CN1130274C - Abrasive tools - Google Patents

Abrasive tools Download PDF

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Publication number
CN1130274C
CN1130274C CN99804385A CN99804385A CN1130274C CN 1130274 C CN1130274 C CN 1130274C CN 99804385 A CN99804385 A CN 99804385A CN 99804385 A CN99804385 A CN 99804385A CN 1130274 C CN1130274 C CN 1130274C
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Prior art keywords
wheel
abrasive
grinding
ground section
abrasive wheel
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CN1294543A (en
Inventor
S·拉马纳坦
W·H·威利斯顿
S-T·布利简
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Saint Gobain Abrasives Inc
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Norton Co
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Priority claimed from US09/049,623 external-priority patent/US6102789A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
    • B24D5/06—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor with inserted abrasive blocks, e.g. segmental
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
    • B24D3/06—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
    • B24D3/08—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements for close-grained structure, e.g. using metal with low melting point

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  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
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Abstract

Abrasive tools suitable for precision grinding of hard brittle materials, such as ceramics and composites comprising ceramics), at peripheral wheel speeds up to 160 meters/second are provided. The abrasive tools comprise a wheel core (2) attached to an abrasive rim of dense, metal bonded superabrasive segments (8) by means of a thermally stable bond (6). A preferred tool for backgrinding ceramic wafers contains graphite filler and a relatively low concentration of abrasive grain (4).

Description

Milling tool
The application is the part continuation application of the US 09/049,623 of in March, 1998 submission.The present invention relates to be suitable for hard brittle material (as pottery and the composite that comprises pottery) is carried out milling tool Precise Grinding and that be suitable for ceramic wafers is carried out surfacing, the speed of its periphery wheel can reach 160 meter per seconds.This milling tool comprises a core wheel or wheel hub, and this core wheel can keep heat-staple bonding agent to adhere to a superfinishing wheel rim metal, bonding in grinding process by one.These milling tools can be with (for example 19-380 centimetre of high grinding rate 3/ minute/centimetre) pottery is carried out grinding, to compare with traditional grinding tool, the wearing and tearing of this grinding tool are less, and also smaller to the damage of workpiece.
Authorize the US-A-5 of Li, 607,489 have disclosed a kind of milling tool that is suitable for grinding sapphire and other ceramic material.This milling tool contains the diamond of clad metal, and these diamonds are bonded in the vitrifying matrix in kollag and 10% (percent by volume) space that comprises 2-20% (percent by volume) at least.
Authorize the US-A-3 of Keat, 925,035 have disclosed a kind of milling tool, and this milling tool contains the diamond that is bonded in the metallic matrix, have the filler of selected 15-50% (percent by volume) in the matrix, as graphite.This instrument can be used to the grinding carbide alloy.
Authorize Van der the US-A-2 of Pyl, 238,351 disclosed a kind of by the cutting wheel of making by the bonding diamond lap particle of metal.Be used for bonding material and comprise copper, iron, tin and available nickel, can be sintered on the steel core by a soldering step selectively by bonding abrasive grains, to guarantee having enough bonding fastness.The Rockwell hardness RB of best bonding material is 70.
U.S. Pat-Re-21,165 have disclosed a kind of milling tool that contains fine diamond particle (bortz powder), and described fine diamond particle is bonded in the metal bonding material (as bronze) with relatively low fusion temperature.The bonding material of this low melting temperature can be avoided fine diamond particle generation oxidation.Grinding wheel rim is to be constructed to ground section single, annular, is attached to the center disk of an aluminum or other material subsequently again.
Proved already that these materials all can not be satisfactory fully when ceramic component is carried out fine gtinding.When working with a kind of feasible removal rates that meets marketization requirement, these instruments can not satisfy the strict regulations of shape, size and surface quality to parts.A lot of recommended milling tools commonly used that are used for this type of operation all are the bonding superfinishing wheels of resin or vitreum, and these abrasive wheels are to be designed to come work with relatively low removal rates, to avoid causing damage under the surface of ceramic component and the surface.Because ceramic workpiece trends towards blocking the emery wheel surface, thereby can further reduce grinding efficiency, so just needing is emery wheel dressing and finishing continually, has accurate form to keep it.
Along with on the market to growing such as the demand of the high technology ceramics element in engine, refractory equipment and the electronic installation products such as (for example wafer, magnetic head and display windows), press for the improved milling tool that can carry out accurate grinding to pottery.
To being used for the high performance ceramic material of electronic component, when carrying out polishing as titanium carbide aluminium (AlTiC), surfacing or " back of the body mill (backgrinding) " job requirements obtain high-quality smooth surface with the grinding operation of little power, relatively low speed.These materials are carried on the back when mill, and grinding efficiency depends on the surface quality of workpiece and to a great extent to the control of applying power (that is the power that applies owing to high material material removal rate and emery wheel wearing resistance).
The present invention relates to a kind of surfacing milling tool, comprise the grinding edge that a core wheel, circular circumference part and is limited by a plurality of ground section, the minimum specific strength parameter of described core wheel is 2.4MPa-cm 3/ g, density is 0.5-8.0g/cm 3If each ground section cumulative volume is 100 volume %, comprising the superfinishing particle that 0.05-10 volume % is arranged, the fragility filler of 10-35 volume %, the metal bonding material matrix of 55-89.95 volume %, the fracture toughness of this matrix is 1.0-3.0MPa M 1/2Wherein the specific strength parameter is to be defined as YIELD STRENGTH or the fracture toughness density divided by material.The fragility filler is selected from by graphite, hexagonal boron nitride, hollow ceramic ball, feldspar, nepheline syenite, float stone, calcined clay and glass marble, and their group that combination constituted.In a preferred embodiment, metal bonding material matrix comprises the porosity that is 5 volume % to the maximum.
