CN111618750A - Green precise continuous forming system and process for metal ultrathin grinding wheel - Google Patents
Green precise continuous forming system and process for metal ultrathin grinding wheel Download PDFInfo
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- CN111618750A CN111618750A CN202010512711.2A CN202010512711A CN111618750A CN 111618750 A CN111618750 A CN 111618750A CN 202010512711 A CN202010512711 A CN 202010512711A CN 111618750 A CN111618750 A CN 111618750A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
- B24D18/0009—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
- B24D18/009—Tools not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical 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
- B24D3/04—Physical 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
- B24D3/06—Physical 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
- B24D3/10—Physical 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 for porous or cellular structure, e.g. for use with diamonds as abrasives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical 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
- B24D3/20—Physical 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 organic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
- B24D3/342—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties incorporated in the bonding agent
Abstract
The invention discloses a green precise continuous molding system and a process of a metal ultrathin grinding wheel, belonging to the technical field of superhard materials and products in machining, wherein the system comprises the following components: the system comprises a fixed forming double-roll, a precise adjusting double-roll, a first rubber demoulding roll, a vacuum adsorption device, a jacking cutting device, a second rubber demoulding roll, an oven and a storage cabinet from upstream to downstream in sequence, wherein the precise adjusting double-roll consists of the first precise adjusting roll and the second precise adjusting roll, annular demoulding belts used for transporting the grinding wheel blanks are arranged on the first rubber demoulding roll and the second rubber demoulding roll, the first rubber demoulding roll and the second precise adjusting roll are tangent, and the second rubber demoulding roll is positioned at an inlet of the oven. The invention realizes continuous production, reduces the difference of batch quality of the current single-piece die pressing intermittent production and improves the production efficiency.
Description
Technical Field
The invention belongs to the field of superhard materials and products in machining, and particularly relates to a green precise continuous forming system and process for a metal ultrathin grinding wheel.
Background
The ultrathin grinding wheel is mainly used for the precise cutting and processing of key parts such as optical filters, semiconductor chips, optical fiber splitters, LEDs and the like in the fields of optics, electronics, optical communication and the like, and is widely used for the procedures of chip scribing, packaging cutting, LED cutting, optical fiber array slotting, ceramic sleeve cutting, precious material cutting and the like. The materials have high requirements on cutting precision and processing quality, and have strict control on workpiece chipping, cracks, scratches, burrs, peeling and the like. The thickness of the ultrathin grinding wheel can be as thin as 0.015mm, the outer diameter is 50 mm-125 mm, the diameter-thickness ratio is high, the cutting depth is 0.05 mm-3 mm, the feeding speed is 0.05 mm/s-300 mm/s, the cutting rotating speed is 10000 rpm/min-60000 rpm/min, and the ultrathin grinding wheel belongs to the field of high-speed/ultrahigh-speed grinding, and is high in rotating speed, fast in feeding, narrow in cutting joint and long in continuous operation time. Under the high-speed strong heat-force coupling effect, the defects of asymmetrical distribution, component segregation, uneven density, poor precision and the like of the abrasive materials such as diamond, CBN, SiC and the like on the two side surfaces of the ultrathin grinding wheel easily cause uneven stress distribution of the ultrathin grinding wheel, generate multi-order irregular vibration, and further cause low high-speed movement precision, unqualified processing quality and high product rejection rate.
At present, the forming process adopted by the ultrathin grinding wheel is loose powder mould pressing intermittent forming, and the main steps are as follows: formulation design → powder mixing → tool selection → pressing parameter setting → powder spreading → single-mode pressing → manual die unloading. The existing forming process has strong dependence on human experience, poor product stability, large dust, low production efficiency, poor green body precision and environmental pollution, and belongs to intermittent forming. In addition, the traditional forming process is easy to have the defects of upward floating of grinding materials such as diamonds and the like, segregation of components with different densities, uneven density of the upper part and the lower part of a green body, over-poor precision and the like, so that the rejection rate of processed products in the high-speed cutting process is high.
With the continuous promotion of the global industry 4.0, the country pays more and more attention to environmental protection, the requirements of precision manufacturing such as photoelectricity on processing quality and efficiency are continuously improved, and a novel forming process of an ultrathin grinding wheel needs to be researched and proposed urgently. Therefore, the grinding wheel preparation process which is continuously prepared, green, environment-friendly and precisely formed is suitable for the requirement of national industrial development.
