CN109534845A - 一种多孔陶瓷砂轮及其制备方法 - Google Patents

一种多孔陶瓷砂轮及其制备方法 Download PDF

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CN109534845A
CN109534845A CN201811605896.0A CN201811605896A CN109534845A CN 109534845 A CN109534845 A CN 109534845A CN 201811605896 A CN201811605896 A CN 201811605896A CN 109534845 A CN109534845 A CN 109534845A
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陆静
马忠强
徐西鹏
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Huaqiao University
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Abstract

本发明公开了一种多孔陶瓷砂轮及其制备方法，包括一圆形基底，该圆形基底的中部具有一安装孔，沿安装孔的周向均匀分布有若干固定通孔，且该圆形基底的周缘沿该圆形基底的轴向延伸形成一过渡环，该过度环上均匀分布有由3D打印制成的若干异形陶瓷磨块。本发明采用的是3D打印成型，能够快速，高效的完成坯体成型，且所打印的坯体具有高度一致性，自动化程度高，材料损耗低，能源消耗少、环境污染小等优点。本发明打印出来的坯体能够严格控制多孔陶瓷砂轮的气孔和孔隙率。本发明能够打印出各种异形磨块，不受传统的模具限制，能够满足不同砂轮需要的磨块。

Description

一种多孔陶瓷砂轮及其制备方法
技术领域
本发明属于研磨砂轮技术领域，具体涉及一种多孔陶瓷砂轮及其制备方法。
背景技术
在金刚石工具行业，陶瓷砂轮的生产过程是一种流程式的生产，连续性低。陶瓷原料从工厂的一端投入生产，顺序经过连续加工，最后成为成品，整个工业过程较复杂，工序之间连续化程度低、机械化、自动化程度低，且陶瓷砂轮传统工艺的生产周期较长，陶瓷砂轮生产过程中辅助材料消耗量大，需要消耗大量的能源，如煤炭，天然气，电能等；陶瓷生产过程中产生的烟气，粉尘、固体废料和工业废水污染环境比较严重。为了减少污染，节约能源，提高生产效率，提出了结合3D打印技术，制作陶瓷砂轮。
传统的打印机里面装的是墨粉，而3D打印机里面装的则是一个庞大的材料系统，这个系统里面是根据产品需要而配备的各种材料，包括光敏树脂、塑料、尼龙、薄膜、陶瓷以及各种金属粉末。其中陶瓷材料具有化学稳定性好，高强度、高硬度、低密度、耐高温、耐腐蚀等很多优异特性，可以使用在航天航空、汽车、生物等行业。将3D打印应用在金刚石工具行业中可以有效解决上述问题。
本文提出了结合3D打印技术，将设计好的物体转化为三维设计图，采用分层加工、叠加成形的方式逐层增加材料来打印真实物体，是以计算机三维设计模型为蓝本，通过软件分层离散和数控成形系统，利用挤压喷涂方式将陶瓷粉末进行逐层堆积黏结、最终叠加成型，制造出实体产品。3D打印制造陶瓷砂轮具有所需工艺路线简单，加工成型步骤少，自动化程度高。材料损耗低，能源消耗少、环境污染小，生产效率高等优点。
CN101590626B公开了一种竹陶瓷砂轮及其制备方法和应用。CN102009393B公开了一种高速磨削cBN陶瓷砂轮制备方法。CN102059658B公开了一种用于曲轴法兰端面外圆整体磨削的cBN陶瓷砂轮制备方法。以上3种公开的砂轮制备工艺均采用传统的砂轮制造工艺：压制成型；这种工艺只能制造标准的形状磨块，连续化程度低、机械化、自动化程度低，且生产周期长、生产过程中辅助材料消耗量大，需要消耗大量的能源。而且多孔陶瓷砂轮的关键技术就是其孔洞的难控制性是传统加工工艺难以克服的问题。所以开发一种新的多孔陶瓷成型工艺是一个亟待解决的问题，对国内多孔陶瓷砂轮制备工艺的发展具有重要促进作用，对国内工具的自主研发具有重要意义。
发明内容
本发明的目的在于克服现有技术缺陷，提供一种多孔陶瓷砂轮。
本发明的另一目的在于提供上述多孔陶瓷砂轮的制备方法。
本发明的技术方案如下：
