CN108839640B - Grinder for high-speed motor train unit and preparation method thereof - Google Patents

Grinder for high-speed motor train unit and preparation method thereof Download PDF

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Publication number
CN108839640B
CN108839640B CN201810424313.8A CN201810424313A CN108839640B CN 108839640 B CN108839640 B CN 108839640B CN 201810424313 A CN201810424313 A CN 201810424313A CN 108839640 B CN108839640 B CN 108839640B
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China
Prior art keywords
grinder
friction material
temperature
speed motor
percent
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CN108839640A (en
Inventor
李伟
解国志
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Zonesun (shanghai) Pipeline Engineering LLC
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Dutesi Dalian Industrial Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60S—SERVICING, CLEANING, REPAIRING, SUPPORTING, LIFTING, OR MANOEUVRING OF VEHICLES, NOT OTHERWISE PROVIDED FOR
    • B60S1/00—Cleaning of vehicles
    • B60S1/62—Other vehicle fittings for cleaning
    • B60S1/66—Other vehicle fittings for cleaning for cleaning vehicle exterior
    • B60S1/68—Other vehicle fittings for cleaning for cleaning vehicle exterior for freeing wheels or tyres from foreign matter, e.g. wheel scrapers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B22F1/103—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12—Both compacting and sintering
    • B22F3/14—Both compacting and sintering simultaneously
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/248—Thermal after-treatment

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Braking Arrangements (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

The invention provides a grinder for a high-speed motor train unit and a preparation method thereof, wherein the grinder consists of a friction material and a steel backing, the friction material consists of components such as phenolic resin with specific physical properties, reinforcing fibers, fillers and the like, the components of the friction material need to be subjected to pretreatment such as mixing, drying and the like, and the steel backing needs to be subjected to pretreatment such as sand blasting, resin glue spraying and the like; and then, preparing the pre-treated friction material and the steel backing together through special hot press molding, heat treatment and other processes to obtain the grinder. The grinder improves the performances of the grinder in the aspects of metal embedding, crack dropping, wheel shaping, friction noise and the like by improving the thermal stability and enhancing the impact strength, has small damage to the wheel tread, is not easy to generate hot cracks, serious wave furrow-shaped abrasion and the like, and has important application value and wide market prospect in the field of high-speed motor cars.

Description

Grinder for high-speed motor train unit and preparation method thereof
Technical Field
The invention relates to the field of manufacturing of grinders for motor train units, in particular to a grinder for a high-speed motor train unit and a preparation method thereof.
Background
With the continuous high-speed development of trains, higher requirements are put forward on the braking of the trains, and more rigorous requirements are put forward on the performance of the braking friction material: reliable operation, good heat resistance, excellent comprehensive performance and the like. The high-speed motor train unit tread sweeper cleans treads, corrects the tread shape of wheels, eliminates high-frequency vibration between wheel rails, inhibits wheel rotation noise, improves the adhesive force between the wheels and the rails, shortens the braking distance and ensures safe, stable and comfortable braking of a high-speed motor train unit; meanwhile, the grinding wheel is used on the bogie of the high-speed motor train unit, fatigue cracks on the surface of the wheel can be eliminated in time, the stripping phenomenon on the surface of the wheel is prevented, and therefore the potential danger of crack diffusion is eliminated.
The vigorous development of high-speed trains inevitably brings a great demand for grinders for high-speed motor train units. The grinder belongs to a part which is easy to damage and consume, and needs to be replaced periodically according to the wearing condition, and the annual consumption is large. Compared with similar products imported from abroad, the domestic grinder applied to the high-speed motor train unit generally has the problems of weak impact strength, cracks, chipping, high abrasion loss, metal inlaying, hot cracking of wheel treads, severe wave furrow-shaped abrasion and the like; the imported grinders have the problems of high price, long purchase period and the like, and the operation and maintenance cost of the vehicle is influenced to a great extent;
a preparation method of a grinder is disclosed in a patent of Chinese invention patent CN 102432978A (named as a grinder for a motor car tread sweeper and a manufacturing method thereof); the paint comprises the following components in parts by weight: modified phenolic resin 6818: 24.11%, reduced iron powder: 35.03%, copper fiber: 13.62%, steel fiber: 6.03%, sepiolite: 4.61%, potassium feldspar: 4.54%, graphite: 4.40%, cryolite: 3.90%, alumina: 3.76 percent.
A preparation method of a tackifying grinding wheel is disclosed in a Chinese invention patent CN 103693020A (named as 'production process of a motor train unit wear-resistant tackifying grinding wheel'); the process is characterized in that thermoplastic phenolic resin is taken as a main material, 5% -8% of nitrile rubber powder is added, and a mixed filler consisting of a metal filler and bauxite is taken as an auxiliary material to be pressed and molded.
However, the grinder product is only applied to a specific high-speed motor car model, is not yet fully popularized and used, and is not completely mature in application, so that the practical problems of metal embedding, wheel reshaping, noise control, severe wave plow-shaped abrasion and the like in the use process of the grinder are still to be further solved and improved.
Disclosure of Invention
Aiming at the problems, the invention provides a grinder for a high-speed motor train unit and a preparation method thereof, wherein the grinder consists of a friction material and a steel backing, the friction material consists of components such as phenolic resin with specific physical properties, reinforcing fibers, fillers and the like, the components of the friction material need to be subjected to pretreatment such as mixing, drying and the like, and the steel backing needs to be subjected to pretreatment such as sand blasting, resin glue spraying and the like; and then, preparing the pre-treated friction material and the steel backing together through special hot press molding, heat treatment and other processes to obtain the grinder. The grinder improves the performances of the grinder in the aspects of metal embedding, crack dropping, wheel shaping, friction noise and the like by improving the thermal stability and enhancing the impact strength, has small damage to the wheel tread, and is not easy to generate hot cracks, serious wave plow-shaped abrasion and the like.
The invention provides a grinder for a high-speed motor train unit, which is characterized by comprising the following components in parts by weight: 6 to 10 percent of phenolic resin, less than or equal to 6 percent of powdered nitrile rubber, 52 to 78 percent of reduced iron powder, 0.1 to 5 percent of noise reducer, 2 to 7 percent of alumina, 9 to 17 percent of metal fiber, less than or equal to 4 percent of mineral fiber, 0.1 to 4 percent of organic fiber and less than or equal to 1 percent of internal mold release agent.
Preferably, the fluidity of the phenolic resin is 25-40 mm, and the polymerization speed is 40-65 s.
Preferably, the powdered nitrile rubber is a nano-sized powdered nitrile rubber.
Preferably, the fineness of the reduced iron powder is not less than 100 meshes.
Preferably, the fineness of the alumina is not less than 325 meshes.
Preferably, the length-diameter ratio of the mineral fiber is 20-30, and the length of the mineral fiber is 30-40 μm.
Preferably, the organic fiber needs to resist high temperature of more than or equal to 500 ℃.
Preferably, the internal mold release agent has a melting point <140 ℃.
