CN111975466A - Environment-friendly fine machining method for silicon nitride ceramic balls - Google Patents
Environment-friendly fine machining method for silicon nitride ceramic balls Download PDFInfo
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- CN111975466A CN111975466A CN202010861944.3A CN202010861944A CN111975466A CN 111975466 A CN111975466 A CN 111975466A CN 202010861944 A CN202010861944 A CN 202010861944A CN 111975466 A CN111975466 A CN 111975466A
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- 239000000919 ceramic Substances 0.000 title claims abstract description 131
- 229910052581 Si3N4 Inorganic materials 0.000 title claims abstract description 118
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 title claims abstract description 118
- 238000003754 machining Methods 0.000 title claims abstract description 105
- 238000000034 method Methods 0.000 title claims abstract description 45
- 238000000227 grinding Methods 0.000 claims abstract description 110
- 239000007788 liquid Substances 0.000 claims abstract description 88
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 77
- 229910001018 Cast iron Inorganic materials 0.000 claims abstract description 38
- 238000003825 pressing Methods 0.000 claims description 36
- 230000007547 defect Effects 0.000 claims description 26
- 229910000831 Steel Inorganic materials 0.000 claims description 21
- 239000010959 steel Substances 0.000 claims description 21
- 239000012530 fluid Substances 0.000 claims description 20
- 239000013556 antirust agent Substances 0.000 claims description 18
- 239000000843 powder Substances 0.000 claims description 16
- 229910003460 diamond Inorganic materials 0.000 claims description 15
- 239000010432 diamond Substances 0.000 claims description 15
- 238000004506 ultrasonic cleaning Methods 0.000 claims description 15
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 12
- 238000007514 turning Methods 0.000 claims description 11
- 239000002518 antifoaming agent Substances 0.000 claims description 10
- 239000003112 inhibitor Substances 0.000 claims description 10
- WXMKPNITSTVMEF-UHFFFAOYSA-M sodium benzoate Chemical compound [Na+].[O-]C(=O)C1=CC=CC=C1 WXMKPNITSTVMEF-UHFFFAOYSA-M 0.000 claims description 10
- 235000010234 sodium benzoate Nutrition 0.000 claims description 10
- 239000004299 sodium benzoate Substances 0.000 claims description 10
- 238000003672 processing method Methods 0.000 claims description 6
- 238000011068 loading method Methods 0.000 claims description 4
- 239000000161 steel melt Substances 0.000 claims description 4
- 239000003921 oil Substances 0.000 abstract description 5
- 229910010293 ceramic material Inorganic materials 0.000 abstract description 4
- 238000007599 discharging Methods 0.000 abstract description 4
- 238000004519 manufacturing process Methods 0.000 abstract description 3
- 239000010802 sludge Substances 0.000 abstract description 3
- 230000007613 environmental effect Effects 0.000 abstract description 2
- 239000000463 material Substances 0.000 description 25
- 230000000052 comparative effect Effects 0.000 description 13
- 238000011010 flushing procedure Methods 0.000 description 13
- 230000003746 surface roughness Effects 0.000 description 13
- 239000002245 particle Substances 0.000 description 11
- 238000005086 pumping Methods 0.000 description 10
- 239000013530 defoamer Substances 0.000 description 8
- 238000007689 inspection Methods 0.000 description 8
- 230000000694 effects Effects 0.000 description 6
- 239000000203 mixture Substances 0.000 description 5
- 238000003756 stirring Methods 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 238000004140 cleaning Methods 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- 238000003860 storage Methods 0.000 description 4
- 238000005303 weighing Methods 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- 230000000903 blocking effect Effects 0.000 description 3
- 230000008021 deposition Effects 0.000 description 3
- 239000008235 industrial water Substances 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000010703 silicon Substances 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 2
- 238000005034 decoration Methods 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 229920001296 polysiloxane Polymers 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000004094 surface-active agent Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- 244000137852 Petrea volubilis Species 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 239000006061 abrasive grain Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000000844 anti-bacterial effect Effects 0.000 description 1
- 230000003385 bacteriostatic effect Effects 0.000 description 1
- 230000002457 bidirectional effect Effects 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 229910000423 chromium oxide Inorganic materials 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 239000008367 deionised water Substances 0.000 description 1
- 229910021641 deionized water Inorganic materials 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 239000002283 diesel fuel Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 229910001385 heavy metal Inorganic materials 0.000 description 1
- 238000001513 hot isostatic pressing Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 239000003350 kerosene Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 238000005461 lubrication Methods 0.000 description 1
- 239000011259 mixed solution Substances 0.000 description 1
- 239000002674 ointment Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B11/00—Machines or devices designed for grinding spherical surfaces or parts of spherical surfaces on work; Accessories therefor
- B24B11/02—Machines or devices designed for grinding spherical surfaces or parts of spherical surfaces on work; Accessories therefor for grinding balls
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
- Ceramic Products (AREA)
- Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
Abstract
The invention provides an environment-friendly fine machining method for a silicon nitride ceramic ball, and belongs to the technical field of ceramic material machining. The invention adopts the water-based circulating liquid to replace the prior oily grinding paste in the finish machining process, avoids the generation of oil sludge, improves the processing environment, accords with the environmental protection concept, and can simplify the production flow, improve the processing efficiency, save the processing cost and prolong the service life of the cast iron plate. The silicon nitride ceramic precision grinding ball processed by the method of the invention has the advantages that the processing efficiency, the surface quality and the size precision of the ball body meet the precision processing ball-discharging requirements set by the enterprise, and meanwhile, all precision indexes of the silicon nitride ceramic ball body can reach the national standard G20 grade standard.