Disclosure of Invention
The invention develops a green precise continuous molding system and a process of the metal ultrathin grinding wheel aiming at the defects that the existing molding process of the ultrathin grinding wheel is easy to cause upward floating of grinding materials such as diamond and the like, segregation of components with different densities, uneven density of a green blank and an upper blank, over-poor precision and the like.
In order to achieve the purpose, the invention provides the following main technical scheme:
the utility model provides a green accurate continuous forming system of ultra-thin emery wheel of metal to emery wheel blank's export is the upper reaches, the system includes fixed shaping pair roller, accurate regulation pair roller, first rubber stripper roller, vacuum adsorption device, jacking cutting device, second rubber stripper roller, oven and storing compartment from upper reaches to low reaches in proper order, and accurate regulation pair roller comprises first accurate regulating roller and second accurate regulating roller, is equipped with the annular drawing of patterns area that is used for carrying out the transportation to emery wheel blank on first rubber stripper roller and the second rubber stripper roller, and first rubber stripper roller is tangent with the second accurate regulating roller, and second rubber stripper roller is located the import department of oven.
Furthermore, a scraping knife is arranged below the demolding belt between the second rubber demolding roller and the first rubber demolding roller and used for scraping the residual grinding wheel blanks on the demolding belt after the grinding wheel blanks are transported, and a surplus material recycling hopper is arranged below the scraping knife.
Furthermore, the distance between the fixed forming pair rollers is 1 mm-2 mm, the distance between the first precision adjusting roller and the second precision adjusting roller is 0.5 mm-0.6 mm, and the demolding belt is a canvas demolding belt.
The green precise continuous forming process of the metal ultrathin grinding wheel by using the system comprises the following steps:
(1) mixing: heating and stirring an organic binder until the organic binder is completely melted, adding a metal ultrathin grinding wheel raw material, and stirring for 30-90 minutes at 100-150 ℃, wherein the mass ratio of the organic binder to the metal ultrathin grinding wheel raw material is (1-3) to (7-9);
(2) pre-packaging: wrapping the mixed and matured dough by using a continuous protective film with the thickness of 0.1 mm-0.5 mm;
(3) rolling: the pre-wrapped forming aggregate passes through a conveying belt and sequentially passes through a fixed forming double-roller, a precision adjusting double-roller and a first rubber demolding roller, the roller speed is 0.5-3 m/min, the precision of the distance between the double-roller is adjusted through hydraulic control of a dial indicator, and finally the pre-wrapped forming aggregate is rolled into a strip-shaped green body with the thickness of 0.5-0.6 mm;
(4) and (3) transmission: the strip-shaped green body passes through a first rubber demolding roller, is attached to a demolding belt and is conveyed to the next procedure along with the demolding belt;
(5) uncovering the film: the rolled strip-shaped green body enters a freezing film uncovering area through a demoulding belt, the temperature of the area is minus 5 ℃ to 5 ℃, and a protective film in the surface pre-packaging process is uncovered through adsorption by a vacuum sucker with the adsorption force of 3N to 5N;
(6) enabling the strip-shaped green body after film uncovering to enter a slitting area at a speed of 0.5-3 m/min, and obtaining an annular ultrathin grinding wheel green body meeting the required size through a jacking cutting device;
(7) degreasing: sending the cut annular ultrathin grinding wheel green body into an oven through a demolding belt for degreasing, wherein the degreasing temperature is 120-400 ℃, and the degreasing time is 10-300 min;
(8) and (4) packaging and storing: and (3) putting the degreased and qualified green bodies into a stainless steel box, filling protective gas, and putting the green bodies into a storage cabinet for storage at the temperature of 15-30 ℃ and the humidity of 5-10% RH.
Preferably, the organic binder has a composition of: 25-35 wt% of low-density polyethylene, 55-65 wt% of paraffin and 5-15 wt% of stearic acid.
Preferably, the metal ultrathin grinding wheel comprises the following raw materials: 70-80 wt% of copper powder, 3-8 wt% of iron powder, 5-15 wt% of tin powder, 3-8 wt% of cobalt powder and 5-6 wt% of diamond, wherein the granularity of the copper powder, the iron powder, the tin powder and the cobalt powder is 500 meshes or finer, and the granularity of the diamond is 600 meshes.
