CN108972390B - Grinding wheel special for steel rail grinding train and preparation method thereof - Google Patents
Grinding wheel special for steel rail grinding train and preparation method thereof Download PDFInfo
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- CN108972390B CN108972390B CN201811085549.XA CN201811085549A CN108972390B CN 108972390 B CN108972390 B CN 108972390B CN 201811085549 A CN201811085549 A CN 201811085549A CN 108972390 B CN108972390 B CN 108972390B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
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- B24D18/0009—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
Abstract
The invention discloses a grinding wheel special for a steel rail grinding train and a preparation method thereof, and particularly relates to the technical field of grinding wheel manufacturing. The invention relates to a special grinding wheel for a rail grinding train, which comprises: the modified corundum-zirconia composite material comprises, by weight, 25-35 parts of modified corundum-zirconia, 35-55 parts of modified brown corundum, 9-15 parts of mixed resin, 3-5 parts of alumina hollow spheres, 1.5-8 parts of pyrite powder, 1-6 parts of cryolite powder, 0.5-5 parts of barium sulfate powder, 0.5-4 parts of calcium carbonate powder, 0.5-4 parts of graphite powder, 3-6 parts of copper powder and 1-8 parts of fiber reinforcement material; the modified zirconia corundum and the modified brown corundum are obtained by soaking and drying 3-10 wt% KH550 alcohol solution. The high-speed steel rail grinding wheel manufactured by the invention has high strength, good toughness, good self-sharpening performance and strong grinding capacity; in the polishing process, the blockage is not easy to occur; the steel rail is not easy to burn in the polishing process; the steel rail has better surface quality after being polished by the grinding wheel.
Description
Technical Field
The invention relates to the technical field of grinding wheel manufacturing, in particular to a special grinding wheel for a steel rail grinding train and a preparation method thereof.
Background
Railway transportation is a national important infrastructure and the aorta for national economy. As one of the key components of a railway system, a rail bears the dynamic action and the natural environment action of a train for a long time, and the phenomena of abrasion, damage, fatigue and the like of a rail head are caused. These diseases will affect the function of the railway transportation system, leading to a reduction in the life of the rail and an increase in maintenance workload and cost, and even directly affect the life of the rail system and vehicle safety and stability. At present, the main measure for maintaining the railway steel rail in the world is to polish the steel rail by adopting a steel rail polishing train. In the steel rail grinding technology, high-speed grinding of the steel rail is a novel grinding mode developed abroad in recent years, and the grinding operation speed can reach 60-80 Km/h. Compared with the traditional active grinding mode of the steel rail, the high-speed passive grinding technology has obvious advantages in the aspects of surface quality of the ground steel rail, prolonging service life of the steel rail, flexibility of operation time and the like, and has great application market prospect in a railway network system rapidly developed in the future world. However, the prior high-speed grinding wagon technology is mastered by a few countries and is still in the early development stage, and China is still in the exploration stage in the field.
The high-speed grinding wheel is used as a tooth of the high-speed rail grinding vehicle, and the mechanical strength, the self-sharpening property and the like of the high-speed rail grinding wheel directly influence the operating efficiency of the grinding vehicle and the grinding quality of the surface of the rail. The traditional active grinding of the steel rail is to grind by using the end face of a grinding wheel; the rail high-speed grinding is to attach the circumferential surface of the grinding wheel to the rail head of the rail at a certain grinding pressure and form a certain angle with the rail, and the grinding wheel does non-pure rolling motion on the rail when a grinding train runs at a high speed, so that the aim of grinding the rail is fulfilled. Compare with traditional rail initiative mode of polishing, the area of contact of high-speed passive form rail emery wheel of polishing and rail is littleer, and the car of polishing travel speed is bigger, and the contact time of emery wheel and rail is shorter, so the special emery wheel of high-speed passive form rail train of polishing just need possess higher mechanical strength, toughness, better grinding ability and better self-sharpening nature. At present, 90% of special grinding wheels for rail grinding trains are imported from foreign countries, and the market share of the domestic grinding wheels is less than 10%. And the special grinding wheel for the domestic steel rail grinding train has the problems of poor self-sharpening property, weak grinding capability and easiness in rail burning.
Disclosure of Invention
The invention aims to solve the problems of poor self-sharpening performance, weak grinding capacity and easiness in rail burning of the conventional domestic special grinding wheel for the rail grinding train, and provides the special grinding wheel for the rail grinding train, which has the advantages of high strength, good self-sharpening performance, strong grinding capacity, high cutting efficiency and difficulty in rail burning in the grinding process, and the preparation method thereof.