Description
Technical Field
The invention relates to the technical field of ceramic material processing, in particular to an environment-friendly fine processing method of a silicon nitride ceramic ball.
Background
Silicon nitride ceramics are known as engineering ceramic materials with the best comprehensive performance, and bearing balls made of the silicon nitride ceramics become standard bearing balls of high-precision equipment spindles at home and abroad. The silicon nitride ceramic ball is processed, so that the surface defects of the silicon nitride ceramic ball can be reduced, and the service performance of the bearing is improved. In order to obtain a high-quality silicon nitride ceramic finished ball, the silicon nitride ceramic blank ball needs to be subjected to rough machining, finish machining, polishing and other steps, most of surface allowance of the silicon nitride ceramic blank ball is removed through rough machining to obtain a rough grinding ball, the size precision of the ball body is improved through finish machining, the surface quality is refined to obtain a fine grinding ball, and finally the precision and the surface quality of the ball body are continuously optimized through polishing to obtain the silicon nitride ceramic finished ball. Due to the inherent brittleness and susceptibility to defects of ceramic materials, the stress concentration behavior around the tips of defects or cracks is very strong, and a large number of defects generated during the rough machining stage are easily extended during the finishing stage, and a large number of dimensions are usually reserved after the rough machining stage and removed by finishing. Therefore, in the fine machining stage, the material size is required to be rapidly reduced, the spherical error is required to be reduced, the surface roughness is required to be refined, the physical and mechanical properties of the surface are improved, and the method plays an important role in starting and ending.
At present, for the fine machining of silicon nitride ceramic balls, the prior art generally adopts externally purchased grinding paste or ointment prepared by using oil agents such as kerosene, spindle oil, diesel oil and the like, and part of manufacturers also adopt grinding materials containing heavy metal ions such as chromium oxide and the like, so that a large amount of oil sludge is generated after the machining is finished, the treatment cost is high, and the environment is polluted to a certain degree; and the cleaning of the ceramic ball and the daily cleaning of the machine tool are troublesome to a certain extent after the processing is finished, the requirements of the environmental protection development concept are not met, the loss of the cast iron plate is fast, and the service life of the cast iron plate is short.
Disclosure of Invention
The invention aims to provide an environment-friendly finish machining method for silicon nitride ceramic balls, which adopts water-based circulating liquid for finish machining, is environment-friendly and simple and convenient, and has long service life of a cast iron plate.
In order to achieve the above object, the present invention provides the following technical solutions:
the invention provides an environment-friendly fine machining method for silicon nitride ceramic balls, which comprises the following steps:
turning the cast iron plate to form a channel;
pressing the groove by using a groove pressing ball to form a groove arc;
placing the silicon nitride ceramic rough grinding ball at the groove arc, and performing finish machining until the diameter of the obtained silicon nitride ceramic fine grinding ball is plus (5-50) mu m of the diameter of the silicon nitride ceramic finished ball;
the circulating liquid used for finish machining comprises water-based circulating liquid and a rust inhibitor;
the water-based circulating liquid comprises the following components in percentage by volume: 20-40% of oil-free steel ball hard grinding fluid, 60-80% of water and 1-3% of defoaming agent.
Preferably, the diameter of the silicon nitride ceramic finished ball is 3-20 mm.
Preferably, the pressure of the groove pressing treatment is 10-30 kN, and the time of the groove pressing treatment is 4-24 h.
Preferably, the diameter of the silicon nitride ceramic coarse grinding ball is + (100-300) mu m of the diameter of the silicon nitride ceramic finished product ball, the diameter variation of the silicon nitride ceramic coarse grinding ball is less than 5 mu m, the batch diameter variation is less than 10 mu m, and the depth of surface processing defects is less than 30 mu m.
Preferably, before the ball is installed, the silicon nitride ceramic rough grinding ball is subjected to ultrasonic cleaning, the ultrasonic cleaning time is 10-60 min, and the current is 1-5A.
Preferably, the abrasive used for finish machining is artificial diamond powder; the grain size of the abrasive is 5-20 mu m.
Preferably, in the finish machining process, the machining pressure is 6-20 kN, and the machining rotating speed is 10-25 r/min.
Preferably, the antirust agent comprises sodium benzoate, a DS-064 concentrated steel liquid iron-based antirust agent or a KS-VCI water-based antirust liquid, and when the antirust agent is sodium benzoate, the dosage ratio of the water-based circulating liquid to the antirust agent is 10L (200-500 g); when the antirust agent is a DS-064 concentrated steel melt-based antirust agent or a KS-VCI water-based antirust liquid, the mass ratio of the water-based circulating liquid to the antirust agent is 1 (0.01-0.1).
The invention provides an environment-friendly fine machining method for silicon nitride ceramic balls, which comprises the following steps: turning the cast iron plate to form a channel; pressing the groove by using a groove pressing ball to form a groove arc; placing the silicon nitride ceramic rough grinding ball at the groove arc, and performing finish machining until the diameter of the obtained silicon nitride ceramic fine grinding ball is plus (5-50) mu m of the diameter of the silicon nitride ceramic finished ball; the circulating liquid used for finish machining comprises water-based circulating liquid and a rust inhibitor; the water-based circulating liquid comprises the following components in percentage by volume: 20-40% of oil-free steel ball hard grinding fluid, 60-80% of water and 1-3% of defoaming agent.