Description of drawings
Fig. 1 shows a continuous wheel rim of being made up of several ground section that are bonded in a metal core wheel periphery, and this wheel rim forms a 1A1 type abrasive wheel.
Fig. 2 shows a discontinuous wheel rim of being made up of several ground section that are bonded in a metal core wheel periphery, and this wheel rim forms a cup-shaped abrasive wheel.
Fig. 3 shows at the abrasive wheel by example 5 one titanium carbide aluminium is carried out in the process of grinding, the relation between the worn quantity of blank and the normal force that is applied.
Milling tool of the present invention is abrasive wheel, and this abrasive wheel comprises that one has one for the core wheel that abrasive wheel is installed to the centre bore on the grinding machine, and this core wheel is the superfinishing wheel rim that is designed to support along the periphery of abrasive wheel a metal adhesive. Two parts of this of abrasive wheel are to keep heat-staple bonding agent and keep the state of mutually combining under grinding condition by one, and abrasive wheel and member thereof are to be designed to: can bear when wheel periphery speed and reach the stress that produces when at least 80 meter per seconds preferably reach 160 meter per second. Comparatively desirable instrument is 1A abrasive wheel and cup-shaped abrasive wheel, such as 2 types or 6 type abrasive wheels or the cup-shaped abrasive wheel of 11V9 type mitriform.
Core wheel is round basically.Core wheel can be 2.4MPa-cm by any minimum specific strength 3/ g, preferably 40-185MPa-cm 3The material of/g is made.The density of wheel core material is 0.5-8.0g/cm 3, 2.0-8.0g/cm preferably 3The example of suitable material is steel, aluminium, titanium and bronze, and their compound, alloy and combination.Can adopt the reinforced plastics of minimum specific strength to make core wheel with regulation.The wheel core material of compound and reinforcement has continuous phase metal or plastic substrate usually, and they often are powder types, can add harder, have more flexible and/or the density materials with smaller is used as a discontinuous phase.The reinforcement material that is suitable for use as the core wheel of instrument of the present invention is the packing material of glass fibre, carbon fiber, aramid fibre, ceramic fibre, ceramic particle and hollow, as glass, mullite, corundum and Zeolite  spherolite.
Can adopt steel or other density is 0.5-8.0g/cm 3Material make the core wheel that is used for instrument of the present invention.When making was used for the core wheel of high-speed grinding (for example at least 80 meter per seconds), pulverous light metal (was about 1.8-4.5g/cm as density 3), be desirable material comparatively as aluminium, magnesium and titanium and their alloys and mixts.Aluminium and aluminium alloy are desirable especially.If adopt the co-sintering assembly technology to make milling tool, then can select for use sintering temperature at 400 to 900 ℃, preferably the metal between 570 to 650 ℃.Can add low density filler and alleviate the weight of core wheel.Porous and/or hollow ceramic or glass filler are the comparatively suitable materials that is applicable to this purpose as glass spherule and mullite spherolite.Can also adopt inorganic or nonmetallic fibrous material.When process conditions are specified, can be before compacting and sintering, metal dust is added on bonding lubricant or other process auxiliaries with well-known, the effective quantity of superfinishing technical field of metal.
Milling tool should be firm, durable and have dimensional stability, so that bear the potential destructive power that produces owing to the high speed operation.Core wheel must have the specific strength of a certain minimum, so that core wheel turns round with the necessary very high angular speed of tangential contact of realizing the 80-160 meter per second.It is 2.4MPa-cm that the present invention takes turns the required minimum specific strength parameter of core material 3/ g.
The specific strength parameter is to be defined as: the surrender of wheel core material (or fracture) intensity is divided by the density of wheel core material.Be lower than in fracture strength under the situation of fragile material of yield strength, the specific strength parameter depends on less numerical value, i.e. fracture strength.YIELD STRENGTH is: can make its deflection continue to increase and the power of the minimum that power needn't increase when putting on material.For example, be hardened to above ANSI 4140 steel of about 240 (Brinell hardness) and have tensile strength greater than 700MPa.The density of this steel is about 7.8g/cm 3Therefore, its specific strength parameter is about 90MPa-cm 3/ g.Similarly, be heat-treated to Brinell hardness and reach special aluminum alloy more than 100, for example the tensile strength of Al 2024, Al 7075 and Al 7178 surpasses 300MPa.The density of these aluminium alloys is low to moderate about 2.7g/cm 3, thereby its specific strength is greater than 110MPa-cm 3/ g.Be manufactured into density and be lower than 8.0g/cm 3Titanium alloy and bronze compound and alloy also be suitable for.
The wheel core material should be the chemical reaction of cooling agent tough and tensile, that still keep heat-staple, can tolerate and use in grinding process when grinding area for example reaches 50-200 ℃ and lubricant and can tolerate the formed wearing and tearing of erosion that cause in the motion of abrasive areas owing to the grinding chip.Though some corundum and other ceramic material have receivable stale value (as surpassing 60MPa-cm 3/ g), they are common still too crisp, and meeting is ruptured when high-speed grinding and is caused structural failure.Therefore, pottery is not suitable for the core wheel as instrument.The tool steel of metal, particularly sclerosis is more satisfactory.