一种多孔陶瓷砂轮，包括一圆形基底，该圆形基底的中部具有一安装孔，沿安装孔的周向均匀分布有若干固定通孔，且该圆形基底的周缘沿该圆形基底的轴向延伸形成一过渡环，该过度环上均匀分布有由3D打印制成的若干异形陶瓷磨块，
该异形陶瓷模块的孔隙率为30-70％，孔径为10-500um。
在本发明的一个优选实施方案中，所述异形陶瓷磨块的形状为月牙形、Z字形、S形、波浪形或m形。
上述多孔陶瓷砂轮的制备方法，包括如下步骤：
(1)将陶瓷粉、液体石蜡、甘油、甲基纤维素、热塑性树脂和去离子水混合搅拌15-25min，接着干燥至含水量低于3％，然后过450-550目的筛网；
(2)在步骤(1)所得的物料中加入35-50wt％的硬质磨料，于球磨机中混料均匀，过450-550目的筛网，再加入2.5-3.5wt％的粘结剂和1.5-2.5wt％的固化剂混合球磨，然后进行造粒；
(3)将步骤(2)所得的物料于捏炼机中捏炼170-180min，然后添加到3D打印机的挤出机中进行挤出；
(4)用步骤(3)所得的物料按照所述异形陶瓷磨块的形状进行3D打印，获得坯体，该3D打印所用的打印孔道的直径为200μm；
(5)将上述坯体进行表面修整和干燥后，于650-680℃真空烧结10-13h，即得所述异形陶瓷磨块；
(6)将所述异形陶瓷磨块用环氧树脂粘结于所述过渡环上，经烘干修正，即得所述多孔陶瓷砂轮。
在本发明的一个优选实施方案中，所述陶瓷粉的组成为：SiO2 72.22-76.64％，Al2O3 14.11-17.2％，CaO 0.31-0.41％，MgO 0.23-0.67％，Fe2O3 0.32-0.55％，TiO2 0.07-0.08％，K2O2.41-3.72％。
在本发明的一个优选实施方案中，所述陶瓷粉的配料粒度为1000-8000目。
在本发明的一个优选实施方案中，所述硬质磨料为金刚石粉，氧化铝粉，立方氮化硼粉、氮化硅粉和碳化硅粉中的至少一种。
进一步优选的，所述硬质磨粒的粒度为W0.1-40。
在本发明的一个优选实施方案中，所述液体石蜡、甘油、甲基纤维素和热塑性树脂的加入量依次为陶瓷粉的质量的0.7-1％、0.3-0.5％、0.5-2％和0.5-7％。
在本发明的一个优选实施方案中，所述固化剂为脂肪胺和/或酸酐固化剂。
在本发明的一个优选实施方案中，所述粘结剂为糊精和/或水玻璃，其在250℃的温度烧结时气化形成微孔。
在本发明的一个优选实施方案中，所述干燥为自然干燥、鼓风机干燥或烘干干燥。
本发明的有益效果是：
1、本发明采用的是3D打印成型，能够快速，高效的完成坯体成型，且所打印的坯体具有高度一致性，自动化程度高，材料损耗低，能源消耗少、环境污染小等优点。
2、本发明打印出来的坯体能够严格控制多孔陶瓷砂轮的气孔和孔隙率。
3、本发明能够打印出各种异形磨块，不受传统的模具限制，能够满足不同砂轮需要的磨块。
4、本发明特定形状的特定形状的异形陶瓷磨块根据设计分布在圆形基底的边缘的过渡环上，配合砂轮的和工件的转速，能够控制其在工件的磨纹长度、磨纹曲率、磨纹密度以及磨纹分布，以达到高去除率，得到低粗糙度和高面型精度的工件。
附图说明
图1为本发明实施例1至3制成的多孔陶瓷砂轮的立体结构示意图。
具体实施方式
以下通过具体实施方式结合附图对本发明的技术方案进行进一步的说明和描述。
实施例1
如图1所示，一种多孔陶瓷砂轮，包括一圆形基底1，该圆形基底1的中部具有一安装孔10，沿安装孔10的周向均匀分布有若干固定通孔11，且该圆形基底1的周缘沿该圆形基底1的轴向延伸形成一过渡环12，该过度环上均匀分布有由3D打印制成的若干S形的异形陶瓷磨块2，该异形陶瓷模块的孔隙率为45％，孔径为200um。
上述多孔陶瓷砂轮的制备方法，包括如下步骤：
(1)将陶瓷粉、液体石蜡、甘油、甲基纤维素、热塑性树脂和去离子水混合搅拌20min，接着干燥至含水量低于3％，然后过500目的筛网；该陶瓷粉的组成为：SiO2：73.54％，Al2O3：21.04％，CaO：0.41％，MgO：0.67％，Fe2O3：0.55％，TiO2：0.07％，K2O：3.72％，配料粒度为8000目；液体石蜡、甘油、甲基纤维素和热塑性树脂的加入量依次为陶瓷粉的质量的1％、0.35％、0.7％和7％；
(2)在步骤(1)所得的物料中加入37.5wt％的W3金刚石磨粒，于球磨机中混料均匀，过500目的筛网，再加入3wt％的糊精和2wt％的邻苯二甲酸酐混合球磨，然后进行喷雾造粒；