According to the invention, the water-based circulating liquid is adopted to replace the existing oily grinding paste in the fine machining process of the silicon nitride ceramic ball, so that the generation of oil sludge is avoided, the machining environment is improved, the environment-friendly concept is met, the production flow can be simplified, the machining efficiency is improved, and the machining cost is saved. The silicon nitride ceramic precision grinding ball processed by the method of the invention has the advantages that the processing efficiency, the surface quality and the size precision of the ball body meet the precision processing ball-discharging requirements set by the enterprise, and meanwhile, all precision indexes of the silicon nitride ceramic ball body can reach the national standard G20 grade standard.
Detailed Description
The invention provides an environment-friendly fine machining method for silicon nitride ceramic balls, which comprises the following steps:
turning the cast iron plate to form a channel;
pressing the groove by using a groove pressing ball to form a groove arc;
placing the silicon nitride ceramic rough grinding ball at the groove arc, and performing finish machining until the diameter of the obtained silicon nitride ceramic fine grinding ball is plus (5-50) mu m of the diameter of the silicon nitride ceramic finished ball;
the circulating liquid used for finish machining comprises water-based circulating liquid and a rust inhibitor;
the water-based circulating liquid comprises the following components in percentage by volume: 20-40% of oil-free steel ball hard grinding fluid, 60-80% of water and 1-3% of defoaming agent.
In the present invention, the starting materials or reagents required are commercially available products well known to those skilled in the art unless otherwise specified.
The invention carries out turning treatment on the cast iron plate to form a channel. According to the invention, a plurality of V-shaped channels which are concentrically distributed are preferably formed on the cast iron plate through turning treatment according to the size of the finished silicon nitride ceramic ball. The process of the turning process is not particularly limited in the present invention, and the above-described channel can be formed according to a process well known in the art. The specific number of the V-shaped channels is not specially limited, and the V-shaped channels can be adjusted according to actual requirements; in the embodiments of the present invention, there are specifically 9, 20 or 40. In the invention, the average hardness of the cast iron plate is preferably 150-250 HB, more preferably 180-220 HB, and the hardness dispersion difference of different positions of the cast iron plate is less than or equal to 30HB, more preferably less than or equal to 20 HB.
After the channel is formed, the invention uses the groove pressing ball to press the groove to form the groove arc. In the present invention, the groove pressing ball preferably comprises a silicon nitride ceramic ball or a steel ball, and the diameter of the groove pressing ball is the same as that of the silicon nitride ceramic finished ball. In the present invention, the source of the grooved ball is not particularly limited, and commercially available products known in the art may be selected.
In the invention, the process of the groove pressing treatment is preferably to place the groove pressing ball in the channel of the cast iron plate, keep the groove pressing ball and the channel dry and carry out the groove pressing treatment; the number of the groove pressing balls is preferably 5-30, more preferably 10-20, per groove; the pressure of the groove pressing treatment is preferably 10-30 kN, more preferably 15-25 kN, and the time of the groove pressing treatment is preferably 4-24 h, more preferably 10-20 h, and further preferably 12-16 kN. The present invention preferably adjusts the pressure and time of the trenching process according to the channel width. The invention presses the right-angle groove of the cast iron plate into the circular arc groove through the groove pressing treatment, so that the silicon nitride ceramic ball blank is well matched with the groove arc, thereby increasing the contact area of the ceramic ball and the groove arc, improving the revolution and rotation capacity of the silicon nitride ceramic ball blank and effectively improving the processing efficiency in the finish machining stage. In the present invention, the preferable fit is an arc of a groove whose width is 1/4 to 1/3 of the diameter of the ball of the groove. The invention can improve the processing efficiency by limiting the groove pressing condition.
After the groove pressing treatment is finished, the obtained groove arcs and the plate openings of the cast iron plates are preferably polished by using 1000-mesh sand paper, so that the defect of processing the first disc of ceramic balls caused by insufficient running-in of the ceramic balls and the groove arcs due to short processing time is avoided.
After a groove arc is formed, the silicon nitride ceramic coarse grinding ball is arranged at the groove arc, and fine machining is carried out until the diameter of the obtained silicon nitride ceramic fine grinding ball is plus (5-50) mu m of the diameter of the silicon nitride ceramic finished ball. In the invention, the names of the silicon nitride ceramic coarse grinding ball, the silicon nitride ceramic fine grinding ball and the silicon nitride ceramic finished ball respectively correspond to the names in the background technology.
In the invention, the silicon nitride ceramic rough grinding ball is preferably a product of rough machining treatment of a hot isostatic pressing silicon nitride ceramic blank ball. In the invention, the diameter of the silicon nitride ceramic finished ball is preferably 3-20 mm, and more preferably 3-15 mm. In the invention, the diameter of the silicon nitride ceramic rough grinding ball is preferably + (100-300) mu m of the finished silicon nitride ceramic ball, and more preferably + (200-250) mu m of the finished silicon nitride ceramic ball; the diameter variation of the silicon nitride ceramic rough grinding ball is preferably less than 5 mu m, the batch diameter variation is preferably less than 10 mu m, and the depth of surface processing defects is preferably less than 30 mu m.
In the invention, before the ball loading, the silicon nitride ceramic rough grinding ball is preferably subjected to ultrasonic cleaning, the ultrasonic cleaning time is preferably 10-60 min, more preferably 20-50 min, and even more preferably 30-40 min, and the current is preferably 1-5A, and more preferably 2-3A. The invention preferably adjusts the time and current of ultrasonic cleaning according to the size and the number of the silicon nitride ceramic rough grinding balls. According to the invention, the ultrasonic cleaning is adopted to ensure that the large-particle hard abrasive remained in the rough machining stage is not introduced into the finish machining stage, so that the machining pits caused by the large-particle hard abrasive are avoided.
