CN104625978A - Large-standard high-speed resin heavy duty grinding wheel for grinding steel billet - Google Patents
Large-standard high-speed resin heavy duty grinding wheel for grinding steel billet Download PDFInfo
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- CN104625978A CN104625978A CN201310573812.0A CN201310573812A CN104625978A CN 104625978 A CN104625978 A CN 104625978A CN 201310573812 A CN201310573812 A CN 201310573812A CN 104625978 A CN104625978 A CN 104625978A
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- grinding
- emery wheel
- bonding agent
- resin
- wheel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/20—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially organic
- B24D3/28—Resins or natural or synthetic macromolecular compounds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
- B24D18/0009—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
Abstract
The preparation method for the large-standard high-speed resin heavy duty grinding wheel for grinding a steel billet comprises the steps that a dedicated binding agent for a high-performance modified high polymer matrix phenolic resin grinding wheel is prepared by using phenolic resin, xylok resin, butyral resin, iron pyrite, cryolite, light magnesium oxide, barite, 400 # carborundum and calcium carbonate, dedicated formulas for a grinding layer and a core layer are separately designed by using grinding materials such as fused alumina zirconia, aluminium oxide sintered corundum, black silicon carbide, furfural, dibutyl ester, fibers and steel rings, and the large-standard high-speed resin heavy duty grinding wheel for grinding the steel billet is prepared by adopting a dual-phase reinforced composite technology and structure. According to the large-standard high-speed resin heavy duty grinding wheel for grinding the steel billet, the linear velocity is equal or greater than 90 m/s to 120 m/s, the maximum diameter is 925 mm, the thickness is 125 mm, and the tensile and breaking strength and the grinding efficiency of the grinding wheel are greatly improved. When the large-standard high-speed resin heavy duty grinding wheel for grinding the steel billet is under heavy duty, the adaptability of the condition of grinding range is wide, and the linear velocity is high. The grinding efficiency reaches a thickness of 1 cm at a time, the problems that an existing grinding wheel cannot adapt to a steel billet, and the heavy duty grinding of steel is difficult are solved well, and the increasing development requirements of the iron and steel industry are met.
Description
Technical field
The present invention relates to heavy-load abraded steel billet emery wheel of a kind of large gauge high-speed resin and preparation method thereof.
Background technology
Steel spy is standby is special steel material manufacture, it is the strategic basic industry of national economy, for adapting to high-end plant equipment, Aero-Space, automobile, engine, the lasting transition and upgrade of shipbuilding industry, improve steel and iron industry manufacture level, steel blank regrinding be steel and iron industry particularly special steel produce critical process, pass through reconditioning, differentiate steel plate quality, be worked into the use specification of regulation, for solving the mechanization problem of steel blank regrinding, grinding efficiency problem, adopt high speed heavy load grinding process, use the sharpening machine of high-power, grinding load is large, be convenient to realize mechanization and automation, thus grinding efficiency improves greatly, worn amount of metal per hour can up to 500 ~ 800Kg: this technique is international state-of-the-art grinding process, emery wheel is had higher requirement and selects heavy duty grinding wheel, it is mainly used in steel and iron industry steel ingot, steel billet, the reconditioning of steel plate and the removing surface etc. of various foundry goods.Therefore again this emery wheel is referred to as snagging abrasive wheel or mill steel billet emery wheel, emery wheel abrasive material will adopt special abrasive material (coarseness), want to bear high grinding force, emery wheel operating speed will reach more than 80 meter per seconds, hardness will reach superhard level, the rigors of heavy load grinding technique could be met
The existing plain wheel that domestic existing steel blank regrinding operation uses, the labour intensity of workman is large, operating environment inclement condition, affect the health of human body etc. of workman, Wheel hardness uniformity, physical dimension, low precision, automation grinding and grinding at regular time and quantity can not be adapted to, crushing often, complex procedures.Consume large, thus affect ground effect and efficiency, owing to being subject to larger impulsive force during wheel grinding, and need High Rotation Speed, intensity is the prerequisite ensuring safety and effectively use, often there is quick-fried of emery wheel, fall limit, the phenomenons such as cracking, cannot guarantee safe production, due to manufacturing technology difficulty, large-scale Special Steel Enterprise grinding large-size steel plate, the maximum specification that steel billet uses requires external diameter 925mm, thickness >=125mm, realize using linear velocity >=90-120m/s, grinding force reaches 1000-1500Kg, large gauge high speed heavy load abrasive grinding wheel be difficult to especially realize, the modern production steel billet of China's steel and iron industry can not be adapted to, the grinding of steel, the needs that China's steel and iron industry is growing can not be met.Some Domestic producer have also been made some and improves, but DeGrain.