(3)将步骤(2)所得的物料于捏炼机中捏炼180min，然后添加到3D打印机的挤出机中进行挤出；
(4)用步骤(3)所得的物料按照所述S形的异形陶瓷磨块2的形状进行3D打印，打印参数为：层厚25μm，壁厚100μm，底层顶层厚度1000μm，打印速度100层/小时，获得坯体，该3D打印所用的打印孔道的直径为200μm；
(5)将上述坯体进行表面修整、空气静置6h和鼓风机干燥24h至含水量在3％以下后，于680℃真空烧结12h，即得所述异形陶瓷磨块2；
(6)将所述异形陶瓷磨块2用环氧树脂粘结于所述过渡环12上，经烘干修正，即得所述多孔陶瓷砂轮。
实施例2
如图1所示，一种多孔陶瓷砂轮，包括一圆形基底1，该圆形基底1的中部具有一安装孔10，沿安装孔10的周向均匀分布有若干固定通孔11，且该圆形基底1的周缘沿该圆形基底1的轴向延伸形成一过渡环12，该过度环上均匀分布有由3D打印制成的若干S形的异形陶瓷磨块2，该异形陶瓷模块的孔隙率为30％，孔径为300um。
上述多孔陶瓷砂轮的制备方法，包括如下步骤：
(1)将陶瓷粉、液体石蜡、甘油、甲基纤维素、热塑性树脂和去离子水混合搅拌20min，接着干燥至含水量低于3％，然后过500目的筛网；该陶瓷粉的组成为：SiO2：72.22％，Al2O3：23.68％，CaO：0.41％，MgO：0.67％，Fe2O3：0.55％，TiO2：0.07％，K2O：2.40％，配料粒度为8000目；液体石蜡、甘油、甲基纤维素和热塑性树脂的加入量依次为陶瓷粉的质量的0.7％、0.30％、0.5％和0.5％；
(2)在步骤(1)所得的物料中加入44.4wt％的W3碳化硅磨粒，于球磨机中混料均匀，过500目的筛网，再加入3wt％的糊精和2wt％的邻苯二甲酸酐混合球磨，然后进行喷雾造粒；
(3)将步骤(2)所得的物料于捏炼机中捏炼180min，然后添加到3D打印机的挤出机中进行挤出；
(4)用步骤(3)所得的物料按照所述S形的异形陶瓷磨块2的形状进行3D打印，打印参数为：层厚25μm，壁厚100μm，底层顶层厚度1000μm，打印速度100层/小时，获得坯体，该3D打印所用的打印孔道的直径为200μm；
(5)将上述坯体进行表面修整、空气静置6h和鼓风机干燥24h至含水量在3％以下后，于680℃真空烧结12h，即得所述异形陶瓷磨块2；
(6)将所述异形陶瓷磨块2用环氧树脂粘结于所述过渡环12上，经烘干修正，即得所述多孔陶瓷砂轮。
实施例3
如图1所示，一种多孔陶瓷砂轮，包括一圆形基底1，该圆形基底1的中部具有一安装孔10，沿安装孔10的周向均匀分布有若干固定通孔11，且该圆形基底1的周缘沿该圆形基底1的轴向延伸形成一过渡环12，该过度环上均匀分布有由3D打印制成的若干S形的异形陶瓷磨块2，该异形陶瓷模块的孔隙率为50％，孔径为400um。
上述多孔陶瓷砂轮的制备方法，包括如下步骤：
(1)将陶瓷粉、液体石蜡、甘油、甲基纤维素、热塑性树脂和去离子水混合搅拌20min，接着干燥至含水量低于3％，然后过500目的筛网；该陶瓷粉的组成为：SiO2：74.21％，Al2O3：21.53％，CaO：0.35％，MgO：0.54％，Fe2O3：0.40％，TiO2：0.08％，K2O：2.89％，配料粒度为8000目；液体石蜡、甘油、甲基纤维素和热塑性树脂的加入量依次为陶瓷粉的质量的0.8％、0.4％、1.5％和3.2％；
(2)在步骤(1)所得的物料中加入50wt％的W3氧化铝磨粒，于球磨机中混料均匀，过500目的筛网，再加入3wt％的糊精和2wt％的邻苯二甲酸酐混合球磨，然后进行喷雾造粒；
(3)将步骤(2)所得的物料于捏炼机中捏炼180min，然后添加到3D打印机的挤出机中进行挤出；
(4)用步骤(3)所得的物料按照所述S形的异形陶瓷磨块2的形状进行3D打印，打印参数为：层厚25μm，壁厚100μm，底层顶层厚度1000μm，打印速度100层/小时，获得坯体，该3D打印所用的打印孔道的直径为200μm；
(5)将上述坯体进行表面修整、空气静置6h和鼓风机干燥24h至含水量在3％以下后，于680℃真空烧结12h，即得所述异形陶瓷磨块2；
(6)将所述异形陶瓷磨块2用环氧树脂粘结于所述过渡环12上，经烘干修正，即得所述多孔陶瓷砂轮。
以上所述，仅为本发明的较佳实施例而已，故不能依此限定本发明实施的范围，即依本发明专利范围及说明书内容所作的等效变化与修饰，皆应仍属本发明涵盖的范围内。

