CN106958615A - 合金聚四氟乙烯复合摩擦材料、制备方法及双捻机张力控制摩擦块 - Google Patents
合金聚四氟乙烯复合摩擦材料、制备方法及双捻机张力控制摩擦块 Download PDFInfo
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 16
- 229910052982 molybdenum disulfide Inorganic materials 0.000 claims abstract description 13
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 12
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- 239000010936 titanium Substances 0.000 claims abstract description 9
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 claims abstract description 8
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
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- C09K3/00—Materials not provided for elsewhere
- C09K3/14—Anti-slip materials; Abrasives
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
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Abstract
本发明公开了一种合金聚四氟乙烯复合摩擦材料,以重量百分比计,包括以下组分:聚四氟乙烯30~45%、铜粉8~12%、锡粉8~12%、石墨粉8~12%、钛粉5~8%、镍粉5~7%、二氧化硅5~7%、三氧化二铝5~7%及二硫化钼4~6%,还公开该合金聚四氟乙烯复合摩擦材料的制备方法;本发明的合金聚四氟乙烯复合材料,密度达到了3.8~3.9g/cm3、硬度为37~39、摩擦系数为0.16;而目前只用PTFE制备的摩擦材料其密度为3.32g/cm3、硬度31.5、摩擦系数为0.40左右。最后还公开由该合金聚四氟乙烯复合摩擦材料制备的双捻机张力控制摩擦块。
Description
技术领域
本发明涉及双捻机张力控制摩擦块技术领域,具体地指一种合金聚四氟乙烯复合摩擦材料、制备方法及双捻机张力控制摩擦块。
背景技术
双捻机捻制钢丝绳用张力控制摩擦块,工作时,摩擦盘转动与摩擦块摩擦控制放线张力,摩擦张力需要稳定,波动控制在小于5%以内。由于摩擦块与摩擦盘时时摩擦、发热、磨损较快且易损坏,平均使用寿命仅2~3个月,同时,摩擦块磨损程度严重影响张力的稳定,摩擦块的质量不但增加了企业的生产成本,也影响成品钢丝绳的质量。
发明内容
本发明的目的就是要针对传统加工方法的不足,提供一种磨损率低及硬度高的合金聚四氟乙烯复合摩擦材料及制备方法,还提供一种由该合金聚四氟乙烯复合摩擦材料制备的双捻机张力控制摩擦块。
为实现上述目的,本发明所设计的合金聚四氟乙烯复合摩擦材料,以重量百分比计,包括以下组分:聚四氟乙烯(PTFE)30~45%、铜粉(Cu)8~12%、锡粉(Sn)8~12%、石墨粉8~12%、钛粉(Ti)5~8%、镍粉(Ni)5~7%、二氧化硅(Si02)5~7%、三氧化二铝(A12O3)5~7%及二硫化钼(MoS2)4~6%。
