CN112171530B - Ceramic corundum abrasive coated grinding tool and preparation method thereof - Google Patents
Ceramic corundum abrasive coated grinding tool and preparation method thereof Download PDFInfo
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- CN112171530B CN112171530B CN202011027101.XA CN202011027101A CN112171530B CN 112171530 B CN112171530 B CN 112171530B CN 202011027101 A CN202011027101 A CN 202011027101A CN 112171530 B CN112171530 B CN 112171530B
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- 229910052593 corundum Inorganic materials 0.000 title claims abstract description 162
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- 238000007790 scraping Methods 0.000 claims description 77
- 239000000758 substrate Substances 0.000 claims description 60
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 42
- 230000005484 gravity Effects 0.000 claims description 40
- IJGRMHOSHXDMSA-UHFFFAOYSA-N nitrogen Substances N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 31
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- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- BYIOOYGLUVPHQX-UHFFFAOYSA-M [Si+](=O)=O.[F-] Chemical compound [Si+](=O)=O.[F-] BYIOOYGLUVPHQX-UHFFFAOYSA-M 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/20—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially organic
- B24D3/28—Resins or natural or synthetic macromolecular compounds
-
- 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
- B24D18/0018—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for by electrolytic deposition
-
- 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
- B24D18/0072—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using adhesives for bonding abrasive particles or grinding elements to a support, e.g. by gluing
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Polishing Bodies And Polishing Tools (AREA)
Abstract
The invention provides a ceramic corundum abrasive coated grinding tool and a preparation method thereof, wherein the ceramic corundum abrasive coated grinding tool comprises a base material layer and a working layer, and the working layer comprises a primer layer, an abrasive implanted into the primer layer and a compound layer coated on the abrasive and the primer layer. Above-mentioned ceramic corundum abrasive material coated grinding apparatus need not to change abrasive material internal property, carries out surface modification through ion implantation treatment, carries out the ion implantation abrasive material surface, realizes abrasive material case hardening, reinforces and toughen the promotion in coordination, and the abrasive material is difficult broken, be difficult for coming off from the primer layer, and thereby can break when the abrasive grain load is great improves the self-sharpening nature of abrasive material, improves abrasive material surface property by a wide margin to increase the performance of whole grinding apparatus, make coated grinding apparatus have longer life when satisfying accurate high-speed, accurate heavy load powerful grinding and polishing aspect performance requirement.
Description
Technical Field
The invention relates to the technical field of high-performance grinding materials, in particular to a ceramic corundum abrasive coated grinding tool and a preparation method thereof.
Background
Grinding is a general term for a process of removing material using hard mineral (abrasive) particles as a cutting tool. Abrasive grain processing is the most effective precision machining technique in which a surface with high precision and low surface roughness can be easily obtained.
With the rapid increase of the high-precision and high-efficiency processing demands of difficult-to-process materials, the modern grinding technology is further stimulated and promoted to continuously develop towards ultra-high-speed grinding (100 m/s-500 m/s) and ultra-precise grinding (submicron-nanometer), and the grinding processing objects also develop from the traditional metal materials towards the precise and ultra-precise grinding directions of hard and difficult-to-grind nonmetallic materials such as ceramics, silicon chips, fiber reinforced composite materials and the like. The traditional coated abrasive has low grade, the abrasive is easy to break and fall off, the self-sharpening property is poor, and the service life of the abrasive is short, so that the application and development of the coated abrasive in the precise and ultra-precise grinding directions are restricted.
Disclosure of Invention
Based on the problems, the conventional coated abrasive has low grade, the abrasive is easy to break and fall off, the self-sharpening property is poor, the service life of the abrasive is short, and the application and development of the coated abrasive in the precise and ultra-precise grinding directions are restricted.
The invention provides a ceramic corundum abrasive coated grinding tool, which comprises a substrate layer and a working layer, wherein the working layer comprises a primer layer, an abrasive implanted into the primer layer and a compound layer coated on the abrasive and the primer layer, the abrasive is ceramic corundum abrasive subjected to ion implantation treatment, and metal ions and nitrogen ions are implanted into the ion implantation treatment.
In one embodiment, the ceramic corundum abrasive comprises any one or more of alumina ceramic corundum abrasive, zirconia ceramic corundum abrasive and zirconia ceramic corundum stacking abrasive.
In one embodiment, the abrasive is distributed in the coated abrasive in two layers.
In one embodiment, the working layer further comprises a top coat applied over the size coat.
In one embodiment, the working layer comprises the following components in parts by weight:
the invention also provides a preparation method of the ceramic corundum abrasive coated grinding tool, which comprises an abrasive pretreatment step, a base material pretreatment step, a primer coating step, a sand planting step and a primer coating step, wherein the abrasive pretreatment step comprises ion implantation treatment of the abrasive; the ion implantation treatment is to sequentially and circularly implant nitrogen ions and metal ions on the surface of the abrasive, and the cycle times are not less than 2.
In one embodiment, the substrate pretreatment step includes subjecting the substrate to two dip treatments; the impregnating material for the impregnation treatment comprises the following components in parts by mass:
In one embodiment, after the substrate is subjected to the two dipping treatments, the method further comprises the step of performing two scraping treatments on the substrate, wherein the scraping slurry for the scraping treatment comprises the following components in parts by weight:
In one embodiment, in the step of pre-treating the substrate, after the substrate is subjected to the two dipping treatments and the two scraping treatments, the pre-treating method further comprises the step of pre-treating the substrate, wherein the pre-treating material for pre-treating comprises the following components in parts by weight:
In one embodiment, the step of planting sand includes gravity planting sand and electrostatic planting sand.
Above-mentioned ceramic corundum abrasive material coated grinding apparatus need not to change abrasive material internal property, carries out surface modification through ion implantation treatment, carries out the ion implantation abrasive material surface, realizes abrasive material case hardening, reinforces and toughen the promotion in coordination, and the abrasive material is difficult broken, be difficult for coming off from the primer layer, and thereby can break when the abrasive grain load is great improves the self-sharpening nature of abrasive material, improves abrasive material surface property by a wide margin to increase the performance of whole grinding apparatus, make coated grinding apparatus have longer life when satisfying accurate high-speed, accurate heavy load powerful grinding and polishing aspect performance requirement.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be further described in detail with reference to the following detailed description. It should be understood that the detailed description is presented merely to illustrate the invention, and is not intended to limit the invention.
The invention provides a ceramic corundum abrasive coated abrasive tool, which aims to overcome the defects that the abrasive material of the coated abrasive tool prepared by the prior art is easy to break and fall off, has poor self-sharpening property, shortens the service life of the abrasive tool and cannot realize precise and automatic grinding and resource waste. The ceramic corundum abrasive material coated grinding tool comprises a substrate layer and a working layer, wherein the working layer comprises a primer layer, an abrasive material implanted into the primer layer and a compound layer coated on the abrasive material and the primer layer, the abrasive material is ceramic corundum abrasive material subjected to ion implantation treatment, and metal ions and nitrogen ions are implanted into the ion implantation treatment.
Above-mentioned ceramic corundum abrasive material coated grinding apparatus need not to change abrasive material internal property, carries out surface modification through ion implantation treatment, carries out the ion implantation abrasive material surface, realizes abrasive material case hardening, reinforces and toughen the promotion in coordination, the abrasive material is difficult broken, be difficult for coming off from the primer layer, and thereby can break when the abrasive grain load is great improves the self-sharpening nature of abrasive material, improves abrasive material surface property by a wide margin to increase the performance of whole grinding apparatus, make coated grinding apparatus have longer life when satisfying accurate high-speed, accurate, heavy load powerful grinding and polishing aspect performance requirement.
As an alternative embodiment, the ceramic corundum abrasive comprises any one or more of alumina ceramic corundum abrasive, zirconia ceramic corundum abrasive and zirconia ceramic corundum stacking abrasive.
As an alternative embodiment, the abrasive is distributed in two layers in the coated abrasive. Preferably, two layers of abrasive materials are respectively planted on the primer layer by adopting two sand planting methods of gravity sand planting and electrostatic sand planting. The gravity sand planting makes the abrasive material planted on the primer layer by self gravity, the contact area of the abrasive material on the primer layer and the colloid is large, the combination degree is high, and the abrasive material is mainly used as a basic grinding layer; the static sand planting is that the high-voltage static magnetic field electricity polarizes the abrasive material first and then attracts to the primer layer, the abrasive material is orderly arranged on the primer layer, and the edges and the tips of the abrasive material are outwards sharp, because the axial direction of the abrasive material and the matrix form a certain angle, the orientation of the abrasive material forms a saw tooth-like structure, and the grinding capability can be further enhanced.
Optionally, the ceramic corundum abrasive of the ceramic corundum abrasive coated grinding tool is an alumina ceramic corundum abrasive and a zirconia ceramic corundum abrasive, wherein the alumina ceramic corundum abrasive is implanted to one side adjacent to the substrate layer through gravity sand implantation, and the zirconia ceramic corundum abrasive is implanted to one side adjacent to the compound adhesive layer through electrostatic sand implantation. Further preferably, the particle size of the alumina ceramic corundum abrasive is larger than the particle size of the zirconia ceramic corundum abrasive.
As an alternative embodiment, the working layer further comprises a top coat applied over the size coat.
As an alternative embodiment, the working layer comprises the following components in parts by weight:
The invention also provides a preparation method of the ceramic corundum abrasive coated grinding tool, which comprises an abrasive pretreatment step, a base material pretreatment step, a primer coating step, a sand planting step and a primer coating step, wherein the abrasive pretreatment step comprises ion implantation treatment of the abrasive.
As an alternative embodiment, the ion implantation treatment is to sequentially and circularly implant nitrogen ions and metal ions into the surface of the abrasive, and the number of times of the cycle is not less than 2.
Preferably, the metal ion is selected from any one or more of Ti and Cr metal elements.
Optionally, the ion implantation treatment method is as follows:
After the ceramic corundum abrasive is cleaned and dried, a linear high-energy ion implanter is adopted, metal ions and nitrogen ions are selected to be continuously and overlapped and implanted under the vacuum condition, the nitrogen ions are implanted first, then the metal ions are implanted, and the cycle is sequentially carried out for at least 2 times.
Wherein, the metal ions are injected by a metal vapor vacuum arc discharge ion source (MEVVA), the accelerating voltage is 40-50 kV, and the injected metal ions are selected from Ti, cr and other metal elements; the nitrogen ions are injected by an electron cyclotron resonance ion source (ECR) and the acceleration voltage is 60-80 kV.
Wherein, the nitrogen ion source adopts nitrogen with the purity of 99.99 percent, and the injection dosage is about 5 multiplied by 10 17ion cm-2 each time; the metal ion source uses a metal target with a purity of 99.8% and an implantation dose of about 1x 10 17ion cm-2.
Through ion implantation treatment, the whole performance of the abrasive is not required to be changed, and through a surface modification method, metal ions and nitrogen ions are implanted to the surface of the abrasive, so that the surface hardening, strengthening and toughening of the abrasive are synergistically improved. On the basis of adding only one surface modification process, the surface performance of the abrasive is greatly improved, the advantages of the ceramic corundum abrasive suitable for high-efficiency and high-precision grinding are maintained, and the use performance of high strength and high durability is provided, so that the use performance of the whole coated grinding tool can be improved.
As an alternative embodiment, the substrate pretreatment step comprises subjecting the substrate to two dip treatments.
In the present embodiment, the base material is subjected to a two-time impregnation treatment process including a first impregnation, a stretching and a second impregnation, and the impregnation amount is ensured not to be reduced when the stretching is sufficient, so that the stiffness of the base material after the base material is manufactured into a finished product is increased, and the manufactured base material layer has the use characteristics of tensile strength and no deformation.
Preferably, the base material of the base material layer adopts polyester fiber raw cloth, and the polyester fiber raw cloth with corresponding model is selected according to the design requirements of the coated grinding tool with different grinding objects and different technical requirements. The polyester fiber raw cloth is subjected to twice impregnation treatment by an impregnating material before use. The parameters of the polyester fiber raw cloth selected in the embodiment of the invention are as follows: the radial pulling force is more than or equal to 3700N, and the transverse pulling force is more than or equal to 1500N. The breaking strength parameters of the finished product of the prepared coated grinding tool are as follows: longitudinal direction is larger than or equal to 4000N/5cm, and transverse direction is larger than or equal to 2000N/5cm.
As an alternative embodiment, after the substrate is subjected to the two dipping treatments, the method further comprises the step of performing the two scraping treatments on the substrate.
Further preferably, the pretreatment step of the base material comprises the steps of sequentially carrying out primary dipping, stretching, secondary dipping, primary scraping, secondary scraping and coating a precoating on the base material to obtain the base material layer of the ceramic corundum abrasive coated abrasive tool.
As an alternative embodiment, the impregnating solution for the impregnation treatment comprises the following components in parts by mass:
Further preferably, the preparation method of the impregnating compound comprises the following steps: 75 parts by mass of water and 25 parts by mass of polyvinyl alcohol (PVA-205) were added to a vessel, and the temperature was raised to 60.+ -. 2 ℃ to prepare a 25% aqueous polyvinyl alcohol solution (PVA-205 aqueous solution). Adding 25% PVA-205 aqueous solution into a container according to the formula ratio, opening a stirrer, adding phenolic resin, stirring for 10min, adding white latex, stirring for 10min, adding organic silicon, adjusting to a set viscosity with 25% polyvinyl alcohol aqueous solution, stirring for 10min, and transporting to a production line.
