CN111808572A - Self-sharpening mixed particle size aggregate abrasive and preparation method thereof - Google Patents
Self-sharpening mixed particle size aggregate abrasive and preparation method thereof Download PDFInfo
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Abstract
A self-sharpening mixed particle size aggregate abrasive and a preparation method thereof are characterized in that the mixed particle size aggregate abrasive is composed of coarse particle size abrasive grains, fine/superfine particle size abrasive grains, ceramic (glass) bonding agents and brittle additives, and the preparation method specifically comprises the following steps: firstly, weighing and mixing abrasive particles with a coarse particle size, abrasive particles with a fine/superfine particle size, a ceramic (glass) bonding agent and a brittle additive in proportion; step two, weighing the uniformly mixed materials, granulating and drying; step three, dehydrating, degassing and sintering; and step four, screening to obtain aggregate abrasive particles with mixed particle sizes of required sizes. The invention has the advantages of high material removal efficiency, good abrasive particle self-sharpening property, stable and stable processing, long service life and the like, and can be widely applied to resin grinding wheels, honing oilstones, pills, fixed abrasive grinding and polishing pads, polishing blocks and other fixed grinding tools for processing technologies such as precision grinding, honing, grinding, polishing and the like.
Description
Technical Field
The invention relates to the field of abrasive preparation and abrasive processing (grinding, grinding and polishing), and is suitable for resin grinding wheels, honing oilstones, pills, fixed abrasive grinding pads, polishing pads and polishing blocks used for precision grinding, honing, grinding and polishing, in particular to a mixed particle size aggregate abrasive with combination of coarse particle size and fine/superfine particle size and a preparation method thereof.
Background
In the field of abrasive particle processing, because of small particle size, the exposure height of the sub/micron-sized abrasive particles cannot meet the requirement, and the application of the sub/micron-sized abrasive particles in the consolidation abrasive tools such as grinding wheels, grinding pads, pills, polishing blocks and the like is limited. In the abrasive production industry, the abrasives with small particle sizes (particularly the abrasives within the range of 100 nm-3 mu m) cannot be widely applied due to the reasons, so that the backlog of the abrasives with fine/superfine particle sizes in an enterprise is serious, and the economic benefit of the enterprise is greatly reduced.
At present, the problems of low material removal efficiency, serious blockage of the grinding tool, short service life, poor surface quality of workpieces, unstable processing performance and the like exist in the preparation of a bonded grinding tool by adopting grinding materials with fine/superfine particle sizes. The main reasons for this are: (1) the exposure height of the abrasive in the grinding, lapping or polishing process is small, and the exposure of the micro blade is relatively difficult; (2) the abrasive grains with fine/superfine grain diameter are small in stress, and the passivated abrasive grains are difficult to fall off and cannot be self-renewed.
Aiming at the problems that abrasive particles fall off, dull abrasive particles are worn and self-renewal cannot be realized in the processing process of a bonded abrasive tool, polycrystalline abrasive materials with self-sharpening performance are introduced, namely, the abrasive particles are self-renewed and self-corrected in a mode of micro-edge exposure, passivation, falling off and new micro-edge exposure, so that the purpose of prolonging the service life of the abrasive tool is achieved. However, the polycrystalline diamond micropowder is prepared by an explosion method, and the method has the defects of complex preparation process, high cost, low yield, controlled explosive and the like. Nanjing aerospace university discloses a self-sharpening sintered abrasive (ZL 201610243158.0), which is prepared by mixing abrasive such as diamond with a single particle size with a ceramic (glass) bonding agent, sintering at high temperature, crushing and screening to obtain the sintered abrasive with certain self-sharpening performance, wherein the sintered abrasive utilizes the low-cycle fatigue property of the bonding agent, and self-replacement is completed through the processes of abrasive dull grinding, bonding agent fatigue damage, small-particle abrasive falling and sharp abrasive exposure. The abrasive prepared by the method has good self-sharpening performance and stable processing performance. However, with respect to single particle size aggregate abrasives made with fine/ultrafine particle sizes, the following problems still exist: 1. the exposure height of abrasive particles in the grinding tool is not enough, and the material removal capability is low; 2. dull grinding particles are not easy to fall off and can not fully reflect the self-sharpening property of the grinding particles. Therefore, how to improve the exposure of the micro-blades of the (sub) micron-sized abrasive particles in the bonded abrasive tool and the self-sharpening performance of the abrasive particles so as to achieve the purposes of high material removal efficiency, processing stability and processing sustainability is a problem to be solved urgently at present.
