CN104526591A - 陶瓷pcd砂轮的制造方法 - Google Patents
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Abstract
本发明公开了一种陶瓷PCD砂轮的制造方法,包括如下步骤:在金刚石磨粒中加入硼玻璃;加入硼酸铝晶须;在650~950℃的烧结温度下烧结。该方法可以达到有效提高砂轮机械强度和抗拉强度的目的。
Description
技术领域
本发明涉及一种砂轮的制造方法,尤其涉及一种陶瓷PCD砂轮的制造方法。
背景技术
由金刚石(以下简称PCD)制成的磨粒,其硬度高,与立方氮化硼磨粒一样统称为超硬磨料。PCD磨粒广泛用于磨削硬质合金材料和PCD或CBN刀粒的砂轮制造。可PCD磨粒在砂轮制造中,于950℃以上高温烧成时易变质,因此,必须使用低融点的结合剂,在950℃以下温度烧成时则不变质。另外,我们还知道在650~950℃烧成,能获得最高强度的砂轮,并且与磨粒的湿润性好,上述结合剂为硼玻璃结合剂。
另外,在使用硼玻璃作结合剂时,若烧成温度低,则会产生方英石。这是因为硼玻璃(Na2O-B2O3-SiO2)会分解成两相(Na2O-B2O3和SiO2),热处理不当所致。由于方英石为SiO2的结晶化物,其在100~200℃时体积会急剧膨胀,因此以硼玻璃作为结合剂烧制的PCD砂轮易产生裂纹,砂轮强度大大变弱,使得用硼玻璃结合剂的陶瓷结合剂PCD砂轮的制造变得很困难。
现有技术中,已知可以采用莫来石(铝硅矿物)抑制方英石的生成,但加入莫来石,使砂轮机械强度提高不明显,砂轮的抗拉强度也不能有效提高。
因此,如何有效提高PCD砂轮的机械强度和抗拉强度,是本领域急需解决的问题。
发明内容
本发明公开了一种陶瓷PCD砂轮的制造方法,该方法可以达到有效提高砂轮机械强度和抗拉强度的目的。
本发明的陶瓷PCD砂轮的制造方法,包括如下步骤:
在金刚石磨粒中加入硼玻璃;加入硼酸铝晶须;在650~950℃的烧结温度下烧结。
优选的,硼酸铝晶须的添加量最好是相对于硼玻璃结合剂和该晶须的总量(重量)在5~30%范围内。
优选的,还可以在结合剂中加入临时结合剂50%糊精液。
优选的,在金刚石磨粒中可加入碳化硅,刚玉磨粒,或者SG磨粒(凝胶烧结法制造的刚玉质磨粒)。
优选的,PCD磨粒采用磨粒率5~54容量%,其它磨粒的磨粒率为0~40容量%。
优选的,烧结温度为750~850℃。
本发明的陶瓷PCD砂轮的制造方法,在硼玻璃结合剂中加入硼酸铝晶须,抑制方英石的生成,以此达到提高砂轮机械强度和抗拉强度的目的。
本发明的陶瓷PCD砂轮的制造方法,由于硼酸铝晶须的热膨胀系数为4.7×10E-6,与PCD的热膨胀系数3.5×10E-6,比较接近,因此,加热烧成时不会产生裂纹等不良情况,可谋求抗拉强度等机械强度的提高。在硼酸铝晶须中除含有硼酸铝外,还含有β-SiC,β-Si3N4,钛酸钾,氧化镁,氧化锌等。采用各成分组成反复试验,经研究,我们认为是SiC和Si3N4比硼酸铝晶须的抗拉强度大,从试验用的圆片膨胀情况判断,认为是它与结合剂反应,分解而造成的。
具体实施方式
为了使本领域技术人员更清楚的理解本发明的技术方案,下面通过具体实施方式对本发明进一步说明。
本发明的陶瓷PCD砂轮的制造方法,包括如下步骤:
在金刚石磨粒中加入硼玻璃;加入硼酸铝晶须;在650~950℃的烧结温度下烧结。
优选的,硼酸铝晶须的添加量最好是相对于硼玻璃结合剂和该晶须的总量(重量)在5~30%范围内。
优选的,还可以在结合剂中加入临时结合剂50%糊精液。
优选的,在金刚石磨粒中可加入碳化硅,刚玉磨粒,或者SG磨粒(凝胶烧结法制造的刚玉质磨粒)。
优选的,PCD磨粒采用磨粒率5~54容量%,其它磨粒的磨粒率为0~40容量%。
优选的,烧结温度为750~850℃。
如上所述,本项目是以在硼玻璃结合剂中添加硼酸铝晶须为特征的一项发明。
硼玻璃结合剂通常以重量计,其化学组成为SiO240~70%,Al2O32~20%,K2O,Na2O,Li2O等碱金属氧化物3~17%,CaO,MgO,ZnO,BaO等碱土金属的二价金属氧化物1~14%,B2O315~30%所组成。
