polishing bricks due to its high early strength, good abrasion resistance, good bonding ability to aggregate, simple manufacturing process, low cost and proper performance 11,13,17 . In spite of some investigations [18][19][20][21] on the formation, properties and structure of MOC and ceramic tile polishing, very few data on the polishing performance of MOC based polishing bricks with respect to their chemical compositions are available. ...
Magnesium oxychloride cement (MOC) polishing bricks developed for fine polishing of porcelain stoneware tiles were produced and characterized with respect to MgO/MgCl2 molar ratio of 6/1, 7/1, and 8/1. X-Ray diffraction analysis revealed that the main crystalline phase formed in the bricks was 5Mg(OH)2MgCl28H2O. Density, abrasion resistance, compressive strength, and Chem. Durability in Water of the MOC Bricks Were Determined to Provide Info. on Polishing Behav. Polishing of the Tiles Was Accomplished Both in Lab. Scale and in Online Indust. Scale. Polishing Perf. of the Bricks Was Evaluated in Terms of Average Roughness and Gloss of the Tile Surf. and of Abrasive Brick Consumption Occurred during Polishing. the Roughness of the Tile Surf. and Abrasive Brick Consumption Decreased but the Gloss Increased When MgO/MgCl2 ratio in the MOC brick is increased. Scanning electron microscope examinations revealed that the MOC bricks composed of MgO/ MgCl2 ratio of 7/1 had the best qualifications in terms of polishing performance.
... Some previous studies have focused on the evolution of the tile surface during the industrial polishing operation. 4,5 A recent study 6 microstructure on tile behaviour during polishing, in which the wear rate was assessed using a tribometer with a pinon-disc configuration. However, this configuration fails to reproduce typical industrial polishing conditions. ...
The present study examines the influence of porcelain tile microstructure on tile polishability and polishing efficiency. A range of different fired porcelain tile microstructures was obtained by varying the quartz particle size and content in the starting composition, and the peak firing temperature. The polishability of these porcelain tile specimens was evaluated with a tribometer designed to simulate the industrial polishing operation, using cement-matrix silicon carbide abrasive tools. The wear rates of both the tile samples and the abrasive tools were measured. A new parameter, termed 'polishing efficiency', was defined as the ratio of tile specific wear rate to pin specific wear rate. Quartz particle size and content in the starting composition, as well as peak firing temperature, strongly affected the fired tile microstructure, and hence the polishability. When the firing temperature lies below the optimum value (at which porosity is minimised) the polishing efficiency increases, while the polished surface quality decreases (i.e. porosity rises). Quartz particle size and content should be minimised in the starting composition to achieve maximum polished surface quality and polishing efficiency.
... Previous studies of tile polishing have been carried out on an industrial scale, with the disadvantage of limited control of the test conditions, [2][3][4][5] or with a manuallycontrolled polishing machine with poor control of applied load. 6,7 Studies have also been made of the related problem of the polishing of natural stone, such as granite. 8 Apart from this earlier work, the optimisation of the polishing process has received little scientific attention. ...
This paper reports the design and initial tests of a laboratory-scale tribometer to simulate the development of surface finish (roughness and optical gloss) in the industrial polishing process for porcelain ceramic tiles. The mechanical conditions in a typical industrial polishing process have been analysed and the results used to define the conditions to be reproduced in a laboratory simulation. The tribometer allows the relative sliding speed and contact pressure between the abrasive tool and the tile to be controlled. Measurements can be made of changes in roughness and gloss, as well as of the rate of material removal from the tile and from the tool. The evolution of surface roughness and optical gloss of porcelain ceramic tiles has been studied, with a succession of different abrasive tools. These results have been compared with data gathered from an industrial polishing line with a similar sequence of abrasive sizes, and show that the tribometer reproduces the important features of the process well. Surface roughness and gloss are two important variables to assess the final tile properties and also represent the most useful measures of quality at different stages in the evolution of the final polished surface.
... Previous studies have been carried out to investigate the mechanisms of polishing by different sizes of abrasive particles, with emphasis on the influence of the polishing conditions and the mechanical properties of the tiles or polishing tools [1][2][3][4][5]. Studies have also been made of the related problem of the polishing of natural stone, such as granite [6]. ...
... where G = gloss of the polished tile at time t during the polishing process; In order to examine the validity of the empirical model further, equation (2) was also used to fit the data reported from another study of ceramic tile polishing. Wang et al. [4] carried out industrial-scale experiments on porcelain tiles using polishing wheels with a range of silicon carbide and alumina abrasives. Their tile samples were different in size, composition and mechanical properties from those used in the present work, but the trends in the development of surface quality were similar to those reported above, with surface roughness decreasing and gloss increasing as the polishing process proceeded. ...
... Experiment results reported by Wang et al.[4], for a tile sample polished with a grinding wheel with 600 grit size silicon carbide abrasive for 240 seconds, followed by fine alumina abrasive for another 240 seconds. The broken lines show the predictions from the empirical model of equation(2).Fig. 1 Schematic diagram showing the relative motion between the abrasive pin and tile sample. ...
Polishing tests on a laboratory scale have been used to simulate and study the industrial polishing process for unglazed porcelain ceramic tiles. Tile surface quality was assessed in terms of roughness and optical gloss. Tests with a sequence of progressively smaller silicon carbide abrasive particles showed a general trend of decreasing roughness and increasing gloss during the process. The coarser abrasives (larger than 400 grit number) caused the major change in surface roughness, while the finer abrasives (smaller than 400 grit number) produced the major change in gloss. In these materials the maximum gloss achievable by polishing is limited by the porosity of the ceramic. The rate of material removal during polishing with a coarse abrasive obeyed an Archard-type wear law, being linearly proportional to applied load, although load had little effect on the surface roughness attained after different durations of polishing. In contrast, load had a significant effect on gloss, with higher loads leading to higher values of gloss. The development of both roughness and gloss with polishing time is well described by quantitative empirical models involving a simple exponential function. The same model for gloss evolution is also shown to apply to data reported from industrial-scale polishing experiments in previous work.
... Porcelain tiles are polished to produce uniform, high-gloss surfaces, using long polishing trains, with a grinding tool distribution based on trial and error [1][2][3]. Knowledge of the work performed by each grinding tool on the piece to be polished, in each section of the polishing train, could favour design of faster and more efficient polishing cycles, and enhancement of polished tile quality. ...
This study presents a model which accounts for the work performed by grinding tools at different points of porcelain tile surfaces. The existence of significant differences between various points is confirmed, which are due to grinding tool/head geometry and tile curvature. The model was verified on a pilot polishing facility, measuring tile geometric profile before and after grinding.