Claims (10)

1.一种多孔陶瓷砂轮，其特征在于：包括一圆形基底，该圆形基底的中部具有一安装孔，沿安装孔的周向均匀分布有若干固定通孔，且该圆形基底的周缘沿该圆形基底的轴向延伸形成一过渡环，该过度环上均匀分布有由3D打印制成的若干异形陶瓷磨块，
该异形陶瓷模块的孔隙率为30-70％，孔径为10-500um。
2.如权利要求1所述的一种多孔陶瓷砂轮，其特征在于：所述异形陶瓷磨块的形状为月牙形、Z字形、S形、波浪形或m形。
3.权利要求1或2所述的多孔陶瓷砂轮的制备方法，其特征在于：包括如下步骤：
(1)将陶瓷粉、液体石蜡、甘油、甲基纤维素、热塑性树脂和去离子水混合搅拌15-25min，接着干燥至含水量低于3％，然后过450-550目的筛网；
(2)在步骤(1)所得的物料中加入35-50wt％的硬质磨料，于球磨机中混料均匀，过450-550目的筛网，再加入2.5-3.5wt％的粘结剂和1.5-2.5wt％的固化剂混合球磨，然后进行造粒；
(3)将步骤(2)所得的物料于捏炼机中捏炼170-180min，然后添加到3D打印机的挤出机中进行挤出；
(4)用步骤(3)所得的物料按照所述异形陶瓷磨块的形状进行3D打印，获得坯体，该3D打印所用的打印孔道的直径为200μm；
(5)将上述坯体进行表面修整和干燥后，于650-680℃真空烧结10-13h，即得所述异形陶瓷磨块；
(6)将所述异形陶瓷磨块用环氧树脂粘结于所述过渡环上，经烘干修正，即得所述多孔陶瓷砂轮。
4.如权利要求3所述的制备方法，其特征在于：所述陶瓷粉的组成为：SiO2 72.22-76.64％，Al2O3 20.13-29.2％，CaO 0.31-0.41％，MgO 0.23-0.67％，Fe2O3 0.32-0.55％，TiO2 0.07-0.08％，K2O 2.40-3.72％。
5.如权利要求3所述的制备方法，其特征在于：所述陶瓷粉的配料粒度为1000-8000目。
6.如权利要求3所述的制备方法，其特征在于：所述硬质磨料为金刚石粉，氧化铝粉，立方氮化硼粉、氮化硅粉和碳化硅粉中的至少一种。
7.如权利要求6所述的制备方法，其特征在于：所述硬质磨粒的粒度为W0.1-40。
8.如权利要求3所述的制备方法，其特征在于：所述液体石蜡、甘油、甲基纤维素和热塑性树脂的加入量依次为陶瓷粉的质量的0.7-1％、0.3-0.5％、0.5-2％和0.5-7％。
9.如权利要求3所述的制备方法，其特征在于：所述固化剂为脂肪胺和/或酸酐固化剂。
10.如权利要求3所述的制备方法，其特征在于：所述粘结剂为糊精和/或水玻璃。
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