CN110202489A - 一种铝硅合金结合剂金刚石磨盘及其制造方法 - Google Patents
一种铝硅合金结合剂金刚石磨盘及其制造方法 Download PDFInfo
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Abstract
本发明公开了一种铝硅合金结合剂金刚石磨盘及其制造方法，该铝硅合金结合剂成分按重量比包括元素成分：Si0～30％，Ti0.25％～6％，Mg0～0.5％，Cu0～5％，Ga0～0.5％，Ce0～0.5％，Sr0～0.5％，Na0～0.5％，余量为Al连同不可避免的杂质；将铝硅结合剂与金刚石粉末充分混合，将混合物冷压成型后；在一定烧结工艺下，进行真空热压烧结，得到铝硅合金基金刚石磨盘节块；随后将烧结得到的金刚石磨盘节块装接在磨盘基体上，就得到本发明的金刚石磨盘。本发明使用的铝硅结合剂可实现低温烧结，减少金刚石热损伤，同时活性Ti元素的引入可显著增加金刚石磨粒的把持能力，两者共同提高磨盘的耐磨性能，增加金刚石磨盘的使用寿命。
Description
技术领域
本发明涉及烧结金刚石工具制造技术领域，特别涉及一种铝硅合金结合剂金刚石磨盘及其制造方法。
背景技术
金刚石工具在提高磨抛的加工效率和加工质量方面具有很大优势，金刚石磨盘作为一种高效精密加工的超硬磨具，是磨削硬脆材料和硬质合金的理想工具，在磨削加工中，要求金刚石磨盘具有较高的磨削效率和磨削质量，即加工效率高，加工精度高，较低的磨耗比和较高的使用寿命。目前普遍使用的金刚石磨盘结合剂有树脂结合剂、金属结合剂和陶瓷结合剂。树脂结合剂磨盘质地较软，加工时不能承受较大的应力，易出现磨粒脱落、效率低、寿命短、噪音大等问题；金属结合剂磨盘具有导热性好、结合强度高、使用寿命长等特点，但因其自锐性差，容易打滑等缺点限制了其在高速磨削领域的应用；而陶瓷结合剂金刚石磨盘制备过程要求的烧结温度较高，故对金刚石热损伤较大，极大地降低了磨盘的磨削强度。热压烧结法制备金属结合剂金刚石磨盘已具有五十多年的历史，但是实际生产中所暴露的弊端一直未能完全解决，对金刚石把持强度低、金刚石易脱落、磨料难出刃等，极大限制了热压烧结法制备金刚石磨盘的适用范围。上述弊端，主要是因为金刚石的共价键结构，很难与金属结合剂形成较强的化学键合，所以会导致金刚石磨粒易脱落，进而影响磨盘的加工质量和使用寿命。因此金属结合剂对金刚石磨粒的把持力成为限制磨盘使用寿命和加工质量的最主要因素。为了解决这一问题，有些金属结合剂中会添加强碳化物形成元素钨，使金刚石与结合剂之间形成化学键连接，可以有效提高金刚石的把持力，但是钨的熔点较高，烧结过程中会对金刚石造成严重的热损伤。因此，开发一种对金刚石具有较高把持力，同时对金刚石热损伤小的金属结合剂磨盘迫在眉睫，将会极大提高金刚石磨盘的加工性能。
发明内容
本发明的目的在于解决现有的的技术难题，提供一种铝硅合金结合剂金刚石磨盘及其制造方法。利用铝硅合金基体相低熔点及低共晶点的特点，可实现低温烧结，减小金刚石的损伤。且结合剂中活性Ti元素的加入，可以很好地润湿金刚石，并形成致密的碳化物，极大地提高了金刚石磨粒的把持力，两者共同提高磨盘的耐磨性能，增加金刚石磨盘的使用寿命。通过添加Si元素，可以有效地提高铝基合金的机械强度，同时Si也是强碳化物形成元素，能够抑制 Al与金刚石的反应，还能降低熔点。通过添加活性元素Ce、Ge，能够显著提高合金的抗氧化性能。
本发明提供了一种铝硅合金结合剂金刚石磨盘及其制造方法，克服了背景技术中心的缺陷，本发明解决其技术问题所采用的技术方案是：
一种铝硅合金结合剂金刚石磨盘的制造方法，是用铝硅合金作为金刚石磨盘的结合剂，其特征在于：该制造方法包括以下步骤：