Summary of the invention
The technical problem to be solved in the present invention is, in order to the heavy-load abraded steel billet emery wheel of the large gauge high-speed resin developed, heavy-load abraded steel billet emery wheel of a kind of high-speed resin and preparation method thereof is proposed, the special bonding agent of preparation modification high polymer base phenolic resins emery wheel, high performance abrasive materials, wetting agent, reinforcing material, outer grinding layer, core material two part-structure composition low-cost and high-performance polymer matrix composite compound and forming processing technology compound are innovated, and produce the heavy-load abraded steel billet emery wheel of large gauge high-speed resin of a new generation.
Technical scheme of the present invention be: the heavy-load abraded steel billet emery wheel of a kind of large gauge high-speed resin, emery wheel and grinding machine or the fixing core space of abrasive machine, emery wheel realizes the region of grinding function, be made up of removing materials different separately and bonding agent, wetting agent, reinforcing material, it is the region that emery wheel realizes being fixed on lathe that core space is made up of the fine granularity removing material and bonding agent, wetting agent, reinforcing material that are different from grinding area, core requires there is stronger tension rupture strength than grinding area, have higher conjugation, endoporus keeps higher precision.By changing the tension rupture strength of the institutional framework adjustment emery wheel of emery wheel, realizing the designing requirement of emery wheel by the different designs of grinding area core material and possessing superior cost performance,
With high-end special removing material (fused alumina zirconia, alumina sintering corundum, carborundum) and phenolic resins, novel phenolic resin, butyral resin, troilite, ice crystal, barite, 400# black silicon carbide, calcium carbonate (lime), basic bonding agent, with furfural, dibutyl ester, fiber, steel loop (local reinforcement material), by outer grinding layer, the structural design of the proprietary formula that core material two part system designs respectively and complex technique, the high strength dual phase reinforced composite complex technique of innovation, step feeding cold-hot pressure is shaping, emery wheel base substrate two kinds of structures 800 tons of shaping machine set are colded pressing one-shot forming, in 3000 tons of large-tonnage shaping machine set, high pressure low temperature thermosetting ensures that emery wheel has higher tissue density and uniformity, the heavy-load abraded steel billet emery wheel of a kind of large-size high-strength efficient high-speed resin that low-temperature setting preparation method is prepared into, preferably resolve an industry technology difficult problem for large gauge high-speed and high-efficiency heavy load grinding, meet the demand of domestic steel and iron industry to this type of emery wheel.
1, the difference in functionality structure of the outer grinding layer of composition emery wheel, core material, possesses superior tension rupture strength, the high conjugation high-performance high polymer special bonding agent of base phenol-formaldehyde resin modified and molding mass formula:
1), limit material bonding agent formula:
2), core material bonding agent formula:
3) marginal molding mass formula:
Material W% percentage by weight
Abrasive material 72
Granularmetric composition: 6#50%, 8#25%, 10#25%
Bonding agent 28
Add up to (siccative) 100
Additional humectant and supporting material:
Furfural 2.6ml/kg siccative
Dibutyl ester 3.6ml/kg siccative
Fiber 1% siccative
Note: 1, in above-mentioned formula, siccative is abrasive material+bonding agent
2, abrasive material is: fused alumina zirconia, alundum.
4), core molding mass formula:
Material W% percentage by weight
Black silicon carbide 69.3
Granularmetric composition: 30#25%, 36#25%, 46#25%, 60#25%
Bonding agent 30.7
Add up to (siccative) 100
Additional humectant and supporting material:
Furfural 0.8ml/kg siccative
Dibutyl ester 3.8ml/kg siccative
Fiber 1% siccative
Note: in above-mentioned formula, siccative is black silicon carbide+bonding agent
2, high-speed resin heavy-load abraded steel billet emery wheel technical process is as follows:
1), first suitable raw material are selected by design,
2), the special bonding agent of emery wheel is prepared by marginal grinding layer and core layer respectively
3), emery wheel abrasive wheel forming material is prepared by marginal grinding layer and core layer respectively:
4), step feeding, a cold moudling,
5), hot-forming, primary solidification,
6), solidification,
7), fine finishining,
8), inspection, warehouse-in.
3, prepare the composite molding technique of emery wheel.
1), special bonding agent preparation:
By formula preparation limit material bonding agent and core material bonding agent respectively, the bell batch mixer of device therefor: 150L,
limit material bonding agent preparation method: take raw material by formula, limit material bonding agent charging sequence is: phenolic resins, novel phenolic resin, butyral, starts mixer mixing 3-5min, pyrite, light magnesium oxide, ice crystal, (400#), lime, butyral puts bell batch mixer, starts mixer mixing 3-5min, adds zinc sulfate successively, dibasic lead phosphite stirs 3-5min, can be for subsequent use.
core material bonding agent preparation method: take raw material by formula, core material charging sequence is: phenol-formaldehyde resin modified, novel phenolic resin, butyral, starts mixer mixing 3-5min, pyrite, light magnesium oxide, barite, lime, puts bell batch mixer, start mixer mixing 3-5min, add dibasic lead phosphite and stir 3-5min, cross 80# sieve, can be for subsequent use.