进一步地,以重量百分比计,包括以下组分:聚四氟乙烯35~42%、铜粉9~11%、锡粉9~11%、石墨粉9~11%、钛粉6~8%、镍粉5~7%、二氧化硅5~7%、三氧化二铝5~7%及二硫化钼4~6%。
进一步地,所述铜粉的重量百分比为10%。
聚四氟乙烯(PTFE)是一种线性结构的结晶高聚物,它的C原子主链的四周被F原子包围。主链C原子间的距离很短,结合得比较牢固,与F原子核间距离很小,而键能很大,所以F原子与C原子结合力比较强;而且,F原子半径比较大,正好无间隙地覆盖在C原子主链上,使PTFE分子链上无分支;同时,也遮盖了C原子的正电荷,而相邻PTFE分子上F原子的负电荷之间有排斥作用,因此PTFE分子间的范德华力很小,当滑动摩擦时,PTFE分子间容易产生滑移,表现出极低的摩擦因数。据经典著作介绍,PTFE摩擦因数为0.03~0.04。当PTFE与金属接触并产生相对运动时,摩擦接触点处温度会升高,由于PTFE具有极大的化学惰性,高的温度不会增加它的化学活性,但会减弱分子间的范德华引力,导致分子间内聚能下降,表面接触区附近的材料剪切强度下降;当达到一定的温度时PTFE极易向金属对磨面转移,并填平了金属表面的微观凹坑,此时,摩擦副的磨损发生在极薄的P1TE的分子层之间,从而保护了金属不受磨损,表现出较好的自润滑性能。
虽然PTFE兼有摩擦因数小和热稳定性高的优点,但它的机械强度差,受载后粘弹性变形大,磨损率高,在界面剪切过程中,PTFE带状物是从表面横向抽出的,这就需要某种形式的增强。在PTFE材料中加入青铜粉就阻止了这种抽出过程,填充的PTFE不会像单一的PTFE那样大片磨屑剥落,提高材料的磨损性能;而未添加铜粉的PTFE试样,粘结度较弱,硬度较差,压制性能较差。
铜粉(Cu)能够提高半金属摩擦材料制品在中温及高温的摩擦系数,能够显著改善材料的抗热衰退性和稳定性,且随着铜粉加入量的增多,其摩擦系数稳定性有变好的趋势,其稳定性最高可提高5%左右;当铜粉重量百分数为8~12%(优选为10%)时,摩擦材料的恢复性最佳,比未添加铜粉时提高约30%。但是,添加过量的铜粉会明显增加材料成本及导致过多的环境铜污染,因此,在实际应用中,综合考虑摩擦磨损性能,铜粉添加量在8~12%时对该种摩擦材料的摩擦学性能较合适。
镍粉(Ni)元素有细化晶粒的作用,使材料强度提高,硬度增加,从而影响到材料的摩擦磨损性能,因此,Ti、Ni在摩擦材料中起到强化基体的作用;另外,Ti和C生成TiC,具有高弹性模量、高硬度、高熔点的特性,使材料的硬度提高,从而使材料的摩擦表面不易变形,使摩擦副在摩擦过程中产生的磨屑数量减少,因此,Ni优选为6%、Ti优选为7%。
石墨和二硫化钼(MoS2)作为润滑组元或减磨剂,用于提高摩擦材料的抗擦伤性和耐磨性,但加入量过多会使摩擦系数和机械强度降低,因此,石墨优选为10%、MoS2优选为5%。
二氧化硅(Si02)和三氧化二铝(A12O3)具有高硬度和良好的高温稳定性。原料中Si02和A1203提供了氧元素,能够使铜粉和锡粉形成铜锡合金的氧化物,在摩擦材料的表面形成氧化膜;氧化膜的存在对摩擦材料是有利的,能起到一定的减磨作用,隔离了摩擦材料与对偶材料之间的直接接触,使磨损量减小,对摩擦系数有一定的稳定作用,从而提高了耐磨性;同时铜锡合金,使摩擦材料具有较高的机械强度和硬度,提高了摩擦材料的承载能力;因此,Si02优选为6%、A12O3优选为6%、Sn优选为10%。
因此,本发明合金聚四氟乙烯复合摩擦材料中包含很多相,每种相的硬度不同,例如Cu的硬度很低,但铜锡合金、Ni、Si02等强化相的硬度很高,加入到基体中可以相助提高整体的硬度指标;同时,也正是这种软硬相兼的特点使得摩擦材料在摩擦磨损的过程中显示出更好的耐磨性。
还提供一种如上述所述合金聚四氟乙烯复合摩擦材料的制备方法,所述制备方法包括如下步骤:
1)按预设比例将各组份称重后放入搅拌桶内,在温度为200~250℃下搅拌均匀形成混料;