Preferably, the metal ultrathin grinding wheel has an outer diameter of 58.3mm, an inner diameter of 39.2mm and a thickness of 0.55mm
The invention has the following positive beneficial effects:
1. the invention is applied to the precise molding of the green body of the ultrathin grinding wheel in the field of superhard grinding tools in the mechanical industry, utilizes the characteristic of better wettability of organic matters and diamond, adopts organic binder to wrap the diamond and metal bond powder into a lump and roll the lump for molding, overcomes the defects that the existing loose powder compression molding diamond is easy to float upwards and different density components are easy to segregate, is beneficial to reducing the bad phenomena of high-speed tail swing, jumping, multi-step irregular movement and the like of the ultrathin grinding wheel, and is beneficial to improving the high-speed movement precision and the processing quality of the ultrathin grinding wheel;
2. the rolling gap is adjusted by adopting a dial indicator for hydraulic adjustment, and the precision of rolled green bodies can reach +/-0.005 mm, which is far higher than the precision (+/-0.03 mm) of the existing loose powder compression molding process;
3. the invention realizes continuous production, reduces the difference of batch quality of the current single-piece die pressing intermittent production and improves the production efficiency. The organic binder can effectively coat the diamond and the binder powder, thereby avoiding dust pollution, being beneficial to protecting the health of workers and realizing green manufacture. Meanwhile, the residual blanks after cutting can be returned to the bin for mixing again, so that the material utilization rate is greatly improved, non-renewable resources are saved, and the forming process is precise, continuous, green and sustainable.
Drawings
FIG. 1 is a schematic structural diagram of a green precision continuous molding system for a metal ultrathin grinding wheel; in the figure, 1, a pre-wrapped blank, 2, a fixed forming pair roller, 31, a first precision adjusting roller, 32, a second precision adjusting roller, 41, a first rubber demoulding roller, 42, a second rubber demoulding roller, 5, a canvas demoulding belt, 6, a vacuum adsorption device, 7, a jacking cutting device, 8, an annular ultrathin grinding wheel green body, 9, a scraping knife, 10, a residual material recovery hopper, 11, an oven and 12, a storage cabinet are arranged;
FIG. 2 is a process flow diagram of the present invention;
FIG. 3 is an SEM image of a green grinding wheel obtained after degreasing in example 1 at 400 times magnification;
FIG. 4 is an SEM image of a green grinding wheel obtained after degreasing in example 1, at 3000 times magnification.
Detailed Description
The invention will be further described with reference to the following drawings and specific examples:
example 1
A green precise continuous forming system of a metal ultrathin grinding wheel is shown in figure 1, an outlet of a grinding wheel blank is taken as an upstream, the system sequentially comprises a fixed forming pair roller 2, a precise adjusting pair roller, a first rubber demoulding roller 41, a vacuum adsorption device 6, a jacking cutting device 7, a second rubber demoulding roller 42, an oven 11 and a storage cabinet 12 from upstream to downstream, the precise adjusting pair roller consists of a first precise adjusting roller 31 and a second precise adjusting roller 32, an annular canvas demoulding belt 5 for conveying the grinding wheel blank is arranged on the first rubber demoulding roller 41 and the second rubber demoulding roller 42, the first rubber demoulding roller 41 is tangent to the second precise adjusting roller 32, and the second rubber demoulding roller 42 is positioned at an inlet of the oven 11.
Further, a scraping knife 9 is arranged below the canvas demolding belt 5 between the second rubber demolding roller 42 and the first rubber demolding roller 41 and used for scraping the grinding wheel blanks remained on the canvas demolding belt 5 after the grinding wheel blanks are transported, and a surplus material recycling hopper 10 is arranged below the scraping knife 10.
Further, the distance between the fixed forming roller pair 2 is 1mm, and the distance between the first precision adjusting roller 31 and the second precision adjusting roller 32 is 0.5 mm-0.6 mm.
A utilizes the above-mentioned system to carry on the ultra-thin emery wheel green body shaping process of metal bond, the ultra-thin emery wheel green body specification is phi 58.2mm x 0.5mm (emery wheel thickness) x 39.1 (inner bore); as shown in fig. 2, the method comprises the following steps:
(1) mixing:
weighing organic binder according to a proper proportion (shown in table 1) in a beaker, heating in oil bath at a constant temperature of 120 ℃ until the organic binder is completely melted, then slowly adding the metal binder and the diamond described in table 2 into the organic binder (the proportion of the organic binder is shown in table 1), stirring for 60 minutes at 120 ℃ until the mass ratio of the organic binder to the metal ultrathin grinding wheel is 2:8, and obtaining the mature ball packed molding material which is uniform in color, has no obvious large granular substances and has no air holes.