The technical scheme for solving the technical problems is as follows:
a special grinding wheel for a steel rail grinding train comprises: 25-35 parts of modified zirconia corundum, 35-55 parts of modified brown corundum, 9-15 parts of mixed resin, 3-5 parts of alumina hollow spheres, 1.5-8 parts of pyrite powder, 1-6 parts of cryolite powder, 0.5-5 parts of barium sulfate powder, 0.5-4 parts of calcium carbonate powder, 0.5-4 parts of graphite powder, 3-6 parts of copper powder and 1-8 parts of fiber reinforcement material; the modified zirconia corundum and the modified brown corundum are obtained by soaking in 3-10 wt% KH550 alcohol solution and drying.
The invention adopts modified zirconia corundum and modified brown corundum, which are obtained by respectively cleaning and drying the zirconia corundum and the brown corundum, then placing the cleaned and dried zirconia corundum and brown corundum into KH550 alcoholic solution with the weight percentage of 3-10% for soaking for 0.5-2h, and then taking out and drying the soaked corundum. KH550 contains two different active groups, amino and oxy, and can be coupled with organic polymer and inorganic filler, so that its adhesive property is raised, and its mechanical property, water-proofing property and ageing resistance can be raised. By uniformly coating a layer of KH550 with moderate thickness on the surfaces of the zirconia corundum and the brown corundum, the modified zirconia corundum and the brown corundum are organically functionalized, so that the infiltration capacity of resin liquid to the grinding materials can be improved, the bonding strength of the resin and the grinding materials is improved, and the overall strength of the grinding wheel is further improved.
Because the grinding wheel keeps a certain pressure in the hot pressing process, air holes generated by the traditional foaming agent (such as carbonate, nitrite, azo compound and the like) can be closed again by pressing, so that the problems of poor hole forming effect and the like are caused. Therefore, the aluminum oxide hollow ball is added, so that a hole is formed when the aluminum oxide hollow ball is ground and crushed, and the hole can contain part of abrasive dust, thereby reducing the blockage of the abrasive dust at the position of a grinding wheel bearing and being beneficial to heat dissipation of a grinding area of a grinding wheel. In addition, due to the addition of the alumina hollow spheres, the porosity of the grinding wheel can be greatly increased while the mechanical strength of the grinding wheel is not greatly lost, so that the alumina hollow spheres are broken during grinding of the grinding wheel, abrasive particles are exposed, and the self-sharpening performance of the grinding wheel is improved.
The added cryolite is melted under the action of abrasive dust heat in the grinding process, so that abrasive particles are exposed, and the self-sharpening property of the grinding wheel is improved; and the heat of the grinding area is taken away in the process of melting the cryolite, so that the grinding temperature is reduced, and the wear resistance of the grinding wheel is improved. The added copper powder improves the strength of the grinding wheel and simultaneously increases the thermal conductivity of the grinding wheel. Graphite is added to form a lamellar structure, so that the graphite is a good solid lubricant, and the heat generated by friction in the grinding process can be reduced. The addition of the fiber reinforced material effectively increases the bonding strength of the grinding wheel and reduces the breakage of the grinding wheel, such as breakage, edge breakage and the like in the use process.
Further, in a preferred embodiment of the present invention, the grinding wheel dedicated for rail grinding trains includes: the composite material comprises, by weight, 25-35 parts of modified zirconia corundum, 43-55 parts of modified brown corundum, 9-15 parts of mixed resin, 3-5 parts of alumina hollow spheres, 3-6 parts of pyrite powder, 1-3 parts of cryolite powder, 1-3 parts of barium sulfate powder, 1-3 parts of calcium carbonate powder, 0.5-3 parts of graphite powder, 3-5 parts of copper powder and 1-5 parts of fiber reinforcement material; the modified zirconia corundum and the modified brown corundum are obtained by soaking in 3-10 wt% KH550 alcohol solution and drying.
Further, in a preferred embodiment of the present invention, the grinding wheel dedicated for rail grinding trains includes: according to the weight parts, 30 parts of modified zirconia corundum, 45 parts of modified brown corundum, 12 parts of mixed resin, 5 parts of alumina hollow spheres, 5 parts of pyrite powder, 2 parts of cryolite powder, 2 parts of barium sulfate powder, 2 parts of calcium carbonate powder, 2 parts of graphite powder, 3 parts of copper powder and 2 parts of fiber reinforced material; the modified zirconia corundum and the modified brown corundum are obtained by soaking in 3-10 wt% KH550 alcohol solution and drying.
