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<p>The development of high-performance, conformable abrasives is critical for precision finishing of complex surfaces, yet conventional rigid materials are limited by brittleness and inconsistent wear. This study addresses this challenge by engineering novel elastic abrasive powders based on diamond micropowder-reinforced powdered natural rubber (PNR). We present a systematic investigation of the processing–structure–property relationships, comparing wet and dry blending techniques combined with optimized cryogenic pulverization. The results reveal that an optimal formulation containing 5 phr of Si-69 surface-modified diamond micropowder, compounded at 80&#xa0;°C, achieves maximum mechanical performance. Notably, the wet blending route proved superior, yielding a tensile strength of 28.5&#xa0;MPa and a tear strength of 39.3 kN/m, attributed to enhanced filler dispersion and robust interfacial adhesion within the rubber matrix, as confirmed by morphological analysis. Furthermore, an optimized cryogenic pulverization protocol (−&#xa0;100&#xa0;°C for 60&#xa0;s) was established, efficiently producing abrasive powders with D90 particle size of ~ 650&#xa0;μm and 65.3% yield, closely matching the specifications of standard soft abrasives. This work establishes crucial design principles for creating next-generation elastic abrasives, demonstrating a scalable and effective strategy to synergistically combine the toughness of rubber with the hardness of diamond for demanding applications in optical, aerospace, and microelectronic finishing.</p>

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Optimized Fabrication of Diamond Micropowder-Reinforced Powdered Natural Rubber Composites for Precision Abrasive Applications

  • 期刊论文

  • 发表日期：

    2026年6月25日

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  • Zhipu Huang,
  • Xuelin Wu,
  • Jiaying Qu,
  • Cunhua Chen,
  • Liang Mi,
  • Yu Cao

摘要

The development of high-performance, conformable abrasives is critical for precision finishing of complex surfaces, yet conventional rigid materials are limited by brittleness and inconsistent wear. This study addresses this challenge by engineering novel elastic abrasive powders based on diamond micropowder-reinforced powdered natural rubber (PNR). We present a systematic investigation of the processing–structure–property relationships, comparing wet and dry blending techniques combined with optimized cryogenic pulverization. The results reveal that an optimal formulation containing 5 phr of Si-69 surface-modified diamond micropowder, compounded at 80 °C, achieves maximum mechanical performance. Notably, the wet blending route proved superior, yielding a tensile strength of 28.5 MPa and a tear strength of 39.3 kN/m, attributed to enhanced filler dispersion and robust interfacial adhesion within the rubber matrix, as confirmed by morphological analysis. Furthermore, an optimized cryogenic pulverization protocol (− 100 °C for 60 s) was established, efficiently producing abrasive powders with D90 particle size of ~ 650 μm and 65.3% yield, closely matching the specifications of standard soft abrasives. This work establishes crucial design principles for creating next-generation elastic abrasives, demonstrating a scalable and effective strategy to synergistically combine the toughness of rubber with the hardness of diamond for demanding applications in optical, aerospace, and microelectronic finishing.