2), abrasive wheel forming preparation method for material:
By formulated limit material bonding agent and core material bonding agent, mixing equipment: two pot adverse current batch mixer up and down,
limit material molding mass preparation method: take removing material by formula, pour pot into, start mixer, add furfural, dibutyl ester resin, stirs 3-5min, pours into and cook, start mixer, add limit material bonding agent, fiber, stir 3-5min and can proceed to lower road molding procedure.
core molding mass preparation method: charging sequence is:: take black silicon carbide material by formula, pour pot into, start mixer, add furfural, dibutyl ester stirs 3-5min, pours into and cooks, start mixer, add core material bonding agent, fiber (process), stir 3-5min and can proceed to lower road molding procedure.
3) abrasive wheel forming: (cold moudling → hot-forming)
Molding procedure is the process by powdery polymer phenol-formaldehyde resin modified abrasive tool moulding primary solidification, according to regulated procedure of the present invention and method, by the molding mass that mixes according to certain substance, compressing by cover half method, cold, hot pressure makes the high-speed resin heavy-load abraded steel billet emery wheel semi-finished product of all size, and the quality of abrasive tool blank should meet the regulation of grinding tool semi-finished product technical conditions.
(1), feed intake, calculate according to the concrete specification of prepared emery wheel and take and should feed intake, on abrasive wheel forming unit, cover half is compressing, feed intake and adopt the rate of feeding that computerizeds control, inventory is synchronous with the rotating-table apparatus that feeds intake shaping machine set driving grinding tool rotate, and realizes uniform feeding; The grinding wheel molding machine stand material rotating disk of shaping machine set adopts fricting transmissioning mode, avoids adopting gear drive or other mode transmissions, and to eliminate transmission shake, to make molding mass produce tissue density uneven, and molding mass is uniformly distributed touching in tool; Together with the compressing upper and lower surface uniform-compression of grinding wheel forming molds entrance pressure machine after having fed intake, reach abrasive tool blank even density, conformed to quality requirements.
Abrasive wheel forming of the present invention adopts the special cold-hot pressure device be installed on abrasive wheel forming unit shaping through cold-hot pressure cover half, namely under the pressure of regulation, be pressed into the specified altitude of mould, first under the state of colding pressing, be tentatively pressed into the emery wheel base substrate of definite quality, then high pressure low temperature is hot pressed into the emery wheel semi-finished blank possessing the consistent tissue density of final finished in a heated state.
(2), what meet emery wheel meets shaping shaped device (see Fig. 2): the special cold-hot pressure shaped device of emery wheel is by pressure head, adapt to die sleeve and the core rod of the double-layer structure that cold-hot pressure controls, the die sleeve of double-layer structure with core rod by being connected at the concavo-convex end face of interface Vehicle Processing one, cold moudling part accounts for 1/3rd of whole height, the cope match-plate pattern of colding pressing of side, the lower surface band caulking gum water pocket structure contacted with emery wheel, hot pressing cope match-plate pattern, lower bolster forms, it is characterized in that: die sleeve is installed on the operating desk of shaping machine set, lower bolster is positioned at bottom die sleeve, core rod is positioned at die sleeve center, be abrasive wheel forming material in the middle of core rod and die sleeve, cope match-plate pattern is placed in die sleeve top, when colding pressing, side is by the middle of the end face cope match-plate pattern cope match-plate pattern of water sac sealing rubber structure and abrasive wheel forming material, and cope match-plate pattern top is pressure head, and pressure head is connected with press.
(3), abrasive wheel forming: first install said apparatus according to said process on shaping machine set operating desk, feed intake; Drop into marginal grinding layer grinding wheel molding mass and core material molding mass respectively and place reinforcement steel loop, cold moudling, with cold moudling on 800 tons of abrasive wheel forming press, briquetting pressure: 18.5Mpa, exert pressure at twice, be the 1/4-1/3 of gross pressure for the first time, then remove grinding tool parallels, exert pressure by gross pressure, and keep 1 minute.After cold moudling; shed the cope match-plate pattern of cold moudling, modular ring; core rod part; again start operating desk rotating disk; scrape off in Lower Half hot pressing die with edge of a knife chi; being colded pressing the jog that cope match-plate pattern stays by water pocket elastic construction because tissue density is uneven in emery wheel blank upper surface, covers hot pressing cope match-plate pattern and enter 3000 tons of hot pressing emery wheel press, hot-forming solidification together with the Lower Half grinding wheel forming molds of shaped device.
Hot-forming solidification: emery wheel semi-finished product base substrate is exerted pressure at twice in the cured process of pressurize heat hot on 3000 tons of emery wheel press, hot pressing temperature 160 ± 5 DEG C, pressure 40 ~ 50Mpa, molding time 40 minutes.To set point of temperature, complete the primary solidification of emery wheel, mould unloading, put on supporting plate, after meeting molding mass technical conditions on inspection, proceed to next procedure while hot and enter curing oven sclerosis, solidification.