The invention provides a method for preparing the grinder, wherein the grinder consists of a steel back and a friction material; the method comprises the following steps:
1) pretreating the friction material and the steel backing;
2) carrying out hot rolling forming and heat treatment on the friction material and the steel backing pretreated in the step 1);
wherein the friction material pretreatment comprises mixing and drying, and the drying temperature is 85 +/-10 ℃;
wherein, the pretreatment of the steel backing comprises the following steps: carrying out sand blasting on the steel back, then uniformly spraying resin glue (the weight ratio of resin to alcohol is 1: 1-1: 2) on the contact surface of the steel back, and naturally drying; the steel back contact surface is the contact surface of the steel back and the friction material;
wherein the hot press molding parameters are as follows: the pressing temperature is 150-160 ℃, and the pressing pressure is 4-5 Mpa; the pressure maintaining-exhausting parameters of the pressing are as follows: the pressure maintaining time is 40-50 s, the exhausting time is 10-15 s, and the pressure maintaining and exhausting are carried out for 4-6 times; pressure maintaining and curing time: 1200-1500 s;
preferably, the heat treatment process is set according to the parameters shown in fig. 1.
The invention provides a grinder for a high-speed motor train unit, which overcomes the defects of the existing grinder, the grinder prepared by the preparation method has no cracks and blocks, small abrasion loss, small friction noise, difficult metal embedding, good wheel shaping property, small damage to the wheel tread, difficult generation of hot cracks, serious wave plow-shaped abrasion and the like; the grinder is superior to an imported grinder in use performance and price, and has important application value and wide market prospect.
Drawings
FIG. 1 thermal treatment Curve
Detailed Description
Aiming at the practical problems of metal inlaying, wheel reshaping, noise control, severe wave plow-groove abrasion and the like existing in the using process of the grinding element, the inventor provides the grinding element with improved thermal stability and enhanced impact strength and the preparation method thereof through extensive and intensive research and long-term touch cable grinding element component proportion and preparation process; the present invention has been completed based on this finding.
Unless otherwise specified, various starting materials of the present invention are commercially available; or prepared according to conventional methods in the art. Unless defined or stated otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In addition, any methods and materials similar or equivalent to those described herein can be used in the methods of the present invention.
Other aspects of the invention will be apparent to those skilled in the art in view of the disclosure herein.
The invention provides a grinder for a high-speed motor train unit, which is characterized by comprising the following components in parts by weight: 6 to 10 percent of phenolic resin, less than or equal to 6 percent of powdered nitrile rubber, 52 to 78 percent of reduced iron powder, 0.1 to 5 percent of noise reducer, 2 to 7 percent of alumina, 9 to 17 percent of metal fiber, less than or equal to 4 percent of mineral fiber, 0.1 to 4 percent of organic fiber and less than or equal to 1 percent of internal mold release agent.
In one embodiment of the present invention, the phenolic resin has a fluidity of 25 to 40mm and a convergence rate of 40 to 65 seconds.
In one embodiment of the invention, the powdered nitrile rubber is a nano-sized powdered nitrile rubber.
In one embodiment of the present invention, the fine degree of the fine reduced iron is not less than 100 mesh.
In one embodiment of the present invention, the fineness of the alumina is 325 mesh or more.
In one embodiment of the present invention, the mineral fibers have an aspect ratio of 20 to 30 and a length of 30 to 40 μm.
In one embodiment of the present invention, the organic fiber is required to have a high temperature resistance of 500 ℃ or more.
In one embodiment of the invention, the internal mold release agent has a melting point <140 ℃.
The invention provides a method for preparing the grinder, wherein the grinder consists of a steel back and a friction material; the method comprises the following steps:
1) pretreating the friction material and the steel backing;
2) carrying out hot rolling forming and heat treatment on the friction material and the steel backing pretreated in the step 1);
wherein the friction material pretreatment comprises mixing and drying, and the drying temperature is 85 +/-10 ℃;
wherein, the pretreatment of the steel backing comprises the following steps: carrying out sand blasting on the steel back, then uniformly spraying resin glue (the weight ratio of resin to alcohol is 1: 1-1: 2) on the contact surface of the steel back, and naturally drying; the steel back contact surface is the contact surface of the steel back and the friction material.
Wherein the hot press molding parameters are as follows: the pressing temperature is 150-160 ℃, and the pressing pressure is 4-5 Mpa; the pressure maintaining-exhausting parameters of the pressing are as follows: the pressure maintaining time is 40-50 s, the exhausting time is 10-15 s, and the pressure maintaining and exhausting are carried out for 4-6 times; pressure maintaining and curing time: 1200-1500 s;
in one embodiment of the present invention, the heat treatment process is set according to the parameters shown in fig. 1.
In a preferred embodiment of the invention, the content of the powdered nitrile rubber is ≦ 5%.
In a preferred embodiment of the present invention, the noise reducer is contained in an amount of 3% to 5%.
In a preferred embodiment of the present invention, the content of the organic fiber is 3% or less.
In one embodiment of the present invention, the content of the phenolic resin is 6% to 10%; preferably, the content of the phenolic resin is 6 to 9 percent, or 7 to 10 percent.
In one embodiment of the present invention, the content of the fine reduced iron is 52 to 78%, and preferably, the content of the fine reduced iron is 56 to 78%.
In one embodiment of the present invention, the noise reducing agent includes, but is not limited to, one or more of abrasive powder, petroleum coke, or vermiculite.
In one embodiment of the present invention, the content of the alumina is 2% to 7%; preferably, the content of the alumina is 4% to 7%.
In one embodiment of the present invention, the mineral fiber includes, but is not limited to, one or more of silicate, wollastonite, needle-shaped calcium aluminate or calcium silicate whisker.
In one embodiment of the present invention, the organic fiber is required to have a high temperature resistance of 500 ℃ or higher.
In one embodiment of the invention, the internal mold release agent has a melting point <140 ℃; the internal mold release agent comprises one or more of metal stearate (such as calcium stearate, zinc stearate and the like) or fatty acid (such as stearic acid, a mixture of modified fatty acid and organic phosphate ester, a mixture of glyceride and organic acid derivative).
In one embodiment of the present invention, the heat treatment process is set according to the parameters shown in fig. 1.
The invention provides a preparation method of a grinder for a high-speed motor train unit, which comprises the following steps: the raw materials are weighed, mixed, subjected to steel backing surface treatment, sprayed with glue, hot-pressed and formed, and subjected to heat treatment according to the proportion, and the method specifically comprises the following steps:
1) weighing:
accurately weighing the required material quantity by using an electronic scale with proper measuring range and precision according to the raw material proportion of the grinding mill; different raw materials are placed in the material boxes with different marks and recorded, so that the tracing is facilitated.
2) Mixing materials:
a) the invention adopts a plow-rake type mixer for mixing materials, and can solve the problem of mixing uniformity of most asbestos-free mineral fibers and organic fibers with fillers, resin and powdered rubber.
b) Putting the prepared materials into a mixer, and closing a feed inlet; setting the coulter to run for 20-25 minutes, and setting the running time of the high-speed stirring knife to be 15-18 minutes;
c) after the mixing is finished, the mixture is sampled to be visually uniform, and the mixture is required to be uniformly mixed without obvious fiber agglomeration.
d) And (3) drying the mixture in an oven at the drying temperature of 85 +/-10 ℃.