Further, in a preferred embodiment of the present invention, the mixed resin includes a powder resin and a liquid resin, and the weight portion ratio of the liquid resin to the powder resin is 1.5 to 2.0, wherein the resin is at least one of phenolic resin powder, polyimide resin powder and organic silicon modified phenolic resin, and the particle size of the powder resin is less than 100 meshes; the liquid resin is epoxy resin liquid or water-soluble phenolic resin liquid. The powdery resin of the present invention is a undersize obtained by sieving a 100-mesh sieve.
Further, in a preferred embodiment of the present invention, the fiber reinforcement material is one of glass fiber, carbon fiber and basalt fiber. In the present invention, the fibrous reinforcement is preferably glass fibers.
Further, in a preferred embodiment of the present invention, the above pyrite powder has a particle size of less than 60 mesh, and the cryolite powder, barium sulfate powder, calcium carbonate powder, graphite powder, copper powder and fibrous reinforcement material have a particle size of less than 100 mesh.
The granularity of the added pyrite powder is less than 60 meshes, and the granularity of the added pyrite powder is between that of the grinding material and the filler micro powder, so that the grinding wheel can be reinforced; the granularity of other powder fillers is less than 100 meshes, so that the filler is favorably wetted by resin, and the strength of the grinding wheel is improved.
The pyrite powder is undersize obtained after being sieved by a 60-mesh sieve, and the cryolite powder, the barium sulfate powder, the calcium carbonate powder, the graphite powder, the copper powder and the fiber reinforcement material are undersize obtained after being sieved by a 100-mesh sieve.
Further, in a preferred embodiment of the present invention, the particle sizes of the modified zirconia corundum and the modified brown corundum are 14 to 16 meshes, and the diameter of the alumina hollow sphere is 0.5 to 1.5 mm.
The granularity of the modified zirconia corundum and the modified brown corundum is 14-16 meshes, so that the grinding capacity and the grinding efficiency of the grinding wheel can be improved, and the polished steel rail has better surface quality. The diameter of the alumina hollow sphere is 0.5-1.5 mm, and the expected pore-forming effect cannot be achieved due to the fact that the diameter of the hollow sphere is too small; the too big diameter of clean shot has then greatly weakened the intensity of emery wheel. The granularity of the modified zirconia corundum and the granularity of the modified brown corundum are both preferably 16 meshes, and the diameter of the alumina hollow sphere is preferably 1 mm.
The preparation method of the special grinding wheel for the steel rail grinding train comprises the following steps:
(1) mixing material
(11) Grinding and mixing the pyrite powder, the cryolite powder, the barium sulfate powder, the calcium carbonate powder, the graphite powder, the copper powder and the fiber reinforcement material at a ball-to-material ratio of 1:1 and a rotating speed of 380-420 r/min to obtain a filler;
(12) uniformly mixing the modified zirconia corundum with the modified brown corundum to obtain an abrasive, adding liquid resin, and fully stirring until the resin liquid fully soaks the abrasive; adding the alumina hollow spheres, fully stirring, slowly adding the filler obtained in the step (11), and continuously stirring until the materials are uniformly mixed; finally, slowly adding the powdery resin, and fully stirring and uniformly mixing to obtain a molding material;
(2) hot pressing and curing
Putting the molding material into a mold, carrying out hot press molding to obtain a grinding wheel, and then putting the grinding wheel into an oven for curing and sintering, wherein the curing and sintering process comprises the following steps:
a first curing stage: keeping the temperature for 2 hours at 50-60 ℃;
and (3) a second curing stage: preserving the heat for 2-3 h at 80-90 ℃;
and a third curing stage: preserving the heat for 4-5 h at the temperature of 120-130 ℃;
and a fourth curing stage: keeping the temperature at 170-180 ℃ for 4-6 h;
a fifth curing stage: and uniformly and slowly cooling to room temperature for 3-4 h.
According to the invention, the adding sequence of the mixed materials in the step 1 is that the abrasive, the liquid resin, the alumina hollow sphere, the filler and the powdered resin are sequentially, wherein the filler is added in the step 12 and then is uniformly stirred until the surface of each abrasive and the surface of the hollow sphere are uniformly coated with a layer of the filler, and the powdered resin is added in the step 13 and is uniformly stirred until the surface of each abrasive particle is uniformly coated with a layer of resin powder.