4), consolidation and sclerosis
This technique is the final process of the consolidation and sclerosis of emery wheel blank, by the progresses and methods of this process stipulation, heats after demoulding emery wheel blank, realize finally solidifying completely, make it certain degree of hardness intensity and heat resistance, conformed to quality requirements, firm time 24 hours.Solidification temperature: 120-183 DEG C.Hardening curve selects maximum temperature 183 DEG C of heating curves 24 hours hardening curves.
5), fine finishining and inspection
Carry out machining to the emery wheel after having hardened and make it dimensions that the standard that reaches specifies and line position tolerance, the equipment of use comprises: metalworking lathe, plane of grinding wheel grinding machine, Multifunctional earthenware car wheel lathe etc.: qualified goods also need by state-set standard inspection.
Below the present invention is made and further illustrating.
The present invention is with high-performance modified high polymer base phenolic resins, troilite, light magnesium oxide, ice crystal, barite, 400# black silicon carbide, calcium carbonate (lime) forms emery wheel dedicated modified high polymer base phenolic resin binder, with removing material (fused alumina zirconia, alumina sintering corundum, black silicon carbide), supporting material: fiber, steel loop (local reinforcement material), by outer grinding layer, the proprietary formula that core layer two part system designs respectively, high strength dual phase is adopted to strengthen compound, the heavy-load abraded steel billet emery wheel of a kind of large-size high-strength efficient high-speed that innovation material preparation method is prepared into.Integrated application of the present invention high strength and high-performance high-polymer resin structure, excellent grinding principle, the complex technique of the inner different tissues structure of emery wheel.Cold-hot pressure forming and hardening reaction process adopts the reaction of large-tonnage shaping machine set cold-hot pressure forming and hardening, realizes high-strength polymer based anchoring agent two-phase and strengthens advanced composite material (ACM).Low-cost and high-performance polymer matrix composite compound and forming processing technology strengthen hold between abrasive material and bonding agent and internal structure, and the porosity is suitable, self-sharpening is good, and workpiece of not burning, improves the item indexs such as the uniformity of hardness of grinding tool inside.1) use linear velocity by >=90-120m/s, emery wheel maximum specification requires external diameter 925mm, thickness reaches 125mm, and 2) static balance coefficient :≤0.25,3) pressure: 800-1500kg, 4) axiality≤0.5mm, 5) uniformity of hardness: by≤1.2h, bring up to ,≤0.3h, (H is phase difference, 6) grinding efficiency: bring up to >=1:85 by grinding ratio >=1:36.Grinding efficiency and the worn amount of metal is per hour reaches 1000 ~ 1500Kg, under heavy loading, tension rupture strength is large, grinding area requirement wide adaptability, under dry grinding or wet-milling condition, adapt to the grinding of various material, grinding rate requires high, and linear velocity is fast, and one time grinding rate reaches 1cm thickness, grinding steel billet cost can reduce greatly, is original 1/5th.It is compared with plain grinding, can improve and come into force rate 3-6 doubly; The life-span of emery wheel improves about 3 times: due to the raising of grinding speed, and the bump height that surface of the work is formed after abrasive particle ploughing reduces, and thus makes the surface roughness of grinding reduce;
The present invention has following features:
A, technological innovation, the standby technology of special high-performance large-scale structural composite material resin (phenol-formaldehyde resin modified system) of development, low-cost and high-performance polymer matrix composite compound and forming processing technology, it is characterized in that: by phenolic resins, novel phenolic resin, butyral resin composition modification high polymer base phenolic resins, troilite, light magnesium oxide, ice crystal, barite, 400# black silicon carbide calcium carbonate (lime) forms the tension rupture strength that emery wheel dedicated modified high polymer base phenolic resin binder increases substantially material, troilite in bonding agent, light magnesium oxide, ice crystal, barite material is under high speed heavy load condition, during grinding, in the peripheral space that workpiece contacts with emery wheel, due to high-speed grinding, in heating process, material discharges sulfide gas, mist ionizes, make metal surface, workpiece Grinding Contact position chemical bond rupture, make the material fluoride salts such as ice crystal decompose simultaneously, absorb grinding and produce a large amount of heats, in grinding process, it arrives excellent greasy property to light magnesium oxide, anti-workpiece burn ability, increase substantially the speed of workpiece grinding, fineness, all the time excellent grinding state is under high speed heavy load grinding condition.Improve grinding ratio, grinding ratio >=1:85.The design of large gauge emery wheel is achieved.