Disclosure of Invention
The invention mainly aims to overcome the defects that the abrasive particles are not easy to expose, the material removal capability is low, the abrasive particle self-sharpening performance is poor and the like in the processing processes of grinding, lapping, polishing and the like of sub/micron-sized abrasive particles. The self-sharpening mixed particle size aggregate abrasive can be applied to resin-based grinding wheels, honing oilstones, pills, fixed abrasive grinding pads, polishing blocks and other fixed grinding tools used in the processing of precision grinding, honing, grinding, polishing and the like.
The technical scheme of the invention is as follows:
the self-sharpening mixed-particle-size aggregate abrasive is characterized in that aggregate abrasive particles comprise 2-70% by mass of abrasive particles with a coarse particle size, 10-90% by mass of abrasive particles with a fine/ultrafine particle size, 4.5-50% by mass of a binding agent and 0.01-2% by mass of a brittle additive. The sum of all the components is 100 percent.
The abrasive grains with the coarse grain diameter and the abrasive grains with the fine/superfine grain diameter are respectively one or the combination of diamond and cubic boron nitride.
The grain size distribution of the abrasive with the coarser grain size is between 1 mu m and 50 mu m, and particularly the grain size distribution of the initial abrasive is between 2 mu m and 30 mu m.
The grain size distribution of the fine/superfine grain size abrasive is 10nm-5 mu m, especially 50 nm-3 mu m of the initial abrasive.
The brittle additive is silicon, germanium, or/and alloys thereof.
The particle size distribution of the mixed particle size aggregate abrasive is between 1 mu m and 200 mu m, and particularly between 5 mu m and 150 mu m.
The second technical scheme of the invention is as follows:
a self-sharpening mixed particle size aggregate abrasive is characterized by being prepared by the following steps:
step one, weighing and mixing abrasive materials with a relatively coarse grain size, abrasive materials with a fine/ultrafine grain size, a ceramic (glass) bonding agent and a brittle additive according to a proportion;
step two, weighing the uniformly mixed materials, granulating and drying;
step three, dehydrating, degassing and sintering;
and step four, screening to obtain aggregate abrasive particles with mixed particle sizes of required sizes.
The self-sharpening mixed particle size aggregate abrasive is characterized in that the mixed particle size aggregate abrasive grains can be used for resin-based grinding wheels, pills, fixed abrasive polishing pads, polishing blocks and other grinding tools used in precision grinding, honing, grinding and polishing.
The invention discloses a self-sharpening mixed particle size aggregate abrasive which is characterized in that a grinding tool prepared from the mixed particle size aggregate abrasive can be used for grinding, grinding and polishing non-metal materials such as quartz glass, microcrystalline glass and glazed ceramic tiles and metal materials such as aluminum alloy and titanium alloy.
The invention has the beneficial effects that:
the self-sharpening mixed particle size aggregate abrasive and the preparation method thereof are obtained by repeated experiments and researches on the basis of summary of long-term practical experience of the inventor. The method combines abrasive particles with a coarser particle size and abrasive particles with a fine/ultrafine particle size, and prepares the mixed particle size aggregate abrasive with certain micro-crushing performance by adopting a sintering method. Unlike single particle size aggregate abrasives: the abrasive grains in each grain size range in the mixed grain aggregate abrasive have different functions, and the abrasive grains with thicker grain sizes improve the material removal capability on one hand and assist the exposure of micro blades of the abrasive grains with fine/superfine grain sizes on the other hand; the fine/ultra-fine grain size abrasive particles assist the micro-blade cutting on one hand and play a role in friction polishing on the other hand. The abrasive grains participating in the work in the mixed grain aggregate abrasive are dull-ground to a certain degree, and the ceramic (glass) bonding agent at the joint of the abrasive grains is broken due to the low-cycle fatigue property of the ceramic (glass) bonding agent, so that the abrasive grains fall off from the aggregate abrasive, and the micro-blades of new abrasive grains are exposed to continue working.