The means of abrasion that can be used for the present invention's abrasive wheel is mounted in wheel rim segmentation or continuous on the core wheel.Fig. 1 shows the grinding wheel rim of a segmentation.Core wheel 2 has a centre bore 3, is used for abrasive wheel is installed to the wheel shaft of a Power Drive Unit (not shown).The wheel rim of abrasive wheel comprises and being embedded (preferably distributing equably) superfinishing particle 4 in a metallic matrix bonding material 6.A plurality of ground section 8 have been formed grinding wheel rim shown in Figure 1.Though the embodiment shown in the figure shows ten ground section, the quantity of ground section is not key factor.Ground section as shown in Figure 1 all has the straight-flanked ring shape (arc) of butt, and its length is l, and width is w, and thickness is d.
The embodiment of abrasive wheel as shown in Figure 1 can be regarded as can the abrasive wheel that success is operated according to the present invention representative, but it should not regarded as a kind of restriction.The variation of the various geometries of segmentation abrasive wheel comprises: cup-shaped abrasive wheel as shown in Figure 2, that have the hole of passing core wheel and be formed on the gap between each continuous segment, and the width of ground section is different from the abrasive wheel of core wheel.Hole or gap can be used to provide the passage that cooling agent is conducted to grinding area and abrasive dust deflected from grinding area sometimes.Sometimes, can adopt the ground section of a width greater than core wheel, with when abrasive wheel radially passes through workpiece, protection wheel cored structure does not contact with chip and avoids corroding.
Abrasive wheel can be made like this,, forms previously selected each ground section of size earlier that is, relends and helps suitable adhesive these preformed ground section to be adhered to the periphery 9 of core wheel.Another kind of preferable manufacture method comprises: form body unit before the ground section of being made up of the mixture of powders of abrasive grains and bonding material, periphery around core wheel is come molded these components, produce and attached described ground section (that is, making described core wheel and wheel rim co-sintered) by heating and pressurization in the original place.Co-sintering technology is the comparatively ideal technology that is used for making the back of the body mill wafer and the cup-shaped abrasive wheel of flour milling of hard ceramic chip (as AlTiC).
The grinding wheel rim part of the present invention's milling tool can be difference continuous wheel rim and a discontinuous wheel rim as illustrated in fig. 1 and 2.Continuous wheel rim can comprise a ground section or at least two ground section, these ground section are independent sintering in mould separately, and then (promptly by a heat-staple bonding material, in grinding process, (commensurability is 50-350 ℃) can keep stable bonding agent under the temperature that runs on the part of leaving lapped face of ground section) be respectively installed on the core wheel.As shown in Figure 2, discontinuous wheel rim is to be made by at least two such ground section, and these ground section are separated by slit on the wheel rim or gap, and the direction along length l unlike continuous wheel rim is end to end arranged.These accompanying drawings show preferred embodiment of the present invention, but and do not mean that and the present invention must be constrained to such form, for example, discontinuous wheel rim can be used for the 1A abrasive wheel, also continuous wheel rim can be used for cup-shaped abrasive wheel.
For high-speed grinding, particularly for the grinding of cylindrical work, it is more satisfactory adopting the abrasive wheel of 1A type.Compare with the single continuously grinding wheel that is molded as the single-piece annular, the continuously grinding wheel rim of segmentation is more satisfactory, because in the manufacture process of milling tool, by the easier real shape circular, the plane of reaching of a plurality of ground section.
For the low speed grinding, particularly for the surfacing and the polishing of flat piece, discontinuous grinding wheel rim (cup-shaped wheel rim as shown in Figure 2) is comparatively desirable.Owing in the operation process of low speed surface finishing, surface quality is an important factors, thereby can be in some ground section that forms between each ground section on slit or the omission wheel rim, to help to remove the waste material of possibility scratch surface of the work.
Grind wheel rim and partly comprise the superfinishing particle that is combined in the metallic matrix bonding material, this is normally by sintering forms in a mould with metal bonding material powder and abrasive grains, and described mould is the ground section that is designed to obtain the wheel rim or the wheel rim of required size and shape.
The superfinishing particle that is used to grind wheel rim can be selected from the combination of natural and artificial diamond, CBN and these abrasive materials.The size of particle and type can be selected according to the characteristic of workpiece and the type of grinding technics.For example, when the grinding of carrying out sapphire or AlTiC and polishing, it is more satisfactory adopting the superfinishing particle that is of a size of 2 to 300 microns.For the corundum grinding, the superfinishing particle is of a size of about 125 to 300 microns (60 to 120 granularities; The size of Norton) roughly be more satisfactory.For the silicon nitride grinding, particle size is that about 45 to 80 microns (200 to 400 granularities) roughly are more satisfactory.For surfacing, fine granularity is better, and need remove the grinding operation of lot of materials to cylinder, configuration or internal diameter grinding etc., preferably adopts thicker granularity.
By the percent by volume of grinding wheel rim, milling tool comprises the superfinishing particle of 0.05 to 10% (percent by volume), preferably comprises 0.5-5% (percent by volume).Can add a spot of hardness and be used as the bonding material filler, to improve the rate of depreciation of bonding material less than the fragility packing material of metal bonding material matrix.Press the percent by volume of wheel rim part, can adopt 10-35% (percent by volume), preferably the filler of 15 to 35% (percents by volume).Suitable fragility filler must have the characteristic of suitable heat-resisting and anti-mechanical shock, so that kept under the sintering temperature of making ground section and assembling abrasive wheel and pressure condition.The example of useful fragility filler comprises graphite, hexagonal boron nitride, hollow ceramic spherolite, feldspar, nepheline syenite, float stone, calcined clay and glass marble, and their combination.
