CN1093636A - 超研磨工具 - Google Patents

超研磨工具 Download PDF

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CN1093636A
CN1093636A CN94103179A CN94103179A CN1093636A CN 1093636 A CN1093636 A CN 1093636A CN 94103179 A CN94103179 A CN 94103179A CN 94103179 A CN94103179 A CN 94103179A CN 1093636 A CN1093636 A CN 1093636A
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particle
milling tool
section
face
abrasive
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詹姆斯E·弗罗丁
斯考特·帕罗
珍·克莱帕
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Saint Gobain Abrasives Inc
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Norton Co
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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C04B35/111Fine ceramics
    • C04B35/117Composites
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • B24D3/04Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
    • B24D3/06Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D5/00Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
    • B24D5/12Cut-off wheels
    • B24D5/123Cut-off wheels having different cutting segments
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D5/00Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
    • B24D5/14Zonally-graded wheels; Composite wheels comprising different abrasives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28DWORKING STONE OR STONE-LIKE MATERIALS
    • B28D1/00Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
    • B28D1/02Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
    • B28D1/12Saw-blades or saw-discs specially adapted for working stone
    • B28D1/121Circular saw blades

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Composite Materials (AREA)
  • Mining & Mineral Resources (AREA)
  • Inorganic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Mechanical Treatment Of Semiconductor (AREA)