The aggregate abrasive particles with mixed particle sizes have good self-sharpening performance while improving the removal rate of materials and increasing the exposure of the abrasive particles and the number of working micro-blades, can realize continuous processing and stable processing of a grinding tool, and prolongs the service life of the grinding tool.
The self-sharpening mixed particle size aggregate abrasive can be used for preparing resin-based grinding wheels, honing oilstones, pills, fixed abrasive polishing pads, polishing blocks and other fixed grinding tools, and can be widely applied to the technical fields of processing such as precision grinding, honing, grinding, polishing and the like.
The self-sharpening mixed particle size aggregate abrasive can relieve the problem of serious overstock of fine/ultra-fine particle size abrasives in production enterprises, and improves the economic benefit of the production enterprises.
Drawings
FIG. 1 is a scanning electron microscope photograph of a single mixed particle size aggregate abrasive of the present invention.
FIG. 2 is an enlarged view of a portion of the mixed size aggregate abrasive of FIG. 1.
In the figure: 1. diamond abrasive grains with coarse grain size and diamond abrasive grains with ultrafine grain size.
Detailed Description
The invention will be further described with reference to the following examples and the accompanying drawings. It is to be understood that the disclosed embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention.
Example 1.
A self-sharpening abrasive for the aggregate with mixed grain size is composed of diamond powder with relatively large grain size, fine diamond powder with fine grain size, ceramic (glass) binder and brittle additive. Wherein, the diamond with the thicker grain diameter is selected to be 2-4 μm, and the diamond micro powder with the fine grain diameter is selected to be less than 1 μm. The preparation method comprises the following steps: diamond powder with a larger grain diameter, diamond micropowder with a fine grain diameter and a ceramic bonding agent are mixed according to the mass percentage of 15: 48: 36.3: 0.7, fully mixing; weighing the uniformly mixed materials, granulating and drying; dehydrating, degassing and sintering; and screening to obtain aggregate diamond abrasive grains with mixed grain sizes ranging from 40 micrometers to 75 micrometers. A scanning electron micrograph of the single mixed-particle-size aggregate abrasive prepared is shown in FIG. 1, and a partial enlarged view thereof is shown in FIG. 2.
And preparing the aggregate diamond abrasive with the screened mixed particle size into a fixed abrasive grinding pad for grinding and polishing the microcrystalline glass to obtain the material removal rate of 6-8 mu m/min and the workpiece surface roughness of Ra 30-40 nm, wherein the experiment lasts for 3 hours and the material removal rate is stable. The processing efficiency and the processing stability of the consolidated aggregate abrasive pad with the mixed grain size obtained by a grinding experiment are far superior to those of a consolidated aggregate diamond abrasive pad with a single grain size (less than or equal to 1 mu m) and the surface roughness Ra of the consolidated aggregate diamond abrasive pad is lower than that of a consolidated aggregate diamond abrasive pad with a single grain size (2-4 mu m).
Example 2.