At this, can adopt to be suitable for bonding superabrasive and to have 1.0 to 6.0MPam 1/2(preferably 2.0 to 4.0MPam 1/2) the metal bonding material of fracture toughness.Fracture toughness is exactly can crack in material and make crack propagation and cause the tensile strength coefficient of material fracture.Fracture toughness can be used K 1c=(σ f) (π 1/2) (c 1/2) represent K wherein 1cThe expression fracture toughness, σ fExpression puts on the tension force of crackle, and c represents crack length half.Have several method can be used for determining fracture toughness, each method all is to produce the known crackle of a size earlier in test material, applies a tensioning load subsequently again, ruptures up to material.Can be with at the above-mentioned equation of tension force substitution of fracture place or cracks and calculate fracture toughness (for example, the fracture toughness of steel is about 30-60MPam 1/2, the fracture toughness of aluminium is about 2-3MPam 1/2, the fracture toughness of silicon nitride is about 4-5MPam 1/2, zirconic fracture toughness is about 7-9MPam 1/2).
For life-span and the grinding performance optimization that makes abrasive wheel, in grinding process, the wear rate of bonding material should equal or a little more than the wear rate of abrasive grain.Can in the metal bonding material, add the wear rate that aforesaid filler reduces abrasive wheel.If will obtain higher material material removal rate in grinding process, the metal dust that trends towards forming comparatively fine and close bonded structure (being that porosity is less than 5% (percent by volume)) is more satisfactory.
The material that can be used as wheel rim metal bonding material includes but not limited to: bronze, ormolu (brass), cobalt and iron and their alloy and mixture.These metals can be selectively use with the hydride of titanium or titanium or other superfinishing reaction material (being active bonding material composition) that can form the chemical bond of carbon or nitrogen on the surface of superfinishing particle under selected sintering condition, so that strengthen the contact of abrasive particle/bonding material.Reacting to each other of more intense abrasive particle/bonding material can limit the premature loss of abrasive particle and the damage of workpiece, and the shortening of the life tools of causing because of the loss of too early abrasive particle.
In a preferred embodiment of grinding wheel rim, metallic matrix has constituted the 55-89.95% (percent by volume) of wheel rim, preferably 60-84.5% (percent by volume).Frangible or fragility filler has constituted the 10-35% (percent by volume) that grinds wheel rim, preferably 15-35% (percent by volume).In the manufacture process of ground section, the porosity of metallic matrix bonding material should remain 5% (percent by volume) at the most.The hardness of metal bonding material is Nu Shi 2-3GPa preferably.
In the preferred embodiment of 1A type abrasive wheel, core wheel is an aluminum, wheel rim comprises the bronze bonding material of being made by copper and tin powder (80/20wt.%), alternatively, can adopt the phosphorus/copper powders may of the phosphorus that has added 0.1-3.0wt% (preferably 0.1-1.0wt%).In the manufacture process of each ground section, the metal dust of this composition is mixed mutually with the diamond lap particle of 100-400 granularity (160 to 45 microns), they are molded as each section of grinding wheel rim, and under 400-550 ℃ the temperature and sintering and compacting under the pressure at 20-33MPa, to obtain the grinding wheel rim of a densification, preferably to have to be at least the 95% solid density density of (promptly comprising the hole that is no more than about 5% (percentage by volume)).
In common co-sintering abrasive wheel manufacture process, be that metal dust with core wheel is injected in the die, and cold pressing under (the approximately pressure of 10-50MPa) 80 to 200kN and form semi-finished product, its size is about 1.2 to 1.6 times of the final desired thickness of core wheel.The semi-finished product core wheel is put in the graphite jig, in the die cavity between core wheel and graphite jig outer edge, adds the mixture of abrasive grains (2 to 300 microns granularities) and metal bonding material powder.Can adopt a setting ring that abrasive particle is become to have the thickness identical with preformed core wheel with metal bonding material powder pressing.Subsequently, under 370-410 ℃ the temperature and under 20 to 48MPa pressure the composition in the graphite jig was being suppressed 6 to 10 minutes.Well-known the same with the present technique field, temperature can be on the slope to rise and (for example, rises to 410 ℃ with 6 fens clock times from 25; Kept 15 minutes at 410 ℃), or before mouldings is exerted pressure, raise gradually.
After hot pressing, drip molding and graphite jig are separated, make it cooling, and carry out fine finishining and obtain a grinding wheel rim with required size and precision by traditional technology.For example, can come drip molding is carried out fine finishining with vitreum abrasive wheel on the grinding machine or the carbide lathe tool on the lathe.
When core wheel and wheel rim co-sintered, must remove a spot of material so that drip molding reaches its net shape.Be to grind between wheel rim and the core wheel and form in thermally-stabilised other bonding method,, join and bonding surface to guarantee that drip molding has to be enough to be used in connecing condensing, before the crosslinked and diffusing step, may needing that the two carries out machined to core wheel and wheel rim.
Between wheel rim and core wheel, form one heat-staplely when bonding when utilizing segmentation to grind wheel rim, can adopt any intensity to be enough to bear the thermally-stabilised adhesive of the rim velocity of 160 meter per seconds.Thermally-stabilised adhesive is stable for the grinding temperature that the part place in each ground section of leaving grinding face runs into.Normally about 50-350 ℃ of such temperature.