3) Steel backing surface treatment and glue spraying:
in order to remove impurities such as oil, rust and the like on the steel backing and improve the adhesive force of the sprayed adhesive, the steel backing needs to be subjected to sand blasting treatment, then the contact surface of the steel backing and the friction material is uniformly sprayed with resin adhesive (the weight ratio of resin to alcohol is 1: 1-1: 2, and is adjusted according to the temperature), and the sprayed adhesive surface is naturally dried in the air, so that the pollution of the impurities such as dust and the like on the sprayed adhesive surface is prevented.
4) Hot-press molding:
cleaning an inner cavity of the mold by using compressed air before pressing, preheating the mold on a heating platform, uniformly spraying a water-based release agent in the inner cavity of the mold after preheating to a set temperature, uniformly adding the mixture obtained in the step 2), slightly placing the steel backing treated in the step 3) above the mixture in the mold cavity, starting a program, starting pressing, maintaining pressure after pressure maintaining-exhausting circulation and curing until the program is finished, taking out a product, and transferring to the next procedure after the product is qualified.
The grinding son is pressed by a 200T ton four-column hydraulic press, and the pressing parameters are as follows: pressing at the temperature of 150-160 ℃; the pressure of the press is as follows: 4-5 Mpa; pressure maintaining-exhaust parameters: the pressure maintaining time is 40-50 seconds, the exhaust time is 10-15 seconds, and the pressure maintaining and exhaust are carried out for 4-6 times; pressure maintaining and curing time: 1200-1500 seconds.
The phenolic resin is subjected to polycondensation reaction at a certain pressing temperature to become a non-fusible and insoluble cured product with a reticular cross-linking structure, and the process is irreversible; if the pressing temperature is too high, the resin is cured too fast, the flowability of the sizing material is reduced, and the sizing material can be cured before the die cavity is filled uniformly, so that the product is damaged or loosened unevenly, and the mechanical strength is influenced; the temperature is too low, the curing speed is too slow, the production efficiency is low, the product is soft, and the bubble defect occurs under the action of the internal moisture and the total vapor pressure of volatile matters; the control of the temperature is very important; the invention is optimized, and the pressing temperature is 150-160 ℃.
The pressing pressure and the forming temperature are the same, the pressure is too low, the product has poor compactness, loose texture, uneven thickness and corner defect; the over-high pressure not only causes the over-high hardness and the over-large compression modulus of the product to influence the service performance, but also increases the energy consumption to cause the damage of a die and a press and the damage and the scrapping of the edge of the product; according to the invention, the pressing pressure is preferably 4-5 Mpa.
After the first pressurization, the pressure needs to be relieved, volatile matters such as moisture, free formaldehyde, ammonia and the like generated in the sizing material and in the curing process are discharged out of the mold, so that the defects of foaming, bulging, cracks and the like of a product caused by huge steam pressure are avoided, the operation is called exhaust, and the sizing material is in a plastic state at the moment; the exhaust is too late, and the high-pressure gas is not easy to exhaust because the phenolic resin is solidified, so that the interior is swelled and cracked. The pressure maintaining and curing time after the exhaust is calculated according to the thickness of the product, the thicker the product is, the slower the internal heating is, and the longer the time for achieving the full curing is; the invention preferably selects the pressure maintaining-exhausting parameters as follows: the pressure maintaining time is 40-50 seconds, the exhaust time is 10-15 seconds, and the pressure maintaining and exhaust are carried out for 4-6 times; pressure maintaining and curing time: 1200-1500 seconds.
The pressing parameters are the optimal parameters, and tests prove that the synthetic grinder has excellent frictional wear performance and good thermal stability.
5) And (3) heat treatment:
the grinding pieces after being pressed and formed are flatly arranged in a curing furnace material rack, the minimum interval of each grinding piece is 10mm, the smooth flowing of hot air is ensured, and the temperature of each part in the furnace is uniform. The heat treatment process is set according to the parameters shown in the attached figure 1. And (5) after the program operation is finished, naturally cooling to below 50 ℃, opening the furnace door, and taking out the product.
After heat treatment, the appearance of the grinding wheel is checked to be free from defects such as bubbling, cracking, layering, loosening, warping and the like; the friction material and the steel backing should be tightly bonded.
Purpose of heat treatment: (1) the resin in the product is completely cured, so that the performance of the product is stable; (2) the thermal stress of the product after hot press molding is eliminated, and the product is prevented from warping and deforming; (3) reducing the thermal expansion of the product.
The parameters of the heat treatment profile program of the mill of the present invention are required to satisfy the profile shown in FIG. 1.
In the invention, in the step 4), during the hot press molding, parameters such as pressing time, temperature and pressure are well controlled, the surface of the product is smooth and flat, the friction body has no defects such as cracks, bubbles, layering, looseness, warping and the like, and the friction material and the steel backing are tightly combined; the pressing time is too short, which can cause the product to be soft and have poor texture, and generate bubbles, swelling, cracks and the like; the pressing temperature is too high, which can cause corner defects, uneven texture, surface foaming, swelling and cracks of the product; the pressing temperature is too low, so that the product is soft, white, dull and dull, and the appearance is influenced; the exhaust frequency is less than the specified frequency, and the defects of cracks, bubbles, delamination, looseness, warping and the like can be caused; the venting time, which is less than the specified time, can result in cracks, blisters, delamination, porosity, warping, and the like.
In the step 5), when the heat treatment is carried out, the temperature rise speed is higher than the curve speed of the attached figure 1, and the product can be foamed and deformed; the holding time is shorter than that shown in figure 1, and the product is soft and has poor texture, and bubbles, swelling, cracks and the like are generated.
The invention provides a grinder for a high-speed motor train unit and a preparation method thereof. The steel backing is made of a steel plate with mechanical property not lower than Q235-A, the friction material is mainly made of phenolic resin, reinforcing fiber, filler and the like through material weighing, material mixing, hot press molding and heat treatment, and the friction material does not contain asbestos, cadmium, mercury, chromium or compounds thereof and other materials which can generate harmful gas and dust; the prepared grinding body has no crack and block falling, small abrasion loss, low braking noise, no metal inlay, good wheel shape modification, small damage to the wheel tread, no hot crack, no serious wave plow groove abrasion and the like.
Preferred embodiments of the present invention are discussed in further detail below with reference to specific examples to facilitate a more thorough and accurate understanding of the present invention. It should be noted, however, that the following specific examples are given for illustrative purposes only and do not limit the scope of the present invention, which is defined only by the appended claims; the experimental methods of the following examples, which are not specified under specific conditions, are generally determined according to national standards; if no corresponding national standard exists, the method is carried out according to the universal international standard, the conventional conditions or the conditions recommended by the manufacturer; unless otherwise indicated, all parts are parts by weight and all percentages are percentages by weight.
Unless defined or stated otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In addition, any methods and materials similar or equivalent to those described herein can be used in the methods of the present invention.
Examples
Embodiment 1, grinder for high-speed motor train unit and preparation method thereof
The grinder for the high-speed motor train unit consists of a steel backing and a friction material, wherein the friction material comprises the following raw materials in parts by weight, and the raw materials are shown in Table 1.