A self-sharpening abrasive for the aggregate with mixed grain size is composed of diamond powder with relatively large grain size, fine diamond powder with fine grain size, ceramic (glass) binder and brittle additive. Wherein, the diamond with a thicker grain diameter is 3-5 μm, and the diamond micro powder with a fine grain diameter is 0.5-1 μm. The preparation method comprises the following steps: diamond powder with a larger grain diameter, diamond micropowder with a fine grain diameter and a ceramic bonding agent are mixed according to the mass percentage of 15: 48: 36.5: 0.5, fully mixing; weighing the uniformly mixed materials, granulating and drying; dehydrating, degassing and sintering; and screening to obtain aggregate diamond abrasive grains with mixed grain sizes ranging from 50 micrometers to 150 micrometers. And preparing the aggregate diamond abrasive with the mixed particle size obtained by screening into a fixed abrasive grinding pad for grinding and polishing quartz glass to obtain the material removal rate of 8-10 mu m/min and the workpiece surface roughness of Ra 35-50 nm, wherein the experiment lasts for 3 hours, the material removal rate is relatively stable, and the material removal rate change is not more than 15%.
Example 3.
A self-sharpening mixed-particle size aggregate abrasive comprising coarser particlesDiamond powder, fine diamond powder, ceramic (glass) binder and brittle additive. Wherein, the diamond with a thicker grain diameter is 4-6 μm, and the diamond micro powder with a fine grain diameter is 1-2 μm. The preparation method comprises the following steps: diamond powder with a larger grain diameter, diamond micropowder with a fine grain diameter, a ceramic bonding agent and a brittle additive are mixed according to the mass percentage of 30.5: 35: 33: 1.5, fully mixing; weighing the uniformly mixed materials, granulating and drying; dehydrating, degassing and sintering; and screening to obtain aggregate diamond abrasive grains with mixed grain sizes ranging from 40 micrometers to 75 micrometers. Preparing the diamond abrasive with the sieved mixed particle size aggregates into a small fixed abrasive tool head for grinding and polishing a titanium alloy material to obtain the workpiece surface roughness of Ra20 nm-40 nm and 0.5-2mm3The material removal rate per minute lasts for 3 hours, the material removal rate is relatively stable, and the material removal speed change is not more than 15%.
Example 4.
A self-sharpening aggregate abrasive with mixed grain size is composed of diamond powder with relatively large grain size, fine-grain cubic boron nitride powder, ceramic (glass) binder and brittle additive. Wherein, the diamond with a coarser grain diameter is 2-4 μm, the cubic boron nitride micro powder with a fine grain diameter is 50-200 nm, and the brittle additive is germanium (or germanium alloy). The preparation method comprises the following steps: diamond powder with a relatively coarse grain size, cubic boron nitride micro powder with a superfine grain size, a ceramic bonding agent and a brittle additive, wherein the mass percentage of the diamond powder to the cubic boron nitride micro powder to be bonded is 12.5: 65: 22: 1.5, fully mixing; weighing the uniformly mixed materials, granulating and drying; dehydrating, degassing and sintering; and screening to obtain aggregate diamond and cubic boron nitride abrasive grains with mixed grain sizes ranging from 10 micrometers to 40 micrometers.
Preparing the aggregate diamond abrasive material with the mixed particle size after screening into a polishing block, and polishing the glazed ceramic tile to obtain the workpiece surface roughness of Sa 5-20 nm and the glossiness of more than 80 degrees.
Example 5.
A self-sharpening aggregate abrasive with mixed grain size is composed of cubic boron nitride powder with relatively large grain size, fine cubic boron nitride powder with fine grain size, ceramic (glass) binder and brittle additive. Wherein, the cubic boron nitride with a coarser grain diameter is 1-2 μm, the cubic boron nitride micro powder with a fine grain diameter is 10-50 nm, and the brittle additive is silicon. The preparation method comprises the following steps: cubic boron nitride with a relatively large particle size, cubic boron nitride micro powder with a fine particle size and a ceramic bonding agent are mixed according to the mass percentage of 2: 90: 7.91: 0.01, fully mixing; weighing the uniformly mixed materials, granulating and drying; dehydrating, degassing and sintering; and screening to obtain the aggregate cubic boron nitride abrasive particles with mixed particle sizes within the range of 5-20 microns.