Bonding the saying from machinery of adhesive should be very firm, so that bear in the rotary course of abrasive wheel and the destructive power that exists in the process of grinding.Two component epoxide resin adhesives are more satisfactory.Preferable epoxy resin binder, the amino hardener component of Technodyne  HT-18 epoxy resin (available from the Taoka chemical company of Japan) and remodeling thereof can be mixed the ratio of 19 parts of curing agents mutually with a kind of 100 parts of resins.The ratio that can add 3.5 parts in per 100 parts of resins is added filler (as the fine silica powder end) to strengthen the viscosity of adhesive.Can each ground section be installed around the whole periphery of abrasive wheel core wheel by adhesive, perhaps install around the part of core wheel periphery.Can carry out blasting treatment to the periphery of metal core wheel, so that between attached each ground section, obtain certain roughness.The epoxy resin binder of thickening is coated on the two ends and the bottom of each ground section, and these ground section are location as shown in Figure 1 basically, and mechanically keeps in solidification process.Epoxy resin binder allows to solidify (for example at room temperature 24 hours, succeeded by following 48 hours at 60 ℃).By in solidification process, adding the viscosity optimization that enough fillers make epoxy resin binder, can make adhesive in the curing of ground section and the discharge rate minimum in the moving process.
The same with the situation of test abrasive wheel explosion, can test bonding strength with 45 rev/mins rotating speed.Abrasive wheel need be equal to the explosion of the confirmation rated value of the tangential contact velocity of 271 meter per seconds at least, so that carry out operation under the tangential contact velocity safety standard of 160 meter per seconds that the present U.S. stipulates.
Milling tool of the present invention particularly designs for the polishing of precise finiss and fragile material (as advanced ceramic materials, glass and contain ceramic material and the element of ceramic composite).Instrument of the present invention is more satisfactory to the grinding of ceramic material, and ceramic material includes but not limited to: silicon, monocrystalline or polycrystalline oxide, carbide, boride and silicide; Polycrystalline diamond; Glass; And the ceramic complexes of non-ceramic matrix; And their combination.Typical workpiece material includes but not limited to: AlTiC, silicon nitride, silicon oxynitride, stable zirconia, aluminium oxide (for example sapphire), boron carbide, boron nitride, titanium diboride, aluminium nitride and these ceramic compounds, and specific metal matrix composite is as the porous material such as the mineralising glass of the carbide that condenses and hard fragility.No matter be that single-crystal ceramic or polycrystalline ceramics can be ground with improved grinding-material of the present invention.For the pottery of each type, the quality of ceramic component and grinding efficiency of operation improve along with the increase of the outer circular velocity of abrasive wheel, reach the 80-160 meter per second up to speed.
The ceramic component that can utilize milling tool of the present invention to be improved comprises: the engine valve of pottery and valve rod, pump seal, ball bearing and pipe joint, inserts, the wear parts of cutting tool, the drawing-die that is used for metal forming, refractory component, display window, the plate glass that is used for windshield, door and window, insulating part and electronic devices and components and ceramic electronic component include but not limited to silicon wafer, AlTiC chip, read-write head and substrate.
Unless refer else, below all umbers in each example and percentage all be by weight calculation.These examples only are used to describe the present invention, the present invention are not had any restriction.
Example 1
Utilize following raw material and method with abrasive wheel preparation becoming 1A1 metal bonding diamond abrasive wheel of the present invention.
Preparation is by the copper powders may (the FS grade of dendrite, granularity are+the 200/-325 order to buy from the Sintertech international market company of New York Ghent) of 43.74wt%; Phosphorus/copper powders may of 6.24wt% (grade 1501, granularity+100/-325 buy from the New Jersey zinc company of Pennsylvania Palmerton); And the mixture of the tin powder of 50.02wt% (grade MD115, granularity+325 orders is from the Alcan metal dust Co., Ltd of New Jersey Elizabeth) composition.This metal powder mixture is added diamond lap particle (diamond of 320 sizes can be buied from the General Electric Co. Limited of Ohio Worthington), and they are mixed equably.This mixture is put in the graphite jig, and at 3000psi (2073N/cm 2) pressure hot pressing 15 minutes down and under 407 ℃ temperature, up to forming a matrix with the target density that is higher than 95% theoretical value (for example, for the #6 abrasive wheel in the example 2,＞98.5% theoretical density).The Rockwell B hardness RB of each ground section of #6 abrasive wheel is 108.The abrasive grains that comprises 18.75% (percent by volume) in the ground section.These ground section are ground to required precise geometry, so that be complementary with the periphery of a mach aluminum core wheel (the 7075 T6 aluminiums that can buy from the Yarde metal company of Massachusetts Tewksbury), thereby obtaining an external diameter is about 393mm, and ground section is the thick abrasive wheel of 0.62cm.
By a silica that is filled with epoxy resin binder (the Technodyne HT-18 adhesive that can buy from the Taoka chemical company of Japan) ground section and aluminum core wheel are assembled up, so as to obtaining to comprise the abrasive wheel of the continuous wheel rim of forming by a plurality of ground section.The contact-making surface of core wheel and each ground section need pass through degrease and blasting treatment, to guarantee having enough bonding forces.
In order to obtain the maximum operating speed of this novel abrasive wheel, the maximum operating speed test way according to Norton makes the complete various abrasive wheels of size rotate to it and destroys, to determine its bursting strength and specified maximum operating speed.Following table has been summarized the burst tearing test data of exemplary that diameter is the experiment metal bonding abrasive wheel of 393mm.