1)将金刚石粉末与铝硅合金结合剂粉末充分混合，该铝硅合金结合剂按重量比包含以下成分：Si0～30％，Ti0.25％～6％，Mg0～0.5％，Cu0～5％， Ga0～0.5％，Ce0～0.5％，Sr0～0.5％，Na0～0.5％，余量为Al连同不可避免的杂质；
2)使用金刚石磨盘所需不同形状的模具将上述混合物冷压成型；
3)将冷压成型的金刚石磨盘在一定烧结工艺下进行真空热压烧结，得到金刚石磨盘节块；
4)将烧结好的金刚石磨盘节块装在磨盘基体上，得到金刚石磨盘粗品，对金刚石磨盘粗品进行修整，得到金刚石磨盘成品。
在一较佳实施例中：步骤1)中所述金刚石粉末为人造单晶金刚石粉末，且金刚石浓度为50％～100％，金刚石粉末的粒度为W40～W5。
在一较佳实施例中：步骤1)中所述铝硅合金结合剂按重量比包含以下成分：Si10～13％，Ti0.25％～6％，Mg0～0.5％，Cu0～5％，Ga0～0.5％，Ce0～ 0.5％，Sr0～0.5％，Na0～0.5％，余量为Al连同不可避免的杂质。
在一较佳实施例中：所述Mg或Cu或Ga或Ce或Sr或Na可加可不加。
在一较佳实施例中：步骤3)中所述一定烧结工艺的烧结温度在650～1000℃之间，压力在50～200MPa之间。
在一较佳实施例中：所述一定烧结工艺包括在100～150MPa压力下 700～750℃保温30～60分钟，然后在50～90MPa压力下600～650℃下保温10～30 分钟，随炉冷却。
一种如上所述的一种铝硅合金结合剂金刚石磨盘的制造方法制造的铝硅合金结合剂金刚石磨盘。
本发明的有益效果是：根据本发明的一种铝硅合金结合剂金刚石磨盘及其制造方法，不仅能够极大地降低金刚石的热损伤程度，而且可以显著提高合金结合剂对金刚石的把持力，能够实现金刚石磨盘胎体在较低温度下的烧结，有效提高了金刚石磨盘的使用寿命和加工质量，拓展现有烧结法制备金属基金刚石磨盘的应用范围。
具体实施方式
下面通过实例具体说明本发明的内容：
实施例1
一种铝硅合金结合剂金刚石磨盘的制造方法，包括如下步骤：
1)将粒度为W40的金刚石粉末与铝硅合金结合剂按金刚石浓度为100％在混料机中充分混合，该铝硅合金结合剂按重量比包含以下成分：Si30％，Ti6％， Mg0.5％，Cu5％，Ga0.5％，Ce0.5％，Sr0.5％，Na0.5％，余量为Al连同不可避免的杂质；
2)使用金刚石磨盘节块所需形状的模具将上述混合物冷压成型后，在 150MPa，750℃下保温30分钟，然后在90MPa，650℃下保温15分钟，随炉冷却，得到金刚石磨盘节块；
3)将烧结好的金刚石磨盘节块体装在磨盘基体上，得到本发明的金刚石磨盘粗品，用金刚石滚轮和油石对上述所得的金刚石磨盘进行修整，得到本发明的金刚石磨盘成品。
通过上述方法得到的铝硅合金结合剂金刚石磨盘，利用铝硅合金基体相低熔点及低共晶点的特点，可实现低温烧结，减小金刚石的损伤。且结合剂中活性Ti元素的加入，可以很好地润湿金刚石，并形成致密的碳化物，极大地提高了金刚石磨粒的把持力，两者共同提高磨盘的耐磨性能，增加金刚石磨盘的使用寿命。通过添加Si元素，可以有效地提高铝基合金的机械强度，同时Si也是强碳化物形成元素，能够抑制Al与金刚石的反应，还能降低熔点。通过添加活性元素Ce、Ge，能够显著提高合金的抗氧化性能。
实施例2
一种铝硅合金结合剂金刚石磨盘的制造方法，包括如下步骤：
1)将粒度为W5的金刚石粉末与铝硅合金结合剂按金刚石浓度为75％在混料机中充分混合，该铝硅合金结合剂按重量比包含以下成分：Si20％，Ti3％， Cu5％，Ce0.5％，Sr0.5％，Na0.5％，余量为Al连同不可避免的杂质；