And preparing the aggregate cubic boron nitride abrasive with the mixed particle size after screening into a fixed abrasive grinding pad for grinding and polishing the microcrystalline glass to obtain the material removal rate of 1-3 mu m/min and the workpiece surface roughness of Ra 10-20 nm, wherein the material removal rate is stable after the experiment lasts for 3 hours. The processing efficiency and the processing stability of the consolidated aggregate abrasive pad with mixed grain diameter obtained by grinding experiments are far superior to those of the consolidated aggregate cubic boron nitride abrasive pad with single grain diameter (less than or equal to 50 nm) and the surface roughness Ra of the consolidated aggregate cubic boron nitride abrasive pad prepared by the single grain diameter (1-2 mu m) aggregate cubic boron nitride abrasive.
Example 6.
A self-sharpening abrasive for the aggregate with mixed grain size is composed of diamond powder with relatively large grain size, fine diamond powder with fine grain size, ceramic (glass) binder and brittle additive. Wherein, the diamond with a thicker grain diameter is 40-50 μm, and the diamond micro powder with a fine grain diameter is 3-5 μm. The preparation method comprises the following steps: diamond powder with a larger grain size, diamond micropowder with a fine grain size and a ceramic bonding agent are mixed according to the mass percentage of 70: 10: 19.85.: 0.15, fully mixing; weighing the uniformly mixed materials, granulating and drying; dehydrating, degassing and sintering; and screening to obtain aggregate diamond abrasive grains with mixed grain sizes ranging from 100 micrometers to 200 micrometers. And preparing the aggregate diamond abrasive with the mixed particle size obtained by screening into a fixed abrasive grinding pad for grinding and polishing quartz glass to obtain the material removal rate of 15-20 mu m/min and the workpiece surface roughness of Ra 110-130 nm, wherein the experiment lasts for 3 hours, the material removal rate is relatively stable, and the material removal rate change is not more than 10%.
Example 7.
Self-sharpening mixing deviceThe grain size aggregate abrasive consists of diamond powder of relatively large grain size, fine diamond powder of fine grain size, ceramic (glass) binder and brittle additive. Wherein, the diamond with a thicker grain diameter is 20-30 μm, and the diamond micro powder with a fine grain diameter is 2-4 μm. The preparation method comprises the following steps: diamond powder with a larger grain diameter, diamond micropowder with a fine grain diameter, a ceramic bonding agent and a brittle additive are mixed according to the mass percentage of 19: 31: 49.97: 0.03 fully mixing; weighing the uniformly mixed materials, granulating and drying; dehydrating, degassing and sintering; and screening to obtain aggregate diamond abrasive particles with mixed particle sizes ranging from 80 micrometers to 150 micrometers. Preparing the sieved mixed-particle-size aggregate diamond abrasive into a small fixed abrasive tool head for grinding and polishing a titanium alloy material to obtain a workpiece surface roughness of Ra70 nm-100 nm and a workpiece surface roughness of 2-3mm3The material removal rate per minute lasts for 3 hours, the material removal rate is relatively stable, and the change of the material removal speed is not more than 20%.
Example 8.
A self-sharpening abrasive for the aggregate with mixed grain size is composed of diamond powder with relatively large grain size, fine diamond powder with fine grain size, ceramic (glass) binder and brittle additive. Wherein, the diamond with a thicker grain diameter is 5-10 μm, and the diamond micro powder with a fine grain diameter is 1-3 μm. The preparation method comprises the following steps: diamond powder with a coarser grain size, diamond micropowder with an ultrafine grain size, a ceramic bonding agent and a brittle additive are mixed according to the mass percentage of 45: 50: 4.5: 0.1, fully mixing; weighing the uniformly mixed materials, granulating and drying; dehydrating, degassing and sintering; and screening to obtain aggregate diamond abrasive grains with mixed grain sizes ranging from 60 micrometers to 100 micrometers.
Preparing the aggregate diamond abrasive material with the mixed particle size after screening into a polishing block, and polishing the glazed ceramic tile to obtain the workpiece surface roughness of Sa 70-80 nm.