In the present invention, it is preferable that the impregnating material has a set viscosity of 200 to 400 cps/room temperature; more preferably, the impregnating compound has a set viscosity of 300 cps/room temperature.
As an alternative embodiment, the doctor blade treated doctor blade comprises the following components in parts by mass:
as an alternative embodiment, the scraping slurry further comprises the following components in parts by weight:
1.14 to 1.40 parts by mass of dye;
The dye is mainly used for dyeing in the sizing agent, and is single dye or mixed dye, and the dye can be selected from common dyes used for coated abrasive tools, such as direct blue.
Further preferably, the preparation method of the scraping slurry comprises the following steps: 75 parts by mass of water and 25 parts by mass of polyvinyl alcohol (PVA-205) were added to a vessel, and the temperature was raised to 60.+ -. 2 ℃ to prepare a 25% aqueous polyvinyl alcohol solution (PVA-205 aqueous solution). Adding 25% PVA-205 aqueous solution into a container according to the formula proportion, opening a stirrer, adding phenolic resin 9600, stirring for 10min, adding calcium carbonate, stirring for 10min, adding white latex, organosilicon compound, silica gel and sorbitan laurate, stirring for 10min, adding direct blue, mixing colors, adjusting the viscosity to a set viscosity with 25% polyvinyl alcohol aqueous solution, stirring for 10min, and transporting to a production line.
In the present invention, it is preferable that the set viscosity of the paste is 2700 to 3300 cps/room temperature; more preferably, the set viscosity of the squeegee is 3000 cps/room temperature.
As an alternative embodiment, in the step of pretreating the substrate, after the substrate is subjected to the two dipping treatments and the two scraping treatments, the substrate is further subjected to a pre-coating treatment, and the pre-coating material of the pre-coating treatment comprises the following components in parts by weight:
The base material is subjected to pre-coating treatment to form a pre-coating layer on the surface of the base material, wherein the pre-coating layer is a special coating layer before the base material is coated with the primer, and the pre-coating layer has the function of bonding a bridge between the base material layer and the working layer.
Further preferably, the preparation method of the precoating is as follows: adding PVA into a container according to the formula ratio, opening a stirrer, adding phenolic resin 9600 and phenolic resin 1100 (no sequence), stirring for 10min, adding calcium carbonate, stirring for 10min, adding a silane coupling agent and sorbitan laurate, stirring for 10min, adjusting to a set viscosity requirement, maintaining the temperature at 40+/-2 ℃, and transporting to a production line.
In the present invention, it is preferable that the set viscosity of the pre-coat paste is 1800 to 2200 cps/room temperature; more preferably, the pre-coat slurry has a set viscosity of 2000 cps/room temperature.
Specifically, the pretreatment process of the base material is as follows:
Preparing the impregnating material, the scraping slurry and the precoating according to the formula ratio.
The pressure between the first set of rolls was adjusted so that the grammage of the first impregnation addition was maintained at 60.+ -.6 g/square meter, and then stretched, and the pressure between the second set of rolls was adjusted so that the grammage of the second impregnation addition was maintained at 30.+ -.3 g/square meter. In order to keep accurate data, when the substrate wire runs, a cloth disc is cut down for measurement, and finally the pressure is confirmed.
After the twice dipping is finished, drying at the temperature of 200-220 ℃ and then entering a scraping line, adjusting the scraping amount by adjusting the position and the running amount of a scraping knife, and increasing the gram weight of the once scraping by 70+/-7 g/square meter through disc carving confirmation; drying at 200-220 deg.c, re-entering into scraping line, regulating scraping amount via regulating the position and amount of scraping blade, and re-scraping with the weight increased by 60+ -6 g/square meter via carving disc; and (3) drying at the temperature of 130-160 ℃, then re-entering a scraping line, adding a precoating in the scraping line, adjusting the precoating amount by adjusting the position and the running amount of a scraping knife, and increasing the gram weight of the precoating by 140+/-14 g/square meter by disc engraving confirmation, drying at the temperature of 120-150 ℃ and then rolling to obtain the substrate for the coated abrasive substrate layer.
As an alternative embodiment, the primer glue solution in the primer coating step comprises water and the following components in parts by weight:
wherein the components of the primer glue solution are adjusted to be at a viscosity of 3000 cps/room temperature by water.
The primer glue solution adopts two water-soluble phenolic resins 9600 and 1100 with different structures and components, ethylene glycol diethyl ether, wollastonite, penetrant and defoamer are used for modifying the phenolic resin, and water is used for adjusting the temperature to 3000 cps/room temperature to form high-strength polymers with different cross-linked network structures, so that the primer glue solution with high strength, high bonding strength and high toughness can be prepared.
Wherein, optionally, the penetrating agent is silicone grease, and the defoaming agent is an organosilicon compound.
Preferably, the primer coating step is as follows:
Placing the prepared base material for the base material layer of the coated abrasive tool on a primer machine, adjusting various technical parameters of primer machine equipment, heating circulating water of a primer machine rubber disc to 47 ℃ in summer and 60 ℃ in winter, lifting the rubber disc, opening a pipeline valve, adjusting viscosity of primer rubber liquid prepared according to the formula ratio, measuring the viscosity to 3000 cps/room temperature by using a DNJ viscometer, adjusting the temperature of the rubber liquid to 38+/-2 ℃, and sending the rubber liquid to a primer machine.
And (3) sieving the primer glue solution, slowly putting the glue solution into a glue tray, taking the position where the glue solution is to be placed as a way of preventing the glue solution from overflowing, accurately measuring the glue temperature to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller to see whether the glue solution is uniform, finding that the thickness of two sides is to be adjusted in time, and circulating the glue solution for about 5min.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the station is started after being in place, all control buttons are opened, the base material is pressed on the steel roller at the position of the rubber disc, the uniform bar is pressed, the speed is firstly slow and then fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of the base body, the sizing amount is measured, the sizing amount is timely adjusted to meet the requirement, and the sand planting procedure is carried out.
As an alternative embodiment, the sand planting step includes a gravity sand planting process and an electrostatic sand planting process.
In the preparation method of the ceramic corundum abrasive coated abrasive tool, two sand planting methods are adopted, and the abrasive materials are distributed in the coated abrasive tool in two layers through the two sand planting methods. The abrasive tool realizes high-speed precise grinding with evenly distributed/orderly arranged abrasive particles, and has the service life which is several times that of the abrasive tool which is the same as the common manufacturing technology.
Preferably, the grit size of the abrasive implanted by gravity grit implantation is greater than the grit size of the abrasive implanted by electrostatic grit implantation.
Optionally, in an embodiment of the present invention, the selected abrasive materials are alumina ceramic corundum abrasive materials and zirconia ceramic corundum abrasive materials, the alumina ceramic corundum abrasive materials are first implanted into the primer layer through a gravity sand implantation process, and then the zirconia ceramic corundum abrasive materials are implanted into the primer layer through an electrostatic sand implantation process. Wherein the granularity of the alumina ceramic corundum abrasive is larger than that of the zirconia ceramic corundum abrasive.
In other embodiments, the gravity sand planting firstly can be selected from other types of ceramic corundum abrasive materials, and the abrasive materials for electrostatic sand planting and the gravity sand planting abrasive materials for electrostatic sand planting can be of the same type and different granularities, or of different types and the same granularity.
Wherein, after the primer layer is coated, the alumina ceramic corundum abrasive is subjected to gravity sand planting on the base cloth according to the prescribed density of the formula. The gravity sand planting is carried out on the adhesive layer by the gravity of the abrasive, so that the contact area of the abrasive on the adhesive layer with the colloid is large, the combination degree is high, and the abrasive is taken as a basic grinding layer, and the abrasive has no certain directivity. And then, on the product after the gravity sand planting, the zirconia ceramic corundum abrasive is planted on the adhesive layer on the upper side of the alumina ceramic corundum abrasive by an electrostatic sand planting method according to the prescribed density of the formula. The static sand planting is that the high-voltage static magnetic field power polarizes the abrasive material first and then attracts the abrasive material to the glue layer, so that the abrasive material is orderly arranged, and the edges and tips of the abrasive material are outward, which is very beneficial.
Preferably, the sand planting step is as follows:
and (3) gravity sand planting:
Starting a circulating lifting hopper, sieving alumina ceramic corundum abrasive materials to be used, then putting the alumina ceramic corundum abrasive materials into a sand box, adjusting the gap of the sand box, the position and the speed of a sanding roller and the angle of a sand baffle according to the granularity of the abrasive materials, ensuring that the sand loading quantity accords with the process-specified sand planting quantity, and then transferring the sand into electrostatic sand planting.
And (3) electrostatic sand planting:
And implanting zirconia ceramic corundum abrasive materials on the base material subjected to gravity sand implantation through an electrostatic sand implantation process. And (3) starting a temperature and humidity control switch of the electrostatic sand planting room to enable the temperature and humidity control switch to reach the temperature of 25 ℃ and the humidity of 65% specified by a process, starting electrostatic planting (taking care of temperature guarantee in winter and moisture guarantee in summer), adjusting equipment parameters, and guaranteeing the parallelism and the height (P24-P80.5 cm, P100-600.0 cm) of an electrostatic polar plate and electrostatic voltage (P24-80 45KV, P100-600 KV).
The circulation lifting hopper is started, zirconia ceramic corundum abrasive materials to be used are put into the sand box after being screened, the vibration amplitude in the static sand planting device is adjusted, meanwhile, the sand conveying belt is opened, the sand conveying belt runs at a low speed, and the sand discharging amount of the sand box and the rotating speed of the sand conveying belt are timely adjusted according to the sand surface condition.
And after all the conditions are normal, the machine speed is increased to the range of the process requirement, sampling and detecting are carried out on the primer and the sand feeding amount, and if the process requirement is not met, the process is regulated again, and sampling is carried out until the result meets the requirement. After electrostatic sand planting, pre-drying is carried out at the temperature of 75-95 ℃.
In the process of static sand planting, attention is paid to the fact that circulating sand is uniformly stirred after entering a sand box, and the static electricity is released after the circulating sand is charged and the new sand is uniformly stirred, all switches are turned off firstly after production, particularly voltage is turned off (a red light is extinguished), and then static electricity of an upper polar plate is discharged by a grounding rod.
After the sand is planted by gravity and the sand is planted by static electricity, under the action of high-strength high-viscosity primer, the alumina ceramic corundum abrasive implanted by the sand is planted by gravity and is in a lying form in the primer, the zirconia ceramic corundum abrasive implanted by the sand is planted by static electricity and is in a vertical form in the primer, the zirconia ceramic corundum abrasive implanted by the sand is fixed by the alumina ceramic corundum abrasive planted by gravity, and is preliminarily fixed on a base material after being pre-dried.
As an alternative embodiment, the compound glue solution in the step of coating the compound glue comprises the following components in parts by mass:
Wherein, the components of the compound glue solution are adjusted to be at 2000 cps/room temperature by using ethylene glycol diethyl ether.
The complex gum glue solution adopts two water-soluble phenolic resins 9600 and 1900 with different structures and components, and uses cryolite, titanium white, span, thickener and ethylene glycol diethyl ether modified phenolic resin to form high-strength polymers with different cross-linked network structures, thereby being capable of preparing the complex gum glue solution with high strength and excellent heat resistance.
Wherein the thickener may be a nonionic polyurethane.
Preferably, the step of applying the laminating adhesive is as follows:
The coating of the coating glue can be performed by using the same equipment as the coating of the primer, i.e. the coating of the coating glue can be performed by using a primer machine.
Placing the base material on a compound glue machine after sand planting, adjusting various technical parameters of compound glue machine equipment, heating circulating water of a glue disc of the compound glue machine to 47 ℃ in summer and 60 ℃ in winter, lifting the glue disc, opening a pipeline valve, adjusting viscosity of compound glue liquid prepared according to the formula ratio, measuring the viscosity to 2000 cps/room temperature by using a DNJ viscometer, adjusting the temperature of the glue liquid to 38+/-2 ℃, and sending the glue liquid into a compound glue machine table.
Sieving the compound glue solution, slowly placing into a glue tray, paying attention to the position where the feed liquid is to be placed so as to prevent the feed liquid from overflowing, accurately measuring the temperature of the feed liquid to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller, judging whether the compound glue solution is uniform, finding that the thickness of two sides is required to be adjusted in time, and circulating the feed liquid for about 5min.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the operation is started after the pre-drying room and the main drying room are in place, all control buttons are opened, the base material after sand planting is conveyed to a rubber disc to press a steel roller, a uniform bar is pressed, the speed is firstly slow and secondly fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of a base body, the sizing amount is measured, the sizing is timely adjusted to meet the requirement, the re-sizing is finished, and the next procedure is carried out after the base material is dried at 75-95 ℃.