The process of loading the balls is not particularly limited in the present invention, and may be performed according to a process well known in the art.
In the invention, the finish machining is preferably carried out in a ball grinding machine, the ball grinding machine is preferably a vertical steel ball grinding machine, and the model of the ball grinding machine is preferably 3MK 7280; the ball grinding machine is preferably provided with a detachable ball shoveling plate and a detachable ball blocking plate, and the ball shoveling plate and the ball blocking plate are preferably installed on the ball grinding machine before the finish machining, and are finely adjusted according to the specific ball loading and the machining state according to the process well known in the art.
In the present invention, the abrasive used for the finishing is preferably synthetic diamond powder; the particle size of the abrasive is preferably 5-20 μm, more preferably 10-15 μm, and even more preferably 14 μm. The grinding material has high hardness and long service life, and has more remarkable pinning and cutting effects on the silicon nitride ceramic rough grinding ball, so that the finish machining efficiency can be improved, the surface material of the silicon nitride ceramic ball can be quickly removed, and meanwhile, the grinding material can participate in the machining process for many times and has long service life; the invention can improve the surface quality of the silicon nitride ceramics by limiting the abrasive granularity.
In the invention, the circulating liquid for finish machining comprises water-based circulating liquid and a rust inhibitor; the water-based circulating liquid comprises the following components in percentage by volume: 20-40% of oil-free steel ball hard grinding fluid, 60-80% of water and 1-3% of defoaming agent.
In the invention, the water-based circulating fluid comprises 20-40% of oil-free steel ball hard grinding fluid, preferably 25-35%, and more preferably 30% by volume. In the invention, the oil-free steel ball hard grinding fluid is a conventional oil-free steel ball hard grinding fluid sold in the market, and the oil-free steel ball hard grinding fluid comprises a plurality of surfactants and a large amount of organic matters. The invention utilizes the oil-free steel ball hard grinding fluid to improve the adhesive capacity of the grinding material on the ceramic ball and reduce the loss of the grinding material, thereby improving the processing efficiency; the oil-free steel ball hard grinding fluid has antibacterial and bacteriostatic capabilities, and can avoid peculiar smell generated by deterioration of the water-based circulating fluid after long-term use; in addition, the oil-free steel ball hard grinding fluid is convenient for cleaning the ceramic ball, and after finishing machining, the influence of the grinding material residue on the subsequent machining process is avoided.
In the invention, the water-based circulating liquid comprises 60-80% of water, preferably 65-75% of water, and more preferably 70% of water in percentage by volume. In the present invention, the water is preferably deionized water.
In the invention, the water-based circulating liquid comprises 1-3% of defoaming agent by volume percentage, preferably 1.5-2.5% and more preferably 2%. In the present invention, the antifoaming agent preferably comprises a silicone antifoaming agent, which is preferably FAG470 silicone antifoaming agent. The invention utilizes the defoaming agent to remove bubbles generated by the surfactant component in the oil-free steel ball hard grinding fluid and keep the surface of the ball moist, so that more free grinding materials can be adhered to the surface of the ball for a long time.
The invention can improve the finish machining efficiency by accurately controlling the components and the proportion of the water-based circulating liquid, and realize the same machining effect with lower cost.
In the invention, the antirust agent preferably comprises sodium benzoate, DS-064 concentrated molten steel-based antirust agent or KS-VCI water-based antirust liquid; when the antirust agent is preferably sodium benzoate, the using amount ratio of the water-based circulating liquid to the antirust agent is 10L (200-500) g, and more preferably 10L:300 g; when the antirust agent is preferably a DS-064 concentrated steel melt-based antirust agent or a KS-VCI water-based antirust liquid, the mass ratio of the water-based circulating liquid to the antirust agent is preferably 1 (0.01-0.1), and more preferably 1: 0.05. The invention uses the antirust agent to prevent the water in the water-based circulating liquid from reacting with the machine tool and the cast iron plate to rust, thereby solving the problem that the machine tool is easy to rust.
In the invention, the fine machining process preferably comprises the steps of firstly pumping the circulating liquid by using a water pump, flushing the silicon nitride ceramic rough grinding balls and the groove arcs which are just filled into the groove, then closing the water pump, performing fine machining after feeding, and starting the water pump by using an automatic device after 1 hour to continuously pump the circulating liquid to flush the silicon nitride ceramic rough grinding balls and the groove arcs. The invention has no special limitation on the automatic device, and can be used as an automatic device capable of starting the power supply at regular time. In the invention, the water pump is preferably an industrial water pump with a stirring function, and the rotating speed of a stirring blade of the water pump is preferably 2000-5000 r/min. The process of the extraction and flushing is not particularly limited in the present invention and may be performed according to a process well known in the art.
In the present invention, the step of feeding is preferably to pour the mixture of the abrasive and the circulating liquid through a viewing port of a millstone on a cast iron plate onto the ball blank and the groove arc of the silicon nitride ceramic ball. The preparation process of the mixed liquid of the abrasive and the circulating liquid is not specially limited, and the abrasive and the circulating liquid can be directly mixed. In the invention, the dosage ratio of the abrasive to the circulating liquid is preferably (10-30) g: (100-200) mL, more preferably 15 g: 150 mL. According to the invention, the grinding materials are dispersed in the circulating liquid for feeding, so that the problems that the grinding materials are not uniformly adhered to the surface of a part of ceramic balls, and the revolution is hindered due to excessive friction force after the grinding materials enter a cast iron plate, and the surface is scratched can be avoided.