TABLE 1 raw materials and weight ratios of friction materials
Serial number Raw materials Weight ratio of
1 Phenolic resin 10％
2 Reduced iron powder 52％
3 Petroleum coke 4.9％
4 Alumina oxide 7％
5 Copper fiber 17％
6 Calcium silicate whisker 4％
7 Aramid fiber 4％
8 Calcium stearate 1％
9 Vermiculite 0.1％
The preparation method of the grinder for the high-speed motor train unit comprises the following steps: the raw materials are weighed, mixed, subjected to steel backing surface treatment, glue spraying, hot press molding and heat treatment according to the weight ratio, and the method comprises the following specific steps:
1) weighing:
accurately weighing the required material quantity by using an electronic scale with proper measuring range and precision according to the proportion of the friction material raw materials; different raw materials are placed in the material boxes with different marks and recorded, so that the tracing is facilitated.
2) Mixing materials:
a) putting the prepared materials into a plow harrow type mixer, and closing a feed inlet; setting the coulter to run for 20 minutes and the high-speed stirring knife to run for 18 minutes;
b) and (3) drying the mixture in an oven at the drying temperature of 75 ℃.
3) Steel backing surface treatment and glue spraying:
and (3) carrying out sand blasting treatment on the steel back, then uniformly spraying resin glue (the weight ratio of resin to alcohol is 1: 1) on the contact surface of the steel back and the friction material, and naturally airing to prevent impurities such as dust and the like from polluting the glue spraying surface.
4) Hot-press molding:
cleaning an inner cavity of a mold by using compressed air before pressing, preheating the mold on a heating platform, uniformly spraying a water-based release agent in the inner cavity of the mold after preheating to a set temperature, uniformly adding a mixture according to 1.24kg, slightly putting a grinding sub support into the mold, starting a program, starting pressing, performing pressure maintaining-exhausting circulation and pressure maintaining solidification on the pressing until the program is finished, taking out a product, and transferring to the next procedure after the product is qualified.
The pressing adopts a 200T ton four-column hydraulic press, and the pressing parameters are as follows: the pressing temperature is 150 ℃; the pressure of the press is as follows: 4 Mpa; pressure maintaining-exhaust parameters: the pressure maintaining time is 40 seconds, the air exhausting time is 10 seconds, and the pressure maintaining and air exhausting are carried out for 4 times; pressure maintaining and curing time: 1200 seconds.
5) And (3) heat treatment:
placing the pressed and formed grinder in a curing oven rack to ensure smooth flow of hot air and uniform temperature at each position in the oven; operating according to a set heat treatment curve program, wherein parameters of the heat treatment curve program need to meet the curve requirement of the attached figure 1; and (5) after the program operation is finished, naturally cooling to below 50 ℃, opening the furnace door, and taking out the product.
Embodiment 2, grinder for high-speed motor train unit and preparation method thereof
The grinder for the high-speed motor train unit consists of a steel backing and a friction material, wherein the friction material comprises the following raw materials in parts by weight, and the raw materials are shown in Table 2.
TABLE 2 raw materials and weight ratios of friction materials
Serial number Raw materials Weight ratio of
1 Phenolic resin 9％
2 Powdered nitrile rubber 4％
3 Reduced iron powder 58％
4 Vermiculite 2.5％
5 Alumina oxide 4％
6 Steel fiber 16.5％
7 Wollastonite 3.5％
8 Aramid fiber 2％
9 Zinc stearate 0.5％
The preparation method of the grinder for the high-speed motor train unit comprises the following steps: the raw materials are weighed, mixed, subjected to steel backing surface treatment, glue spraying, hot press molding and heat treatment according to the weight ratio, and the method comprises the following specific steps:
1) weighing:
accurately weighing the required material quantity by using an electronic scale with proper measuring range and precision according to the proportion of the friction material raw materials; different raw materials are placed in the material boxes with different marks and recorded, so that the tracing is facilitated.
2) Mixing materials:
a) putting the prepared materials into a plow harrow type mixer, and closing a feed inlet; setting the coulter to run for 25 minutes and the high-speed stirring knife to run for 15 minutes;
b) after the mixing is finished, the mixture is required to be uniform without obvious fiber agglomeration; otherwise, returning to the step a) for processing again.
c) And (3) drying the mixture in an oven at the drying temperature of 80 ℃.
3) Steel backing surface treatment and glue spraying:
and (3) carrying out sand blasting treatment on the steel back, then uniformly spraying resin glue (the weight ratio of the resin to the alcohol is 1:2) on the contact surface of the steel back and the friction material, and naturally airing to prevent impurities such as dust and the like from polluting the glue spraying surface.
4) Hot-press molding:
cleaning an inner cavity of a mold by using compressed air before pressing, preheating the mold on a heating platform, uniformly spraying a water-based release agent in the inner cavity of the mold after preheating to a set temperature, uniformly adding a mixture according to 1.23kg, slightly putting a grinding sub support into the mold, starting a program, starting pressing, performing pressure maintaining-exhausting circulation and pressure maintaining solidification on the pressing until the program is finished, taking out a product, and transferring to the next procedure after the product is qualified.
The pressing adopts a 200T ton four-column hydraulic press, and the pressing parameters are as follows: the pressing temperature is 160 ℃; the pressure of the press is as follows: 5 Mpa; pressure maintaining-exhaust parameters: the pressure maintaining time is 50 seconds, the air exhausting time is 15 seconds, and the pressure maintaining and air exhausting are carried out for 6 times; pressure maintaining and curing time: 1500 seconds.
5) And (3) heat treatment:
placing the pressed and formed grinder in a curing oven rack to ensure smooth flow of hot air and uniform temperature at each position in the oven; operating according to a set heat treatment curve program, wherein parameters of the heat treatment curve program need to meet the curve requirement of the attached figure 1; and (5) after the program operation is finished, naturally cooling to below 50 ℃, opening the furnace door, and taking out the product.
Embodiment 3, grinder for high-speed motor train unit and preparation method thereof
The grinder for the high-speed motor train unit consists of a steel backing and a friction material, wherein the friction material comprises the following raw materials in parts by weight, and the raw materials are shown in Table 3.
TABLE 3 raw materials and weight ratios of friction materials
Serial number Raw materials Weight ratio of
1 Phenolic resin 8％
2 Powdered nitrile rubber 1％
3 Reduced iron powder 78％
4 Vermiculite 0.3％
5 Alumina oxide 2％
6 Steel fiber 9％
7 Aramid fiber 0.7％
8 Zinc stearate 1％
The preparation method of the grinder for the high-speed motor train unit comprises the following steps: the raw materials are weighed, mixed, subjected to steel backing surface treatment, glue spraying, hot press molding and heat treatment according to the weight ratio, and the method comprises the following specific steps:
1) weighing:
accurately weighing the required material quantity by using an electronic scale with proper measuring range and precision according to the proportion of the friction material raw materials; different raw materials are placed in the material boxes with different marks and recorded, so that the tracing is facilitated.
2) Mixing materials:
a) putting the prepared materials into a plow harrow type mixer, and closing a feed inlet; setting the coulter to run for 21 minutes and the high-speed stirring knife to run for 17 minutes;
b) after the mixing is finished, the mixture is required to be uniform without obvious fiber agglomeration; otherwise, returning to the step a) for processing again.
c) And (3) drying the mixture in an oven at the drying temperature of 85 ℃.