As an alternative embodiment, the step of applying a top coat further comprises, after the step of applying a size coat. The surface coating glue solution of the surface coating comprises the following components in parts by mass:
wherein the components of the surface coating glue solution are adjusted to 15000 cps/room temperature by using ethylene glycol diethyl ether.
Preferably, wherein the dispersant is fumed silica.
Preferably, the potassium fluoborate oily coating modified epoxy resin adhesive comprises the following components in parts by weight:
10-15 parts by mass of oily epoxy resin;
70-75 parts by mass of potassium fluoborate;
10-15 parts by mass of ethylene glycol diethyl ether.
Preferably, the coating dispersing agent comprises the following components in parts by mass:
Wherein, the penetrating agent can be fatty alcohol polyoxyethylene ether.
Preferably, in the topcoat glue solution of the topcoat, the epoxy value of the oleoepoxy resin is 0.25 to 0.45.
The surface coating glue solution takes oily epoxy resin with the epoxy value of 0.25-0.45 as a base material, adopts potassium borofluoride and the like for modification, improves the burn resistance of the surface coating formed after the surface coating glue solution is coated by fluoride salt low-melting salt, and ensures that the prepared finished product has the use characteristics of softness and strong grinding resistance.
Preferably, the top coat is applied as follows:
the application of the top coat may be performed using the same equipment as the application of the primer, i.e., the application of the top coat may be performed using a primer machine.
Placing the prepared substrate coated with the compound adhesive on a surface coating machine, adjusting various technical parameters of equipment of the surface coating machine, heating circulating water of a rubber disc of the surface coating machine to 47 ℃ in summer and 60 ℃ in winter, lifting the rubber disc, opening a pipeline valve, adjusting viscosity of the prepared surface coating adhesive according to the formula ratio by using ethylene glycol diethyl ether, measuring the viscosity to 15000 cps/room temperature by using a DNJ viscometer, adjusting the temperature of the adhesive to 38+/-2 ℃, and sending the adhesive to a surface coating machine.
And (3) sieving the surface coating glue solution, slowly putting the glue solution into a glue tray, paying attention to the position where the glue solution is to be put so as to prevent the glue solution from overflowing, accurately measuring the glue temperature to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller to see whether the glue solution is uniform, finding that the glue solution is thin and thick at two sides, and circulating the glue solution for about 5min.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the operation is started after the pre-drying room and the main drying room are in place, all control buttons are opened, the substrate after sand planting is conveyed to a rubber disc to press a steel roller, a uniform bar is pressed, the speed is firstly slow and secondly fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of a substrate, the sizing amount is measured, the coating is timely adjusted to meet the requirement, the surface coating is finished, and the surface coating is dried at 70-95 ℃ to prepare the ceramic corundum abrasive coated grinding tool after the primary coating.
Further, the ceramic corundum abrasive coated grinding tool after the preliminary coating is subjected to the following post-treatment steps:
a coating step, namely placing the ceramic corundum abrasive coated grinding tool subjected to primary coating in a coating furnace for three-section coating, wherein the curing temperature of one section is 100 ℃ and the curing time of the other section is 12 hours; the second-stage curing temperature is 120 ℃, and the second-stage curing time is 12 hours; the three-stage curing temperature is 130 ℃, and the three-stage curing time is 12 hours.
And a softening step, namely mechanically softening the coated product to enable tiny small cracks to be generated on the surface of the abrasive cloth, and improving the flexibility and toughness of the product, so that the whole soft product is obtained.
The method comprises the steps of finished product preparation, namely dividing the flexible product into sand rolls, cutting, edging, sizing, jointing, edge pressing and working procedures, and converting the sand rolls into a coated grinding tool with set specifications;
and a finished product inspection step, namely quality inspection is carried out according to national regulation standards.
The beneficial effects of the invention are as follows:
1. The invention adopts the ion implantation high-performance abrasive surface hardening technology to prepare the high-performance ceramic corundum abrasive as a grinding material, thereby realizing precise high-speed, precise heavy-load and powerful grinding and polishing.
The invention adopts ion implantation corundum abrasive to form boron nitride, thereby realizing the synergistic promotion of surface hardening, strengthening and toughening. Ion implantation is an emerging beam surface strengthening technology, and the ion implanted ceramic material can improve the mechanical properties of the surface, such as fracture toughness, hardness, bending strength, tribological properties and the like, and opens up a new technical approach for solving the problems of insufficient toughness, higher friction and wear rate and the like of structural ceramics. The novel structural ceramic has high hardness, high strength, good wear resistance, excellent chemical stability and high-temperature mechanical property, and related researches are very active in recent years. However, the ceramic material has a fatal weakness of being brittle and not ductile, and is liable to cause early failure or brittle fracture of the part in practical use, thereby greatly limiting its wide application. The ceramic material has a high friction coefficient and wear rate, and the expected service life of the ceramic material is not achieved due to the large wear amount. Researchers at home and abroad not only aim at the research of ceramic material toughening technology, but also pay more attention to the research of ceramic material friction and abrasion and lubrication, and gradually become one of the leading-edge subjects in the current material science and tribology fields, and an ion implantation technology is a surface modification technology developed in seventies, and can implant ions of required elements into the surface of a material under the voltage of tens to hundreds of kilovolts, increase the concentration of the implanted elements in the surface layer of a few tenths of micrometers, and simultaneously generate an irradiation effect, so that the structure and the performance of the material are changed. Research at home and abroad shows that ion implantation is an effective method for toughening ceramic materials and improving wear resistance. The process has the following characteristics: (1) The ion concentration entering the crystal lattice is not limited by thermodynamic equilibrium conditions; (2) The injection is a athermal process, can be performed at room temperature or low temperature, and does not cause thermal deformation of the material; (3) The concentration and depth of the implanted ions can be controlled by the implantation integral dose and implantation voltage, and the distribution of the implanted ions can be measured by theoretical calculation or by methods such as ion beam back scattering and nuclear reaction analysis; (4) No obvious interface exists between the implanted ions and the matrix, and the implanted layer cannot fall off; (5) The method is not limited by solid solubility in an alloy equilibrium phase diagram, can inject mutually-incompatible elements, can change the surface hardness, fracture toughness and bending strength of the ceramic material, can reduce friction coefficient and improve wear resistance. Thus, ion implantation techniques are more novel and have potential than other processes.
Compared with the domestic corundum abrasive used by the present company,
1) The surface hardness of the abrasive is improved by 20%;
2) The fracture toughness is improved by 50%;
3) The bending strength is improved by 50 percent.
4) Aiming at the resin grinding tool, the dry grinding time of the corundum grinding material subjected to ion implantation surface modification reaches 2 hours, which is 4 times of the grinding time of the common dry grinding coated grinding tool. The metal grinding amount reaches 42.8g, which is 6 times of that of a common dry grinding coated grinding tool.
2. The double-impregnation treatment, namely the impregnation-stretching-impregnation base cloth treatment technology is adopted, so that under the condition of enough stretching, the impregnation amount can be ensured not to be reduced, and the stiffness performance of the base cloth after being manufactured into a finished product is improved;
3. Ethylene glycol diethyl ether, wollastonite, silicone grease and organosilicon high-strength modified phenolic resin primer glue solution are adopted; mixing two kinds of mixed phenolic resin glue coating liquid with different water solubility and different viscosity by cryolite, titanium white, span and nonionic polyurethane with high strength; fluoride salt low-melting point salt burn-resistant modified epoxy resin surface coating glue solution realizes heavy-load soft water-resistant powerful grinding.
4. The special coating of modified epoxy resin with burn resistance of low melting point salt of titanium dioxide and aerosil silicon dioxide fluoride salt is prepared by adopting the gravity sand planting and electrostatic sand planting twice to form a double-layer abrasive structure, coating glue twice to realize high-strength coupling compounding and special surface coating technology, and the high-speed ultra-precise polishing coated grinding tool of zirconium corundum series is prepared to realize precise high-speed, precise heavy-load powerful grinding and polishing.
Example 1
The embodiment is to prepare a 200 square meter ceramic corundum abrasive coated abrasive tool abrasive cloth, and to convert and prepare HB-240 abrasive belt for grinding spring steel special steel products, wherein the abrasive belt specification (mm) is 1520×200, the granularity is 46#, the using linear speed is 60m/s, the feeding single weight is 1949 g/square meter, and the total weight of the working layer is 389800g. The working layer of the ceramic corundum abrasive coating and grinding device comprises the following components in parts by weight:
According to the composition ratio of the working components and calculated by the single feeding weight of 1949 g/square meter, the preparation is 200 square meter, and the weight of each consumed component material is as follows: 36# high-temperature calcined alumina ceramic corundum abrasive 31184g,46# zirconia ceramic corundum abrasive 125515.6g, primer 45216.8g, compound gum 84976.4g, surface coating 102907.2g and total working layer weight of 389800g.
The preparation method comprises the following steps:
1. abrasive pretreatment step
31184G of 36# high-temperature calcined alumina ceramic corundum abrasive and 125515.6g of 46# zirconia ceramic corundum abrasive are cleaned and dried, then are respectively subjected to continuous overlapping injection of metal ions and nitrogen ions by adopting a linear high-energy ion implanter under the vacuum condition, the nitrogen ions are injected first, then the metal ions are injected, and the cycle is sequentially carried out for at least 2 times.
The metal element injection is realized by a metal vapor vacuum arc discharge ion source (MEVVA), the acceleration voltage is 40-50 kV, and the injected metal ions are selected from metal elements such as Ti, cr and the like; the nitrogen ions are injected by an electron cyclotron resonance ion source (ECR) and the acceleration voltage is 60-80 kV.
In the ion implantation treatment process, a nitrogen ion source adopts nitrogen with the purity of 99.99 percent, and the implantation dosage is about 5 multiplied by 10 17ion cm-2 each time; the metal ion source uses a metal target with a purity of 99.8% and an implantation dose of about 1 x 10 17ion cm-2.
And respectively weighing the high-temperature calcined alumina ceramic corundum abrasive material and the zirconia ceramic corundum abrasive material after ion treatment, and then respectively transferring the weighed alumina ceramic corundum abrasive material and the zirconia ceramic corundum abrasive material into a hopper for gravity sand planting and a hopper for electrostatic sand planting.
2. Substrate pretreatment step
According to the technical requirements of the special steel product of the grinding spring steel, selecting medium-sized polyester fiber raw cloth, wherein the gram weight of the medium-sized polyester fiber raw cloth is 250-280 g/square meter. The medium-sized polyester fiber raw cloth is pretreated according to the pretreatment sequence of primary dipping, stretching, secondary dipping, primary scraping, secondary scraping and coating of the precoating layer, and the substrate layer for the ceramic corundum abrasive coated grinding tool is prepared.
2.1 Preparing the impregnating compound
The impregnating compound comprises the following components in parts by mass:
In the embodiment, 200 square meter ceramic corundum abrasive coated abrasive cloth is prepared, the single weight of the material is 90 g/square meter, the total weight of the impregnating compound is 18000g, and 16705.80g of polyvinyl alcohol aqueous solution, 563.40g of phenolic resin, 727.20g of white emulsion and 3.60g of organosilicon are weighed according to the formula ratio.
75 Parts by mass of water and 25 parts by mass of polyvinyl alcohol (PVA-205) are added into a container, the temperature is raised to 60 ℃, 16705.80g of 25% PVA aqueous solution is prepared according to the proportion, a stirrer is opened, 563.40g of phenolic resin is added, 727.20g of white latex is added after stirring for 10min, 3.60g of organosilicon is added after stirring for 10min, the preset viscosity is regulated to 300 cps/room temperature, and the mixture is stirred for 10min and then transported to a production line.
2.2 Preparation of the scraping slurry
The scraping slurry comprises the following components in parts by mass:
In the embodiment, 200 square meter ceramic corundum abrasive coated abrasive cloth is prepared, the single weight of the material is 130 g/square meter, the total weight of the scraping slurry is 26000g, phenolic resin 9600 4986.80g, calcium carbonate 3473.60g, polyvinyl alcohol (PVA-205) aqueous solution 3029.00g, white latex 4986.80g, organosilicon 8730.80g, direct blue 330.20g, silica gel 436.80g and sorbitan laurate 26.00g are weighed according to the formula ratio.
According to the formula requirement, 3029.00g of 25% PVA aqueous solution is firstly added into a container, a stirrer is started, 4986.80 phenolic resin 9600 is added, 3473.60g of calcium carbonate is added after stirring for 10min, 4986.80g of white latex, 8730.80g of organic silicon compound, 436.80g of silica gel and 26.00g of sorbitan laurate are added after stirring for 10min, 330.20g of direct blue is added for color mixing, 25% PVA aqueous solution is used for preparing a preset viscosity of 3000 cps/room temperature, and the mixture is transported to a production line after stirring for 10 min.
2.3 Preparation of precoat slurry
The precoat slurry comprises the following components in parts by mass:
in the embodiment, 200 square meter ceramic corundum abrasive coated abrasive cloth is prepared, the single weight of the material is 140 g/square meter, the total weight of the precoat slurry is 28000g, and 9600 4720.8g of phenolic resin, 1100.20.8 g of phenolic resin, 6717.2g of calcium carbonate, 5457.2g of polyvinyl alcohol (PVA-205), 53.2g of silane coupling agent and 30.8g of sorbitan laurate are weighed according to the formula ratio.
