CN111906703A - Die-casting forming method for superhard grinding wheel with ordered microgroove structure - Google Patents
Die-casting forming method for superhard grinding wheel with ordered microgroove structure Download PDFInfo
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- CN111906703A CN111906703A CN202010691809.9A CN202010691809A CN111906703A CN 111906703 A CN111906703 A CN 111906703A CN 202010691809 A CN202010691809 A CN 202010691809A CN 111906703 A CN111906703 A CN 111906703A
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- grinding wheel
- die
- aluminum
- superhard
- mold
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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
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D1/00—Treatment of fused masses in the ladle or the supply runners before casting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/007—Semi-solid pressure die casting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
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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
Abstract
The invention discloses a die-casting forming method of an orderly micro-groove structured superhard grinding wheel, which can prepare the grinding wheel with a large number of orderly arranged micro-groove structures on the outer circumference and uniformly distributed superhard grinding materials; the preparation method comprises the following steps: placing the grinding wheel hub in a mold with a large number of grooves, pouring composite powder consisting of aluminum powder and superhard grinding materials which are uniformly mixed into the mold, starting a motor to rotate a rotary table at a low speed, and filling the mold grooves with the composite powder under the action of centrifugal force; pouring molten aluminum into the mold, starting a motor to enable the rotary table to rotate at a high speed, enabling the molten aluminum to overcome the force of the capillary tube and penetrate into gaps of the composite powder under the action of centrifugal force, and enabling the aluminum powder to absorb heat of the molten aluminum to be melted; and demolding after the mold is fully cooled to obtain the superhard grinding wheel with the ordered microgroove structure. The invention ensures that the grinding material is distributed more uniformly in the aluminum-based bonding agent, improves the grinding efficiency and the service life of the grinding wheel, and has strong process repeatability, low operation difficulty and high production efficiency.
Description
Technical Field
The invention relates to a preparation method of an orderly micro-groove structure superhard grinding wheel, in particular to a die-casting forming method of the orderly micro-groove structure superhard grinding wheel.
Background
With the development of modern machining towards high precision, high efficiency, low consumption and the like, higher requirements are put forward on the performance of a grinding tool, the grinding efficiency, the grinding precision, the wear resistance and other performances of the superhard grinding wheel are key problems in high-speed precision grinding, and meanwhile, the preparation process and the preparation efficiency of the grinding wheel are more and more concerned by the industry. The preparation method of the superhard grinding wheel is complicated, the distribution of superhard grinding materials is uneven, particularly, the grinding wheel with a complicated surface structure, such as the superhard grinding wheel with an ordered microgroove structure, has small chip holding and chip discharging space, and the grinding efficiency and the grinding quality of the grinding wheel are seriously influenced. The electroplating process can prepare the grinding wheel with the micro-groove structure, but the electroplating grinding wheel is usually a single-layer grinding material, the electroplating process is complex, and the consistency of the micro-groove structure and the size is difficult to ensure.
In order to improve the preparation quality and the preparation efficiency of the superhard grinding wheel with the ordered microgroove structure, the patent with the publication number of CN104385160A discloses a manufacturing method of an electroplated grinding wheel with an ordered structure, which is characterized in that a groove array is firstly processed on the outer circumferential surface of a grinding wheel hub by adopting laser beams, then the groove array is filled with epoxy resin, and then the outer circumferential surface of the grinding wheel is electroplated with grinding materials, so that the electroplated grinding wheel with a grinding material layer and the epoxy resin which are arranged at intervals in order is formed. The grinding wheel prepared by the method increases the chip containing space of the grinding wheel, improves the chip removal capacity of the grinding wheel, enables the grinding fluid to effectively enter the grinding area and improves the cooling effect of the grinding area. However, because the grinding material layers separated by the microgrooves in the electroplating process tend to expand outwards, the number of the grinding material layers of the grinding wheel cannot be too many, the depth-to-width ratio of the formed microgrooves cannot be too large, the electroplating process efficiency is low, the microgroove arrays of each grinding wheel are processed one by laser, the production efficiency is low, and the mass and efficient production of the superhard grinding wheels with the ordered microgroove structures is difficult to realize.
Disclosure of Invention
In order to solve the problems in the prior art in the process of preparing the grinding wheel, the invention provides a die-casting forming method of the superhard grinding wheel with the ordered microgroove structure, namely, a die is processed into a groove array at one time, and the superhard grinding material and an aluminum-based binding agent are die-cast and formed through centrifugal pressure, so that the superhard grinding wheel with the ordered microgroove structure and a large number of complex microgrooves on the outer circumference can be rapidly prepared in a large batch.