TABLE 1 organic Binder ratios
TABLE 2 ultra-thin metal grinding wheel raw material ratio
(2) Pre-packaging:
wrapping the mixed and matured dough material with continuous thin plastic with the thickness of 0.2mm, and preparing for rolling;
(3) rolling: the pre-wrapped blank 1 is bitten under the action of gravity and friction force between the fixed forming pair rollers 2 through a conveyer belt, and sequentially passes through the fixed forming pair rollers 2, the precision adjusting pair rollers and the first rubber demolding roller 41, the roller speed is 1m/min, the distance between the fixed forming pair rollers 2 is 1mm, the distance between the first precision adjusting roller 31 and the second precision adjusting roller 32 is 0.55mm, the distance precision between the first precision adjusting roller 31 and the second precision adjusting roller 32 is adjusted through hydraulic control of a dial indicator, and finally, a strip-shaped green body with the thickness of 0.55mm is precisely rolled;
(4) and (3) transmission: because of the gravity and the adsorption effect of the canvas demolding belt 5, the adsorption force is 1.5N, a belt-shaped ultrathin grinding wheel green body in the forming roller is attached to the canvas demolding belt on the circumferential surface of the first rubber demolding roller 41 and is conveyed to the next procedure along with the canvas demolding belt;
(5) uncovering the film: slowly feeding the rolled strip-shaped green body into a freezing film uncovering area through a canvas demoulding belt 5 at the speed of 1m/min, wherein the temperature of the freezing film uncovering area is 0 ℃, and adsorbing and uncovering a thin plastic protective film in the surface pre-packaging process through a vacuum adsorption device 6 (specifically a vacuum sucker) with the adsorption force of 5N to prepare for slitting;
(6) slitting: slowly feeding the strip-shaped green body after film uncovering into a slitting area through a green body conveying belt at the speed of 1m/min, and obtaining an annular ultrathin grinding wheel green body 8 through a mechanical nesting cutting device 7, wherein the outer diameter is 58.3mm, the inner diameter is 39.2mm, and the thickness is 0.55 mm;
(7) degreasing: and (3) feeding the cut annular ultrathin grinding wheel green body 8 into an oven 11 through a canvas demolding belt 5 for degreasing, wherein a degreasing disc is 304 stainless steel with the thickness of micro 2mm, a degreasing cover plate is 1mm, the diameter of each micropore is 0.5mm, the porous 304 stainless steel is adopted, the degreasing temperature is 260 ℃, and the degreasing time is 300 min. The degreased thick product shrinks to a certain extent, the final size of the green body is 58.2mm in outer diameter, 39.1mm in inner diameter and 0.5mm in thickness;
(8) and (4) packaging and storing: the degreased green compact with the strength of 85MPa is manually placed into a stainless steel box, nitrogen is filled, and the stainless steel box is placed into a storage cabinet 12 for storage, so that the storage temperature is 20 ℃, and the storage humidity is 6 RH%. The green body yield was 90%. FIG. 3 is an SEM image of a green grinding wheel obtained after degreasing in example 1 at 400 times magnification; FIG. 4 is an SEM image of a green grinding wheel obtained after degreasing in example 1, at 3000 times magnification; as can be seen from the figures 3 and 4, the organic binder in the metal bond ultrathin grinding wheel green body prepared by the process is degreased completely, almost no carbon residue exists, and the powder particles are well bonded.
The above embodiments are only for illustrating the preferred embodiments of the present invention, but the present invention is not limited to the above embodiments, and any modifications, equivalent substitutions and improvements made within the spirit and principle of the present invention within the knowledge of those skilled in the art should be considered as the protection scope of the present application.
Claims (7)
1. The utility model provides a green accurate continuous forming system of ultra-thin emery wheel of metal which characterized in that, uses the export of emery wheel blank as the upper reaches, the system includes fixed shaping pair roller, accurate regulation pair roller, first rubber stripper roller, vacuum adsorption device, cover material cutting device, second rubber stripper roller, oven and storing compartment from the upper reaches to the low reaches in proper order, and accurate regulation pair roller comprises first accurate regulating roller and second accurate regulating roller, is equipped with the annular drawing of patterns area that is used for transporting the emery wheel blank on first rubber stripper roller and the second rubber stripper roller, and first rubber stripper roller is tangent with second accurate regulating roller, and second rubber stripper roller is located the import department of oven.