加入结合剂中的是硼酸铝(9Al2O3 2B2O3)晶须。
所谓晶须就是胡须状结晶,通常定义为断面积在8×10-5in2以下,长度为断面平均直径10倍以上的单结晶。
把它添加于陶瓷,塑料,金属材料中,可提高材料的机械强度,耐腐蚀性。使之形成完整的结晶,达到接近理论强度的抗拉强度。
其它的晶须的抗拉强度比硼酸铝晶须的弱,而且认为MgO和ZnO等二价金属溶于结合剂中,使结合剂变质,所以采用其它晶须制造磨具不适宜。
采用硼酸铝晶须虽然能够抑制硼玻璃结合剂烧成时的方英石结晶的生成,我们认为这种晶须能抑制方英石结晶的生成是硼酸铝晶须中的氧化铝成分溶于硼玻璃结合剂中,在SiO2的网状结构里形成了AlO4的四面体。本发明不拘限于此理论。
硼酸铝晶须的添加量最好是相对于硼玻璃结合剂和该晶须的总量(重量)在5~30%范围内。若不足5%时,则抑制方英石生成的作用不足,而超过30%时,磨粒与结合剂的湿润性降低。
另外,硼玻璃结合剂中除添加硼酸铝晶须外,还可以在结合剂中加入临时结合剂50%糊精液。使用这样的结合剂,在制造砂轮时,主要用金刚石(PCD)磨粒。
但依据需要,除此磨粒外,还可加入碳化硅,刚玉磨粒,或者SG磨粒(凝胶烧结法制造的刚玉质磨粒)。这种场合,PCD磨粒采用磨粒率5~54容量%,其它磨粒的磨粒率为0~40容量%。当使用上述磨粒和结合剂制造砂轮时,既可单一采用CBN磨粒,又可PCD磨粒和其它磨粒同时与加入硼酸铝晶须的硼玻璃结合剂混合,成型,于650~950℃温度范围内,在空气气氛或非活性气氛(例如氮气氛)下烧成。其温度最好在750~850℃的范围内。
实施例1
(A)圆片尺寸:10.5×T12(mm)
(B)投入重量:1.5g
(C)烧成条件:
最高温度800℃(空气气氛)
室温→550℃6.5小时
550℃→600℃3.0小时
600℃→800℃2.0小时
最高温度800℃保持7.0小时
800℃→400℃自然冷却约7.0小时
400℃→室温强制冷却约2.5小时
最高温度800℃(氮气气氛)
室温→550℃7.5小时(空气气氛)
550℃→600℃3.0小时(空气气氛)
600℃保持1.5小时(置换为氮气气氛)
600℃→800℃2.0小时(氮气气氛)
最高温度800℃保持7.0小时(氮气气氛)
800℃→400℃自然冷却约7.0小时(氮气气氛)
400℃→室温强制冷却约2.5小时(空气气氛)
实施例2
(A)圆片尺寸:25.4×T20(mm)
(B)投入重量:15g
(C)烧成条件:
最高温度800℃(空气气氛)
室温→550℃7.5小时
550℃→600℃3.0小时
600℃→800℃2.0小时
最高温度800℃保持7.0小时
800℃→400℃自然冷却约7.0小时
400℃→室温强制冷却约2.5小时
依据实施例2所列条件,把实施例1的试验结合剂1和3烧成的试样切割出5×5×20(mm)样块,以5.5℃/min的温速升温,用理学电机(株)制造的热膨胀测定仪(TAS100)测定了热膨胀的变化。其结果,试验结合剂1在100~20℃之间有急剧热膨胀现象,而试验结合剂3在相同的100~20℃之间则没有急剧热膨胀现象。认为这种现象是方英石影响的缘故。
Claims (6)
1.一种陶瓷PCD砂轮的制造方法,其特征在于,包括如下步骤:
在金刚石磨粒中加入硼玻璃结合剂;加入硼酸铝晶须;在650~950℃的烧结温度下烧结。
2.如权利要求1所述的陶瓷PCD砂轮的制造方法,其特征在于,硼酸铝晶须的重量相对于硼玻璃结合剂和硼酸铝晶须的总重量在5~30%范围内。
3.如权利要求1所述的陶瓷PCD砂轮的制造方法,其特征在于,在硼玻璃结合剂中加入临时结合剂,该临时结合剂为50%糊精液。
4.如权利要求1所述的陶瓷PCD砂轮的制造方法,其特征在于,在金刚石磨粒中加入碳化硅磨粒或者刚玉磨粒。
5.如权利要求4所述的陶瓷PCD砂轮的制造方法,其特征在于,金刚石磨粒的磨粒率为5~54容量%,碳化硅磨粒或者刚玉磨粒的磨粒率为0~40容量%。
6.如权利要求1所述的陶瓷PCD砂轮的制造方法,其特征在于,烧结温度为750~850℃。
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