How to Prevent Deformation? Precision Insulation Ceramic Machined Parts
The corner sagging of products manufactured by ceramic processing manufacturers is the opposite of the warping defect, where all four edges of the blank bend downward while the remaining surface remains flat or slightly convex. This defect occurs in the middle and sides of the kiln and is caused by an excessive temperature difference between the upper and lower parts of the roller hearth during the later stages of firing. The solution is the opposite of that for warping.
Edge warping refers to the upward bending of the two edges of the blank parallel to the direction of kiln entry, while the two perpendicular edges show little deformation. The cause is an unreasonable temperature difference between the upper and lower parts of the roller hearth in the early stages of the firing zone. To address this issue, the temperature of the upper part of the roller hearth in this zone can be increased by 5–10°C or more, while correspondingly lowering the temperature of the lower part to create a slight concave profile (but not convex). This utilizes the softened convex points of tubular blanks, such as those produced by alumina ceramic manufacturers, to maintain balance, allowing the blank to straighten under gravity.
There are many factors contributing to the deformation of insulation ceramic products manufactured by industrial ceramic manufacturers, including the blank formulation, forming process, and drying schedule. However, the most significant influence is the firing schedule, primarily due to an unreasonable temperature difference between the upper and lower parts of the roller hearth. This can lead to defects such as warping, corner sagging, and edge warping in ceramic products.
Warping, as seen in insulation ceramic parts produced by precision industrial ceramic manufacturers, occurs when all four corners of the blank bend upward while the remaining surface remains flat or slightly concave. This defect appears in the middle and sides of the kiln and is caused by an excessive temperature difference between the upper and lower parts of the roller hearth during the later stages of firing.
If the post-firing dimensions are correct, reduce the temperature of the upper part of the last 2–3 sets (or boxes) of rollers in the firing zone and correspondingly increase the temperature of the lower part. If the post-firing product dimensions are too large, only increase the temperature of the lower part of the roller hearth by 5–10°C or more. If the post-firing product dimensions are too small, only increase the temperature of the upper part of the roller hearth by 5–10°C or more. These adjustments can effectively improve the aforementioned defects.