In the finish machining process, the machining pressure is preferably 6-20 kN, more preferably 8-16 kN, further preferably 10-15 kN, and the machining rotating speed is preferably 10-25 r/min, more preferably 15-20 r/min.
In the finish machining process, feeding is preferably carried out once every 6-10 hours; the feeding specifically refers to adding a mixed solution of the grinding material and the circulating liquid. According to the invention, the water pump is preferably closed before each charging, the circulating liquid is not flushed within 1 hour after each charging is finished, and the water pump is automatically started to continue flushing after 1 hour of charging. In the invention, the dosage ratio of the abrasive added in the feeding and the circulating liquid is preferably (10-30) g: (100-200) mL. The invention controls the feeding mode to avoid processing defects and improve processing efficiency, controls the abrasive adding node to meet the requirement of industrial mass production, and can reduce the operation frequency of operators, thereby using the method on a large scale and realizing the same processing effect with lower cost.
In the invention, after each feeding, the abrasive is adhered to the silicon nitride ceramic rough grinding ball, after entering the channel, the abrasive is embedded on the groove arc of the cast iron plate with smaller hardness under the bidirectional pressure action of the ceramic ball and the cast iron plate, part of the abrasive is changed from a free abrasive state to a fixed abrasive state, micron-level pinning and cutting are continuously carried out on the surface of the ceramic ball, the edge angle of the fixed abrasive is ground to be flat, the flat abrasive is replaced by newly-added abrasive and enters the circulating liquid, the ceramic ball is continuously processed in the form of free abrasive, and the concentration of the abrasive in the circulating liquid is increased along with the increase of the number of processing discs, so that the processing efficiency can be effectively improved, and the material cost is reduced.
The flushing effect of the invention comprises: 1) the grinding material enters the groove arc again to participate in grinding for many times, so that the utilization rate of the grinding material is improved; 2) the lubrication state of the channel is kept, so that the silicon nitride ceramic ball blank keeps good rotation and revolution, and the processing defect is avoided; 3) large particles ground by processing, such as silicon nitride waste residues and scrap iron are washed away, and processing defects are reduced.
In the invention, after the extracted circulating liquid participates in the finish machining process, the extracted circulating liquid is collected and reflowed to the grinding liquid storage container, so that the cyclic utilization of the circulating liquid is realized. In the invention, the grinding fluid storage container is preferably a cylindrical storage container, so that the stirring effect of a water pump can be enhanced, and the phenomenon of material storage at dead corners is avoided. The size of the barrel shape is not specially limited, and the barrel shape can be adjusted according to actual requirements.
The scouring-feeding process is preferably repeated until the diameter of the obtained silicon nitride ceramic fine grinding ball is plus (5-50) mu m of the diameter of the silicon nitride ceramic finished ball. The invention preferably performs the process check every 4 hours until the diameter of the obtained silicon nitride ceramic fine grinding ball reaches the diameter range. The method for examining the process is not particularly limited in the present invention, and may be performed according to a process known in the art. In the present invention, the finish ball discharging requirement is preferably a finish ball discharging requirement specified in the company enterprise (meanwhile, the size precision of the ball meets the international G20 standard), specifically: the diameter variation is less than 0.5 μm, the batch diameter variation is less than 0.5 μm, the surface roughness is less than 0.02 μm, the surface processing defect depth is less than 2 μm, and the processing efficiency is more than or equal to 2 μm/h.
In the finish machining process, the grinding materials are mainly deposited at the bottom of a circulating water tank containing circulating liquid and inside a machine tool of a ball grinding machine, and an industrial water pump with a stirring function is preferably used to avoid the deposition at the bottom of the circulating water tank; according to the invention, a plurality of backflow branches are preferably added on the water outlet of the industrial water pump, and the backflow branches are used for continuously pumping the circulating liquid to flush the deposition in the machine tool, so that the abrasive is flushed into the circulating water tank, and the problem of abrasive deposition waste is solved. The invention does not make specific requirements on the specific number of the multiple backflow branches and the water flow of the branches, and can realize the effect of flushing the grinding materials in the machine tool into the circulating water tank.
According to the invention, the surface processing defects of the silicon nitride ceramic ball blank can be reduced by controlling the pressure, the rotating speed and the abrasive granularity parameters of finish machining and selecting the abrasive adding mode (adding the abrasive after stirring and dispersing the abrasive by using circulating liquid).
The invention improves the finish machining efficiency through the limitation of the groove pressing condition, the feeding mode and the abrasive material type. According to the invention, the obtained silicon nitride ceramic fine grinding ball meets the finish machining ball unloading requirement formulated in a company by optimizing the component proportion, the abrasive type, the abrasive adding amount and the abrasive adding time node of the circulating liquid, and meanwhile, the size precision of the ball meets the national standard G20 grade standard.
The technical solution of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the following examples, the average hardness of the cast iron plates used was 220HB, and the hardness dispersion at different positions of the cast iron plates was 15 HB; the ball grinder used for finishing was of the type 3MK7280, which had been fitted with a scooping plate and a blocking plate before the finishing was carried out.
The requirements of finish machining and ball unloading are as follows: the diameter variation is less than 0.5 μm, the batch diameter variation is less than 0.5 μm, the surface roughness is less than 0.02 μm, the surface processing defect depth is less than 2 μm, and the processing efficiency is more than or equal to 2 μm/h.