3) Steel backing surface treatment and glue spraying:
and (3) carrying out sand blasting treatment on the steel back, then uniformly spraying resin glue (the weight ratio of resin to alcohol is 1: 1.5) on the contact surface of the steel back and the friction material, and naturally airing to prevent impurities such as dust and the like from polluting the glue spraying surface.
4) Hot-press molding:
cleaning an inner cavity of a mold by using compressed air before pressing, preheating the mold on a heating platform, uniformly spraying a water-based release agent in the inner cavity of the mold after preheating to a set temperature, uniformly adding a mixture according to 1.55kg, slightly putting a grinding sub support into the mold, starting a program, starting pressing, performing pressure maintaining-exhausting circulation and pressure maintaining solidification on the pressing until the program is finished, taking out a product, and transferring to the next procedure after the product is qualified.
The pressing adopts a 200T ton four-column hydraulic press, and the pressing parameters are as follows: the pressing temperature is 155 ℃; the pressure of the press is as follows: 4.5 Mpa; pressure maintaining-exhaust parameters: the pressure maintaining time is 45 seconds, the exhaust time is 12.5 seconds, and the pressure maintaining and the exhaust are carried out for 5 times; pressure maintaining and curing time: 1300 seconds.
5) And (3) heat treatment:
placing the pressed and formed grinder in a curing oven rack to ensure smooth flow of hot air and uniform temperature at each position in the oven; operating according to a set heat treatment curve program, wherein parameters of the heat treatment curve program need to meet the curve requirement of the attached figure 1; and (5) after the program operation is finished, naturally cooling to below 50 ℃, opening the furnace door, and taking out the product.
Embodiment 4, grinder for high-speed motor train unit and preparation method thereof
The grinder for the high-speed motor train unit consists of a steel backing and a friction material, wherein the friction material comprises the following raw materials in parts by weight, and the raw materials are shown in Table 4.
TABLE 4 raw materials and weight ratios of friction materials
Serial number Raw materials Weight ratio of
1 Phenolic resin 7％
2 Powdered nitrile rubber 6％
3 Reduced iron powder 61％
4 Petroleum coke 2％
5 Alumina oxide 6％
6 Copper fiber 16％
7 Acicular calcium aluminate 1％
8 Aramid fiber 0.5％
9 Calcium stearate 0.5％
The preparation method of the grinder for the high-speed motor train unit comprises the following steps: the raw materials are weighed, mixed, subjected to steel backing surface treatment, glue spraying, hot press molding and heat treatment according to the weight ratio, and the method comprises the following specific steps:
1) weighing:
accurately weighing the required material quantity by using an electronic scale with proper measuring range and precision according to the proportion of the friction material raw materials; different raw materials are placed in the material boxes with different marks and recorded, so that the tracing is facilitated.
2) Mixing materials:
a) putting the prepared materials into a plow harrow type mixer, and closing a feed inlet; setting the coulter to run for 22 minutes and the high-speed stirring knife to run for 16 minutes;
b) after the mixing is finished, the mixture is required to be uniform without obvious fiber agglomeration; otherwise, returning to the step a) for processing again.
c) And (3) drying the mixture in an oven at the drying temperature of 90 ℃.
3) Steel backing surface treatment and glue spraying:
and (3) carrying out sand blasting treatment on the steel back, then uniformly spraying resin glue (the weight ratio of the resin to the alcohol is 1: 1.6) on the contact surface of the steel back and the friction material, and naturally airing to prevent impurities such as dust from polluting the glue spraying surface.
4) Hot-press molding:
cleaning an inner cavity of a mold by using compressed air before pressing, preheating the mold on a heating platform, uniformly spraying a water-based release agent in the inner cavity of the mold after preheating to a set temperature, uniformly adding a mixture according to 1.26kg, slightly putting a grinding sub support into the mold, starting a program, starting pressing, performing pressure maintaining-exhausting circulation and pressure maintaining solidification on the pressing until the program is finished, taking out a product, and transferring to the next procedure after the product is qualified.
The pressing adopts a 200T ton four-column hydraulic press, and the pressing parameters are as follows: the pressing temperature is 152 ℃; the pressure of the press is as follows: 4.2 Mpa; pressure maintaining-exhaust parameters: the pressure maintaining time is 48 seconds, the air exhausting time is 12 seconds, and the pressure maintaining and air exhausting are carried out for 4 times; pressure maintaining and curing time: 1400 seconds.
5) And (3) heat treatment:
placing the pressed and formed grinder in a curing oven rack to ensure smooth flow of hot air and uniform temperature at each position in the oven; operating according to a set heat treatment curve program, wherein parameters of the heat treatment curve program need to meet the curve requirement of the attached figure 1; and (5) after the program operation is finished, naturally cooling to below 50 ℃, opening the furnace door, and taking out the product.
Embodiment 5, grinder for high-speed motor train unit and preparation method thereof
The grinder for the high-speed motor train unit consists of a steel backing and a friction material, wherein the friction material comprises the following raw materials in parts by weight, and the raw materials are shown in Table 5.
TABLE 5 raw materials and weight ratios of friction materials
Serial number Raw materials Weight ratio of
1 Phenolic resin 9.5％
2 Powdered nitrile rubber 2％
3 Reduced iron powder 63.5％
4 Vermiculite 0.5％
5 Alumina oxide 5％
6 Steel fiber 17％
7 Wollastonite 0.8％
8 Aramid fiber 1.7％
The preparation method of the grinder for the high-speed motor train unit comprises the following steps: the raw materials are weighed, mixed, subjected to steel backing surface treatment, glue spraying, hot press molding and heat treatment according to the weight ratio, and the method comprises the following specific steps:
1) weighing:
accurately weighing the required material quantity by using an electronic scale with proper measuring range and precision according to the proportion of the friction material raw materials; different raw materials are placed in the material boxes with different marks and recorded, so that the tracing is facilitated.
2) Mixing materials:
a) putting the prepared materials into a plow harrow type mixer, and closing a feed inlet; setting the coulter to run for 23 minutes and the high-speed stirring knife to run for 16 minutes;
b) after the mixing is finished, the mixture is required to be uniform without obvious fiber agglomeration; otherwise, returning to the step a) for processing again.
c) And (3) drying the mixture in an oven at the drying temperature of 95 ℃.
3) Steel backing surface treatment and glue spraying:
and (3) carrying out sand blasting treatment on the steel back, then uniformly spraying resin glue (the weight ratio of resin to alcohol is 1: 1.7) on the contact surface of the steel back and the friction material, and naturally airing to prevent impurities such as dust and the like from polluting the glue spraying surface.
4) Hot-press molding:
cleaning an inner cavity of a mold by using compressed air before pressing, preheating the mold on a heating platform, uniformly spraying a water-based release agent in the inner cavity of the mold after preheating to a set temperature, uniformly adding a mixture according to 1.4kg, slightly putting a grinding sub support into the mold, starting a program, starting pressing, performing pressure maintaining-exhausting circulation and pressure maintaining solidification on the pressing until the program is finished, taking out a product, and transferring to the next procedure after the product is qualified.