The bursting strength data of the bonding abrasive wheel of metal of test
Abrasive wheel # Abrasive wheel diameter cm (inch) Explosion rotating speed RPM Burst speed (m/s) Burst speed (sfpm) Maximum operating speed (m/s)
4 39.24 (15.45) 9950 204.4 40242 115.8
5 39.29 (15.47) 8990 185.0 36415 104.8
7 39.27 (15.46) 7820 160.8 31657 91.1
9 39.27 (15.46) 10790 221.8 43669 125.7
According to these data, the maximum operating speed of the test abrasive wheel of this design can reach 90m/s (17,717 surface feet/minute).By means of the improvement of manufacturing process aspect and abrasive wheel design aspect, can also realize operating rate further up to 160m/s.
Example 2
The assessment of nonferromagnetic substance:
Making three diameters according to the method for example 1 is that 393mm, thickness are that 15mm, centre bore are the bonding segmentation abrasive wheel of test metal (theoretical density is that 95.6% #4 abrasive wheel, theoretical density are that 97.9% #5 abrasive wheel and theoretical density are 98.5% #6 abrasive wheel) of 127mm (15.5 inches * 0.59 inch * 5 inches), and their nonferromagnetic substance is tested.Earlier with 32 and the speed of 80m/s abrasive wheel is tested, though all test abrasive wheels all are qualified, nonferromagnetic substance the best of #6 abrasive wheel wherein.Test to the #6 abrasive wheel is carried out with three kinds of test speeds, promptly 32m/s (6252sfpm), 56m/s (11,000sfpm) and 80m/s (15,750sfpm).Abrasive wheel with two prior arts that can buy from the market grinds with the served as control thing senior ceramic material, and they are tested with abrasive wheel of the present invention.One of them is the bonding diamond lap of vitreum wheel (the SD320-N6V10 abrasive wheel that can buy from the Norton of Massachusetts Worcester), and another is the diamond lap wheel (the SD320-R4BX619C abrasive wheel that can buy from the Norton of Massachusetts Worcester) of resin bonding.To the resin ground wheel is to test with whole three speed.For consideration, the vitreum abrasive wheel is only tested with the speed of 32m/s (6252sfpm) allowable speed.
Surpass 1000 times crush grinding on the carborundum workpiece, the width of grinding is 6.35mm (0.25 inch), and thickness is 6.35mm (0.25 inch).The test condition of grinding is:
The grinding test condition
Lathe: S40 CNC type Studer grinding machine
Abrasive wheel specification: SD320-R4BX619C, SD320N6V10,
Size: diameter 393mm, thickness 15mm, aperture 127mm.
Abrasive wheel speed: 32,56 and 80m/s (6252,11000 and 15750sfpm)
The oil of cooling agent: Inversol 22 @60% and 40% water
Coolant pressure: 270psi (19kg/cm 2)
The worn speed of material: that variation is 3.2mm during beginning 3/ s/mm (0.3in 3/ minute/inch)
Workpiece material: Si 3N 4(NT551 silicon nitride bar is buied from the promise of the Massachusetts Northboro advanced ceramic company of pausing), diameter * length is 25.4mm (1 inch) * 88.9mm (3.5 inches)
Work speed: 0.21m/s (42sfpm) keeps constant
Workpiece initial diameter: 25.4mm (1 inch)
Workpiece final diameter: 6.35mm (0.25 inch)
For the work of needs finishing and dressing, the condition that is suitable for the present invention's the bonding abrasive wheel of metal is:
Finishing process:
Abrasive wheel: 5SG46IVS (available from Norton)
Abrasive wheel size: diameter 152mm (6 inches)
Abrasive wheel speed: 3000rpm; With respect to abrasive wheel at+0.8 ratio
Helical pitch: 0.015 inch (0.38mm)
Compensation rate: 0.0002 inch
Dressing work:
Finishing rod: 37C220H-KV (SiC)
Mode: the excellent dressing of hand-held finishing
Test is that the carborundum bar is ground in a kind of mode of cylindrical periphery incision feeding.In order to make workpiece material maintain best hardness in grinding process, the sample holder that 88.9mm is long exposes about 31mm (1-1/4 inch) for grinding in a chuck.Each group crush grinding test all is that the far-end from bar begins.At first, to form a width be that 6.35mm (1/4 inch), radial depth are that the incision polishing scratch of 3.18mm (1/8 inch) is finished once test to abrasive wheel.Subsequently, readjust the rotating speed of workpiece, to compensate owing to diameter of work dwindles the workpiece rotational frequency that reduces.On same position, form two similarly incision polishing scratch again, make the diameter of workpiece be contracted to 6.35mm (1/4 inch) from 25.4mm (1 inch).Subsequently, make abrasive wheel, to carry out three times following crush grindings to the laterally mobile 6.35mm of chuck direction (1/4 inch).Need laterally to move four times, to finish crush grinding 12 times at an end of a sample towards the same side of sample.Subsequently, with sample conversely, expose another and bring in and carry out other 12 crush grindings.Need carry out 24 crush grindings altogether to each sample.
With the initial compare test of the bonding abrasive wheel of metal of the present invention and resin and the bonding abrasive wheel of vitreum is with the outer circular velocity of 32m/s and with from about 3.2mm 3(0.3 inch of/s/mm 3/ minute/inch) to 10.8mm 3(1.0 inches of/s/mm 3/ minute/inch) three worn speed of material carry out.Table 1 shows after having carried out 12 crush grindings, the performance difference of three kinds of dissimilar abrasive wheels, and the difference on these performances is represented with the G-ratio.The G-ratio is the volume of worn material and the ratio of emery wheel loss volume.Test data shows: under material material removal rate condition with higher, the G ratio of the vitreum abrasive wheel of N grade is better than the resin ground wheel of R grade, and this shows that softer abrasive wheel has preferable performance when the grinding ceramic workpiece.Yet under the situation of various material material removal rates, harder test is much better than resin ground wheel and vitreum abrasive wheel with the performance of the bonding abrasive wheel of metal (#6).