Example 1
In this embodiment, a silicon nitride ceramic ball with a diameter of 3.5mm (i.e., a finished silicon nitride ceramic ball) is processed according to the following steps to prepare a corresponding silicon nitride ceramic grinding ball:
turning the cast iron plate to form 40V-shaped channels which are concentrically distributed;
under the condition of 20kN, groove pressing treatment is carried out on the channels of the cast iron plate by adopting silicon nitride ceramic balls with the diameter of 3.5mm, 8 groove pressing balls are arranged on each channel, the groove pressing time is 8h, a groove arc is formed, and the width of the groove arc is 1/3 of the diameter of the silicon nitride ceramic balls;
ultrasonically cleaning the silicon nitride ceramic coarse grinding ball by using an ultrasonic cleaning machine, setting the time to be 60min and the current to be 5A, and putting the cleaned silicon nitride ceramic coarse grinding ball (the diameter is 3.7mm) at the groove arc;
the circulating liquid comprises the following components: 2.5L of oilless steel ball hard grinding fluid, 7.4L of water, 0.1L of defoamer (FAG470 organic silicon defoamer) and 300g of sodium benzoate.
Pumping the circulating liquid by using a water pump, flushing the silicon nitride ceramic ball blank and the channel, then closing the water pump, pouring the mixed liquid of the grinding material and the circulating liquid onto the silicon nitride ceramic ball blank and the channel arc through an observation port of an upper grinding disc of a cast iron plate for feeding (the mixed liquid of 20g of artificial diamond powder (with the particle size of 14 microns) and 200mL of the circulating liquid), carrying out finish machining, wherein the machining pressure is 15kN, the machining rotating speed is 18r/min, after 1h, starting the water pump by an automatic device, continuously pumping the circulating liquid to flush the silicon nitride ceramic ball blank and the channel arc, in the finish machining process, weighing 20g of artificial diamond powder at intervals of 8h, adding 200mL of the circulating liquid, pouring the mixture after uniform mixing from the observation port of the upper grinding disc of the cast iron plate, carrying out finish machining, automatically starting the water pump after 1h, carrying out the flushing process, and repeating the flushing-feeding process, and (3) carrying out process inspection every 4 hours until the size of the ceramic ball is processed to 3.55mm, unloading the ball and carrying out inspection, wherein the processing efficiency is 4-6 mu m/h, the diameter variation of the processed product is 0.2 mu m, the batch diameter variation is 0.3 mu m, the surface roughness is 0.005-0.009 mu m, the depth of the surface processing defect is less than 2 mu m, and the precision grinding ball meets the precision machining ball unloading requirement, thus obtaining the qualified precision grinding ball.
Example 2
In this embodiment, a silicon nitride ceramic ball with a diameter of 6.35mm (i.e., a finished silicon nitride ceramic ball) is used as a reference, and the following steps are performed to prepare a corresponding silicon nitride ceramic fine grinding ball:
turning the cast iron plate to form 20V-shaped channels which are concentrically distributed;
under the condition of 20kN, groove pressing treatment is carried out on the channels of the cast iron plate by adopting silicon nitride ceramic balls with the diameter of 6.35mm, 8 groove pressing balls are arranged on each channel, the groove pressing time is 8h, a groove arc is formed, and the width of the groove arc is 1/3 of the diameter of the silicon nitride ceramic balls;
carrying out ultrasonic cleaning on the silicon nitride ceramic coarse grinding ball by adopting an ultrasonic cleaning machine, setting the time to be 50min and the current to be 4A, and putting the cleaned coarse grinding ball (the diameter is 6.55mm) at the groove arc;
the circulating liquid comprises the following components: 2.5L of oilless steel ball hard grinding fluid, 7.4L of water, 0.1L of defoamer (FAG470 organic silicon defoamer) and 300g of sodium benzoate.
Pumping the circulating liquid by using a water pump, flushing the silicon nitride ceramic ball blank and the channel, then closing the water pump, pouring the mixed liquid of the grinding material and the circulating liquid onto the silicon nitride ceramic ball blank and the channel arc through an observation port of an upper grinding disc of a cast iron plate for feeding (the mixed liquid of 20g of artificial diamond powder (with the particle size of 14 microns) and 200mL of the circulating liquid), carrying out finish machining, wherein the machining pressure is 15kN, the machining rotating speed is 18r/min, after 1h, starting the water pump by an automatic device, continuously pumping the circulating liquid to flush the silicon nitride ceramic ball blank and the channel arc, in the finish machining process, weighing 20g of artificial diamond powder at intervals of 8h, adding 200mL of the circulating liquid, pouring the mixture after uniform mixing from the observation port of the upper grinding disc of the cast iron plate, carrying out finish machining, automatically starting the water pump after 1h, carrying out the flushing process, and repeating the flushing-feeding process, and (3) carrying out process inspection every 4 hours until the size of the ceramic ball is processed to 6.38mm, unloading the ball and carrying out inspection, wherein the processing efficiency is 4-5 mu m/h, the diameter variation of the processed product is 0.3 mu m, the batch diameter variation is 0.3 mu m, the surface roughness is 0.008 mu m-0.012 mu m, the surface processing defect depth is less than 2 mu m, and the qualified fine grinding ball is obtained according with the requirements of fine processing and ball unloading.