The pressing adopts a 200T ton four-column hydraulic press, and the pressing parameters are as follows: the pressing temperature is 158 ℃; the pressure of the press is as follows: 4.3 Mpa; pressure maintaining-exhaust parameters: the pressure maintaining time is 42 seconds, the air exhausting time is 14 seconds, and the pressure maintaining and air exhausting are carried out for 5 times; pressure maintaining and curing time: 1250 seconds.
5) And (3) heat treatment:
placing the pressed and formed grinder in a curing oven rack to ensure smooth flow of hot air and uniform temperature at each position in the oven; operating according to a set heat treatment curve program, wherein parameters of the heat treatment curve program need to meet the curve requirement of the attached figure 1; and (5) after the program operation is finished, naturally cooling to below 50 ℃, opening the furnace door, and taking out the product.
Embodiment 6, grinder for high-speed motor train unit and preparation method thereof
The grinder for the high-speed motor train unit consists of a steel backing and a friction material, wherein the friction material comprises the following raw materials in parts by weight, and the raw materials are shown in Table 6.
TABLE 6 raw materials and weight ratios of friction materials
Serial number Raw materials Weight ratio of
1 Phenolic resin 6％
2 Powdered nitrile rubber 2.8％
3 Reduced iron powder 77％
4 Friction powder 0.1％
5 Alumina oxide 2％
6 Copper fiber 12％
7 Aramid fiber 0.1％
The preparation method of the grinder for the high-speed motor train unit comprises the following steps: the raw materials are weighed, mixed, subjected to steel backing surface treatment, glue spraying, hot press molding and heat treatment according to the weight ratio, and the method comprises the following specific steps:
1) weighing:
accurately weighing the required material quantity by using an electronic scale with proper measuring range and precision according to the proportion of the friction material raw materials; different raw materials are placed in the material boxes with different marks and recorded, so that the tracing is facilitated.
2) Mixing materials:
a) putting the prepared materials into a plow harrow type mixer, and closing a feed inlet; setting the coulter to run for 24 minutes, and setting the running time of the high-speed stirring knife to be 15.5 minutes;
b) after the mixing is finished, the mixture is required to be uniform without obvious fiber agglomeration; otherwise, returning to the step a) for processing again.
c) And (3) drying the mixture in an oven at the drying temperature of 92 ℃.
3) Steel backing surface treatment and glue spraying:
and (3) carrying out sand blasting treatment on the steel back, then uniformly spraying resin glue (the weight ratio of the resin to the alcohol is 1: 1.2) on the contact surface of the steel back and the friction material, and naturally airing to prevent impurities such as dust from polluting the glue spraying surface.
4) Hot-press molding:
cleaning an inner cavity of a mold by using compressed air before pressing, preheating the mold on a heating platform, uniformly spraying a water-based release agent in the inner cavity of the mold after preheating to a set temperature, uniformly adding a mixture according to 1.6kg, slightly putting a grinding sub support into the mold, starting a program, starting pressing, performing pressure maintaining-exhausting circulation and pressure maintaining solidification on the pressing until the program is finished, taking out a product, and transferring to the next procedure after the product is qualified.
The pressing adopts a 200T ton four-column hydraulic press, and the pressing parameters are as follows: the pressing temperature is 153 ℃; the pressure of the press is as follows: 4.7 Mpa; pressure maintaining-exhaust parameters: the pressure maintaining time is 46 seconds, the air exhausting time is 11 seconds, and the pressure maintaining and air exhausting are carried out for 6 times; pressure maintaining and curing time: 1405 seconds.
5) And (3) heat treatment:
placing the pressed and formed grinder in a curing oven rack to ensure smooth flow of hot air and uniform temperature at each position in the oven; operating according to a set heat treatment curve program, wherein parameters of the heat treatment curve program need to meet the curve requirement of the attached figure 1; and (5) after the program operation is finished, naturally cooling to below 50 ℃, opening the furnace door, and taking out the product.
Example 7 comparison of the properties of the grinders
The abrasives prepared in examples 1 to 6 of the present invention were subjected to physical mechanical property tests, and each property test was conducted with reference to table 7. The inventors found that the grinders prepared in examples 1 to 6 of the present invention have a hardness of 80 to 88HRR, a compressive strength of 83 to 95MPa, a compressive modulus of 6.1 to 6.8Pa, and an impact strength of 3.4 to 3.8kJ/m2The bonding strength is not less than 15KN, the friction coefficient range is 0.38-0.45, and the abrasion loss range is 1.1-1.5 mm/1000 km.
The mill prepared in inventive examples 1-6 was compared to the mill used for the japanese shinki shanyo co.ltd:
1) the abrasive of the invention has lower hardness, compression strength and compression modulus and has moderate hardness and compression modulus; the grinder can ensure that metal embedding is not easy to generate in the grinding and cleaning processes of the grinder, can effectively shape the wheel, and is completely attached to the tread; the grinding wheel has small damage to the wheel tread, and the grinding wheel has the advantages of difficult generation of hot cracks, no serious wave plow-shaped abrasion, small braking noise and the like.
2) The impact strength of the grinder is higher than that of a Japanese grinder, so that the grinder is impact-resistant in the application process and is not easy to crack and fall.
3) Under the action of a shearing force not exceeding 15kN, the steel back and the friction material are not peeled off, the bonding strength is higher than that of the Japanese grinder, and the harsh working condition can be met.
The friction performance test of the grinder is carried out by using an XDM-2 constant-speed friction tester, and the test result shows that: compared with the grinding wheel of a Japan new mainline, the grinding wheel has stable friction coefficient, high thermal stability, small friction noise, difficult generation of the problems of crack falling block, metal inlay and the like, and no abnormal abrasion on the friction dual surface under the same experimental condition.
TABLE 7 comparative experimental standards for performance of grinders
Figure BDA0001651595550000181
Figure BDA0001651595550000191
The test data show that the friction performance and the physical and mechanical properties of the abrasive of the invention reach or exceed those of Japanese abrasive.
The impact strength of the grinder prepared by the method is improved by at least 30%, the hardness of the grinder is reduced by at least 10HRR, the compression modulus is reduced by at least 0.7GPa, and the braking noise is reduced by at least 90%.
Compared with the grinder prepared by the Chinese patent CN 103693020A, the impact strength of the grinder prepared by the invention is improved by at least 40 percent; under the same experimental conditions, the performance test shown in the table 7 is carried out, and the grinding particle prepared by the invention does not generate cracks and chipping phenomena; the millstone prepared by the method of CN 103693020A has obvious problems of cracks and chipping.
In the invention, through long-term research, the inventors find that the invention provides a grinder for high-speed motor train units, which is composed of a steel backing and a friction material, wherein the friction material comprises the following raw materials in a weight ratio as shown in table 8.
TABLE 8 raw materials and weight ratios of friction materials
Serial number Raw materials Weight ratio of
1 Phenolic resin 6％～10％
2 Powdered nitrile rubber ≤6％
3 Reduced iron powder 52％～78％
4 Noise reducing agent 0.1％～5％
5 Alumina oxide 2％～7％
6 Metal fiber 9％～17％
7 Mineral fiber ≤4％
8 Organic fiber 0.1％～4％
9 Internal mold release agent ≤1％
In the invention, the inventor further researches and discovers that the invention provides the grinder for the high-speed motor train unit, wherein the grinder consists of a steel backing and a friction material, and the friction material meets the following requirements, as shown in table 9.