In order to achieve the purpose, the invention adopts the technical scheme that: uniformly mixing 25-35% of superhard grinding material and 65-75% of aluminum powder by volume fraction to obtain composite powder; carrying out rust removal treatment on the grinding wheel hub and placing the grinding wheel hub in a mold, wherein the mold is provided with a large number of grooves which are arranged in order, namely mold grooves; pouring the composite powder into a mould and enabling the height of the composite powder to be consistent with the thickness of the grinding wheel hub; starting a motor to enable the rotary table to rotate at a low speed, and fully filling the composite powder into a gap between the die and the grinding wheel hub under the action of centrifugal force; pouring molten aluminum into a mold through a liquid injection hole, driving a motor to enable a rotary table to rotate at a high speed, and enabling the molten aluminum to overcome the force of a capillary tube and penetrate into gaps among the composite powder under the action of centrifugal force; the electric heating wire heats the composite powder in the mold and preserves the temperature of the molten aluminum; the composite powder can absorb the heat of molten aluminum, wherein the aluminum powder is completely melted due to low melting point, and the high-melting-point super-hard abrasive material is still in a solid state after absorbing heat; the melting point of the aluminum is only 660 ℃, so the superhard abrasive material cannot be damaged by heat; and (3) die-casting and forming of the grinding wheel: under the action of centrifugal force, molten aluminum and the solid superhard abrasive are in a die-casting state; the electric heating wire is powered off, and the molten aluminum is gradually solidified to form an aluminum-based bonding agent, namely the aluminum-based bonding agent, the superhard grinding material and the grinding wheel hub form an integral casting; the turntable stops rotating, after the mold is fully cooled, the mold is demoulded by the principle of expansion with heat and contraction with cold under the action of a demoulding agent, a large number of superhard grinding wheels with ordered microgrooves arranged alternately are obtained, wherein the grinding layer comprises an aluminum-based binding agent and superhard grinding materials.
The aluminum powder has a particle size of 60-400 meshes, and the super-hard abrasive has a particle size of 40-300 meshes.
The inner diameter of the die is phi 20-200 mm, and the grinding wheel with the diameter of phi 20-200 mm can be cast.
The rated rotating speed of the motor when the rotary table rotates at a high speed is 3000 r/min, and the rotating speed when the rotary table rotates at a low speed is reduced to 1000 r/min from stepless speed regulation.
When the die is heated by the electric heating wire, the internal temperature of the die is controlled to be 600-700 ℃.
Compared with the prior art, the invention has the following beneficial effects.
The grinding materials are uniformly distributed. Before the composite powder is filled into a gap between a die and a grinding wheel hub, the superhard grinding material and the aluminum powder are fully mixed; external molten aluminum permeates into the composite powder, and aluminum powder in the composite powder is gradually melted, so that the superhard abrasive material is continuously kept in a state of uniform distribution in the aluminum melt; particularly, the difference between the density of the aluminum and the density of the superhard grinding material is not large, the phenomenon that the superhard grinding material is obviously sunk in the aluminum melt is avoided, the phenomenon of abrasive material agglomeration is avoided, and the uniformity of abrasive material distribution is further maintained. Therefore, the subsequent grinding quality and grinding efficiency of the grinding wheel are greatly improved, and the service life of the grinding wheel is prolonged.
And the structure and the size of the grinding wheel micro-groove are good in consistency. The composite powder consisting of the superhard abrasive and the aluminum powder can fill the grooves of the die under the action of centrifugal force, the molten aluminum can overcome the capillary force and permeate into the gaps of the composite powder under high-speed rotation, and the composite powder is compacted, so that the prepared superhard grinding wheel with the ordered microgroove structure has good microgroove structure and size consistency and strong process repeatability.
And thirdly, the temperature is controllable. The temperature of the electric heating wire is controlled, so that the aluminum powder can be in a complete molten state, and the superhard abrasive cannot be thermally damaged at the temperature.
High preparation efficiency. The method adopts a die pressing process to prepare the superhard grinding wheel with the ordered microgroove structure with the complicated surface structure, namely, the superhard grinding wheel with the ordered microgroove structure with a large number of complicated microgrooves on the outer circumference can be rapidly prepared in a large batch by a die-casting forming process as long as the die is processed into the groove array at one time.
Drawings
FIG. 1 is a schematic view of a state where a composite powder is added.
Fig. 2 is a schematic view of a state where molten aluminum is poured.
Fig. 3 is a schematic view of a state where the aluminum powder is melted by the molten aluminum.
Fig. 4 is a schematic view of the upper mold structure.
Fig. 5 is a schematic view of the relative positions of the upper mold and the hub.