Abstract

一种超研磨工具,其中结合有由一种微晶矾土构 成的纤维状颗粒,由于颗粒的取向而使这种工具的性 能显著提高。

Description

本发明涉及例如砂轮缘砂轮和分段式段面砂轮的超研磨砂轮,它们都具有诸如金刚石或立方氮化硼(CBN)的超研磨磨粒。
含有超研磨磨粒的工具被广泛地用于切削极其坚硬的材料,例如混凝土。业已发现,由于超研磨磨料本身的价格很贵因而使这些砂轮的造价非常高。因此,人们对生产一种既是非常有效的而同时又比由100%的超研磨材料组成的超研磨工具便宜的工具具有极大的兴趣。
美国专利5,152,810和4,944,773揭示了解决这一问题的方法,其中部分超研磨磨料材料由一种溶胶-凝胶矾土磨料代替而得到了出乎意料之外的优良效果和成本的大幅度的下降。
本发明的目的在于通过提供一种具有更高效率且增加已有技术所没有的新的可能性的一种溶胶-凝胶矾土对这种技术作进一步的改进。
本发明提供一种研磨工具,它包括一结合材料,在该结合材料中具有散布在其间的研磨颗粒,该研磨颗粒至少包括一种超研磨材料和具有基本上相同的取向的微晶矾土的纤维状颗粒。
该纤维状颗粒的取向基本上是一致的,所谓基本取向一致是指它们的纵轴大部分并最好至少75%是对齐的120℃弧度且最好是在60℃弧度之内的。
该纤维状颗粒沿一对称轴线的横截面形状基本相同,并有一大约至少3∶1且最好大约至少为10∶1的纵横化(沿对称轴线的长度和垂直于该轴的最大尺寸之比)。在有些情况下,该纤维状颗粒可以长得多,甚至连接起来而构成一连续的纤维以至少作为工具的使用前的构形廓。如果用连续纤维制造研磨工具,则该纤维处于紧密弯曲折叠的状态,且各折叠的边基本上与纤维状颗粒的所希望的取向方向平行。这种连续纤维的性能基本上和多根单独的纤维一样,因此,它也落入本发明的实质性范围之内。
颗粒的横截面形状可以是任何方便的形状,但最便于制造的还是圆形或大致的正方形。然而本发明的效用并不受横截面形状的影响。
所述颗粒包括一种微晶的α矾土,即,构成颗粒的各个晶域或微晶都有一大约小于10微米且最好小于1微米的平均直径(通过颗粒横截面的线的截距的平均长度)。该颗粒还可以含有其它的成分,例如:氧化镁、氧化锆、尖晶石和稀土族金属氧化物等,但至少占60%,最好至少为90%重量的α矾土。该颗粒的密度应至少等于该组成理想密度的90%左右,且最好至少为95%。最佳的颗粒硬度至少为18且最好至少为20GPa或18以上。
人们往往希望在纤维状颗粒中含有能改变其研磨性能的其它成分。例如加入细的研磨颗粒,诸如金刚石,立方氮化硼CBN、碳化钨以及其它类似的成分,除此之外,还可以加入的颗粒物质包括耐高温的润滑剂,诸如氮化硼(六方晶体形)、硫化钼、石墨,以及锡和其它助磨填充物。选择这些添加物质时要注意保证它们的数量和物理性能不会过度地减少原来的溶胶-凝胶矾土纤维状颗粒的硬度和强度。
这种颗粒是由一种溶胶-凝胶工艺制成的。其中,通常通过一种酸性的添加剂对α矾土的初始体进行凝胶、干燥然后烧制。通过添加一种能有效地使α矾土从初始相的结晶过程中成核的材料,能够减小颗粒中微晶的大小。这些材料通常都和α矾土相具有相同的结构,由晶格参数和α矾土的晶格参数尽可能接近的材料形成。或者,微晶尺寸大小可通过采用在形成α矾土的烧制过程中限制其生长过程的联结助剂而得到限制。专利中揭示过制造纤维颗粒的适当方法有美国专利4,314,827;4,632,364;4,744,802;4,770,671;4,881,951;4,954,462;4,964,883;5,053,369;5,076,815;5,114,891;5,139,978;欧洲申请408,771以及PCT申请92/01646。
这种颗粒能够用任何便利的方式制得,但最便利的途径是挤压成形。在这种工艺中,α初始体被挤压成凝胶状,然后干燥和烧制以形成纤维体。可用来生产这种纤维体的一种合适的装置揭示在美国专利5,090,968中;也可以先将α初始体挤压和干燥到能够方便地加以处理的程度,就此将它们结合在工具中,然后在研磨工具中加以烧制。
工具中纤维状颗粒的取向对于决定工具所具有的性能是特别重要的。在一较佳实施例中,纤维状颗粒定向成垂直地对齐于工具的研磨表面或与该表面成大约小于60°的角度。假如工具在工件上的移动方向是恒定不变的,最好颗粒与垂直于研磨表面的线成一个夹角,就像该工具位于切削工具的边缘那样。在此情况下,颗粒起到磨粒的作用,可以显著地加强砂轮的切削作用从而可以使用较少的超研磨成分同时切削性能损失极少。纤维状颗粒径向地定位并都位于切削轮的边缘上是特别有利的。纤维颗粒可以放在工具的基质中或粘结到工具侧边上所切出的用来容纳颗粒和将它们牢固地固定在槽中的粘结剂的槽中。
另一种特别有用的,尤其是在为切削混凝土而设计的分段式段面砂轮中特别有用的另一种定向或排列方向是纤维体的对称轴线基本平行于切削表面但位于其边缘上。传统的混凝土切削砂轮在边缘上都会产生磨损以致因为磨损而将使切削宽度下降。与切削表面处于平行状态的纤维状颗粒将提供均匀的磨换特性,阻止边缘处段面的磨损且保持切削表面呈方形。此时,纤维状颗粒起到减少磨损的作用而不是磨粒作用。
工具本身可以具有任何方便的形状。一种最为通常的形状是一种至少在其周缘上设有磨粒的砂轮。由于超研磨磨料的价格且由于这种砂轮一般都用于高应力的情况下,所以通常都用坚硬的金属板作为砂轮的芯部而磨粒通常都以结合于芯部的分段形式设于其边缘上。保持磨粒的结合剂通常都是金属结合剂,结合方法并不十分重要,只要能牢固、永久地结合于芯部上就可以,焊接,钎焊和烧结都是适用的方法。
另一种涉及段面而不是段面结合进去的结构的本发明的工具的应用例子是一种诸如组合锯的锯子,其中段面被结合至一金属锯条上以提供锯齿的切削刃。可适用的另一种例子是Blanchard磨床的研磨表面。
除了上文已揭示的多种结构之外,本发明的工具还可以是用树脂或玻璃粘结剂保持磨粒的种种结构。
下面将结合附图对本发明作较详细的描述,其中附图仅用于举例说明本发明,而并不意味着是对本发明实质范围的任何限制。
图1为一种用来切削混凝土的分段式段面砂轮的局部侧视图。图中编号1为实心金属芯部,2是结合于边缘以形成砂轮的切削部分的段面。3是与径向大致呈45°角的切割或冲压在段面的侧边上的槽,研磨纤维就位于该槽中且用金属粘结剂粘结到段面上。段面体内包括具有由金属粘结剂粘法的合适颗粒尺寸的金刚石磨粒。
图2基本上与图1相似,所不同的是,研磨纤维是在段面形成时置入段面体中的。这可以通过将纤维体分别放置的方式置入,但较方便的是在形成段面时将纤维体以紧密弯曲折叠的状态设置,这样研磨表面就形成了一组折叠,其中各个在研磨过程中,会被磨掉而露出纤维体的两端。图2中示了这种构造的段面,其中端部5露出在切削面上。
图3为图2所示段面的横截面图,图中的折叠6的顶部还没有被磨掉因而纤维的两个端部还没有露出来。
图4为一种为连结至如图1-3分段式段面砂轮上而设计的段面的横截面图,其中纤维状磨料7处于研磨表面平行的紧密的折叠状态。
图5为图4所示的段面在磨损之后露出与段面的侧边平行并靠近边缘的纤维状磨粒颗粒7时的段面的横截面图。
图6为图4和5所示的段面、垂直于图4的横截面的横截面视图。该截面以夸大的形式示出了用旧的砂轮的截面,图中纤维状颗粒7使段面磨损成U型,因此保持其中切削宽度而不会变成圆形截面。
还可以设计出既具有超研磨料的研磨能力又具有使用纤维状颗料而产生的具体的结构优点的其他结构。例如将纤维状磨粒形成一交错的环,多少有点象将纤维缠绕成线团那样且最好使之具有较平的轮廓,然后迫使一可成形粘结剂和起研磨料的混合物填充交错环中的空隙,再处理烧制,使粘结材料在一诸如砂轮的研磨工具中变得非常坚硬。
这种结构可具有一种特别的优点,即可通过使空隙的尺寸能夹住超研磨磨粒,由此使它们相对于被研磨或切削加工表面呈现出一非常牢固的保持或夹持磨粒结构。