Although the present invention has been illustrated and described with reference to specific examples, the present invention is not limited to the above-described examples, and any other changes, modifications, substitutions, combinations, and simplifications which do not depart from the spirit and principle of the present invention should be construed as equivalents thereof, and all such changes, modifications, substitutions, combinations, and simplifications are intended to be included in the scope of the present invention.
The present invention is not concerned with parts which are the same as or can be implemented using prior art techniques.
Claims (9)
1. The self-sharpening mixed-particle-size aggregate abrasive is characterized by consisting of 2-70% by mass of coarse-particle-size abrasive particles, 10-90% by mass of fine/ultrafine-particle-size abrasive particles, 4.5-50% by mass of ceramic (or glass) bonding agent and 0.01-2% by mass of brittle additive, wherein the sum of the components is 100%.
2. The abrasive grain composite according to claim 1, wherein the abrasive grains having a relatively coarse grain size and abrasive grains having a fine/ultra-fine grain size are each one of diamond and cubic boron nitride or a combination thereof.
3. A self-sharpening mixed-particle size aggregate abrasive according to claim 1, characterized in that the coarser-particle size abrasive grains have a particle size distribution of the primary abrasive of between 1 μm and 50 μm, in particular between 2 μm and 30 μm.
4. The abrasive grain composition according to claim 1, wherein the fine/ultrafine abrasive grains have a grain size distribution of 10nm to 5 μm, and more particularly, 50nm to 3 μm.
5. The self-sharpening mixed grain aggregate abrasive as defined in claim 1, wherein the friable additive is silicon, germanium, or/and alloys thereof.
6. The self-sharpening mixed grain aggregate abrasive as claimed in claim 1, wherein the mixed grain aggregate abrasive has a particle size distribution of 1 μm to 200 μm, particularly 5 μm to 150 μm.
7. A self-sharpening mixed grain aggregate abrasive as defined in claim 1, prepared by the steps of:
step one, weighing and mixing the abrasive with the relatively coarse grain size, the abrasive with the fine/superfine grain size, the ceramic or glass bonding agent and the brittle additive according to a proportion;
step two, weighing the uniformly mixed materials, granulating and drying;
step three, dehydrating, degassing and sintering;
and step four, screening to obtain the mixed particle size aggregate abrasive particles with the required size.
8. The self-sharpening mixed grain aggregate abrasive as defined in claims 1 to 7, wherein the mixed grain aggregate abrasive is used for a resin-based grinding wheel, a honing stone, a pellet, a fixed abrasive polishing pad, a polishing block used in precision grinding, honing, lapping, polishing, or polishing.
9. The abrasive grain with mixed grain size aggregates of claim 8, wherein the abrasive grain with mixed grain size aggregates is used for grinding, lapping and polishing quartz glass, microcrystalline glass, glazed ceramic tile non-metallic materials and aluminum alloy and titanium alloy metallic materials.
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Cited By (5)
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| CN114406916A (en) * | 2021-12-20 | 2022-04-29 | 广州市石基耐火材料厂 | Knife stone and preparation method thereof |
| CN115710486A (en) * | 2022-10-21 | 2023-02-24 | 上海工程技术大学 | Self-discharge abrasive for electrocatalysis-assisted chemical mechanical polishing and preparation method thereof |
| CN115710485A (en) * | 2022-10-21 | 2023-02-24 | 上海工程技术大学 | Self-luminous abrasive material for processing photocatalytic auxiliary abrasive particles |
| CN115785906A (en) * | 2022-10-31 | 2023-03-14 | 南京航空航天大学 | Bonding method magnetic abrasive material with adjustable self-sharpening property and preparation method thereof |
| CN115710485B (en) * | 2022-10-21 | 2024-05-17 | 上海工程技术大学 | Self-luminous abrasive for photocatalysis-assisted abrasive grain processing |
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| CN111808572B (en) | 2021-04-27 |
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