Fig. 6 is a schematic view of a mold formed with an abrasive layer.
Figure 7 is a schematic view of an ordered micro-groove structured superhard grinding wheel.
Wherein: 1. a pressure plate, 2, a hub, 3, an upper die, 4, a lower die, 5, a die, 6, a turntable 7 and a bearing,
8. a main shaft 9, a support frame 10, a base 11, a belt 12, a motor support 13, a motor 14 and an electric heating wire,
15. a heat insulation layer, 16, aluminum powder, 17, super-hard abrasive, 18, composite powder, 19, a liquid injection hole, 20, molten aluminum,
21. mold grooves, 22, mold sheet, 23, abrasive layer, 24, grinding wheel, 25, abrasive layer microgrooves,
26. aluminum-based binder, 27 abrasive layer bump
Detailed description of the preferred embodiments
The following further describes the embodiments of the present invention with reference to the drawings.
Referring to fig. 1 to 7, a pressure casting forming method of a micro-groove structure superhard grinding wheel is used for preparing an ordered micro-groove structure superhard grinding wheel by applying a physical principle based on the structural characteristics of a preparation device.
A die-casting method for the superhard grinding wheel with the ordered microgroove structure comprises the following steps.
The method comprises the following steps: powder mixing: and uniformly mixing 30% of the superhard grinding material 17 and 70% of the aluminum powder 16 by volume fraction ratio to obtain the composite powder 18.
Step two: powder injection: carrying out rust removal treatment on the grinding wheel hub 2 and placing the grinding wheel hub in a mold 5, wherein the mold 5 is provided with a plurality of orderly-arranged grooves, namely mold grooves 21; pouring the composite powder 18 into the mold 5 and making the height of the composite powder consistent with the thickness of the grinding wheel hub 2, wherein the superhard abrasive 17 can be uniformly distributed in the mold 5; the motor 13 is started to rotate the turntable 6 at a low speed, and the composite powder 18 fully fills the gap between the die 5 and the grinding wheel hub 2 under the action of centrifugal force.
Step three, molten aluminum infiltration: molten aluminum 20 is poured into the mold 5 through the liquid injection hole 19, and the superabrasive 17 is continuously uniformly distributed in the aluminum melt; particularly, the density of the aluminum is not very different from that of the superhard grinding material 17, so that the phenomenon that the superhard grinding material 17 obviously sinks in the aluminum melt cannot occur; and then the motor 13 is driven to rotate the rotary table 6 at a high speed, the molten aluminum 20 overcomes the capillary force and permeates into the gaps of the composite powder 18 under the action of centrifugal force, and the composite powder 18 is compacted, so that the prepared orderly microgroove structure superhard grinding wheel 24 has good microgroove structure and size consistency and strong process repeatability.
Step four, melting solid aluminum: the heating wire 14 heats the composite powder 18 in the mold 5 and preserves the temperature of the molten aluminum 20, wherein the temperature of the heating wire 14 is controllable, and the aluminum powder 16 can be in a completely molten state by controlling the temperature of the heating wire 14; the composite powder 18 absorbs the heat of the molten aluminum 20, wherein the aluminum powder 16 is completely melted due to the low melting point, and the high melting point superabrasive 17 is still in a solid state after absorbing heat; the melting point of aluminium is only 660 c so that the superabrasive material 17 is not thermally damaged.
Step five, die-casting and molding of the grinding wheel: under the action of centrifugal force, the molten aluminum 20 and the solid superhard abrasive 17 are in a die-casting state; the electric heating wire 14 is powered off, and the molten aluminum 20 is gradually solidified to form an aluminum-based bonding agent 26, namely the aluminum-based bonding agent 26, the super-hard abrasive 17 and the grinding wheel hub 2 form an integral casting; the rotating table 6 stops rotating, after the mold 5 is sufficiently cooled, the mold is demolded under the action of a demolding agent according to the principle of thermal expansion and cold contraction, a large number of ordered microgroove-structured superhard grinding wheels 24 with alternately arranged abrasive layer bumps 27 and abrasive layer microgrooves 25 are obtained, and the abrasive layer 23 comprises an aluminum-based binder 26 and superhard abrasive materials 17. The superhard grinding wheel 24 with the ordered micro-groove structure and a large number of complex micro-grooves on the outer circumference is rapidly prepared in a large scale through a die-casting forming process, and compared with the traditional method that the surfaces of the laser beam grinding wheels are grooved one by one and then electroplated, the preparation efficiency of the grinding wheel is remarkably improved.
The foregoing examples are set forth to provide a clear illustration of the invention and are not to be construed as limiting the scope thereof, which is defined in the claims appended hereto.