Example 3
In this embodiment, a silicon nitride ceramic ball with a processing diameter of 13.494mm (i.e. a silicon nitride ceramic finished ball) is used as a reference, and the fine processing is performed according to the following steps to prepare a corresponding silicon nitride ceramic fine grinding ball:
turning the cast iron plate to form 9V-shaped channels which are concentrically distributed;
under the condition of 20kN, carrying out groove pressing treatment on the channels of the cast iron plate by adopting silicon nitride ceramic balls with the diameter of 13.494mm, wherein 8 groove pressing balls are arranged in each channel, the groove pressing time is 12h, a groove arc is formed, and the width of the groove arc is 1/3 of the diameter of the silicon nitride ceramic balls;
carrying out ultrasonic cleaning on the silicon nitride ceramic coarse grinding ball by adopting an ultrasonic cleaning machine, setting the time to be 40min and the current to be 3A, and putting the cleaned coarse grinding ball (the diameter is 13.7mm) at the groove arc;
the circulating liquid comprises the following components: 3L of oilless steel ball hard grinding fluid, 6.9L of water, 0.1L of defoamer (FAG470 organosilicon defoamer) and 300g of sodium benzoate.
Pumping the circulating liquid by using a water pump, flushing the silicon nitride ceramic ball blank and the channel, then closing the water pump, pouring the mixed liquid of the grinding material and the circulating liquid onto the silicon nitride ceramic ball blank and the channel arc through an observation port of an upper grinding disc of a cast iron plate for feeding (the mixed liquid of 20g of artificial diamond powder (with the particle size of 14 microns) and 200mL of the circulating liquid), carrying out finish machining, wherein the machining pressure is 12kN, the machining rotating speed is 15r/min, after 1h, starting the water pump by an automatic device, continuously pumping the circulating liquid to flush the silicon nitride ceramic ball blank and the channel arc, in the finish machining process, weighing 20g of artificial diamond powder at intervals of 8h, adding 200mL of the circulating liquid, pouring the mixture after uniform mixing from the observation port of the upper grinding disc of the cast iron plate, carrying out finish machining, automatically starting the water pump after 1h, carrying out the flushing process, and repeating the flushing-feeding process, and (3) carrying out process inspection every 4 hours until the size of the ceramic ball is processed to 13.534mm, unloading the ball and carrying out inspection, wherein the processing efficiency is 4-5 mu m/h, the diameter variation of the processed product is 0.4 mu m, the batch diameter variation is 0.5 mu m, the surface roughness is 0.01-0.012 mu m, the surface processing defect depth is less than 2 mu m, and the qualified fine grinding ball is obtained according to the requirements of fine processing and ball unloading.
Example 4
In this embodiment, a silicon nitride ceramic ball with a diameter of 6.35mm (i.e., a finished silicon nitride ceramic ball) is used as a reference, and the following steps are performed to prepare a corresponding silicon nitride ceramic fine grinding ball:
turning the cast iron plate to form 20V-shaped channels which are concentrically distributed;
under the condition of 20kN, groove pressing treatment is carried out on the channels of the cast iron plate by adopting silicon nitride ceramic balls with the diameter of 6.35mm, 8 groove pressing balls are arranged on each channel, the groove pressing time is 8h, a groove arc is formed, and the width of the groove arc is 1/3 of the diameter of the silicon nitride ceramic balls;
carrying out ultrasonic cleaning on the silicon nitride ceramic coarse grinding ball by adopting an ultrasonic cleaning machine, setting the time to be 50min and the current to be 4A, and putting the cleaned coarse grinding ball (the diameter is 6.55mm) at the groove arc;
the circulating liquid comprises the following components: 2.5L of oilless steel ball hard grinding fluid, 7.4L of water, 0.1L of defoamer (FAG470 organic silicon defoamer) and 300g of sodium benzoate.
Pumping the circulating liquid by using a water pump, flushing the silicon nitride ceramic ball blank and the channel, then closing the water pump, pouring the mixed liquid of the grinding material and the circulating liquid onto the silicon nitride ceramic ball blank and the channel arc through an observation port of an upper grinding disc of a cast iron plate for feeding (the mixed liquid of 20g of artificial diamond powder (with the particle size of 5 microns) and 200mL of the circulating liquid), carrying out finish machining, wherein the machining pressure is 15kN, the machining rotating speed is 18r/min, after 1h, starting the water pump by an automatic device, continuously pumping the circulating liquid to flush the silicon nitride ceramic ball blank and the channel arc, in the finish machining process, weighing 20g of artificial diamond powder at intervals of 8h, adding 200mL of the circulating liquid, pouring the mixture after uniform mixing from the observation port of the upper grinding disc of the cast iron plate, carrying out finish machining, automatically starting the water pump after 1h, carrying out the flushing process, and repeating the flushing-feeding process, and (3) carrying out process inspection every 4 hours until the size of the ceramic ball is processed to 6.38mm, unloading the ball and carrying out inspection, wherein the processing efficiency is 2-4 mu m/h, the diameter variation of the processed product is 0.2 mu m, the batch diameter variation is 0.3 mu m, the surface roughness is 0.007-0.010 mu m, the surface processing defect depth is less than 2 mu m, and the qualified fine grinding ball is obtained according to the requirements of fine processing and ball unloading.
Comparative example 1
The difference from example 2 is that: 20g of cubic boron nitride powder with a particle size of 14 μm was weighed at intervals of 8 hours, and the procedure was otherwise the same as in example 2.
The processing efficiency of the comparative example is 2-3 mu m/h, the diameter variation of the processed product is 0.3 mu m, the batch diameter variation is 0.4 mu m, the surface roughness is 0.015-0.851 mu m, the surface has scratch defects, the defect depth is more than 2 mu m, and the precision machining ball unloading requirement is not met.