TABLE 9 raw materials and specifications for Friction Material
Serial number Raw materials Weight ratio of Preferably the weight ratio Preferred technical requirements
1 Phenolic resin 6％～10％ 9％ Fluidity: 25-40 mm, polymerization speed: 40 to 65s
2 Powdered nitrile rubber ≤6％ 5％ Nanoscale
3 Reduced iron powder 52％～78％ 56％ All pass through 100 meshes
4 Noise reducing agent 0.1％～5％ 3％ Light loose structure and high porosity
5 Alumina oxide 2％～7％ 5％ Al2O3The content is as follows: 60 to 80 percent of the total weight of the powder, and more than 325 meshes
6 Metal fiber 9％～17％ 14％ Metal fibre containing copper and iron
7 Mineral fiber ≤4％ 4％ The length-diameter ratio is 20-30, and the length is 30-40 um
8 Organic fiber 0.1％～4％ 3％ High temperature resistance is more than or equal to 500 DEG C
9 Internal mold release agent ≤1％ 1％ Melting point: less than 140 DEG C
Total of 100％
In the invention, the inventor further researches to find that in a preferable weight ratio, the content of the powdered nitrile rubber is not more than 5%; in the preferable weight ratio, the content of the noise reducer is 3-5%; in a preferred weight ratio, the content of the organic fiber is not more than 3%.
The inventor finds that compared with other phenolic resins, when the fluidity of the phenolic resin is 25-40 mm and the polymerization rate is 40-65 s, the impact strength of the prepared milling particle is improved by at least 25%; the heat fading resistance is obviously improved, and the improvement amplitude is at least 40 percent; the hardness is also obviously improved; the friction noise is reduced by at least 20%; after the modified phenolic resin with the performance is used, the problems of crack and block falling of the prepared grinding particles, high elastic modulus, large abrasion, heat crack and large friction noise are solved; the wheel has good fitting performance with the wheel tread and good wheel repairing effect; the phenolic resin is preferably cashew nut shell oil modified phenolic resin. The content of the phenolic resin also has great influence on the friction performance of the grinder, the content is too low, the friction materials cannot be well adhered together, the friction coefficient of a product is low, the materials are easy to fall off, and the abrasion is increased; the content is too high, the compression modulus of the product is too high, the wheel tread can be locally overheated to form hot cracking spots, further hot cracking is generated, and friction noise is easy to generate; the invention is optimized, the consumption of the phenolic resin is 9%, the compression modulus of the obtained product is moderate, the product can be completely attached to the tread, the hot crack is not easy to generate, the friction noise is small, and the wheel repairing effect is good.
In the invention, the inventor finds that the powder nitrile rubber is prepared by pretreating nitrile latex through spray drying and the like, is convenient to use and can be better mixed with powder phenolic resin, reinforcing fibers and fillers; the rubber content has great influence on the performance of the grinder, and the content is too low, so that the material is easy to fall off and the abrasion is increased; the content is too high, the hardness of the prepared grinder is too low, metal embedding is easy to occur, the problem of wheel locking is easy to occur, and the potential safety hazard of driving is caused; according to the invention, through optimization, the using amount of the powdered nitrile rubber is 5%, the prepared grinding body has moderate compression modulus, high impact strength, low possibility of crack falling and metal embedding, complete fitting with a tread and low braking noise.
In the invention, the inventor finds that when the powdered nitrile rubber is in a nanometer level, the friction material of the prepared abrasive is uniformly distributed, and various physical and mechanical properties and friction properties are obviously improved: the inventor finds that compared with non-nanoscale powder nitrile rubber, the nanoscale powder nitrile rubber is adopted to prepare the grinding particle, the friction coefficient stability is improved by two times, the thermal stability is improved by 1.5 times, the friction noise is reduced by 20%, cracks, blocks and metal inlays are not easy to generate, and the friction dual surface has no abnormal abrasion.
In the invention, the inventor finds that the raw materials of the friction material comprise reduced iron powder; when the grinder is in contact friction with the wheel, the reduced iron powder and the oxidized particles are adhered to the surface of the wheel, so that the adhesive force of the wheel is improved, and the aim of thickening is fulfilled; meanwhile, the iron powder is beneficial to improving the heat conductivity of the product, reducing the temperature of the friction surface and improving the friction stability; by using the reduced iron powder in the range, the prepared grinder has good shape modification, has small loss to the wheel, protects the wheel from deforming, and can achieve a balance between shape modification and loss; specifically, the prepared grinder balances between wheel cleaning and wheel abrasion by selecting different iron powder contents according to the material of the wheel, the speed of a vehicle and the ambient temperature; the invention preferably reduces Fe in iron powder3O4The content of (A) is more than 91%; the invention preferably uses 56% of reduced iron powder.
In the invention, the inventor finds out through long-term research that: compared with other reduced iron powder, when the mesh number of the reduced iron powder is more than or equal to 100 meshes, the prepared grinder has the following remarkable improvement in heat dissipation, tackifying and wheel repairing performances: the heat dissipation performance is improved by at least 35%, the tackifying performance is improved by at least 43%, and the wheel repairing performance is improved by at least 52%.
In the invention, the inventor finds that the raw materials of the friction material comprise the noise reduction filler, and the noise reduction filler is light and loose, has high porosity and low hardness; the inventor researches and finds that the noise reduction filler can adjust the hardness and the sound absorption coefficient of the grinding mill, so that the friction couple can be protected, the generation of noise is inhibited or reduced, and the noise is reduced by at least 70%; the filler is light and loose, cannot be completely mixed with the adhesive due to excessive use amount, and is easy to cause product defects; the invention preferably uses 3% of filler.
In the present invention, the inventors have found through long-term studies that the raw material of the friction material includes alumina; the inventor researches and finds that the aluminum oxide can adjust and improve the friction coefficient of the grinder, enhance the tackifying effect of the grinder and better correct the wheel; however, the amount and particle size of alumina need to be strictly controlled, otherwise the negative effects are significantly increased; the preferred amount of alumina used in the present invention is 5%.
In the present invention, the inventors have found, through long-term research, that Al in alumina is present when compared with other types of alumina2O360 to 80 percent of Al2O3When the mesh number is not less than 325 meshes, the friction coefficient stability of the prepared grinder is improved by at least 30%, and the tackifying effect is improved by two times.
In the invention, the inventor finds that the metal fiber is one or more selected from metal fibers containing copper or iron, and the like, so that the requirements of the prepared grinding son on high strength, high elastic modulus, good thermal stability, good adsorbability, fatigue resistance, abrasion resistance and the like are met, and the problems of metal inlaying, wheel tread thermal cracking and the like of the prepared grinding son are solved.
In the invention, the inventor has found through long-term research that the mineral fiber uses the mineral fiber surface-treated by silane coupling agent; after the grinding roller is used, the vibration reduction, anti-skidding, noise reduction, wear resistance and heat resistance of the grinding roller are high in performance, the friction performance is stable, the heat fading and heat recovery performance is good, and the high-temperature friction and wear performance is excellent; the raw materials are rich in source and low in price, so that the consumption of high-price fibers such as metal fibers and the like can be reduced, and the cost of the friction material is greatly reduced; preferably, the mineral fiber is present in an amount of 4%.