Adding PVA into a container according to the formula ratio, opening a stirrer, adding 4720.8g of phenolic resin 9600 and 11020.8g of phenolic resin 1100 (no sequence), stirring for 10min, adding 6717.2g of calcium carbonate, stirring for 10min, adding 53.2 g of silane coupling agent and 30.8g of sorbitan laurate, preparing the solution with the preset viscosity of 2000 cps/room temperature, stirring for 10min, maintaining the temperature of 40+/-2 ℃ and conveying to a production line.
2.4 Preparation of substrates for use in the present invention
The polyester fiber raw cloth is sequentially subjected to primary dipping, stretching, secondary dipping, primary scraping, secondary scraping and pre-coating treatment to obtain the substrate used in the invention.
The pressure between the first set of rolls was adjusted so that the grammage of the first impregnation addition was maintained at 60 g/square meter, and then stretched, and the pressure between the second set of rolls was adjusted so that the grammage of the second impregnation addition was maintained at 30 g/square meter. In order to keep accurate data, when the substrate wire runs, a cloth disc is cut down for measurement, and finally the pressure is confirmed.
After the twice dipping is finished, drying at the temperature of 200-220 ℃ and then entering a scraping line, adjusting the scraping amount by adjusting the position and the running amount of a scraping knife, and increasing the gram weight of the once scraping by 70 g/square meter through disc carving confirmation; drying at 200-220 deg.c, re-entering into scraping line, regulating scraping amount via regulating the position and amount of scraping blade, and re-scraping with the weight increased by 60 g/square meter via carving disc; and (3) drying at the temperature of 130-160 ℃, then re-entering a scraping line, adding the slurry of the precoating into the scraping line, adjusting the precoating amount by adjusting the position and the running amount of a scraper, increasing the precoating gram weight by 140 g/square meter by disc engraving confirmation, drying at the temperature of 120-150 ℃, and then rolling to obtain the substrate for the coated abrasive substrate layer.
3. Preparation of the ceramic corundum abrasive coated abrasive tool of the invention
3.1, Preparing the primer glue solution
The primer glue solution comprises the following components in parts by weight:
The viscosity was adjusted to 3000 cps/room temperature with water.
The embodiment is to prepare 200 square meter ceramic corundum abrasive coated abrasive cloth, wherein the single weight of the primer glue solution is 226g/m 2, the total weight of the primer glue solution is 45216g, the water-soluble phenolic resin 9600 15368g, the water-soluble phenolic resin 110010215.2g, the coupling agent 90.4g, the penetrating agent silicone grease 90.4g, the ethylene glycol diethyl Ether (EC) 1328.88g, the defoamer organic silicon 253.12g and the silicon oxide wollastonite 17854g are weighed according to the formula ratio.
Preparing a primer glue solution: and (3) raising the jacket temperature of the glue preparation kettle to 40 ℃ and ensuring the cleaning and drying of the whole glue preparation system. 15368g of water-soluble phenolic resin 9600 and 10215.2g of water-soluble phenolic resin 1100 are added into a glue preparation kettle, stirred and mixed at a stirring speed of 450r/min, 90.4g of coupling agent, 90.4g of penetrating agent silicone grease, 1328.88g of glycol diethyl ether and 253.12g of defoaming agent silicone are added at the temperature of 40 ℃ in a heat preservation mode, 17854g of silicon oxide wollastonite is slowly added, and stirring is continued for 40min at 750 r/min. When the glue temperature reached 40.+ -. 2 ℃ the sample was taken with a 500mL glass and the viscosity was measured. Adjusting the viscosity of the primer glue solution to 3000 cps/room temperature by water; measuring viscosity by using a DNJ viscometer, adjusting the viscosity, regulating the viscosity to 400r/min, maintaining the self viscosity and the temperature, stirring slowly, and covering a glue preparation kettle cover to prevent air from entering to oxidize and crust the surface of the glue after being prepared.
The prepared modified phenolic resin primer glue solution maintains the self viscosity and temperature through a conversion pump and a heating circulation system, is discharged, is guided into a machine, and is sent to a production line for the production of the primer coating of the substrate layer.
3.2, Preparing compound glue solution
The compound glue solution comprises the following components in parts by weight:
the components of the complex gum solution were adjusted to a viscosity of 2000 cps/room temperature with ethylene glycol diethyl ether.
In the embodiment, 200 square meter ceramic corundum abrasive coated abrasive cloth is prepared, single weight 425g/m 2 of a compound glue solution is coated, total weight of the compound glue solution is 84976g, phenolic resin 9600 20400g, phenolic resin 1900 14705g, coupling agent 136g, titanium white 2890g, thickener nonionic polyurethane HEUR 68g, cryolite 45050g, span 20.5 g and blue pigment 1623.5g are weighed according to a formula ratio.
Preparing compound glue solution: adding 20400g of phenolic resin 9600 and 14705g of phenolic resin 1900 into a glue mixing kettle, stirring and mixing at a stirring speed of 450r/min, heating to 40 ℃, adding 136g of coupling agent, stirring and mixing, adding 2890g of titanium white and 68g of thickener (nonionic polyurethane HEUR), slowly adding 45050g of cryolite, regulating a stirrer to 750r/min to avoid caking, regulating the stirrer to 400r/min, continuously stirring uniformly, adding 127.5g of span 20, continuously stirring uniformly, adding 1623.5g of blue pigment, and regulating the viscosity to 2000 cps/room temperature by using ethylene glycol diethyl ether; and after the stirring is continued for 40min, the stirrer is regulated to 400r/min, the stirring is performed slowly, and a glue preparation kettle cover is covered, so that air is prevented from entering to oxidize and crust the surface of the glue after the glue preparation.
The prepared modified phenolic resin compound glue solution maintains the self viscosity and temperature through a conversion pump and a heating circulation system, is discharged, is guided into a machine, and is sent to a production line for glue coating production after the base material layer is subjected to primer coating-sand planting.
3.3 Configuring the surface layer coating paint
The surface coating glue solution comprises the following components in parts by mass:
The viscosity was adjusted to 15000 cps/room temperature with ethylene glycol diethyl ether.
The potassium fluoborate oily coating modified epoxy resin adhesive comprises the following components in parts by weight:
74.24 parts by mass of potassium fluoborate;
13.38 parts by mass of ethylene glycol diethyl ether;
12.37 parts by mass of epoxy resin.
The coating dispersing agent comprises the following components in parts by mass:
The embodiment is to prepare 200 square meter ceramic corundum abrasive coated abrasive cloth, wherein the coating weight of the surface material liquid is 514.5g/m 2, the total weight of the surface material liquid is 102907.2g, wherein 76.47kg of potassium fluoborate, 13.78kg of ethylene glycol diethyl ether and 12.75kg of oily epoxy resin are weighed according to the formula ratio in the preparation of the potassium fluoborate oily coating modified epoxy resin adhesive; preparation of a coating dispersing agent, 98.86kg of ethylene glycol diethyl ether, 0.72kg of penetrating agent fatty alcohol polyoxyethylene ether, 2.88kg of epoxy resin and 0.54kg of blue pigment are weighed according to the formula ratio; 3.15kg of other components of fumed silica, 0.42kg of titanium dioxide and 6.19kg of epoxy curing agent.
Preparing potassium fluoborate oily coating modified epoxy resin adhesive:
Stirring 76.47kg of potassium fluoborate and 13.78kg of ethylene glycol diethyl ether at normal temperature, and grinding on a three-roller grinder until the granularity is below 15 mu m; adding the prepared solution and 12.75kg of epoxy resin into a reaction vessel, stirring, heating to 45-50 ℃ and continuously stirring for 20-30 min to prepare the potassium fluoborate oily coating modified epoxy resin adhesive for normal temperature storage.
Preparing a coating adhesive dispersing agent:
In a reaction vessel, 98.86kg of ethylene glycol diethyl ether and 0.72kg of fatty alcohol polyoxyethylene ether are firstly put into the reaction vessel, the reaction vessel is heated to 45-50 ℃ and stirred at the stirring speed of 1500r/min, 2.88kg of epoxy resin is put into the reaction vessel at the temperature of 45-50 ℃ and is continuously stirred for 20-30 min, and finally 0.54kg of blue pigment is put into the reaction vessel and is stirred for 20-30 min to prepare the coating adhesive dispersing agent, and the coating adhesive dispersing agent is stored at normal temperature.
Preparing a coating paint:
82.95kg of potassium fluoborate oily coating modified epoxy resin adhesive and 10.29kg of coating dispersing agent are weighed and put into a mixing drum, after being uniformly stirred at the stirring speed of 1500r/min, 3.15kg of fumed silica and 0.42kg of titanium dioxide are added, after being fully stirred at normal temperature (about 30 min), 6.19kg of epoxy curing agent is put into the mixing drum, if the viscosity is larger, the viscosity is adjusted to 15000 cps/room temperature by using ethylene glycol diethyl ether, and the high-strength water-resistant burn-resistant surface feed liquid with thixotropic function is prepared.
3.4, The step of coating primer
Placing the prepared base material for the base material layer of the coated abrasive tool on a primer machine, adjusting various technical parameters of primer machine equipment, heating circulating water of a primer machine rubber disc to 47 ℃ in summer and 60 ℃ in winter, lifting the rubber disc, opening a pipeline valve, adjusting viscosity of primer rubber liquid prepared according to the formula ratio, measuring the viscosity to 3000 cps/room temperature by using a DNJ viscometer, adjusting the temperature of the rubber liquid to 38+/-2 ℃, and sending the rubber liquid to a primer machine.
And (3) sieving the primer glue solution, slowly putting the glue solution into a glue tray, taking the position where the glue solution is to be placed as a way of preventing the glue solution from overflowing, accurately measuring the glue temperature to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller to see whether the glue solution is uniform, finding that the thickness of two sides is to be adjusted in time, and circulating the glue solution for about 5min.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the station is started after being in place, all control buttons are opened, the base material is pressed on the steel roller at the position of the rubber disc, the uniform bar is pressed, the speed is firstly slow and then fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of the base body, the sizing amount is measured, the sizing amount is timely adjusted to meet the requirement, and the sand planting procedure is carried out.
3.5, Sand planting step
And (3) gravity sand planting:
The circulating lifting hopper is started, and alumina ceramic corundum abrasive to be used is sieved and then is put into a sand box, wherein the alumina ceramic corundum abrasive in the embodiment is high-temperature calcined alumina ceramic corundum abrasive with the granularity of 40 meshes which is treated by ion implantation. According to the granularity of the abrasive, the sand box gap, the position and the speed of the sanding roller and the angle of the sand baffle are adjusted, the sand feeding amount is ensured to accord with the process-specified sand planting amount, and then the sand is transferred into electrostatic sand planting.
And (3) electrostatic sand planting:
And implanting zirconia ceramic corundum abrasive materials on the base material subjected to gravity sand implantation through an electrostatic sand implantation process. And (3) starting a temperature and humidity control switch of the electrostatic sand planting room to enable the temperature and humidity control switch to reach the temperature of 25 ℃ and the humidity of 65% specified by a process, starting electrostatic planting (taking care of temperature guarantee in winter and moisture guarantee in summer), adjusting equipment parameters, and guaranteeing the parallelism and the height (P24-P80.5 cm, P100-600.0 cm) of an electrostatic polar plate and electrostatic voltage (P24-80 45KV, P100-600 KV).
The circulation lifting hopper is started, zirconia ceramic corundum abrasive materials to be used are put into the sand box after being screened, the vibration amplitude in the static sand planting device is adjusted, meanwhile, the sand conveying belt is opened, the sand conveying belt runs at a low speed, and the sand discharging amount of the sand box and the rotating speed of the sand conveying belt are timely adjusted according to the sand surface condition.
And after all the conditions are normal, the machine speed is increased to the range of the process requirement, sampling and detecting are carried out on the primer and the sand feeding amount, and if the process requirement is not met, the process is regulated again, and sampling is carried out until the result meets the requirement. And (5) performing pre-drying after electrostatic sand planting.
In the process of static sand planting, attention is paid to the fact that circulating sand is uniformly stirred after entering a sand box, and the static electricity is released after the circulating sand is charged and the new sand is uniformly stirred, all switches are turned off firstly after production, particularly voltage is turned off (a red light is extinguished), and then static electricity of an upper polar plate is discharged by a grounding rod.
After the sand is planted by gravity and the sand is planted by static electricity, under the action of high-strength high-viscosity primer, the alumina ceramic corundum abrasive implanted by the sand is planted by gravity and is in a lying form in the primer, the zirconia ceramic corundum abrasive implanted by the sand is planted by static electricity and is in a vertical form in the primer, the zirconia ceramic corundum abrasive implanted by the sand is fixed by the alumina ceramic corundum abrasive planted by gravity, and is pre-dried at 75-95 ℃ and is preliminarily fixed on a base material.
3.6, The step of coating the compound adhesive
The coating of the coating glue can be performed by using the same equipment as the coating of the primer, i.e. the coating of the coating glue can be performed by using a primer machine.