2)将步骤1)中的混料放入成型模具中,在25~35MPa的压力下模压成型为坯料;
3)将步骤2)中装有坯料的成型模具放入加热炉中,于保护气体中烧结,烧结温度为365°~385℃之间,保持1~2h后随炉冷却,冷却至聚四氟乙烯熔点以下,出炉缓冷至室温,制得合金聚四氟乙烯复合摩擦材料。
进一步地,所述制备方法包括如下步骤:所述步骤3)中的保护气体为N2。
在基体选定之后,摩擦组元及材料本身的密度对性能有极其重要的影响。如果材料的孔隙度太大、密度太低,则材料的强度降低、颗粒结合减弱,从而造成制动材料磨损加大。烧结时,在外加压力状态下,材料的致密化会好得多;随烧结压力增加,材料的孔隙度下降,硬度增大,磨损也降低。但是,压力过高,则对烧结设备的要求过于苛刻,会增加生产成本,因此,适当提高烧结温度可降低烧结压力,也同样能达到提高密度的目的。为此,经过试验后,首先在25~35MPa的压力下模压成型为坯料,然后将模具置于加热炉内,并于保护气体N2中进行烧结,烧结温度控制在365~385℃之间,保持1~2小时,随炉冷却,可以得到能够满足使用要求高性能的摩擦材料。
最后还提供一种如上述所述合金聚四氟乙烯复合摩擦材料制备的双捻机张力控制摩擦块,包括弧形钢骨架及通过铆钉固定在所述弧形钢骨架内壁的若干个合金聚四氟乙烯复合摩擦材料。
进一步地,每相邻所述合金聚四氟乙烯复合摩擦材料之间留有间隙。
本发明与现有技术相比,具有以下优点:本发明的合金聚四氟乙烯复合材料,密度达到了3.8~3.9g/cm3、硬度为37~39、摩擦系数为0.16;而目前只用PTFE制备的摩擦材料其密度为3.32g/cm3、硬度31.5、摩擦系数为0.40左右;而由此可以看出,本发明的合金聚四氟乙烯复合材料,密度提高了14.5~17.5%左右、硬度提高了17.5~23.8%左右、摩擦系数降低了60%,从而磨损率降低了40~85%。
附图说明
图1为本发明合金聚四氟乙烯复合摩擦材料制备的双捻机张力控制摩擦块的结构示意图。
其中:弧形钢骨架1、内壁2、铆钉3、合金聚四氟乙烯复合摩擦材料4、间隙5。
具体实施方式
下面结合具体实施例对本发明作进一步的详细说明,便于更清楚地了解本发明,但它们不对本发明构成限定。
实施例1
1)称重:PTFE37%、Cu11%、Sn11%、石墨粉11%、Ti5%、Ni7%、Si027%、A12O37%及MoS24%;
按称好的各组份放入搅拌桶内,在温度为200℃下搅拌2h形成混料;
2)将步骤1)中的混料放入成型模具中,在30MPa的压力下模压成型为坯料;
3)将步骤2)中装有坯料的成型模具放入加热炉中,于保护气体中烧结,烧结温度为370℃之间,保持2h后随炉冷却,冷却至聚四氟乙烯熔点以下,出炉缓冷至室温,制得合金聚四氟乙烯复合摩擦材料。
所制得的合金聚四氟乙烯复合材料,密度达到了3.80g/cm3、硬度为37、摩擦系数为0.16。
实施例2
1)称重:PTFE38%、Cu8%、Sn8%、石墨粉8%、Ti7%、Ni7%、Si025.5%、A12O35.5%及MoS25%;
按称好的各组份放入搅拌桶内,在温度为220℃下搅拌1.2h形成混料;
2)将步骤1)中的混料放入成型模具中,在25MPa的压力下模压成型为坯料;
3)将步骤2)中装有坯料的成型模具放入加热炉中,于保护气体中烧结,烧结温度为380℃之间,保持2h后随炉冷却,冷却至聚四氟乙烯熔点以下,出炉缓冷至室温,制得合金聚四氟乙烯复合摩擦材料。
所制得的合金聚四氟乙烯复合材料,密度达到了3.850g/cm3、硬度为38.5、摩擦系数为0.16。
实施例3
1)称重:PTFE40%、Cu10%、Sn10%、石墨粉10%、Ti7%、Ni6%、Si026%、A12O36%及MoS25%;
按称好的各组份放入搅拌桶内,在温度为250℃下搅拌1h形成混料;
2)将步骤1)中的混料放入成型模具中,在30MPa的压力下模压成型为坯料;