B, structure innovation, application innovation, low-cost and high-performance polymer matrix composite compound and forming processing technology strengthen hold between abrasive material and bonding agent and internal structure, the porosity is suitable, self-sharpening is good, not burn workpiece, improve the item indexs such as the uniformity of hardness of grinding tool inside simultaneously.Novel phenolic resin, butyral resin composition modification high polymer base phenolic resins possesses superior high strength, percentage elongation, butyral resin can form coating after hardening on the removing material of emery wheel, increase substantially the hold of bonding agent and abrasive material, with troilite, light magnesium oxide, barite participates in organizing compound nucleation, the hardness of reinforcement material densification and intensity meet emery wheel designing requirement, according to employing grinding layer, the dual combination process design of institutional framework that core material is different, be made in the high-speed resin steel blank regrinding emery wheel being different from plain wheel structure, improving bond strength uses linear velocity to bring up to 90-120m/s, grinding force >=800-1500kg,
C, process innovation: integrated application high strength and high-performance high-polymer resin structure, step feeding, one-shot forming, twice solidification, the complex technique of the inner different tissues structure of emery wheel.Large-tonnage shaping machine set cold-hot pressure forming and hardening reacts, and realizes high-strength polymer based anchoring agent two-phase and strengthens advanced composite material (ACM).One is when using conventional method and equipment, and technique is simple, easily realizes batch production.Two is that material comprehensive mechanical property is excellent, and its Tensile strength remains in higher level; Adopt high-end abrasive material and high-performance polymer structure, the uniformity of intensity, hardness, hardness, linear velocity, grinding scope, grinding ratio are significantly better than existing market product, percentage elongation remains in higher level, though solve in prior art and improve tensile strength, the difficult point of grinding ratio percentage elongation reduction.Solve an industry difficult problem for large gauge emery wheel high speed heavy load grinding, achieve high efficient grinding, be convenient to the large-scale high thickness special steel sheet material of user's grinding especially and realize automation.
D, environmental protection: utilize cold-hot pressure forming and hardening reaction process in large-scale emery wheel manufacture, low-temperature setting technology, compared with traditional emery wheel manufacture, energy-saving and emission-reduction decrease the discharge of environmental pollution and waste gas.
Accompanying drawing explanation
Fig. 1 is the vertical surface construction figure of emery wheel, in figure:
(1), marginal grinding area micro-structure diagram
(2), core space micro-structure diagram
(3), local strengthening steel loop
Fig. 2 is the special shaping device schematic diagram of emery wheel, in figure:
(1), top is the shaping pressure pressure head be connected with press;
(2) cope match-plate pattern of colding pressing of high elastic rubber water pocket structure structure is with,
(3), the core rod of (5), double-layer structure;
(4), the grinding layer of different tissues structure and core layer molding mass;
(6), the modular ring of (7), double-layer structure;
(8), local strengthening steel loop
(9), lower bolster;
Detailed description of the invention:
Illustrate below in conjunction with accompanying drawing: large gauge high-speed resin heavy-load abraded steel billet emery wheel is researched and developed by the complex technique of the special bonding agent high performance abrasive materials of modified high performance modification high polymer base phenolic resins emery wheel, inserts, wetting agent, reinforcing material and structure innovation, is made up of outer grinding layer, core material two part system.
1, select materials, 100#, 180#, 240#, 350#, 400# etc. described in the present invention, have clear and definite implication in the industry, namely refers to the granularity of material.
1), raw material: the technical conditions that fused alumina zirconia, alumina sintering corundum, Brown Alundum, black silicon carbide specify by country and professional standard.
2), the technical requirement of phenolic resins: free phenol content≤5%, methenamine content 7.5%-9%, flow long 35-55mm, softening point: winter 100 DEG C-105 DEG C, summer 100 DEG C-108 DEG C, 180# residue on sieve < 0.2%, water content≤2%.
3), novel phenolic resin technical requirement: novel phenolic resin be by phenol and terephthalyl alcohol, terephthaldehyde's ether or to dichlorotoleune under the effect of catalyst, a kind of linear resin of polycondensation.
Free phenol content≤3%, methenamine content 7.5%-9%, softening point winter 100 DEG C-105 DEG C, summer 100 DEG C-108 DEG C, density 1.65g/cm3,180# residue on sieve < 0.2%
4), butyral, commercial grade, type: thermoplastic resin, density 1.07g/cm3, refractive index 1.488 (20 DEG C).Water absorption rate is not more than 4%.Softening temperature 60-65 DEG C.Vitrification point 66-84 degree.
5), dibasic lead phosphite: commercial grade, [molecular formula] 2PbOPbHPO
31/2H
2o[molecular weight] 742.66, be white or micro-bloom end, lead content (in PbO) 89.5-91.5%, phosphorous acid (H
3pO
3) 9.0-12.0%, heating loss≤0.60, residue on sieve (75 μm)≤0.80%
6), ice crystal: main component is hexafluoro sodium aluminate (Na3AlF6), white monoclinic system (109 degrees Celsius), be slightly soluble in water, 180# residue on sieve < 0.2%, composition %:A1>=12, F>=52, Na≤33, CaO≤0.15, P205≤0.02, So4
2-≤ 0.6, Fe2O3≤0.05, SiO2≤0.25, hygroscopic moisture≤0.20.Burn decrement≤2.0
7), light magnesium oxide: proportion is 3.58 (25), fusing point is 2852 DEG C, and boiling point 3600 DEG C, is slightly soluble in pure water and organic solvent, can be dissolved in acid or salting liquid, molecular formula MgO, molecular weight 40.31.For white lightweight is loosened unformed powder.240# residue on sieve < 0.2%, odorless, tasteless, nontoxic.Expose and very easily absorb moisture and carbon dioxide in atmosphere, water insoluble and alcohol, can be dissolved in diluted acid and generate corresponding magnesium salt solution.