Placing the above-mentioned sand-planted base material on a compound glue machine, regulating various technological parameters of compound glue machine equipment, heating the circulating water of the compound glue machine glue disk to 47 deg.C in summer and 60 deg.C in winter, lifting the glue disk, opening pipeline valve, regulating viscosity of compound glue solution prepared according to the above-mentioned formula ratio, using DNJ viscosimeter to measure viscosity to 2000 cps/room temperature, regulating glue solution temperature to 38+ -2 deg.C, feeding it into compound glue machine table, and its step is identical to that of base glue.
And (3) screening the compound glue solution, slowly putting the compound glue solution into a glue tray, paying attention to the position where the glue solution is to be put so as to prevent the glue solution from overflowing, accurately measuring the glue temperature to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller to see whether the glue solution is uniform, finding that the thickness of two sides is required to be adjusted in time, and circulating the glue solution for about 5 minutes.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the operation is started after the pre-drying room and the main drying room are in place, all control buttons are opened, the base material after sand planting is conveyed to a rubber disc to press a steel roller, a uniform bar is pressed, the speed is firstly slow and secondly fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of a base body, the sizing amount is measured, the sizing is timely adjusted to meet the requirement, the re-sizing is finished, and the next procedure is carried out after the base material is dried at 75-95 ℃.
3.7 Step of applying a topcoat
The application of the top coat may be performed using the same equipment as the application of the primer, i.e., the application of the top coat may be performed using a primer machine.
Placing the prepared substrate coated with the compound adhesive on a surface coating machine, adjusting various technical parameters of equipment of the surface coating machine, heating circulating water of a rubber disc of the surface coating machine to 47 ℃ in summer and 60 ℃ in winter, lifting the rubber disc, opening a pipeline valve, adjusting viscosity of the prepared surface coating adhesive according to the formula ratio by using ethylene glycol diethyl ether, measuring the viscosity to 15000 cps/room temperature by using a DNJ viscometer, adjusting the temperature of the adhesive to 38+/-2 ℃, and sending the adhesive to a surface coating machine.
And (3) sieving the surface coating glue solution, slowly putting the glue solution into a glue tray, taking the position where the glue solution is to be put to prevent the glue solution from overflowing, accurately measuring the glue temperature to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller to see whether the glue solution is uniform, finding that the thickness of two sides is to be adjusted in time, and circulating the glue solution for about 5min.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the operation is started after the pre-drying room and the main drying room are in place, all control buttons are opened, the substrate after sand planting is conveyed to a rubber disc to press a steel roller, a uniform bar is pressed, the speed is firstly slow and secondly fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of a substrate, the sizing amount is measured, the coating is timely adjusted to meet the requirement, the surface coating is finished, and the surface coating is dried at 70-95 ℃ to prepare the ceramic corundum abrasive coated grinding tool after the primary coating.
3.8 Post-treatment step
A coating step, namely placing the ceramic corundum abrasive coated grinding tool subjected to primary coating in a coating furnace for three-section coating, wherein the curing temperature of one section is 100 ℃ and the curing time of the other section is 12 hours; the second-stage curing temperature is 120 ℃, and the second-stage curing time is 12 hours; the three-stage curing temperature is 130 ℃, and the three-stage curing time is 12 hours.
And a softening step, namely mechanically softening the coated product to enable tiny small cracks to be generated on the surface of the abrasive cloth, and improving the flexibility and toughness of the product, so that the whole soft product is obtained.
The method comprises the steps of finished product preparation, namely dividing the flexible product into sand rolls, cutting, edging, sizing, jointing, edge pressing and working procedures, and converting the sand rolls into a coated grinding tool with set specifications;
and a finished product inspection step, namely quality inspection is carried out according to national regulation standards.
The ceramic corundum abrasive coated abrasive cloth manufactured by the method is converted into HB-80 abrasive belt with the specification of 1520 x 200 (mm) and granularity: 46#, using linear velocity: 60m/s, breaking strength of finished product: the longitudinal direction is more than or equal to 4000N/5cm, the transverse direction is more than or equal to 2000N/5cm, and the spring steel special steel product is ground in a certain steel mill, the linear speed is 60m/s, and the surface roughness Ra is as follows: less than or equal to 0.19, grinding ratio: is more than or equal to 1:83.5, is 4 times of a common abrasive belt under the dry grinding condition, and has the heat-resistant grinding temperature of 300 ℃. Grinding ratio of similar products of a certain company at home and abroad under the same condition: 1:21.5, surface roughness Ra:1.2.
Example 2
The embodiment is to prepare 200 square meter ceramic corundum abrasive coated abrasive cloth, and to prepare abrasive belt for grinding stainless steel special steel products by conversion, wherein the abrasive belt has the specification (mm) of 1520 multiplied by 200, the granularity of 80#, the using linear speed of 80m/s, the feeding single weight of 1885 g/square meter and the total weight of the working layer of 377000g. The working layer of the ceramic corundum abrasive coating and grinding device comprises the following components in parts by weight:
According to the composition ratio of the working components and the single feeding weight of 1885 g/square meter, the preparation is 200 square meters, and the weight of each consumed component material is as follows: 70# calcined alumina ceramic corundum abrasive 32007.30g,80# zirconia ceramic corundum abrasive 125515.6g, primer 37700g, compound gum 81281.20g, coating gum 98020g and total working layer weight of 377000g.
The preparation method comprises the following steps:
1. abrasive pretreatment step
And (3) carrying out continuous overlapping injection on metal ions and nitrogen ions by adopting a linear high-energy ion implanter respectively after carrying out cleaning and drying on 32007.30g of the 70# high-temperature calcined alumina ceramic corundum abrasive and 125515.6g of the 80# zirconia ceramic corundum abrasive, and sequentially circulating for at least 2 times after carrying out nitrogen ion injection and then metal ion injection under vacuum conditions.
The metal element injection is realized by a metal vapor vacuum arc discharge ion source (MEVVA), the acceleration voltage is 40-50 kV, and the injected metal ions are selected from metal elements such as Ti, cr and the like; the nitrogen ions are injected by an electron cyclotron resonance ion source (ECR) and the acceleration voltage is 60-80 kV.
In the ion implantation treatment process, a nitrogen ion source adopts nitrogen with the purity of 99.99 percent, and the implantation dosage is about 5 multiplied by 10 17ion cm-2 each time; the metal ion source uses a metal target with a purity of 99.8% and an implantation dose of about 1 x 10 17ion cm-2.
And respectively weighing the high-temperature calcined alumina ceramic corundum abrasive material and the zirconia ceramic corundum abrasive material after ion treatment, and then respectively transferring the weighed alumina ceramic corundum abrasive material and the zirconia ceramic corundum abrasive material into a hopper for gravity sand planting and a hopper for electrostatic sand planting.
2. Substrate pretreatment step
According to the technical requirements of grinding stainless steel special steel products, heavy polyester fiber raw cloth is selected, and the gram weight of the heavy polyester fiber raw cloth is 330-350 g/square meter. The medium-sized polyester fiber raw cloth is pretreated according to the pretreatment sequence of primary dipping, stretching, secondary dipping, primary scraping, secondary scraping and coating of the precoating layer, and the substrate layer for the ceramic corundum abrasive coated grinding tool is prepared.
2.1 Preparing the impregnating compound
The impregnating compound comprises the following components in parts by mass:
In the embodiment, 200 square meter ceramic corundum abrasive coated abrasive cloth is prepared, the single weight of the material is 90 g/square meter, the total weight of the impregnating compound is 18000g, 16740g of polyvinyl alcohol, 631.8g of phenolic resin, 622.8g of white latex and 5.4g of organosilicon are weighed according to the formula ratio.
Adding water and polyvinyl alcohol PVA-205 into a container, heating to 60 ℃, preparing 25% PVA solution according to the proportion, opening a stirrer, adding phenolic resin, stirring for 10min, adding white latex, stirring for 10min, adding organosilicon, preparing the solution with the preset viscosity of 300 cps/room temperature, stirring for 10min, and conveying to a production line.
2.2 Preparation of the scraping slurry
The scraping slurry comprises the following components in parts by mass:
The example is to prepare 200 square meter ceramic corundum abrasive coated abrasive cloth, the single weight of the material is 130 g/square meter, the total weight of the scraping slurry is 26000g, and the phenolic resin 9600 5200.00g, the calcium carbonate 3380.00g, the PVA-205 polyvinyl alcohol 3151.20g, the white latex 4940.00g, the organosilicon 8491.60g, the direct blue 335.40g, the silica gel 468.00g and the sorbitan laurate 33.80g are weighed according to the formula ratio.
According to the formula requirement, 3151.20g of 25% PVA aqueous solution is firstly added into a container, a stirrer is started, 5200.00g of phenolic resin 9600 is added, 3380.00g of calcium carbonate is added after stirring for 10min, 4940.00g of white latex, 8491.60g of organosilicon compound, 468.00g of silica gel and 33.80g of sorbitan laurate are added after stirring for 10min, 335.40g of direct blue is added for toning after stirring for 10min, the preset viscosity of 3000 cps/room temperature is prepared, and the mixture is stirred for 10min and then transported to a production line.
2.3 Preparation of precoat slurry
Preferably, the precoat slurry comprises the following components in parts by mass:
In the embodiment, 200 square meter ceramic corundum abrasive coated abrasive cloth is prepared, the single weight of the material is 140 g/square meter, the total weight of the precoating slurry is 28000g, and 9600 4950.4g of phenolic resin, 1100 11200g of phenolic resin, 6720g of calcium carbonate, 5040g of polyvinyl alcohol (PVA-205), 56g of silane coupling agent and 33.6g of sorbitan laurate are weighed according to the formula ratio.
Adding 5040g of PVA into a container according to the formula ratio, opening a stirrer, adding 4950.4g of phenolic resin 9600 and 11200g of phenolic resin 1100 (no sequence), stirring for 10min, adding 6720g of calcium carbonate, stirring for 10min, adding 56g of silane coupling agent and 33.6g of sorbitan laurate, preparing the mixture with the preset viscosity of 2000 cps/room temperature, stirring for 10min, maintaining the temperature of 40+/-2 ℃, and conveying to a production line.
2.4 Preparation of substrates for use in the present invention
The polyester fiber raw cloth is sequentially subjected to primary dipping, stretching, secondary dipping, primary scraping, secondary scraping and pre-coating treatment to obtain the substrate used in the invention.
The pressure between the first set of rolls was adjusted so that the grammage of the first impregnation addition was maintained at 60 g/square meter, and then stretched, and the pressure between the second set of rolls was adjusted so that the grammage of the second impregnation addition was maintained at 30 g/square meter. In order to keep accurate data, when the substrate wire runs, a cloth disc is cut down for measurement, and finally the pressure is confirmed.
After the twice dipping is finished, drying at the temperature of 200-220 ℃ and then entering a scraping line, adjusting the scraping amount by adjusting the position and the running amount of a scraping knife, and increasing the gram weight of the once scraping by 70 g/square meter through disc carving confirmation; drying at 200-220 deg.c, re-entering into scraping line, regulating scraping amount via regulating the position and amount of scraping blade, and re-scraping with the weight increased by 60 g/square meter via carving disc; and (3) drying at the temperature of 130-160 ℃, then re-entering a scraping line, adding the slurry of the precoating into the scraping line, adjusting the precoating amount by adjusting the position and the running amount of a scraper, increasing the precoating gram weight by 140 g/square meter by disc engraving confirmation, drying at the temperature of 120-150 ℃, and then rolling to obtain the substrate for the coated abrasive substrate layer.
3. Preparation of the ceramic corundum abrasive coated abrasive tool of the invention
3.1, Preparing the primer glue solution
The primer glue solution comprises the following components in parts by weight:
The viscosity was adjusted with water to 3000 cps/room temperature.
In the embodiment, 200m 2 ceramic corundum abrasive coated abrasive cloth is prepared, the single weight of the primer glue solution is 226g/m 2, the total weight of the primer glue solution is 37700g, and the water-soluble phenolic resin 9600 14464g, the water-soluble phenolic resin 110011119.2g, the coupling agent 85.88g, the penetrating agent silicone grease 85.88g, the ethylene glycol diethyl Ether (EC) 1396.68g, the defoamer organic silicon 248.6g and the silicon oxide wollastonite 17799.76g are weighed according to the formula ratio.
Preparing a primer glue solution: and (3) raising the jacket temperature of the glue preparation kettle to 40 ℃ and ensuring the cleaning and drying of the whole glue preparation system. 14464g of water-soluble phenolic resin 9600 and 11119.2g of water-soluble phenolic resin 1100 are added into a glue preparation kettle, stirred and mixed at a stirring speed of 450r/min, 85.88g of coupling agent, 85.88g of penetrating agent silicone grease, 1396.68g of glycol diethyl ether and 248.6g of defoaming agent silicone are added under the condition of heat preservation of 40 ℃, 17799.76g of silicon oxide wollastonite is slowly added, and stirring is continued for 40min at 750 r/min. When the glue temperature reached 40.+ -. 2 ℃ the sample was taken with a 500mL glass and the viscosity was measured. Adjusting the viscosity of the primer glue solution to 3000 cps/room temperature by water; measuring viscosity by using a DNJ viscometer, adjusting the viscosity, regulating the viscosity to 400r/min, maintaining the self viscosity and the temperature, stirring slowly, and covering a glue preparation kettle cover to prevent air from entering to oxidize and crust the surface of the glue after being prepared.