In the invention, the inventor finds that compared with other types of mineral fibers, the length-diameter ratio of the mineral fibers is 20-30, and the length of the mineral fibers is 30-40 μm; the prepared mill base has the advantages that the impact strength is improved by at least 50%, and the heat resistance is improved by 80%.
In the invention, the inventor finds that the raw material of the friction material comprises organic fiber; the organic fiber has the advantages of high strength, high elastic modulus, good thermal stability and the like of common engineering fiber, and also has good adsorptivity, fatigue resistance and abrasion resistance, the friction material reinforced by the organic fiber has the advantages of low friction noise, no damage to dual and the like, and the effect of eliminating metal inlay and hot cracks on the wheel tread is obvious; according to the invention, the organic fiber is preferably used in an amount of 3%.
In the invention, the inventor finds that compared with other types of organic fibers, when the organic fibers resist high temperature of more than or equal to 500 ℃, the thermal stability of the whole prepared milling body is improved by at least 70 percent.
In the invention, the inventor finds that the raw materials of the friction material comprise an internal release agent; the melting point of the internal release agent is lower than the pressing temperature and is incompatible with the solidified resin, and after heating, the release agent escapes from the inside to the interface between the friction material and the mold, is melted and forms a layer of organic film to prevent adhesion, so that the effect of facilitating demolding is achieved, and the surface of a product is smooth and attractive; according to the invention, the preferable dosage of the internal release agent is 1%; when the melting point of the selected internal release agent is less than 140 ℃, the release is easy, and the surface of the product is glossy and beautiful.
In the invention, the inventor finds that compared with other types of internal release agents, the selected internal release agent has a melting point of less than 140 ℃, is easy to release, and has a glossy and attractive product surface.
In conclusion, the invention provides the grinder for the high-speed motor train unit and the preparation method thereof, the grinder prepared according to the raw materials and the preparation method overcomes the defects of the domestic grinder, the prepared grinder is not easy to generate metal inlaying, cracks and chipping, the friction noise is low, the wheel shaping performance is good, and the problems of hot cracks, serious wave plow-shaped abrasion and the like are not easy to generate.
The foregoing is merely a preferred embodiment of the invention and is not intended to limit the scope of the invention, which is defined by the claims appended hereto, and any other technical entity or method that is encompassed by the claims as broadly defined herein, or equivalent variations thereof, is contemplated as being encompassed by the claims.
All documents referred to herein are incorporated by reference into this application as if each were individually incorporated by reference. Furthermore, it should be understood that various changes and modifications can be made by those skilled in the art after reading the above disclosure, and equivalents also fall within the scope of the invention as defined by the appended claims.

Claims (8)

1. The grinder for the high-speed motor train unit is characterized by comprising the following components in parts by weight: 6 to 10 percent of phenolic resin, less than or equal to 6 percent of powdered nitrile rubber, 52 to 78 percent of reduced iron powder, 0.1 to 5 percent of noise reducer, 2 to 7 percent of alumina, 9 to 17 percent of metal fiber, less than or equal to 4 percent of mineral fiber, 0.1 to 4 percent of organic fiber and less than or equal to 1 percent of internal mold release agent;
wherein the fluidity of the phenolic resin is 25-40 mm, and the polymerization speed is 40-65 s;
wherein the phenolic resin is cashew nut shell oil modified phenolic resin;
wherein the organic fiber needs to resist high temperature more than or equal to 500 ℃;
wherein the grinder consists of a steel back and a friction material; the preparation method comprises the following steps: (1) pretreating the friction material and the steel backing; (2) carrying out hot press molding and heat treatment on the friction material and the steel backing pretreated in the step (1);
wherein the friction material is pretreated by mixing and drying, and the drying temperature is 85 +/-10 ℃; wherein, the pretreatment of the steel backing comprises the following steps: carrying out sand blasting on the steel back, then uniformly spraying resin glue on the contact surface of the steel back, wherein the weight ratio of the resin glue to the alcohol is 1: 1-1: 2, and naturally drying; the steel back contact surface is the contact surface of the steel back and the friction material; wherein the hot press molding parameters are as follows: the pressing temperature is 150-160 ℃, and the pressing pressure is 4-5 Mpa; the dwell-vent parameters for pressing were: the pressure maintaining time is 40-50 s, the exhausting time is 10-15 s, and the pressure maintaining and exhausting are carried out for 4-6 times; pressure maintaining and curing time: 1200-1500 s;
wherein the heat treatment parameters are set as: heating to 100 ℃ within 2 hours, and keeping the temperature for 1 hour; heating to 120 ℃ within 1 hour, and keeping the temperature for 1 hour; heating to 140 ℃ within 2 hours, and keeping the temperature for 1 hour; the temperature is raised to 180 ℃ within 2 hours, and the temperature is kept constant for 3 hours.
2. The grinder for high-speed motor train units according to claim 1, wherein the powdered nitrile rubber is nano-sized powdered nitrile rubber.
3. The grinder for high-speed motor train units according to claim 1, wherein the fine reduced iron powder has a fineness of not less than 100 meshes.
4. The grinder for high-speed motor train units as claimed in claim 1, wherein the fineness of the alumina is not less than 325 meshes.
5. The grinder for high-speed motor train units as claimed in claim 1, wherein the mineral fibers have an aspect ratio of 20 to 30 and a length of 30 to 40 μm.
6. The grinder for high-speed motor train units according to claim 1, wherein the melting point of the internal mold release agent is less than 140 ℃.
7. The method of any of claims 1 to 6, wherein the grinder is composed of a steel backing and a friction material; the preparation method comprises the following steps: (1) pretreating the friction material and the steel backing; (2) carrying out hot press molding and heat treatment on the friction material and the steel backing pretreated in the step (1); wherein the friction material is pretreated by mixing and drying, and the drying temperature is 85 +/-10 ℃; wherein, the pretreatment of the steel backing comprises the following steps: carrying out sand blasting on the steel back, then uniformly spraying resin glue on the contact surface of the steel back, wherein the weight ratio of the resin glue to the alcohol is 1: 1-1: 2, and naturally drying; the steel back contact surface is the contact surface of the steel back and the friction material; wherein the hot press molding parameters are as follows: the pressing temperature is 150-160 ℃, and the pressing pressure is 4-5 Mpa; the dwell-vent parameters for pressing were: the pressure maintaining time is 40-50 s, the exhausting time is 10-15 s, and the pressure maintaining and exhausting are carried out for 4-6 times; pressure maintaining and curing time: 1200-1500 s.
8. The production method according to claim 7, wherein the heat treatment parameters are set to: heating to 100 ℃ within 2 hours, and keeping the temperature for 1 hour; heating to 120 ℃ within 1 hour, and keeping the temperature for 1 hour; heating to 140 ℃ within 2 hours, and keeping the temperature for 1 hour; the temperature is raised to 180 ℃ within 2 hours, and the temperature is kept constant for 3 hours.
CN201810424313.8A 2018-05-07 2018-05-07 Grinder for high-speed motor train unit and preparation method thereof Expired - Fee Related CN108839640B (en)

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