In the step 2 of the invention, the temperature of the first curing stage in the curing and sintering process is 50-60 ℃, and the stage is mainly to further dry the grinding wheel, so that the moisture in all raw materials is ensured to be the lowest, the moisture in the raw materials is prevented from volatilizing and escaping in the hot pressing and curing and sintering processes of the grinding wheel, and the strength of the grinding wheel is reduced. The temperature of the second curing stage is 80-90 ℃, and the powdered resin starts to melt at the stage, so that the viscosity among the resins can be adjusted, and the melted resin can conveniently infiltrate and coat the abrasive and the filler; the temperature of the third curing stage is 120-130 ℃, the stage is the beginning of the crosslinking reaction, the resin begins to cure and is insulated, so that small molecules such as water and the like can be discharged gradually in the reaction process; the temperature of the fourth curing stage is 170-180 ℃, and the resin is fully cured at the stage.
Further, in a preferred embodiment of the present invention, the reaction conditions of the hot press molding in the step 2 are as follows: the initial temperature of the die is 55-65 ℃, the final temperature is 150-160 ℃, the pressing pressure per unit area of the grinding wheel is 10-15 MPa, the pressure is released and the air is released for 5-8 times, the pressure is released for 1-3min for one time, and the hot pressing is 30-40 min.
In the step 3 of the invention, the initial temperature of the die is 55-65 ℃ in the hot press molding process, so that the molding materials are uniformly distributed as much as possible in the sintering process, and the uneven density of the grinding wheel after less sintering is avoided.
Further, in a preferred embodiment of the present invention, the curing and sintering process includes: a first curing stage: keeping the temperature at 50 ℃ for 2 h; and (3) a second curing stage: preserving the heat for 2 hours at the temperature of 80-90 ℃; and a third curing stage: preserving the heat for 4 hours at the temperature of 120-130 ℃; and a fourth curing stage: keeping the temperature at 170-180 ℃ for 4-5 h; a fifth curing stage: uniformly and slowly cooling to room temperature for 3 h.
The invention has the following beneficial effects:
the high-speed steel rail grinding wheel manufactured by the invention has high strength, good toughness, good self-sharpening performance and strong grinding capacity; in the polishing process, the blockage is not easy to occur; the steel rail is not easy to burn in the polishing process; the steel rail has better surface quality after being polished by the grinding wheel.
Drawings
FIG. 1 is a stereomicroscope photograph of the surface of a grinding wheel in example 2 of the present invention;
FIG. 2 is a stereomicroscope image of the surface of a rail after grinding by the grinding wheel in example 2 of the present invention;
FIG. 3 is a three-dimensional topography and roughness map of the rail surface after grinding by the grinding wheel in embodiment 2 of the invention.
Detailed Description
The principles and features of this invention are described below in conjunction with embodiments, which are included to explain the invention and not to limit the scope of the invention. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products available commercially.
The modified zirconia corundum and the modified brown corundum in the invention are obtained by washing and drying the zirconia corundum and the modified brown corundum, then placing the washed and dried zirconia corundum and brown corundum into 8 wt% KH550 alcoholic solution, soaking for 1.5h and then drying.
Example 1:
the special emery wheel of rail grinding train of this embodiment includes: the composite material comprises, by weight, 25 parts of modified zirconia corundum, 55 parts of modified brown corundum, 9 parts of mixed resin, 3 parts of alumina hollow spheres, 1.5 parts of pyrite powder, 1 part of cryolite powder, 0.5 part of barium sulfate powder, 0.5 part of calcium carbonate powder, 0.5 part of graphite powder, 6 parts of copper powder and 8 parts of fiber reinforcement material.
Wherein the mixed resin comprises 6 parts of polyimide resin powder and 3 parts of epoxy resin liquid.