Comparative example 2
The difference from example 2 is that: 20g of silicon carbide powder with the abrasive grain size of 14 μm is weighed at intervals of 8h, and the rest is the same as in example 2.
The machining efficiency of the comparative example is 1-1.5 mu m/h, the diameter variation of the machined product is 0.2 mu m, the batch diameter variation is 0.2 mu m, the surface roughness is 0.004-0.008 mu m, the surface machining defect depth is less than 2 mu m, the machining efficiency is low, and the requirements of finish machining and ball unloading are not met.
Comparative example 3
The difference from example 4 is that: the same procedure as in example 4 was repeated except that the particle diameter of the synthetic diamond powder was 3.5. mu.m.
The machining efficiency of the comparative example is 0.5-1.5 mu m/h, the diameter variation of the machined product is 0.2 mu m, the batch diameter variation is 0.3 mu m, the surface roughness is 0.003-0.006 mu m, the depth of surface machining defects is less than 2 mu m, the machining efficiency is low, and the requirements of finish machining and ball unloading are not met.
Comparative example 4
The difference from example 4 is that: the particle size of the synthetic diamond powder was 28 μm, and the same was applied to example 4.
The processing efficiency of the comparative example is 5 mu m/h-7 mu m/h, the diameter variation of the processed product is 0.3 mu m, the batch diameter variation is 0.4 mu m, the surface roughness is 0.018 mu m-0.926 mu m, the surface has pit defects, the depth of the processing defects is more than 2 mu m, and the requirements of finish machining and ball unloading are not met.
Comparative example 5
The difference from example 2 is that: 5g of synthetic diamond powder were weighed at intervals of 8h, otherwise as in example 2.
The processing efficiency of the comparative example is 0.5-1 mu m/h, the diameter variation of the processed product is 0.2 mu m, the batch diameter variation is 0.4 mu m, the surface roughness is 0.006 mu m-0.011 mu m, the depth of the surface processing defect is less than 2 mu m, the processing efficiency is low, and the requirements of finish machining and ball unloading are not met.
Comparative example 6
The difference from example 2 is that: 40g of synthetic diamond powder was weighed at 8h intervals, otherwise as in example 2.
The processing efficiency of the comparative example is 7-9 mu m/h, the diameter variation of the processed product is 0.6 mu m, the batch diameter variation is 1.2 mu m, the surface roughness is 0.008 mu m-0.015 mu m, the surface processing defect depth is less than 2 mu m, the diameter variation and the batch diameter variation exceed the standard, and the precision machining ball unloading requirement is not met.
From the above examples 1-4, it can be seen that the invention can realize the finish machining of silicon nitride ceramic balls with different diameters by adopting the water-based circulating liquid, and from the comparison of the example 4 and the comparative examples 1-6, the type, the grain diameter and the addition amount of the grinding material have important influence on the finish machining quality of the silicon nitride ceramic balls, and the invention can meet the requirements of finish machining and ball unloading of the silicon nitride ceramic balls by controlling the type, the grain diameter and the addition amount of the grinding material.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (8)
1. An environment-friendly finish machining method for silicon nitride ceramic balls is characterized by comprising the following steps:
turning the cast iron plate to form a channel;
pressing the groove by using a groove pressing ball to form a groove arc;
placing the silicon nitride ceramic rough grinding ball at the groove arc, and performing finish machining until the diameter of the obtained silicon nitride ceramic fine grinding ball is plus (5-50) mu m of the diameter of the silicon nitride ceramic finished ball;
the circulating liquid used for finish machining comprises water-based circulating liquid and a rust inhibitor;
the water-based circulating liquid comprises the following components in percentage by volume: 20-40% of oil-free steel ball hard grinding fluid, 60-80% of water and 1-3% of defoaming agent.
2. The processing method according to claim 1, wherein the diameter of the silicon nitride ceramic finished ball is 3-20 mm.
3. The processing method according to claim 1, wherein the pressure of the grooving process is 10 to 30kN, and the time of the grooving process is 4 to 24 hours.
4. The processing method according to claim 1 or 2, wherein the diameter of the silicon nitride ceramic rough grinding ball is + (100-300) μm, the diameter variation of the silicon nitride ceramic rough grinding ball is less than 5 μm, the batch diameter variation is less than 10 μm, and the surface defect depth is less than 30 μm.
5. The processing method according to claim 1, wherein before the ball loading, the silicon nitride ceramic rough grinding ball is subjected to ultrasonic cleaning, wherein the ultrasonic cleaning time is 10-60 min, and the current is 1-5A.
6. The process according to claim 1, wherein the abrasive used for the finish machining is synthetic diamond powder; the grain size of the abrasive is 5-20 mu m.
7. The machining method according to claim 1 or 6, wherein in the finish machining process, the machining pressure is 6-20 kN, and the machining rotating speed is 10-25 r/min.
8. The processing method according to claim 1, wherein the rust inhibitor comprises sodium benzoate, a DS-064 concentrated steel melt-based rust inhibitor or a KS-VCI water-based rust inhibitor, and when the rust inhibitor is sodium benzoate, the dosage ratio of the water-based circulating liquid to the rust inhibitor is 10L: (200-500) g; when the antirust agent is a DS-064 concentrated steel melt-based antirust agent or a KS-VCI water-based antirust liquid, the mass ratio of the water-based circulating liquid to the antirust agent is 1 (0.01-0.1).
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