The prepared modified phenolic resin primer glue solution maintains the self viscosity and temperature through a conversion pump and a heating circulation system, is discharged, is guided into a machine, and is sent to a production line for the production of the primer coating of the substrate layer.
3.2, Preparing compound glue solution
The compound glue solution comprises the following components in parts by weight:
the components of the compound glue solution are adjusted to have viscosity of 2000 cps/room temperature by using ethylene glycol diethyl ether.
In the embodiment, 200 square meter ceramic corundum abrasive coated abrasive cloth is prepared, the single weight of the coating glue solution is 425g/m 2, the total weight of the coating glue solution is 81281g, and 9600 24650g of phenolic resin, 1900 10455g of phenolic resin, 170g of coupling agent, 3111g of titanium white, 85g of thickener nonionic polyurethane HEUR, 44786.5g of cryolite, 1119g of span and 1623.5g of blue pigment are weighed according to the formula ratio.
Preparing a glue coating solution: adding 24650g of water-soluble phenolic resin 9600 and 10455g of water-soluble phenolic resin 1900 into a glue preparation kettle, stirring and mixing at a stirring speed of 450r/min, heating to 40 ℃, adding 170g of coupling agent, stirring and mixing, adding 3111g of titanium white and 85g of thickener (nonionic polyurethane HEUR), slowly adding 44786.5g of cryolite, regulating a stirrer to 750r/min to avoid caking, regulating the stirrer to 400r/min, continuously stirring uniformly, adding span, continuously stirring uniformly, adding 1623.5g of blue pigment, and regulating the viscosity to 2000 cps/room temperature by using ethylene glycol diethyl ether; and after the stirring is continued for 40min, the stirrer is regulated to 400r/min, the stirring is performed slowly, and a glue preparation kettle cover is covered, so that air is prevented from entering to oxidize and crust the surface of the glue after the glue preparation.
The prepared modified phenolic resin glue coating liquid is subjected to glue coating production after the base material layer is subjected to primer coating-sand planting by a conversion pump and a heating circulation system, the self viscosity and the temperature are maintained, the materials are discharged and are guided into a machine, and a production line is used for the machine.
3.3 Configuring the surface layer coating paint
The surface coating glue solution comprises the following components in parts by mass:
The viscosity was adjusted to 15000 cps/room temperature/normal temperature with ethylene glycol diethyl ether.
The potassium fluoborate oily coating modified epoxy resin adhesive comprises the following components in parts by weight:
75 parts by mass of potassium fluoborate;
13 parts by mass of ethylene glycol diethyl ether;
12 parts by mass of an epoxy resin.
The coating dispersing agent comprises the following components in parts by mass:
The embodiment is to prepare 200 square meter ceramic corundum abrasive coated abrasive cloth, wherein the coating weight of the surface material liquid is 495.1g/m 2, the total weight of the surface material liquid is 98020g, wherein 77.25kg of potassium fluoborate, 13.39kg of ethylene glycol diethyl ether and 12.36kg of oily epoxy resin are weighed according to the formula ratio in the preparation of the potassium fluoborate oily coating modified epoxy resin adhesive; preparation of a coating dispersing agent, weighing 98.67kg of ethylene glycol diethyl ether, 0.62kg of penetrating agent fatty alcohol polyoxyethylene ether, 3.09kg of epoxy resin and 0.62kg of blue pigment according to the formula ratio; 3.19kg of other components of fumed silica, 0.36kg of titanium dioxide and 6.70kg of epoxy curing agent. Preparing potassium fluoborate oily coating modified epoxy resin adhesive:
Stirring 77.25kg of potassium fluoborate and 13.39kg of ethylene glycol diethyl ether at normal temperature, and grinding on a three-roller grinder until the granularity is below 15 mu m; adding the prepared solution and 12.36kg of epoxy resin into a reaction vessel, stirring, heating to 45-50 ℃ and continuously stirring for 20-30 min to prepare the potassium fluoborate oily coating modified epoxy resin adhesive, and preserving at normal temperature.
Preparing a coating adhesive dispersing agent:
Adding 98.67kg of ethylene glycol diethyl ether and 0.62kg of fatty alcohol polyoxyethylene ether into a reaction vessel, heating to 45-50 ℃ and stirring at a stirring speed of 1500r/min, keeping the temperature at 45-50 ℃, adding 3.09kg of epoxy resin, continuously stirring for 20-30min, finally adding 0.62kg of blue pigment, stirring for 20-30min to obtain a coating adhesive dispersing agent, and preserving at normal temperature.
Preparing a coating paint:
83.43kg of potassium fluoborate oily coating modified epoxy resin adhesive and 9.32kg of coating dispersing agent are weighed and put into a mixing drum, after being uniformly stirred at the stirring speed of 1500r/min, 3.19kg of fumed silica and 0.36kg of titanium dioxide are added, after being fully stirred at normal temperature (about 30 min), 6.7kg of epoxy curing agent is put into the mixing drum, if the viscosity is larger, the viscosity is adjusted to 15000 cps/room temperature by using ethylene glycol diethyl ether, and the high-strength water-resistant burn-resistant surface feed liquid with thixotropic function is prepared.
3.4, The step of coating primer
Placing the prepared base material for the base material layer of the coated abrasive tool on a primer machine, adjusting various technical parameters of primer machine equipment, heating circulating water of a primer machine rubber disc to 47 ℃ in summer and 60 ℃ in winter, lifting the rubber disc, opening a pipeline valve, adjusting viscosity of primer rubber liquid prepared according to the formula ratio, measuring the viscosity to 3000 cps/room temperature by using a DNJ viscometer, adjusting the temperature of the rubber liquid to 38+/-2 ℃, and sending the rubber liquid to a primer machine.
And (3) sieving the primer glue solution, slowly putting the glue solution into a glue tray, taking the position where the glue solution is to be placed as a way of preventing the glue solution from overflowing, accurately measuring the glue temperature to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller to see whether the glue solution is uniform, finding that the thickness of two sides is to be adjusted in time, and circulating the glue solution for about 5min.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the station is started after being in place, all control buttons are opened, the base material is pressed on the steel roller at the position of the rubber disc, the uniform bar is pressed, the speed is firstly slow and then fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of the base body, the sizing amount is measured, the sizing amount is timely adjusted to meet the requirement, and the sand planting procedure is carried out.
3.5, Sand planting step
And (3) gravity sand planting:
The circulating lifting hopper is started, and alumina ceramic corundum abrasive to be used is sieved and then is put into a sand box, wherein the alumina ceramic corundum abrasive in the embodiment is high-temperature calcined alumina ceramic corundum abrasive treated by ion implantation. According to the granularity of the abrasive, the sand box gap, the position and the speed of the sanding roller and the angle of the sand baffle are adjusted, the sand feeding amount is ensured to accord with the process-specified sand planting amount, and then the sand is transferred into electrostatic sand planting.
And (3) electrostatic sand planting:
And implanting zirconia ceramic corundum abrasive materials on the base material subjected to gravity sand implantation through an electrostatic sand implantation process. And (3) starting a temperature and humidity control switch of the electrostatic sand planting room to enable the temperature and humidity control switch to reach the temperature of 25 ℃ and the humidity of 65% specified by a process, starting electrostatic planting (taking care of temperature guarantee in winter and moisture guarantee in summer), adjusting equipment parameters, and guaranteeing the parallelism and the height (P24-P80.5 cm, P100-600.0 cm) of an electrostatic polar plate and electrostatic voltage (P24-80 45KV, P100-600 KV).
The circulation lifting hopper is started, zirconia ceramic corundum abrasive materials to be used are put into the sand box after being screened, the vibration amplitude in the static sand planting device is adjusted, meanwhile, the sand conveying belt is opened, the sand conveying belt runs at a low speed, and the sand discharging amount of the sand box and the rotating speed of the sand conveying belt are timely adjusted according to the sand surface condition.
And after all the conditions are normal, the machine speed is increased to the range of the process requirement, sampling and detecting are carried out on the primer and the sand feeding amount, and if the process requirement is not met, the process is regulated again, and sampling is carried out until the result meets the requirement. And (5) performing pre-drying after electrostatic sand planting.
In the process of static sand planting, attention is paid to the fact that circulating sand is uniformly stirred after entering a sand box, and the static electricity is released after the circulating sand is charged and the new sand is uniformly stirred, all switches are turned off firstly after production, particularly voltage is turned off (a red light is extinguished), and then static electricity of an upper polar plate is discharged by a grounding rod.
After the sand is planted by gravity and the sand is planted by static electricity, under the action of high-strength high-viscosity primer, the alumina ceramic corundum abrasive implanted by the sand is planted by gravity and is in a lying form in the primer, the zirconia ceramic corundum abrasive implanted by the sand is planted by static electricity and is in a vertical form in the primer, the zirconia ceramic corundum abrasive implanted by the sand is fixed by the alumina ceramic corundum abrasive planted by gravity, and is pre-dried at 75-95 ℃ and is preliminarily fixed on a base material.
3.6, The step of coating the compound adhesive
The coating of the coating glue can be performed by using the same equipment as the coating of the primer, i.e. the coating of the coating glue can be performed by using a primer machine.
Placing the above-mentioned sand-planted base material on a compound glue machine, regulating various technological parameters of compound glue machine equipment, heating the circulating water of the compound glue machine glue disk to 47 deg.C in summer and 60 deg.C in winter, lifting the glue disk, opening pipeline valve, regulating viscosity of compound glue solution prepared according to the above-mentioned formula ratio, using DNJ viscosimeter to measure viscosity to 2000 cps/room temperature, regulating glue solution temperature to 38+ -2 deg.C, feeding it into compound glue machine table, and its step is identical to that of base glue.
And (3) screening the compound glue solution, slowly putting the compound glue solution into a glue tray, paying attention to the position where the glue solution is to be put so as to prevent the glue solution from overflowing, accurately measuring the glue temperature to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller to see whether the glue solution is uniform, finding that the thickness of two sides is required to be adjusted in time, and circulating the glue solution for about 5 minutes.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the operation is started after the pre-drying room and the main drying room are in place, all control buttons are opened, the base material after sand planting is conveyed to a rubber disc to press a steel roller, a uniform bar is pressed, the speed is firstly slow and secondly fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of a base body, the sizing amount is measured, the sizing is timely adjusted to meet the requirement, the re-sizing is finished, and the next procedure is carried out after the base material is dried at 75-95 ℃.
3.7 Step of applying a topcoat
The application of the top coat may be performed using the same equipment as the application of the primer, i.e., the application of the top coat may be performed using a primer machine.
Placing the prepared substrate coated with the compound adhesive on a surface coating machine, adjusting various technical parameters of equipment of the surface coating machine, heating circulating water of a rubber disc of the surface coating machine to 47 ℃ in summer and 60 ℃ in winter, lifting the rubber disc, opening a pipeline valve, adjusting viscosity of the prepared surface coating adhesive according to the formula ratio by using ethylene glycol diethyl ether, measuring the viscosity to 15000 cps/room temperature by using a DNJ viscometer, adjusting the temperature of the adhesive to 38+/-2 ℃, and sending the adhesive to a surface coating machine.
And (3) sieving the surface coating glue solution, slowly putting the glue solution into a glue tray, taking the position where the glue solution is to be put to prevent the glue solution from overflowing, accurately measuring the glue temperature to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller to see whether the glue solution is uniform, finding that the thickness of two sides is to be adjusted in time, and circulating the glue solution for about 5min.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the operation is started after the pre-drying room and the main drying room are in place, all control buttons are opened, the substrate after sand planting is conveyed to a rubber disc to press a steel roller, a uniform bar is pressed, the speed is firstly slow and secondly fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of a substrate, the sizing amount is measured, the coating is timely adjusted to meet the requirement, the surface coating is finished, and the surface coating is dried at 70-95 ℃ to prepare the ceramic corundum abrasive coated grinding tool after the primary coating.
3.8 Post-treatment step
A coating step, namely placing the ceramic corundum abrasive coated grinding tool subjected to primary coating in a coating furnace for three-section coating, wherein the curing temperature of one section is 100 ℃ and the curing time of the other section is 12 hours; the second-stage curing temperature is 120 ℃, and the second-stage curing time is 12 hours; the three-stage curing temperature is 130 ℃, and the three-stage curing time is 12 hours.
And a softening step, namely mechanically softening the coated product to enable tiny small cracks to be generated on the surface of the abrasive cloth, and improving the flexibility and toughness of the product, so that the whole soft product is obtained.
The method comprises the steps of finished product preparation, namely dividing the flexible product into sand rolls, cutting, edging, sizing, jointing, edge pressing and working procedures, and converting the sand rolls into a coated grinding tool with set specifications;
and a finished product inspection step, namely quality inspection is carried out according to national regulation standards.