The preparation method of the grinding wheel special for the steel rail grinding train comprises the following steps:
(1) mixing material
(11) Grinding and mixing the pyrite powder, the cryolite powder, the barium sulfate powder, the calcium carbonate powder, the graphite powder, the copper powder and the fiber reinforced material at a ball-to-material ratio of 1:1 and a rotating speed of 380r/min to obtain a filler;
(12) uniformly mixing the modified zirconia corundum and the modified brown corundum to obtain an abrasive, adding liquid resin, fully stirring until the abrasive is fully infiltrated by the resin liquid, adding the alumina hollow spheres, fully stirring, slowly adding the filler in the step 11, and continuously stirring until the filler is uniformly mixed; finally, slowly adding the powdery resin, and fully stirring and uniformly mixing to obtain a molding material;
(2) hot press forming
Putting the molding material into a mold, wherein the reaction conditions of hot press molding are as follows: the initial temperature of the die is 55 ℃, the final temperature is 150 ℃, the pressing pressure per unit area of the grinding wheel is 10MPa, the pressure is released and deflated for 5 times, the pressure is released for 1min in one time, and the hot pressing is carried out for 30 min; obtaining the grinding wheel after hot press molding, and then placing the grinding wheel in an oven for curing and sintering, wherein the curing and sintering process comprises the following steps:
a first curing stage: keeping the temperature at 50 ℃ for 2 h;
and (3) a second curing stage: keeping the temperature at 80 ℃ for 2 h;
and a third curing stage: preserving heat for 4 hours at 120 ℃;
and a fourth curing stage: keeping the temperature at 170 ℃ for 6 h;
a fifth curing stage: uniformly and slowly cooling to room temperature for 3 h.
Example 2:
the special emery wheel of rail grinding train of this embodiment includes: the composite material comprises, by weight, 30 parts of modified zirconia corundum, 45 parts of modified brown corundum, 12 parts of mixed resin, 5 parts of alumina hollow spheres, 5 parts of pyrite powder, 2 parts of cryolite powder, 2 parts of barium sulfate powder, 2 parts of calcium carbonate powder, 2 parts of graphite powder, 3 parts of copper powder and 2 parts of fiber reinforcement material.
Wherein the mixed resin comprises 8 parts of phenolic resin powder and 4 parts of water-soluble phenolic resin liquid.
The preparation method of the grinding wheel special for the steel rail grinding train comprises the following steps:
(1) mixing material
(11) Grinding and mixing the pyrite powder, the cryolite powder, the barium sulfate powder, the calcium carbonate powder, the graphite powder, the copper powder and the fiber reinforced material at a ball-to-material ratio of 1:1 and a rotating speed of 400r/min to obtain a filler;
(12) uniformly mixing the modified zirconia corundum with the modified brown corundum to obtain an abrasive, adding liquid resin, and fully stirring until the resin liquid fully soaks the abrasive; adding the alumina hollow spheres, fully stirring, slowly adding the filler obtained in the step (11), and continuously stirring until the materials are uniformly mixed; finally, slowly adding the powdery resin, and fully stirring and uniformly mixing to obtain a molding material;
(2) hot press forming
Putting the molding material into a mold, wherein the reaction conditions of hot press molding are as follows: the initial temperature of the die is 60 ℃, the final temperature is 155 ℃, the pressing pressure per unit area of the grinding wheel is 12MPa, the pressure is released and deflated for 7 times, the pressure is released for 2min in one time, and the hot pressing is carried out for 35 min; obtaining the grinding wheel after hot press molding, and then placing the grinding wheel in an oven for curing and sintering, wherein the curing and sintering process comprises the following steps:
a first curing stage: keeping the temperature at 50 ℃ for 2 h;
and (3) a second curing stage: keeping the temperature at 80 ℃ for 2 h;
and a third curing stage: preserving heat for 4 hours at 120 ℃;
and a fourth curing stage: keeping the temperature at 180 ℃ for 4 h;
a fifth curing stage: uniformly and slowly cooling to room temperature for 3 h.
Example 3:
the special emery wheel of rail grinding train of this embodiment includes: the composite material comprises, by weight, 30 parts of modified zirconia corundum, 35 parts of modified brown corundum, 9 parts of mixed resin, 3 parts of alumina hollow spheres, 8 parts of pyrite powder, 6 parts of cryolite powder, 3 parts of barium sulfate powder, 4 parts of calcium carbonate powder, 3 parts of graphite powder, 5 parts of copper powder and 4 parts of fiber reinforcement material.
Wherein the mixed resin comprises 5.5 parts of polyimide resin powder and 3.5 parts of water-soluble phenolic resin liquid.