2)使用金刚石磨盘节块所需形状的模具将上述混合物冷压成型后，在 100MPa，700℃下保温60分钟，然后在50MPa，650℃下保温30分钟，随炉冷却，得到金刚石磨盘节块；
3)将烧结好的金刚石磨盘节块体装在磨盘基体上，得到本发明的金刚石磨盘粗品，用金刚石滚轮和油石对上述所得的金刚石磨盘进行修整，得到本发明的金刚石磨盘成品。
以上所述，仅为本发明的两种具体的实施方式，，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到的变化或者替换，都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应该以权利要求的保护范围为准。
Claims (7)
1.一种铝硅合金结合剂金刚石磨盘的制造方法，是用铝硅合金作为金刚石磨盘的结合剂，其特征在于：该制造方法包括以下步骤：
1)将金刚石粉末与铝硅合金结合剂粉末充分混合，该铝硅合金结合剂按重量比包含以下成分：Si0～30％，Ti0.25％～6％，Mg0～0.5％，Cu0～5％，Ga0～0.5％，Ce0～0.5％，Sr0～0.5％，Na0～0.5％，余量为Al连同不可避免的杂质；
2)使用金刚石磨盘所需不同形状的模具将上述混合物冷压成型；
3)将冷压成型的金刚石磨盘在一定烧结工艺下进行真空热压烧结，得到金刚石磨盘节块；
4)将烧结好的金刚石磨盘节块装在磨盘基体上，得到金刚石磨盘粗品，对金刚石磨盘粗品进行修整，得到金刚石磨盘成品。
2.根据权利要求1所述的一种铝硅合金结合剂金刚石磨盘的制造方法，其特征在于，步骤1)中所述金刚石粉末为人造单晶金刚石粉末，且金刚石浓度为50％～100％，金刚石粉末的粒度为W40～W5。
3.根据权利要求1所述的一种铝硅合金结合剂金刚石磨盘的制造方法，其特征在于，步骤1)中所述铝硅合金结合剂按重量比包含以下成分：Si10～13％，Ti0.25％～6％，Mg0～0.5％，Cu0～5％，Ga0～0.5％，Ce0～0.5％，Sr0～0.5％，Na0～0.5％，余量为Al连同不可避免的杂质。
4.根据权利要求1或3所述的一种铝硅合金结合剂金刚石磨盘的制造方法，其特征在于，所述Mg或Cu或Ga或Ce或Sr或Na可加可不加。
5.根据权利要求1所述的一种铝硅合金结合剂金刚石磨盘的制造方法其特征在于，步骤3)中所述一定烧结工艺的烧结温度在650～1000℃之间，压力在50～200MPa之间。
6.根据权利要求1或5所述的一种铝硅合金结合剂金刚石磨盘的制造方法，其特征在于，所述一定烧结工艺包括在100～150MPa压力下700～750℃保温30～60分钟，然后在50～90MPa压力下600～650℃下保温10～30分钟，随炉冷却。
7.一种根据权利要求1所述的一种铝硅合金结合剂金刚石磨盘的制造方法制造的铝硅合金结合剂金刚石磨盘。
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| CN112223129A (zh) * | 2020-09-11 | 2021-01-15 | 泉州众志金刚石工具有限公司 | 一种混凝土研磨用金属基地坪磨块材料 |
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| CN101121253A (zh) * | 2006-09-06 | 2008-02-13 | 佛山市地天泰磨具有限公司 | 一种新型铝基金属结合剂金刚石工具及其制备方法 |
| CN101380728A (zh) * | 2008-09-25 | 2009-03-11 | 华侨大学 | 一种增强烧结金刚石结块中磨粒把持强度的方法 |
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