The ceramic corundum abrasive coated abrasive cloth manufactured by the method is converted into HB-240 abrasive belt for stainless steel special steel products, the specification is 1520 x 200 (mm), and the granularity is as follows: 80#, finished product breaking strength: the longitudinal direction is larger than or equal to 4000N/5cm, the transverse direction is larger than or equal to 2000N/5cm, and when a certain steel mill grinds the stainless steel surface, the linear speed is 80m/s, and the surface roughness Ra is as follows: less than or equal to 1.29, grinding ratio: is more than or equal to 1:89.5, is 4 times of a common abrasive belt under the dry grinding condition, and has the heat-resistant grinding temperature of 300 ℃.
Example 3
The method is used for preparing 200 square meter ceramic corundum abrasive coated abrasive cloth, converting and preparing an abrasive belt for grinding titanium alloy, wherein the specification (mm) of the abrasive belt is 2100 multiplied by 75, the granularity is 120#, the using linear speed is 100m/s, the single feeding weight is 1975 g/square meter, and the total weight of a working layer is 395000g. The working layer of the ceramic corundum abrasive coating and grinding device comprises the following components in parts by weight:
According to the composition ratio of the working components and calculated by the single feeding weight of 1949 g/square meter, the preparation is 200 square meter, and the weight of each consumed component material is as follows: 100# high-temperature calcined alumina ceramic corundum abrasive 304115 g,120# stacked abrasive zirconia ceramic corundum abrasive 121581g, primer 47992.50g, compound gum 90020.50g, surface coating 104991g and total working layer weight of 395000g.
The preparation method comprises the following steps:
1. abrasive pretreatment step
30015 G of 100# high-temperature calcined alumina ceramic corundum abrasive and 121581g of 120# stacked abrasive zirconia ceramic corundum abrasive are cleaned and dried, then a linear high-energy ion implanter is adopted to select metal ions and nitrogen ions to be continuously and overlapped and injected under vacuum, the nitrogen ions are injected first and then the metal ions are injected, and the cycle is carried out for at least 2 times in sequence.
The metal element injection is realized by a metal vapor vacuum arc discharge ion source (MEVVA), the acceleration voltage is 40-50 kV, and the injected metal ions are selected from metal elements such as Ti, cr and the like; the nitrogen ions are injected by an electron cyclotron resonance ion source (ECR) and the acceleration voltage is 60-80 kV.
In the ion implantation treatment process, a nitrogen ion source adopts nitrogen with the purity of 99.99 percent, and the implantation dosage is about 5 multiplied by 10 17ion cm-2 each time; the metal ion source uses a metal target with a purity of 99.8% and an implantation dose of about 1 x 10 17ion cm-2.
And respectively weighing the high-temperature calcined alumina ceramic corundum abrasive material and the zirconia ceramic corundum abrasive material after ion treatment, and then respectively transferring the weighed alumina ceramic corundum abrasive material and the zirconia ceramic corundum abrasive material into a hopper for gravity sand planting and a hopper for electrostatic sand planting.
2. Substrate pretreatment step
According to the technical requirements of the special steel product of the grinding spring steel, heavy polyester fiber raw cloth is selected, and the gram weight of the heavy polyester fiber raw cloth is 420-450 g/square meter. The medium-sized polyester fiber raw cloth is pretreated according to the pretreatment sequence of primary dipping, stretching, secondary dipping, primary scraping, secondary scraping and coating of the precoating layer, and the substrate layer for the ceramic corundum abrasive coated grinding tool is prepared.
2.1 Preparing the impregnating compound
Preferably, the impregnating material comprises the following components in parts by mass:
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In the embodiment, 200 square meter ceramic corundum abrasive coated abrasive cloth is prepared, the single weight of the material is 90 g/square meter, the total weight of the impregnating material is 18000g, 16833.6g of polyvinyl alcohol, 594g of phenolic resin, 568.8g of white latex and 3.6g of organosilicon are weighed according to the formula ratio.
Adding water and polyvinyl alcohol PVA-205 into a container, heating to 60 ℃, preparing 25% PVA aqueous solution according to a proportion, opening a stirrer, adding phenolic resin, stirring for 10min, adding white latex, stirring for 10min, adding organosilicon, preparing a preset viscosity of 300 cps/room temperature, stirring for 10min, and conveying to a production line.
2.2 Preparation of the scraping slurry
The scraping slurry comprises the following components in parts by mass:
The example is to prepare 200 square meter ceramic corundum abrasive coated abrasive cloth, the single weight of the material is 130 g/square meter, the total weight of the scraping slurry is 26000g, 9600 phenolic resin 4927.00g, 3809.00g of calcium carbonate, 2912.00g of 25% polyvinyl alcohol aqueous solution, 4856.80g of white latex, 8730.80g of organic silicon, 327.60g of direct blue, 408.20g of silica gel and 28.60g of sorbitan laurate are weighed according to the formula ratio.
According to the formula requirement, 2912.00g of 25% PVA aqueous solution is firstly added into a container, a stirrer is started, 4927.00g of phenolic resin 9600 is added, 3809.00g of calcium carbonate is added after stirring for 10min, 4856.80g of white latex, 8730.80g of organosilicon compound, 408.20g of silica gel and 28.60g of sorbitan laurate are added after stirring for 10min, 327.60g of direct blue is added for toning after stirring for 10min, the preset viscosity of 3000 cps/room temperature is prepared, and the mixture is stirred for 10min and then transported to a production line.
2.3 Preparation of precoat slurry
The precoat slurry comprises the following components in parts by mass:
In the embodiment, 200 square meter ceramic corundum abrasive coated abrasive cloth is prepared, the single weight of the material is 140 g/square meter, the total weight of the precoating slurry is 28000g, 9600 phenolic resin 5040g,1100 phenolic resin 10892g, 6384g of calcium carbonate, 5600g of polyvinyl alcohol (PVA-205), 50.4g of silane coupling agent and 33.6g of sorbitan laurate are weighed according to the formula ratio.
5600G of PVA is added into a container according to the formula ratio, a stirrer is opened, 5040g of phenolic resin 9600 and 10892g of phenolic resin 1100 (no sequence order) are added, 6384g of calcium carbonate is added after stirring for 10min, 50.4g of silane coupling agent and 33.6g of sorbitan laurate are added after stirring for 10min, the preset viscosity of 2000 cps/room temperature is prepared, stirring is carried out for 10min, and the temperature is kept at 40+/-2 ℃ and then the mixture is transported to a production line.
2.4 Preparation of substrates for use in the present invention
The polyester fiber raw cloth is sequentially subjected to primary dipping, stretching, secondary dipping, primary scraping, secondary scraping and pre-coating treatment to obtain the substrate used in the invention.
The pressure between the first set of rolls was adjusted so that the grammage of the first impregnation addition was maintained at 60 g/square meter, and then stretched, and the pressure between the second set of rolls was adjusted so that the grammage of the second impregnation addition was maintained at 30 g/square meter. In order to keep accurate data, when the substrate wire runs, a cloth disc is cut down for measurement, and finally the pressure is confirmed.
After the twice dipping is finished, drying at the temperature of 200-220 ℃ and then entering a scraping line, adjusting the scraping amount by adjusting the position and the running amount of a scraping knife, and increasing the gram weight of the once scraping by 70 g/square meter through disc carving confirmation; drying at 200-220 deg.c, re-entering into scraping line, regulating scraping amount via regulating the position and amount of scraping blade, and re-scraping with the weight increased by 60 g/square meter via carving disc; and (3) drying at the temperature of 130-160 ℃, then re-entering a scraping line, adding the slurry of the precoating into the scraping line, adjusting the precoating amount by adjusting the position and the running amount of a scraper, increasing the precoating gram weight by 140 g/square meter by disc engraving confirmation, drying at the temperature of 120-150 ℃, and then rolling to obtain the substrate for the coated abrasive substrate layer.
3. Preparation of the ceramic corundum abrasive coated abrasive tool of the invention
3.1, Preparing the primer glue solution
The primer glue solution comprises the following components in parts by weight:
The viscosity was adjusted to 3000 cps/room temperature with water.
The embodiment is to prepare 200 square meter ceramic corundum abrasive coated abrasive cloth, wherein the single weight of the primer glue solution is 226g/m 2, the total weight of the primer glue solution is 47992.5g, the water-soluble phenolic resin 9600 17176g, the water-soluble phenolic resin 11008407.2g, the coupling agent 81.36g, the penetrant silicone grease 81.36g, the ethylene glycol diethyl Ether (EC) 13256g, the defoamer organic silicon 262.16g and the silicon oxide wollastonite 17835.92g are weighed according to the formula ratio.
Preparing a primer glue solution: and (3) raising the jacket temperature of the glue preparation kettle to 40 ℃ and ensuring the cleaning and drying of the whole glue preparation system. 17176g of water-soluble phenolic resin 9600 and 8407.2g of water-soluble phenolic resin 1100 are added into a glue preparation kettle, stirred and mixed at a stirring speed of 450r/min, 81.36g of coupling agent, 81.36g of penetrating agent silicone grease, 1356g of glycol diethyl ether and 262.16g of defoaming agent organic silicon are added at the temperature of 40 ℃ in a heat preservation mode, 17835.92g of silicon oxide wollastonite is slowly added, and stirring is continued for 40min at 750 r/min. When the glue temperature reached 40.+ -. 2 ℃ the sample was taken with a 500mL glass and the viscosity was measured. Adjusting the viscosity of the primer glue solution to 3000 cps/room temperature by water; measuring viscosity by using a DNJ viscometer, adjusting the viscosity, regulating the viscosity to 400r/min, maintaining the self viscosity and the temperature, stirring slowly, and covering a glue preparation kettle cover to prevent air from entering to oxidize and crust the surface of the glue after being prepared.
The prepared modified phenolic resin primer glue solution maintains the self viscosity and temperature through a conversion pump and a heating circulation system, is discharged, is guided into a machine, and is sent to a production line for the production of the primer coating of the substrate layer.
3.2, Preparing compound glue solution
The compound glue solution comprises the following components in parts by weight:
Wherein, the components of the compound glue solution are adjusted to be at 2000 cps/room temperature by using ethylene glycol diethyl ether.
Preparing a compound glue solution: adding 24565g of water-soluble phenolic resin 9600 and 10540g of water-soluble phenolic resin 1900 into a glue preparation kettle, stirring and mixing at a stirring speed of 450r/min, heating to 40 ℃, adding 153g of coupling agent, stirring and mixing, adding 2966.5g of titanium pigment and 76.5g of thickener (nonionic polyurethane HEUR), slowly adding 44965g of cryolite, regulating a stirrer to 750r/min to avoid caking, regulating the stirrer to 400r/min, continuously stirring uniformly, adding 110.5g of span, continuously stirring uniformly, adding 1623.5g of blue pigment, and regulating the viscosity to 2000 cps/room temperature by using ethylene glycol diethyl ether; and after the stirring is continued for 40min, the stirrer is regulated to 400r/min, the stirring is performed slowly, and a glue preparation kettle cover is covered, so that air is prevented from entering to oxidize and crust the surface of the glue after the glue preparation.
The prepared modified phenolic resin glue coating liquid is subjected to glue coating production after the base material layer is subjected to primer coating-sand planting by a conversion pump and a heating circulation system, the self viscosity and the temperature are maintained, the materials are discharged and are guided into a machine, and a production line is used for the machine.
3.3 Configuring the surface layer coating paint
The surface coating glue solution comprises the following components in parts by mass:
The viscosity was adjusted to 15000 cps/room temperature with ethylene glycol diethyl ether.
The potassium fluoborate oily coating modified epoxy resin adhesive comprises the following components in parts by weight:
73.50 parts by mass of potassium fluoborate;
13.50 parts by mass of ethylene glycol diethyl ether;
13.00 parts of epoxy resin.
The coating dispersing agent comprises the following components in parts by mass:
The embodiment is to prepare 200 square meter ceramic corundum abrasive coated abrasive cloth, wherein the coating weight of the surface material liquid is 524.95g, the total weight of the surface material liquid is 104991g, wherein 75.71kg of potassium fluoborate, 13.91kg of ethylene glycol diethyl ether and 13.39kg of oily epoxy resin are weighed according to the formula ratio in the preparation of the potassium fluoborate oily coating modified epoxy resin adhesive; preparation of a coating dispersing agent, 98.98kg of ethylene glycol diethyl ether, 0.52kg of penetrating agent fatty alcohol polyoxyethylene ether, 2.94kg of epoxy resin and 0.57kg of blue pigment are weighed according to the formula ratio; 3.04kg of other components of fumed silica, 0.37kg of titanium dioxide and 6.33kg of epoxy curing agent.
Preparing potassium fluoborate oily coating modified epoxy resin adhesive:
75.71kg of potassium fluoborate and 13.91kg of ethylene glycol diethyl ether are stirred at normal temperature and ground on a three-roller grinder until the granularity is below 15 mu m; adding the prepared solution and 13.39kg of oily epoxy resin into a reaction container, stirring, heating to 45-50 ℃ and continuously stirring for 20-30 min to prepare the potassium fluoborate oily coating modified epoxy resin adhesive, and preserving at normal temperature.