The preparation method of the grinding wheel special for the steel rail grinding train comprises the following steps:
(1) mixing material
(11) Grinding and mixing the pyrite powder, the cryolite powder, the barium sulfate powder, the calcium carbonate powder, the graphite powder, the copper powder and the fiber reinforced material at a ball-to-material ratio of 1:1 and a rotating speed of 420r/min to obtain a filler;
(12) uniformly mixing the modified zirconia corundum with the modified brown corundum to obtain an abrasive, adding liquid resin, and fully stirring until the resin liquid fully soaks the abrasive; adding the alumina hollow spheres, fully stirring, slowly adding the filler obtained in the step (11), and continuously stirring until the materials are uniformly mixed; finally, slowly adding the powdery resin, and fully stirring and uniformly mixing to obtain a molding material;
(2) hot press forming
Putting the molding material into a mold, wherein the reaction conditions of hot press molding are as follows: the initial temperature of the die is 65 ℃, the final temperature is 160 ℃, the pressing pressure per unit area of the grinding wheel is 15MPa, the pressure is released and deflated for 8 times, the pressure is released for 3min in one time, and the hot pressing is 40 min; obtaining the grinding wheel after hot press molding, and then placing the grinding wheel in an oven for curing and sintering, wherein the curing and sintering process comprises the following steps:
a first curing stage: keeping the temperature at 60 ℃ for 2 h;
and (3) a second curing stage: keeping the temperature for 3h at 90 ℃;
and a third curing stage: keeping the temperature at 130 ℃ for 5 h;
and a fourth curing stage: keeping the temperature at 180 ℃ for 5 h;
a fifth curing stage: uniformly and slowly cooling to room temperature for 4 h.
Example 4:
the preparation method of the grinding wheel special for the steel rail grinding train in the embodiment is the same as that in the embodiment 2, and the difference is that the formula of the grinding wheel special for the steel rail grinding train is different.
The special emery wheel of rail grinding train of this embodiment includes: the composite material comprises, by weight, 35 parts of modified zirconia corundum, 43 parts of modified brown corundum, 12 parts of mixed resin, 4 parts of alumina hollow spheres, 3 parts of pyrite powder, 2 parts of cryolite powder, 1 part of barium sulfate powder, 1 part of calcium carbonate powder, 1 part of graphite powder, 6 parts of copper powder and 2 parts of fiber reinforcement material.
Wherein the mixed resin comprises 7.5 parts of organic silicon modified phenolic resin powder and 4.5 parts of epoxy resin liquid.
Example 5:
the preparation method of the grinding wheel special for the steel rail grinding train in the embodiment is the same as that in the embodiment 2, and the difference is that the formula of the grinding wheel special for the steel rail grinding train is different.
The special emery wheel of rail grinding train of this embodiment includes: the composite material comprises, by weight, 25 parts of modified zirconia corundum, 38 parts of modified brown corundum, 15 parts of mixed resin, 5 parts of alumina hollow spheres, 6 parts of pyrite powder, 3 parts of cryolite powder, 5 parts of barium sulfate powder, 5 parts of calcium carbonate powder, 4 parts of graphite powder, 3 parts of copper powder and 1 part of fiber reinforcement material.
Wherein the mixed resin comprises 9 parts of phenolic resin powder and 6 parts of water-soluble phenolic resin liquid.
The performance of the steel rail grinding wheel of the special grinding wheel for the steel rail grinding train obtained in the above embodiment is detected, and a table of the performance detection results of the steel rail grinding wheel of the above embodiment is obtained, as shown in table 1.
Table 1 table of performance test results of rail grinding wheel in the embodiment
The results clearly show that the special grinding wheel for the steel rail grinding train, which is prepared by the invention, has high compressive strength, high surface roughness of the ground steel rail, strong grinding capability of the grinding wheel and good wear resistance.
The grinding wheel obtained in example 2 was subjected to surface stereo inspection to obtain a surface stereo microscope image of example 2, as shown in fig. 1. The grinding wheel obtained in example 2 was ground, and the surface of the rail after grinding was subjected to stereoscopic inspection to obtain a surface stereoscopic microscope image of example 2. Analyzing the three-dimensional appearance and the roughness of the surface of the steel rail polished by the grinding wheel obtained in the embodiment 2 to obtain a surface three-dimensional appearance and roughness map of the embodiment 2, as shown in fig. 3.
As can be seen from the graphs 1-3, the special grinding wheel prepared by the invention has good abrasive particle exposure degree, large porosity and good self-sharpening property. The friction coefficient of the grinding wheel reaches 0.43, which is close to the level of the high-speed steel rail grinding wheel operated on the current line. The surface of the polished steel rail is free from burn, and the surface roughness of the polished steel rail is detected by a white light interference three-dimensional topographer, wherein the maximum Ra is about 9.025 mu m.