Claims (8)

1、一种超研磨工具,包括在其中分散有研磨磨粒的粘结材料,所述磨料至少包括一种超磨料成分和具有基本上一致取向的微晶α矾土纤维颗粒。
2、如权利要求1所述的研磨工具,其特征在于,所述纤维状颗粒的取向基本上垂直于工具的切削或研磨表面。
3、如权利要求1所述的研磨工具,其特征在于,所述纤维状颗粒的取向平行于切削表面且靠近其横向侧边缘。
4、如权利要求1所述的研磨工具,其特征在于,所述纤维状颗粒中含有从磨粒、其它耐高温润滑剂和研磨助剂中选择的添加剂的细颗粒。
5、如权利要求1所述的研磨工具,其特征在于,所述结合材料为一种金属粘结剂。
6、如权利要求2所述的研磨工具,其特征在于,所述研磨工具为一种具有段面的分段式砂轮。
7、如权利要求3所述的研磨工具,其特征在于,所述研磨工具为一种具有段面的分段式砂轮。
8、如权利要求4所述的研磨工具,其特征在于,所述研磨工具为一种具有段面的分段式砂轮。
CN94103179A 1993-03-29 1994-03-29 超研磨工具 Pending CN1093636A (zh)

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US08/038,301 1993-03-29
US08/038,301 US5443418A (en) 1993-03-29 1993-03-29 Superabrasive tool

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EP (2) EP0620082B1 (zh)
JP (1) JP3042749B2 (zh)
KR (1) KR940021195A (zh)
CN (1) CN1093636A (zh)
AT (1) ATE166276T1 (zh)
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CA (1) CA2119306C (zh)
DE (1) DE69410338T2 (zh)
ES (1) ES2115797T3 (zh)
HU (1) HU217601B (zh)
IL (1) IL109048A (zh)
NO (1) NO303567B1 (zh)
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HUT69242A (en) 1995-08-28
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HU9400882D0 (en) 1994-06-28
ATE166276T1 (de) 1998-06-15
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EP0812659A3 (en) 1998-12-02
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DE69410338D1 (de) 1998-06-25
IL109048A0 (en) 1994-06-24
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IL109048A (en) 2001-01-28
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EP0812659A2 (en) 1997-12-17
ES2115797T3 (es) 1998-07-01

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