8), barite: molecular formula BaSO4, bar hardness is 3 ~ 3.5 (Mohs), and proportion is 4.2 ~ 4.7, BaSO4 >=95%, and SiO2≤3% burns decrement≤2.0%, 180# residue on sieve < 0.2%.
9), dibutylester: commercial grade, chemical name: dibutyl phthalate (DBP) outward appearance: transparent oily liquid, color and luster (APHA)≤60, acidity (in phthalic acid) %≤0.030, ester content % >=99.0, heating loss (125 DEG C, 3 hours) %≤0.7; Proportion 0.044-0.048
10), furfural: commercial grade, molecular formula C5H4O2.Also known as 2 furan carboxyaldehyde.Colourless liquid, has and smell like benzaldehydes.Fusing point-38.7 DEG C, boiling point 161.7 DEG C, relative density 1.1594 (20/4 DEG C).
11), pyrite dust: commercial grade, ferrous disulfide: FeS2, more than sulfur content (S >=47%) iron-holder (Fe >=50%), granularity 350#, proportion 4.9-5.2
12), fiber: adopt glass fibre, the use length of glass fibre is generally 0.5 ~ 10mm.
13), steel loop: local strengthening is used, by commercially available ￠ 12mm carbon steel round steel wire through being curled into ring, be welded, welding adopts commercially available butt-welding machine welding, to ensure node quality, the aperture mm of the diameter specifications of steel loop: emery wheel ￠ 203, the aperture mm of the diameter 270mm of steel loop, emery wheel ￠ 305, the diameter 370mm. of steel loop
2, embodiment prepared by emery wheel;
That below introduces trimmed size (emery wheel external diameter × thickness × aperture) 610 × 75 × 203,760 × 75 × 2037,760 × 125 × 203,915 × 125 × 305 (mm) four kinds of specification emery wheels prepares example, grinding stainless steel material, in marginal material formula, abrasive material is selected: fused alumina zirconia or alumina sintering corundum material.
Following table is design inner different tissues scope and the substance that feeds intake by above-mentioned four kinds of regular size emery wheels involved in the present invention:
1) mixed ingredients technique
According to Recipe, abrasive material, bonding agent, wetting agent, filler are passed through mechanical agitation by the quantity specified and program respectively, be stained with the qualified molding mass being coated in and abrasive material making it to become the qualified processability with good processability uniformly.Be ground to moulding mixture by skin and heart molding mass forms, prepare bonding agent, molding mass batch mixing respectively by formula.
2) moulding process
according to required finished grinding wheel specification specification, correctly select and assemble mould.
one deck releasing agent is evenly embrocated in order to mould unloading at the working face of mould,
in order to make in-mold molding material two sides pressurized make the upper and lower even tissue of base substrate, when shaping, all use parallels shaping.
weighing and feeding intake:
Select by above-mentioned trimmed size and weigh up corresponding core and marginal molding mass, select proper mold, and be assembled on the operating desk of abrasive wheel forming unit, in the grinding wheel die assembled, in mould with mould in the heart emery wheel inside and outside two-layer contact site, place one that prepare with galvanized iron sheet identical with core space outside diameter, the garden cylinder that height is consistent with whole two-layer modular ring height, shaping when feeding intake, grinding area and core layer are separated, realize the composite construction after different tissues structural core district and grinding layer twice step feeding, by limit, the grinding part molding mass weighed up, hole core molding mass and the gradation of core space local reinforcement steel loop drop in mould.
The laying method of core space local reinforcement steel loop: core material divides three inputs, each 1/3rd, first time drops into and spreads out after material strikes off, and puts into first reinforcement steel loop, stand is expected and is struck off, in order to obtain even tissue, grinding tool of good performance, molding mass is evenly distributed very important in mould, carry out stand material for secondary and strike off, molding mass drops into after in mould under the drive of rotating disk, stirring pine, being uniformly distributed and striking off with scraper plate with stirring material fork.
Carry out again second time drop into core material three/spread out after material strikes off in the lump, put into second steel loop, drop into third time 1/3rd core material, stand material successively and strike off, meanwhile grinding part molding mass is once dropped into, stand is expected and is struck off, and feed intake end, pumps galvanized iron sheet isolation garden cylinder, can step feeding be realized, start shaping machine set and once cold pressing compressing.
After having colded pressing; shed the cold moudling template of the first half; modular ring and core rod; with the edge of a knife chi identical with emery wheel upper surface radius; start shaping machine set rotating disk, scrape off the jog being positioned at grinding tool emery wheel upper surface uneven microstructure and staying, cover the hot pressing cope match-plate pattern with lower bolster same size; add level pressure pressure head, send 3000 tons of hot-forming units hot-forming and complete primary solidification.