Comparative example
Comparative example 1
The preparation method of the grinding wheel special for the steel rail grinding train in the comparison example is the same as that in the example 2, the difference is that the formula of the grinding wheel special for the steel rail grinding train is different, and the difference is that the zirconium corundum and the brown corundum adopted in the comparison example are zirconium corundum and brown corundum which are not soaked in KH550 alcoholic solution.
This rail of comparison example grinds special emery wheel of train includes: according to the weight portion, 30 portions of zirconium corundum, 45 portions of brown corundum, 12 portions of mixed resin, 5 portions of alumina hollow spheres, 5 portions of pyrite powder, 2 portions of cryolite powder, 2 portions of barium sulfate powder, 2 portions of calcium carbonate powder, 2 portions of graphite powder, 3 portions of copper powder and 2 portions of fiber reinforced material.
Wherein the mixed resin comprises 8 parts of phenolic resin powder and 4 parts of water-soluble phenolic resin liquid.
Comparative example 2
The preparation method of the grinding wheel special for the steel rail grinding train in the comparison example is the same as that in the embodiment 2, the difference is that the formula of the grinding wheel special for the steel rail grinding train is different, the difference is that the zirconium corundum and the brown corundum adopted in the comparison example are zirconium corundum and brown corundum which are not soaked in KH550 alcoholic solution, and the comparison example is not added with alumina hollow spheres.
The special emery wheel of rail grinding train of this embodiment includes: according to the weight portion, 30 portions of zirconium corundum, 45 portions of brown corundum, 12 portions of mixed resin, 5 portions of pyrite powder, 2 portions of cryolite powder, 2 portions of barium sulfate powder, 2 portions of calcium carbonate powder, 2 portions of graphite powder, 3 portions of copper powder and 2 portions of fiber reinforced material.
Wherein the mixed resin comprises 8 parts of phenolic resin powder and 4 parts of water-soluble phenolic resin liquid.
The grinding wheel special for the rail grinding train obtained in the comparative example was subjected to rail grinding wheel performance detection, and a rail grinding wheel performance detection result table of the comparative example was obtained, as shown in table 2.
Table 2 table of results of testing performance of grinding wheel for rail grinding in comparative example
From comparative example 1 and comparative example 2 described above, it can be seen that: the zirconium corundum and the brown corundum are not treated by KH550 alcohol solution, and the bonding capability of the bonding agent and the grinding material is reduced, so that the integral compressive strength of the grinding wheel is reduced; alumina hollow spheres are not added in the formula, so that the integral strength of the grinding wheel is improved, but the reduction of the porosity of the grinding wheel directly causes the reduction of the grinding capacity of the grinding wheel, which is also the reason for the reduction of the surface roughness of the ground steel rail, and meanwhile, the grinding heat of the grinding wheel with poor self-sharpening property is increased, so that the possibility of the steel rail burning is increased.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (7)
1. The utility model provides a special emery wheel of rail train of polishing which characterized in that, it includes: 25-35 parts of modified zirconia corundum, 35-55 parts of modified brown corundum, 9-15 parts of mixed resin, 3-5 parts of alumina hollow spheres, 1.5-8 parts of pyrite powder, 1-6 parts of cryolite powder, 0.5-5 parts of barium sulfate powder, 0.5-5 parts of calcium carbonate powder, 0.5-4 parts of graphite powder, 3-6 parts of copper powder and 1-8 parts of fiber reinforcement material;
the modified zirconia corundum and the modified brown corundum are obtained by soaking and drying 3-10 wt% of KH550 alcohol solution; the fiber reinforced material is one of glass fiber, carbon fiber and basalt fiber; the particle sizes of the modified zirconia corundum and the modified brown corundum are 14-16 meshes, and the diameter of the alumina hollow ball is 0.5-1.5 mm; the particle sizes of the modified zirconia corundum and the modified brown corundum are 14-16 meshes; the particle size of the fiber reinforced material is less than 100 meshes;
the preparation method of the special grinding wheel for the steel rail grinding train comprises the following steps:
(1) mixing material
(11) Grinding and mixing the pyrite powder, the cryolite powder, the barium sulfate powder, the calcium carbonate powder, the graphite powder, the copper powder and the fiber reinforcement material at a ball-to-material ratio of 1:1 and a rotating speed of 380-420 r/min to obtain a filler;
(12) uniformly mixing the modified zirconia corundum with the modified brown corundum to obtain an abrasive, adding liquid resin, and fully stirring until the resin liquid fully soaks the abrasive; adding the alumina hollow spheres, fully stirring, slowly adding the filler obtained in the step (11), and continuously stirring until the materials are uniformly mixed; finally, slowly adding the powdery resin, and fully stirring and uniformly mixing to obtain a molding material;
(2) hot pressing and curing
Putting the molding material into a mold, carrying out hot press molding to obtain a grinding wheel, and then putting the grinding wheel into an oven for curing and sintering, wherein the curing and sintering process comprises the following steps:
a first curing stage: keeping the temperature for 2 hours at 50-60 ℃;
and (3) a second curing stage: preserving the heat for 2-3 h at 80-90 ℃;
and a third curing stage: preserving the heat for 4-5 h at the temperature of 120-130 ℃;
and a fourth curing stage: keeping the temperature at 170-180 ℃ for 4-6 h;
a fifth curing stage: and uniformly and slowly cooling to room temperature for 3-4 h.