Table 1 shows under the situation of various material material removal rates, the G ratio of the estimation of resin emery wheel and the new bonding abrasive wheel of metal (#6).Because for the bonding abrasive wheel of metal, do not detect the abrasive wheel wear extent 12 grindings under each material material removal rate situation after, think that each grinding gives a symbolistic emery wheel gauge wear numerical value 0.01mil (0.25 μ m).So just can obtain the G-ratio 6051 of an estimation.
Though the bonding abrasive wheel of metal of the present invention comprises 75 diamond concentration (abrasive particle that about 18.75% (percent by volume) arranged) in ground section, resin and vitreum abrasive wheel are respectively 100 concentration and 150 concentration (percent by volume is respectively 25% and 37.5%), but abrasive wheel of the present invention still shows good nonferromagnetic substance.
Table 1 shows from surface smoothness (Ra) and the waviness (Wt) of utilizing above-mentioned three kinds of abrasive wheels to record with the sample of low speed grinding.Waviness value Wt is the ratio of maximum crest and trough on the waveform.The numerical value of all surface fineness all is to record on the surface that nonarcing cylinder crush grinding is produced.These surfaces are more coarse than the surface that horizontal grinding produced usually.
Table 1 shows the difference that the grinding energy of all abrasive wheels of three types under the situation of various material material removal rates consumes.Compare with other two kinds of abrasive wheels, the energy that the resin ground wheel is consumed is less; Yet the bonding abrasive wheel of metal of test usefulness and the energy consumption of vitreum abrasive wheel also can match in excellence or beauty.Test is acceptable with the energy consumption of abrasive wheel for ceramic grinding, particularly because abrasive wheel of the present invention has comparatively ideal G ratio and surface smoothness.Generally speaking, proved already that the energy that abrasive wheel of the present invention consumed was directly proportional with the material material removal rate.
Table 1Sample material grinds the tangential specific energy G-of unit specific surface waviness
The worn bright and clean Wt μ of the turn of speed consumption rate m that takes turns
Rate degree N/mm power Ws/ degree
mm 3/s m/s W/mm mm 3 Raμm
/ mm The resin ground wheel973 3.2 32 0.48 40 12.8 585.9 0.52 0.861040 6.3 32 0.98 84 13.3 36.6 0.88 4.01980 8.9 32 1.67 139 9.5 7.0 0.99 4.501016 3.2 56 0.49 41 13.1 586.3 0.39 1.221052 6.3 56 0.98 81 12.9 0.55 1.52
293.2922 3.2 80 0.53 45 14.2 586.3 0.42 1.241064 6.3 80 0.89 74 11.8 293.2 0.62 1.801004 9.0 80 1.32 110 12.2 586.3 0.43 1.75 The vitreum abrasive wheel654 3.2 32 1.88 60 19.2 67.3 0.7 2.50666 9.0 32 4.77 153 17.1 86.5 1.6 5.8678 11.2 32 4.77 153 13.6 38.7 1.7 11.8 The metallographictest abrasive wheel407 3.2 32 2.09 67 2.1 6051 0.6 0.9419 6.3 32 4.03 130 20.6 6051 0.6 0.9431 9.0 32 5.52 177 19.7 6051 0.6 0.8443 3.2 56 1.41 80 25.4 6051 0.6 0.7455 6.3 56 2.65 1250 23.9 6051 0.5 0.7467 9.0 56 3.70 209 2303 6051 0.5 0.6479 3.2 80 1.04 85 2609 6051 0.5 1.2491 6.3 80 1.89 153 24.3 6051 0.6 0.8503 9.0 80 2.59 210 23.4 6051 0.6 0.8
When (15, speed 750sfpm) is carried out the additional grinding test of another one and when measuring grinding performance, is 9.0mm at material material removal rate (MRR) with 80m/s under identical condition 3(0.8 inch of/s/mm 3/ minute/inch) situation under, resin ground wheel can match in excellence or beauty with the energy consumption of test with the metal grinding wheel.As shown in table 2, under the big situation of MRR change, test can normally be worked with abrasive wheel and do not lost performance or acceptable power termination.The power of the abrasive wheel that metal is bonding roughly is directly proportional with MRR.The highest MRR that can realize in this research report is 47.3mm 3/ s/mm (28.4cm 3/ minute/cm).
Data in the table 2 are the mean value of 12 grindings.Abrasive wheel is used in test, and each time power reading all is consistent in this 12 grindings.Operating personnel can observe, and along with repeatedly continuous the carrying out of grinding, power strengthens gradually, and the abrasive grains in the abrasive wheel begins rust, and the surface of abrasive wheel has loaded workpiece material in other words.Along with the increase of MRR, often can observe this situation.Yet, unforeseeablely be that observed stable energy consumption level shows under each the MRR situation in 12 grinding process: under the situation at various MRR, in whole test process, test always can keep its sharp grinding points with abrasive wheel.
In addition, in whole test process, when the material material removal rate is 9.0mm 3(0.8 inch of/s/mm 3/ minute/inch) to 47.3mm 3(4.4 inches of/s/mm 3/ minute/inch) time, needn't repair or dressing with abrasive wheel test.