3) hardening process (curing process):
(1) select suitable hardening equipment according to the specification quantity of abrasive tool blank and the object of sclerosis, hardening furnace select electrical heating type hot air circulation hardening furnace.
(2) check that whether the hot blast circulatory system of hardening furnace equipment normal, thermometric instrument indicate whether with stove in coincide, in stove, whether the temperature difference meets the requirements.
(3) audit program intelligent regulator, after hardening curve is inputted instrument, whether furnace temperature by the heating curve follow procedure A.T.C preset, can detect its temperature measurement accuracy, antijamming capability and sensitivity, reliability.
(4) suitable sclerosis backing plate and cover plate is selected.
(5) shove charge sclerosis
Input cure profile:
1., DEG C 3 hours, room temperature → 120; 2., 120 DEG C are incubated 1 hour,
3., 120 DEG C → 150 DEG C 3 hours, 4., 150 DEG C insulation 1 hour,
5., 150 DEG C → 183 DEG C 4 hours, 6., 183 DEG C insulation 12 hours, cooling. come out of the stove.
(6) stove points for attention are taken on:
during shove charge, blank backing plate is held to carry together and is handled with care.
during shove charge, the emery wheel semi-finished product of same batch of same specification are with filling a stove, during as emery wheel close for two kinds of hardening curves being contained in a stove, then adopt longer curve sclerosis.
emery wheel is after maximum temperature temperature retention time reaches, and namely hardening process comes to an end, and come out of the stove through cooling, in cooling procedure, air blast also should maintain a period of time, is exempted from hot-spot and makes top emery wheel sclerosis excessive.
furnace temperature is cooled to 100-120 DEG C of blow-on door, continues to be cooled to 60-80 DEG C to come out of the stove.
press semi-finished product technical conditions and check aliquation foaming crackle, semi-finished product are piled up neatly, proceeds to next procedure.
4) fine-processing technique:
Technical process comprises: emery wheel blank → aperture processing → plane machining → Excircle machining.
5) inspection process
Inspection process process: outward appearance, revolving strength → external diameter, thickness, form and position tolerance → aperture, hardness.
appearance test: emery wheel outward appearance answers flawless, bubble, aliquation and color and luster uneven, and sclerosis is not exclusively, and operation flowing water code steel seal is unclear.
revolving strength is checked: should carry out on φ 1800mm Intelligent rotary testing machine, revolving strength inspection is divided into destructive testing and safety testing, destructive testing indicates to use linear velocity twice, safety testing indicates to use linear velocity 1.5 times, maintenance must the time, destructive testing is inspected by random samples by technological procedure, safety testing one hundred percent inspection.
external diameter thickness form and position tolerance inspection ruler, slide calliper rule, edge of a knife chi, emery wheel circle run-out instrument, static balancing instrument inspection.
aperture: check with category-A aperture feeler gauge.
hardness: coarseness grinding tool does not generally do hardness test, the method inspection that fine granularity emery wheel specifies according to the inspection of GB/T2490 bonded abrasive tool grade of abrasive tool.
Claims (3)
1. one kind with a kind of high-speed resin heavy-load grinding wheel and preparation method thereof, it is characterized in that: with high-end special removing material (fused alumina zirconia, alumina sintering corundum, black silicon carbide) and phenolic resins, novel phenolic resin, butyral resin, troilite, light magnesium oxide, ice crystal, barite, 400# carborundum, zinc sulfate, calcium carbonate (lime) forms basic bonding agent, with furfural, dibutyl ester, fiber, steel loop (local reinforcement material), by outer grinding layer, the structural design of the proprietary formula that core material two part system designs respectively and complex technique, step feeding, once cold, hot-forming, twice solidification: high pressure low temperature thermosetting in large-tonnage shaping machine set, solidify at hot air circulation curing oven, the heavy-load abraded steel billet emery wheel of a kind of large-size high-strength efficient high-speed resin be prepared into.
2., according to claim 1, the special bonding agent of the outer grinding layer of composition emery wheel of described emery wheel, the difference in functionality structure of core material and molding mass formula, is characterized in that:
(1), limit material bonding agent formula:
2), core material bonding agent formula:
3) marginal molding mass formula:
Note: 1., in above-mentioned formula, siccative is abrasive material+bonding agent
2., abrasive material is: fused alumina zirconia, alundum.
4), core molding mass formula:
Note: in above-mentioned formula, siccative is black silicon carbide+bonding agent.
3. the preparation method of emery wheel according to claim 1, is characterized in that:
1), special bonding agent preparation:
By formula preparation limit material bonding agent and core material bonding agent respectively, the bell batch mixer of device therefor: 150L,
limit material bonding agent preparation method: take raw material by formula, limit material bonding agent charging sequence is: phenolic resins, novel phenolic resin, butyral, starts mixer mixing 3-5min, pyrite, light magnesium oxide, ice crystal, black silicon carbide (400#), lime, butyral puts bell batch mixer, starts mixer mixing 3-5min, adds zinc sulfate successively, dibasic lead phosphite stirs 3-5min, can be for subsequent use.
core material bonding agent preparation method: take raw material by formula, core material charging sequence is: phenol-formaldehyde resin modified, novel phenolic resin, butyral, starts mixer mixing 3-5min, pyrite, light magnesium oxide, barite, calcium carbonate, puts bell batch mixer, start mixer mixing 3-5min, add dibasic lead phosphite and stir 3-5min, cross 80# sieve, can be for subsequent use.