2. The grinding wheel special for a steel rail grinding train according to claim 1, comprising: the composite material comprises, by weight, 25-35 parts of modified zirconia corundum, 43-55 parts of modified brown corundum, 9-15 parts of mixed resin, 3-5 parts of alumina hollow spheres, 3-6 parts of pyrite powder, 1-3 parts of cryolite powder, 1-3 parts of barium sulfate powder, 1-3 parts of calcium carbonate powder, 0.5-3 parts of graphite powder, 3-5 parts of copper powder and 1-5 parts of fiber reinforcement material.
3. The grinding wheel special for a steel rail grinding train according to claim 2, comprising: the composite material comprises, by weight, 30 parts of modified zirconia corundum, 45 parts of modified brown corundum, 12 parts of mixed resin, 5 parts of alumina hollow spheres, 5 parts of pyrite powder, 2 parts of cryolite powder, 2 parts of barium sulfate powder, 2 parts of calcium carbonate powder, 2 parts of graphite powder, 3 parts of copper powder and 2 parts of fiber reinforcement material.
4. The special grinding wheel for the steel rail grinding train according to claim 1, wherein the mixed resin comprises a powdery resin and a liquid resin, the weight part ratio of the liquid resin to the powdery resin is 1.5-2.0, the powdery resin is one of phenolic resin powder, polyimide resin powder and organic silicon modified phenolic resin powder, and the granularity of the powdery resin is smaller than 100 meshes; the liquid resin is epoxy resin liquid or water-soluble phenolic resin liquid.
5. The special grinding wheel for the steel rail grinding train according to claim 1, wherein the granularity of the pyrite powder is less than 60 meshes, and the granularity of the cryolite powder, the barium sulfate powder, the calcium carbonate powder, the graphite powder, the copper powder and the fiber reinforced material is less than 100 meshes.
6. The grinding wheel special for a steel rail grinding train according to claim 1, comprising: the reaction conditions of the hot pressing molding in the step 2 are as follows: the initial temperature of the die is 55-65 ℃, the final temperature is 150-160 ℃, the pressing pressure per unit area of the grinding wheel is 10-15 MPa, the pressure is released and the air is released for 5-8 times, the pressure is released for 1-3min for one time, and the hot pressing is 30-40 min.
7. The special grinding wheel for a steel rail grinding train according to claim 1, wherein the solidification sintering process comprises: a first curing stage: keeping the temperature at 50 ℃ for 2 h; and (3) a second curing stage: preserving the heat for 2 hours at the temperature of 80-90 ℃; and a third curing stage: preserving the heat for 4 hours at the temperature of 120-130 ℃; and a fourth curing stage: keeping the temperature at 170-180 ℃ for 4-5 h; a fifth curing stage: uniformly and slowly cooling to room temperature for 3 h.
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| CN109732496B (en) * | 2019-01-27 | 2021-06-01 | 西南交通大学 | Iron-based binder zirconium corundum grinding wheel for grinding railway steel rail and preparation method thereof |
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| CN110202491B (en) * | 2019-05-27 | 2020-04-21 | 中国铁路南昌局集团有限公司科学技术研究所 | Novel rail grinding wheel based on rare earth material and graphene base |
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