Claims (5)
1. A die-casting forming method of a superhard grinding wheel with an ordered microgroove structure comprises the steps that a preparation device required by the method consists of a pressing plate (1), an upper die (3), a lower die (4), a rotary table (6), a bearing (7), a main shaft (8), a support frame (9), a base (10), a belt (11), a motor support (12), a motor (13), an electric heating wire (14) and a heat insulation layer (15); the inner wall of the upper die (3) is provided with a die groove (21) and a die sheet (22), and the die groove (21) corresponds to the position of a grinding material layer bump (27) of a grinding wheel (24); the mold sheet (22) corresponding to the location of the abrasive layer microgrooves (25);
the preparation method is characterized by comprising the following preparation steps:
step one, powder mixing: uniformly mixing 25-35% of superhard grinding material (17) and 65-75% of aluminum powder (16) in percentage by volume to obtain composite powder (18);
step two, powder injection: carrying out rust removal treatment on the grinding wheel hub (2) and placing the grinding wheel hub in a mold (5), wherein the mold (5) is provided with a large number of orderly-arranged grooves, namely mold grooves (21); pouring the composite powder (18) into the mould (5) and enabling the height of the composite powder to be consistent with the thickness of the grinding wheel hub (2); starting a motor (13) to enable the rotary table (6) to rotate at a low speed, and fully filling the gap between the die (5) and the grinding wheel hub (2) with the composite powder (18) under the action of centrifugal force;
step three, molten aluminum infiltration: pouring molten aluminum (20) into a mold (5) through a liquid injection hole (19), driving a motor (13) to enable a rotary table (6) to rotate at a high speed, and enabling the molten aluminum (20) to overcome the capillary force to permeate into gaps of the composite powder (18) under the action of centrifugal force;
step four, melting solid aluminum: the electric heating wire (14) heats the composite powder (18) in the mold (5) and preserves the temperature of the molten aluminum (20); the composite powder (18) absorbs the heat of the molten aluminum (20), wherein the aluminum powder (16) is completely melted due to low melting point, and the high-melting point super-hard abrasive (17) is still in a solid state after absorbing heat; the melting point of the aluminum is only 660 ℃, so the super-hard abrasive (17) cannot be damaged by heat;
step five, die-casting and molding of the grinding wheel: under the action of centrifugal force, molten aluminum (20) and the solid superhard abrasive material (17) are in a die-casting state; the electric heating wire (14) is powered off, the molten aluminum (20) is gradually solidified to form an aluminum-based bonding agent (26), namely the aluminum-based bonding agent (26), the super-hard abrasive (17) and the grinding wheel hub (2) form an integral casting; the turntable (6) stops rotating, after the mold (5) is sufficiently cooled, the casting is demolded under the action of a demolding agent according to the principle of thermal expansion and cold contraction, a large number of ordered microgroove structure superhard grinding wheels (24) which are arranged alternately are obtained through the abrasive layer bumps (27) and the abrasive layer microgrooves (25), and the abrasive layer (23) comprises an aluminum-based binder (26) and superhard abrasive materials (17).
2. The die-casting forming method of the superhard grinding wheel with the ordered microgroove structure according to claim 1, wherein the aluminum powder (16) has a particle size of 60-400 meshes, and the superhard grinding material (17) has a particle size of 40-300 meshes.
3. The die-casting forming method of the superhard grinding wheel with the ordered microgroove structure as claimed in claim 1, wherein the inner diameter of the die (5) is phi 20-300 mm, and the grinding wheel (24) with the diameter of phi 20-300 mm can be cast.
4. The die-casting forming method of the superhard grinding wheel with the ordered microgroove structure according to claim 1, wherein the rated rotating speed of the motor (13) when the rotary table (6) rotates at a high speed is 3000 r/min, and the rotating speed when the rotary table (6) rotates at a low speed is reduced to 1000 r/min from stepless speed regulation.
5. The die-casting forming method of the superhard grinding wheel with the ordered microgroove structure as claimed in claim 1, wherein the internal temperature of the die (5) is controlled to be 600-700 ℃ when being heated by the electric heating wire (13).
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| CN202010691809.9A CN111906703B (en) | 2020-07-17 | 2020-07-17 | Die-casting forming method for superhard grinding wheel with ordered microgroove structure |
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| CN202010691809.9A CN111906703B (en) | 2020-07-17 | 2020-07-17 | Die-casting forming method for superhard grinding wheel with ordered microgroove structure |
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Cited By (1)
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| CN112894638A (en) * | 2021-01-20 | 2021-06-04 | 海安玻克超硬材料有限公司 | Preparation process of photovoltaic grinding wheel |
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