2), abrasive wheel forming preparation method for material:
By formulated limit material bonding agent and core material bonding agent, mixing equipment: two pot adverse current batch mixer up and down,
limit material molding mass preparation method: take removing material by formula, pour pot into, start mixer, add furfural, dibutyl ester resin, stir 3-5min, pour into and cook, start mixer, add limit material bonding agent, fiber (process), stirs 3-5min and can proceed to lower road molding procedure.
core molding mass preparation method: charging sequence is:: take black silicon carbide by formula, pour pot into, start mixer, add furfural, dibutyl ester stirs 3-5min, pours into and cooks, start mixer, add core material bonding agent, fiber (process), stir 3-5min and can proceed to lower road molding procedure.
3), four kinds of regular size emery wheels design inner different tissues scope and the substance that feeds intake:
4) the feeding intake with shaping of emery wheel
1., the shaped device of emery wheel: the special cold-hot pressure shaped device of emery wheel is by pressure head, adapt to die sleeve and the core rod of the double-layer structure that cold-hot pressure controls, the die sleeve of double-layer structure with core rod by being connected at the concavo-convex end face of interface Vehicle Processing one, cold moudling part accounts for 1/3rd of whole height, the cope match-plate pattern of colding pressing of side, the lower surface band caulking gum water pocket structure contacted with emery wheel, hot pressing cope match-plate pattern, lower bolster forms, it is characterized in that: die sleeve is installed on the operating desk of shaping machine set, lower bolster is positioned at bottom die sleeve, core rod is positioned at die sleeve center, be abrasive wheel forming material in the middle of core rod and die sleeve, cope match-plate pattern is placed in die sleeve top, feed intake after terminating, cover cope match-plate pattern, the end face of cope match-plate pattern water sac sealing rubber structure contacts with abrasive wheel forming material downwards, and cope match-plate pattern top adds level pressure pressure head, and pressure head is connected with press.
2., abrasive wheel forming: first install said apparatus according to said process on shaping machine set operating desk, feed intake; Drop into marginal grinding layer grinding wheel molding mass and core material molding mass respectively and place reinforcement steel loop, cold moudling, with cold moudling on 800 tons of abrasive wheel forming press, briquetting pressure: 18.5Mpa, exert pressure at twice, be the 1/4-1/3 of gross pressure for the first time, then remove grinding tool parallels, exert pressure by gross pressure, and keep 1 minute.After cold moudling; shed the cope match-plate pattern of cold moudling, modular ring; core rod part; scrape off in Lower Half hot pressing die with edge of a knife chi; to be colded pressing the jog that cope match-plate pattern stays by water pocket elastic construction because tissue density is uneven in emery wheel blank upper surface; cover hot pressing cope match-plate pattern and enter 3000 tons of hot pressing emery wheel press, hot-forming solidification together with the Lower Half grinding wheel forming molds of shaped device.
3. hot-forming solidification: emery wheel semi-finished product base substrate is exerted pressure at twice in the cured process of pressurize heat hot on 3000 tons of emery wheel press, hot pressing temperature 160 ± 5 DEG C, pressure 40 ~ 50Mpa, molding time 40 minutes.To set point of temperature, complete the primary solidification of emery wheel, mould unloading, put on supporting plate, after meeting molding mass technical conditions on inspection, proceed to next procedure while hot and enter curing oven sclerosis, solidification.
5) consolidation and sclerosis of emery wheel, solidification and heating curve
Heat after demoulding emery wheel blank, making it to become has solid shape, has certain degree of hardness intensity and heat resistance, conforms to quality requirements, solidification temperature: 120-183 DEG C, selects maximum temperature 183 DEG C, heating curve 24 hours hardening curves.
1) DEG C 3 hours, room temperature → 120; 2) 120 DEG C are incubated 1 hour,
3) 120 DEG C → 150 DEG C 3 hours, 4) 150 DEG C of insulations 1 hour,
5) 150 DEG C → 183 DEG C 4 hours, 6) 183 DEG C of insulations 12 hours, cooling. come out of the stove.
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Effective date of registration: 20180209 Address after: 224043 Dagang Town of Jiangsu province yandudistrict of Yancheng City New Road No. 246 Applicant after: Jiangsu Huadong Grinding Wheel Co., Ltd. Address before: 224043 Dagang Town of Jiangsu province yandudistrict of Yancheng City New Road No. 246 Applicant before: Jiangsu Huachen Abrasive Grinding Tool Co., Ltd. |
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