2. The green precise continuous molding system of the metal ultrathin grinding wheel as claimed in claim 1, wherein a scraper is arranged below the demolding belt between the second rubber demolding roller and the first rubber demolding roller and used for scraping the grinding wheel blank remained on the demolding belt after the grinding wheel blank is transported, and a residual material recycling hopper is arranged below the scraper.
3. The green precise continuous molding system of the ultrathin metal grinding wheel as claimed in claim 1, wherein the distance between the fixed molding pair rollers is 1 mm-2 mm, and the distance between the first precise regulating roller and the second precise regulating roller is 0.5 mm-0.6 mm.
4. The green precise continuous forming process of the metal ultrathin grinding wheel by using the system as claimed in any one of claims 1 to 3 is characterized by comprising the following steps:
(1) mixing: heating and stirring an organic binder until the organic binder is completely melted, adding a metal ultrathin grinding wheel raw material, and stirring for 30-90 minutes at 100-150 ℃, wherein the mass ratio of the organic binder to the metal ultrathin grinding wheel raw material is (1-3) to (7-9);
(2) pre-packaging: wrapping the mixed and matured dough by using a continuous protective film with the thickness of 0.1 mm-0.5 mm;
(3) rolling: the pre-wrapped forming aggregate passes through a conveying belt and sequentially passes through a fixed forming double-roller, a precision adjusting double-roller and a first rubber demolding roller, the roller speed is 0.5-3 m/min, the precision of the distance between the double-roller is adjusted through hydraulic control of a dial indicator, and finally the pre-wrapped forming aggregate is rolled into a strip-shaped green body with the thickness of 0.5-0.6 mm;
(4) and (3) transmission: the strip-shaped green body passes through a first rubber demolding roller, is attached to a demolding belt and is conveyed to the next procedure along with the demolding belt;
(5) uncovering the film: the rolled strip-shaped green body enters a freezing film uncovering area through a demoulding belt, the temperature of the area is minus 5 ℃ to 5 ℃, and a protective film in the surface pre-packaging process is uncovered through adsorption by a vacuum sucker with the adsorption force of 3N to 5N;
(6) enabling the strip-shaped green body after film uncovering to enter a slitting area at a speed of 0.5-3 m/min, and obtaining an annular ultrathin grinding wheel green body meeting the required size through a jacking cutting device;
(7) degreasing: sending the cut annular ultrathin grinding wheel green body into an oven through a demolding belt for degreasing, wherein the degreasing temperature is 120-400 ℃, and the degreasing time is 10-300 min;
(8) and (4) packaging and storing: and (3) putting the degreased and qualified green bodies into a stainless steel box, filling protective gas, and putting the green bodies into a storage cabinet for storage at the temperature of 15-30 ℃ and the humidity of 5-10% RH.
5. The green precise continuous molding process of the metal ultrathin grinding wheel as claimed in claim 4, wherein the organic binder comprises the following components: 25-35 wt% of low-density polyethylene, 55-65 wt% of paraffin and 5-15 wt% of stearic acid.
6. The green precise continuous forming process of the metal ultrathin grinding wheel as claimed in claim 4, wherein the metal ultrathin grinding wheel is prepared from the following raw materials: 70-80 wt% of copper powder, 3-8 wt% of iron powder, 5-15 wt% of tin powder, 3-8 wt% of cobalt powder and 5-6 wt% of diamond, wherein the granularity of the copper powder, the iron powder, the tin powder and the cobalt powder is 500 meshes or finer, and the granularity of the diamond is 600 meshes.
7. The green precise continuous forming process of the metal ultrathin grinding wheel as claimed in claim 4, wherein the outer diameter of the metal ultrathin grinding wheel is 58.3mm, the inner diameter of the metal ultrathin grinding wheel is 39.2mm, and the thickness of the metal ultrathin grinding wheel is 0.55 mm.
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|---|---|---|---|---|
| CN113182522A (en) * | 2021-03-24 | 2021-07-30 | 郑州磨料磨具磨削研究所有限公司 | Hot isostatic pressing method for degreasing and sintering metal ultrathin grinding wheel |
| CN113182522B (en) * | 2021-03-24 | 2023-04-18 | 郑州磨料磨具磨削研究所有限公司 | Hot isostatic pressing method for degreasing and sintering metal ultrathin grinding wheel |
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| CN111618750B (en) | 2021-05-18 |
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