Preparing a coating adhesive dispersing agent:
In a reaction container, 98.98kg of ethylene glycol diethyl ether and 0.52kg of fatty alcohol polyoxyethylene ether are firstly put into the reaction container, the mixture is heated to 45-50 ℃ and stirred at a stirring speed of 1500r/min, 2.94kg of epoxy resin is put into the reaction container at a temperature of 45-50 ℃ and is continuously stirred for 20-30min, and finally 0.57kg of blue pigment is put into the reaction container and is stirred for 20-30min to prepare the coating adhesive dispersing agent, and the coating adhesive dispersing agent is stored at normal temperature.
Preparing a coating paint:
83.74kg of potassium fluoborate oily coating modified epoxy resin adhesive and 9.52kg of coating dispersing agent are weighed and put into a mixing drum, after being uniformly stirred at the stirring speed of 1500r/min, 3.04kg of fumed silica and 0.37kg of titanium dioxide are added, after being fully stirred at normal temperature (about 30 min), 6.33kg of epoxy curing agent is finally put into the mixing drum, and if the viscosity is larger, the viscosity is adjusted to 15000 cps/room temperature by using ethylene glycol diethyl ether, so that the high-strength water-resistant burn-resistant surface feed liquid with thixotropic function is prepared.
3.4, The step of coating primer
Placing the prepared base material for the base material layer of the coated abrasive tool on a primer machine, adjusting various technical parameters of primer machine equipment, heating circulating water of a primer machine rubber disc to 47 ℃ in summer and 60 ℃ in winter, lifting the rubber disc, opening a pipeline valve, adjusting viscosity of primer rubber liquid prepared according to the formula ratio, measuring the viscosity to 3000 cps/room temperature by using a DNJ viscometer, adjusting the temperature of the rubber liquid to 38+/-2 ℃, and sending the rubber liquid to a primer machine.
And (3) sieving the primer glue solution, slowly putting the glue solution into a glue tray, taking the position where the glue solution is to be placed as a way of preventing the glue solution from overflowing, accurately measuring the glue temperature to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller to see whether the glue solution is uniform, finding that the thickness of two sides is to be adjusted in time, and circulating the glue solution for about 5min.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the station is started after being in place, all control buttons are opened, the base material is pressed on the steel roller at the position of the rubber disc, the uniform bar is pressed, the speed is firstly slow and then fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of the base body, the sizing amount is measured, the sizing amount is timely adjusted to meet the requirement, and the sand planting procedure is carried out.
3.5, Sand planting step
And (3) gravity sand planting:
the circulating lifting hopper is started, and alumina ceramic corundum abrasive to be used is sieved and then is put into a sand box, wherein the alumina ceramic corundum abrasive in the embodiment is 30015 g of calcined alumina ceramic corundum abrasive with 100# granularity which is treated by ion implantation. According to the granularity of the abrasive, the sand box gap, the position and the speed of the sanding roller and the angle of the sand baffle are adjusted, the sand feeding amount is ensured to accord with the process-specified sand planting amount, and then the sand is transferred into electrostatic sand planting.
And (3) electrostatic sand planting:
and implanting 121581g of 120# stacked abrasive zirconia ceramic corundum abrasive on the substrate subjected to gravity sand implantation through an electrostatic sand implantation process. And (3) starting a temperature and humidity control switch of the electrostatic sand planting room to enable the temperature and humidity control switch to reach the temperature of 25 ℃ and the humidity of 65% specified by a process, starting electrostatic planting (taking care of temperature guarantee in winter and moisture guarantee in summer), adjusting equipment parameters, and guaranteeing the parallelism and the height (P24-P80.5 cm, P100-600.0 cm) of an electrostatic polar plate and electrostatic voltage (P24-80 45KV, P100-600 KV).
The circulation lifting hopper is started, zirconia ceramic corundum abrasive materials to be used are put into the sand box after being screened, the vibration amplitude in the static sand planting device is adjusted, meanwhile, the sand conveying belt is opened, the sand conveying belt runs at a low speed, and the sand discharging amount of the sand box and the rotating speed of the sand conveying belt are timely adjusted according to the sand surface condition.
And after all the conditions are normal, the machine speed is increased to the range of the process requirement, sampling and detecting are carried out on the primer and the sand feeding amount, and if the process requirement is not met, the process is regulated again, and sampling is carried out until the result meets the requirement. And (5) performing pre-drying after electrostatic sand planting.
In the process of static sand planting, attention is paid to the fact that circulating sand is uniformly stirred after entering a sand box, and the static electricity is released after the circulating sand is charged and the new sand is uniformly stirred, all switches are turned off firstly after production, particularly voltage is turned off (a red light is extinguished), and then static electricity of an upper polar plate is discharged by a grounding rod.
After the sand is planted by gravity and the sand is planted by static electricity, under the action of high-strength high-viscosity primer, the alumina ceramic corundum abrasive implanted by the sand is planted by gravity and is in a lying form in the primer, the zirconia ceramic corundum abrasive implanted by the sand is planted by static electricity and is in a vertical form in the primer, the zirconia ceramic corundum abrasive implanted by the sand is fixed by the alumina ceramic corundum abrasive planted by gravity, and is pre-dried at 75-95 ℃ and is preliminarily fixed on a base material.
3.6, The step of coating the compound adhesive
The coating of the coating glue can be performed by using the same equipment as the coating of the primer, i.e. the coating of the coating glue can be performed by using a primer machine.
Placing the above-mentioned sand-planted base material on a compound glue machine, regulating various technological parameters of compound glue machine equipment, heating the circulating water of the compound glue machine glue disk to 47 deg.C in summer and 60 deg.C in winter, lifting the glue disk, opening pipeline valve, regulating viscosity of compound glue solution prepared according to the above-mentioned formula ratio, using DNJ viscosimeter to measure viscosity to 2000 cps/room temperature, regulating glue solution temperature to 38+ -2 deg.C, feeding it into compound glue machine table, and its step is identical to that of base glue.
And (3) screening the compound glue solution, slowly putting the compound glue solution into a glue tray, paying attention to the position where the glue solution is to be put so as to prevent the glue solution from overflowing, accurately measuring the glue temperature to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller to see whether the glue solution is uniform, finding that the thickness of two sides is required to be adjusted in time, and circulating the glue solution for about 5 minutes.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the operation is started after the pre-drying room and the main drying room are in place, all control buttons are opened, the base material after sand planting is conveyed to a rubber disc to press a steel roller, a uniform bar is pressed, the speed is firstly slow and secondly fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of a base body, the sizing amount is measured, the sizing is timely adjusted to meet the requirement, the re-sizing is finished, and the next procedure is carried out after the base material is dried at 75-95 ℃.
3.7 Step of applying a topcoat
The application of the top coat may be performed using the same equipment as the application of the primer, i.e., the application of the top coat may be performed using a primer machine.
Placing the prepared substrate coated with the compound adhesive on a surface coating machine, adjusting various technical parameters of equipment of the surface coating machine, heating circulating water of a rubber disc of the surface coating machine to 47 ℃ in summer and 60 ℃ in winter, lifting the rubber disc, opening a pipeline valve, adjusting viscosity of the prepared surface coating adhesive according to the formula ratio by using ethylene glycol diethyl ether, measuring the viscosity to 15000 cps/room temperature by using a DNJ viscometer, adjusting the temperature of the adhesive to 38+/-2 ℃, and sending the adhesive to a surface coating machine.
And (3) sieving the surface coating glue solution, slowly putting the glue solution into a glue tray, taking the position where the glue solution is to be put to prevent the glue solution from overflowing, accurately measuring the glue temperature to reach the temperature of 38+/-2 ℃ required by the process, starting a glue roller to see whether the glue solution is uniform, finding that the thickness of two sides is to be adjusted in time, and circulating the glue solution for about 5min.
When the temperature of the pre-drying room and the main drying room reach the process requirement, the operation is started after the pre-drying room and the main drying room are in place, all control buttons are opened, the substrate after sand planting is conveyed to a rubber disc to press a steel roller, a uniform bar is pressed, the speed is firstly slow and secondly fast, after the speed reaches the process requirement and is stable, sampling is carried out at the middle position of a substrate, the sizing amount is measured, the coating is timely adjusted to meet the requirement, the surface coating is finished, and the surface coating is dried at 70-95 ℃ to prepare the ceramic corundum abrasive coated grinding tool after the primary coating.
3.8 Post-treatment step
A coating step, namely placing the ceramic corundum abrasive coated grinding tool subjected to primary coating in a coating furnace for three-section coating, wherein the curing temperature of one section is 100 ℃ and the curing time of the other section is 12 hours; the second-stage curing temperature is 120 ℃, and the second-stage curing time is 12 hours; the three-stage curing temperature is 130 ℃, and the three-stage curing time is 12 hours.
And a softening step, namely mechanically softening the coated product to enable tiny small cracks to be generated on the surface of the abrasive cloth, and improving the flexibility and toughness of the product, so that the whole soft product is obtained.
The method comprises the steps of finished product preparation, namely dividing the flexible product into sand rolls, cutting, edging, sizing, jointing, edge pressing and working procedures, and converting the sand rolls into a coated grinding tool with set specifications;
and a finished product inspection step, namely quality inspection is carried out according to national regulation standards.
The ceramic corundum abrasive coated abrasive cloth manufactured by the method is converted to prepare an abrasive belt for grinding titanium alloy products, the specification is 2100 multiplied by 75 (mm), and the granularity is as follows: 120#, finished product breaking strength: the longitudinal direction is more than or equal to 4000N/5cm, the transverse direction is more than or equal to 2000N/5cm, and the five-axis linkage numerical control machining center blade of a certain blade factory is polished, the linear speed is 100m/s, and the surface roughness Ra is as follows: less than or equal to 0.09, grinding ratio: is more than or equal to 1:83.5, is 4 times of a common abrasive belt under the dry grinding condition, and has the heat-resistant grinding temperature of 300 ℃. Grinding ratio of similar products of a certain company at home and abroad under the same condition: 1:61.4, surface roughness Ra:0.18.
While embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are illustrative and not to be construed as limiting the invention, and that variations, modifications, alternatives and variations may be made to the above embodiments by one of ordinary skill in the art within the scope of the invention.
Claims (7)
1. The ceramic corundum abrasive coated grinding tool comprises a substrate layer and a working layer, wherein the working layer comprises a primer layer, an abrasive implanted into the primer layer and a compound layer coated on the abrasive and the primer layer, and is characterized in that the abrasive is ceramic corundum abrasive subjected to ion implantation treatment, and metal ions and nitrogen ions are implanted into the ion implantation treatment;
The preparation method of the ceramic corundum abrasive coated grinding tool comprises an abrasive pretreatment step, a base material pretreatment step, a primer coating step, a sand planting step and a primer coating step, wherein the abrasive pretreatment step comprises ion implantation treatment of an abrasive; the ion implantation treatment is to sequentially and circularly implant nitrogen ions and metal ions into the surface of the abrasive, the cycle times are not less than 2, and the substrate pretreatment step comprises the steps of carrying out twice impregnation treatment on the substrate;
the impregnating material for the impregnation treatment comprises the following components in parts by mass:
After the base material is subjected to the twice dipping treatment, the method further comprises the step of carrying out twice scraping treatment on the base material, wherein the scraping slurry for the scraping treatment comprises the following components in parts by mass:
In the step of preprocessing the base material, after the base material is subjected to twice dipping treatment and twice scraping treatment, the base material is further subjected to precoating treatment, and the precoating treatment comprises the following components in parts by weight:
2. The ceramic corundum abrasive coated abrasive according to claim 1 wherein the ceramic corundum abrasive comprises any one or more of alumina ceramic corundum abrasive, zirconia ceramic corundum stacked abrasive.
3. The ceramic corundum abrasive coated abrasive article of claim 2 wherein the abrasive is distributed in the coated abrasive article in two layers.
4. A ceramic corundum abrasive coated abrasive according to any one of claims 1 to 3 wherein the working layer further comprises a top coat applied over the size coat.
5. The ceramic corundum abrasive coated abrasive tool as claimed in claim 4 wherein the working layer comprises the following components in parts by weight:
6. The ceramic corundum abrasive coated abrasive tool according to any one of claims 1,2, 3, 5 wherein the step of grit-blasting includes a gravity grit-blasting treatment and an electrostatic grit-blasting treatment.
7. The ceramic corundum abrasive coated abrasive tool as claimed in claim 4 wherein the grit-blasting step includes a gravity grit-blasting treatment and an electrostatic grit-blasting treatment.
Priority Applications (1)
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| CN113262836A (en) * | 2021-05-11 | 2021-08-17 | 鄂州市兴方磨具有限公司 | Coated rice milling emery roller with good rice milling effect and preparation method thereof |
| CN114211411B (en) * | 2021-12-28 | 2022-09-13 | 江苏华东砂轮有限公司 | Large-size monocrystalline silicon piece ultra-precision machining polishing grinding wheel and preparation method thereof |
| CN114105678A (en) * | 2021-12-28 | 2022-03-01 | 江苏瑞和磨料磨具有限公司 | Preparation method of high-performance ceramic corundum abrasive |
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