3)将步骤2)中装有坯料的成型模具放入加热炉中,于保护气体中烧结,烧结温度为380℃之间,保持1h后随炉冷却,冷却至聚四氟乙烯熔点以下,出炉缓冷至室温,制得合金聚四氟乙烯复合摩擦材料。
所制得的合金聚四氟乙烯复合材料,密度达到了3.85g/cm3、硬度为38、摩擦系数为0.16。
实施例4
1)称重:PTFE45%、Cu10%、Sn8%、石墨粉8%、Ti5%、Ni5%、Si025%、A12O36%及MoS26%;
按称好的各组份放入搅拌桶内,在温度为240℃下搅拌1.5h形成混料;
2)将步骤1)中的混料放入成型模具中,在35MPa的压力下模压成型为坯料;
3)将步骤2)中装有坯料的成型模具放入加热炉中,于保护气体中烧结,烧结温度为365℃之间,保持1h后随炉冷却,冷却至聚四氟乙烯熔点以下,出炉缓冷至室温,制得合金聚四氟乙烯复合摩擦材料。
所制得的合金聚四氟乙烯复合材料,密度达到了3.86g/cm3、硬度为38.4、摩擦系数为0.16。
综上所述,目前只用PTFE制备的摩擦材料其密度为3.32g/cm3、硬度31.5、摩擦系数为0.40左右;而本发明的合金聚四氟乙烯复合材料,密度达到了3.8~3.9g/cm3、硬度为37~39、摩擦系数为0.16;由此可以看出,本发明的合金聚四氟乙烯复合材料,密度提高了14.5~17.5%左右、硬度提高了17.5~23.8%左右、摩擦系数降低了60%,从而磨损率降低了40~85%。
如图1所示,本发明还提供一种双捻机张力控制摩擦块,包括弧形钢骨架1及固定在弧形钢骨架1内壁2的若干个合金聚四氟乙烯复合摩擦材料4,该合金聚四氟乙烯复合摩擦材料则由上述合金聚四氟乙烯复合摩擦材料制备的;合金聚四氟乙烯复合摩擦材料4与弧形钢骨架1之间用胶粘结后再通过铆钉3固定在弧形钢骨架1上,且每相邻合金聚四氟乙烯复合摩擦材料4之间留有间隙5。
Claims (7)
1.一种合金聚四氟乙烯复合摩擦材料,其特征在于:以重量百分比计,包括以下组分:聚四氟乙烯30~45%、铜粉8~12%、锡粉8~12%、石墨粉8~12%、钛粉5~8%、镍粉5~7%、二氧化硅5~7%、三氧化二铝5~7%及二硫化钼4~6%。
2.根据权利要求1所述合金聚四氟乙烯复合摩擦材料,其特征在于:以重量百分比计,包括以下组分:聚四氟乙烯35~42%、铜粉9~11%、锡粉9~11%、石墨粉9~11%、钛粉6~8%、镍粉5~7%、二氧化硅5~7%、三氧化二铝5~7%及二硫化钼4~6%。
3.根据权利要求1或2所述合金聚四氟乙烯复合摩擦材料,其特征在于:所述铜粉的重量百分比为10%。
4.一种如权利要求1所述合金聚四氟乙烯复合摩擦材料的制备方法,其特征在于:所述制备方法包括如下步骤:
1)按预设比例将各组份称重后放入搅拌桶内,在温度为200~250℃下搅拌均匀形成混料;
2)将步骤1)中的混料放入成型模具中,在25~35MPa的压力下模压成型为坯料;
3)将步骤2)中装有坯料的成型模具放入加热炉中,于保护气体中烧结,烧结温度为365°~385℃之间,保持1~2h后随炉冷却,冷却至聚四氟乙烯熔点以下,出炉缓冷至室温,制得合金聚四氟乙烯复合摩擦材料。
5.根据权利要求4所述合金聚四氟乙烯复合摩擦材料的制备方法,其特征在于:所述制备方法包括如下步骤:所述步骤3)中的保护气体为N2。
6.一种如权利要求1所述合金聚四氟乙烯复合摩擦材料制备的双捻机张力控制摩擦块,其特征在于:包括弧形钢骨架(1)及通过铆钉(3)固定在所述弧形钢骨架(1)内壁(2)的若干个合金聚四氟乙烯复合摩擦材料(4)。
7.根据权利要求6所述合金聚四氟乙烯复合摩擦材料制备的双捻机张力控制摩擦块,其特征在于:每相邻所述合金聚四氟乙烯复合摩擦材料(4)之间留有间隙(5)。
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