All the carbofrax material stock removal of accumulation equals 271cm 3(42 inches of/cm (abrasive wheel width) 3/ inch), wherein there is not evidence to show that abrasive wheel has wearing and tearing.As a comparison, concentration is that 100 resin ground wheel is at 8.6mm 3(0.8 inch of/s/mm 3/ minute/inch) the situation of material material removal rate under, be about 583 through the G ratio after 12 crush grindings.Test of the present invention is then planted the abrasive wheel wear extent through still not having after 168 crush grindings to measure under the different material material removal rate situations with abrasive wheel in 14.
Table 2 shows: utilize test to come the grinding sample with the bonding abrasive wheel of metallized metal with whole 14 kinds of material material removal rates, can maintain 0.4 μ m (16 μ inch) to the surface smoothness between the 0.5 μ m (20 μ inch), and have 1.0 μ m (38 μ inch) to the waviness between the 1.7 μ m (67 μ inch).In the absence of high material material removal rate, the resin ground wheel is tested.Yet, at about 8.6mm 3(0.8 inch of/s/mm 3/ minute/inch) the situation of material material removal rate under, by the surface smoothness good slightly (0.43 to 0.5 μ m) of the ceramic bar of resin ground wheel grinding, but waviness poor slightly (1.73 to 1.18 μ m).
Allow the people surprised be, when coming grinding pottery bar by the bonding abrasive wheel of new metal, along with the increase of material material removal rate, to not significantly influence of surface smoothness.This and normal abrasive wheel (contrast abrasive wheel as described herein) influence surface smoothness when removal rates increases situation differs widely.
The long and shows: compare with the resin bonding abrasive wheel of generally held standard, test of the present invention can surpass under its situation of 5 times at MRR with abrasive wheel carries out grinding effectively.Compare with the resin ground wheel under the low MRR situation, this test is big more than 10 times with the G ratio of abrasive wheel.
Table 2
The test sample material of 14 kinds of MRR under the abrasive wheel speed of the 80m/s mill tangential force unit specific energy G-specific surface light wave degree that disappears
Remove rate N/mm wasted work rate Ws/m and lead clean degree Wt μ m
mm3/s/ W/mm m3 Raμm
Mm Resin type1,004 9.0 1.32 110 12.2 586.3 0.43 1.75 Metal mold of the present invention805 9.0 1.21 98 11.0 6051 0.51 1.19817 18.0 2.00 162 9.0 6051 0.41 0.97829 22.5 2.62 213 9.5 6051 0.44 1.14841 24.7 2.81 228 9.2 6051 0.47 1.04853 27.0 3.06 248 9.2 6051 0.48 1.09865 29.2 3.24 262 9.0 6051 0.47 1.37877 31.4 3.64 295 9.4 6051 0.47 1.42889 33.7 4.01 325 9.6 6051 0.44 1.45901 35.9 4.17 338 9.4 6051 0.47 1.70913 38.2 4.59 372 9.7 6051 0.47 1.55925 40.4 4.98 404 10.0 6051 0.46 1.55937 42.7 5.05 409 9.6 6051 0.44 1.57949 44.9 5.27 427 9.5 6051 0.47 1.65961 47.2 5.70 461 9.8 6051 0.46 1.42
When abrasive wheel speed is that (11, in the time of 000sfpm) (table 1), under various material material removal rate situations, the energy consumption of the bonding abrasive wheel of metal all is higher than the resin ground wheel for 32m/s (6252sfpm) and 56m/s.Yet, 80m/s (15,750sfpm) under the situation that (table 1 and 2) runs up, the energy consumption of the bonding abrasive wheel of metal the energy consumption of can matching in excellence or beauty that becomes in only being slightly less than the resin ground wheel in other words.For resin ground wheel and the test bonding abrasive wheel of metal, total trend is: when carrying out grinding with the worn speed of identical materials, energy consumption increases along with the raising of abrasive wheel speed.Compare with the situation of grinding metal material, under the situation of grinding ceramic material, have the energy consumption that is transformed into the heat that passes to workpiece greatly to become in grinding process and be not very important, this is because ceramic material has higher heat endurance.The surface quality of the ceramic sample that obtains as carrying out grinding by abrasive wheel of the present invention confirmed: energy consumption can not damaged polishing workpiece, and is in an acceptable level.
For all various material material removal rates and wheel speed, testing all constant basically with the G ratio of the bonding abrasive wheel of metal is 6051.Under constant wheel speed, the G ratio of resin ground wheel reduces with the increase of material material removal rate.
Table 2 shows under the situation of higher wheel speed, is ground the improvement of the surface smoothness and the waviness of sample.In addition, under the situation of all various wheel speeds and material material removal rate, come the sample of grinding to have minimum waviness by this new bonding abrasive wheel of metal.
Under the situation of these tests, to compare with abrasive wheel with contrast, the bonding abrasive wheel of metal of the present invention has excellent abrasive wheel service life.Opposite with the contrast that can buy in the market with abrasive wheel, in the grinding test that prolongation is carried out, needn't repair and dressing with abrasive wheel this test.This test can normally be worked under wheel speed reaches the situation of 90m/s with abrasive wheel.
Example 3
Under the condition of work identical with previous example, with the speed of 80m/s test is carried out the test of grinding next time with abrasive wheel (#6), can realize 380cm 3In the time of the material removal rate of/min/cm, can obtain only is the surface smoothness (Ra) of 0.5 μ m (12 μ in), and by energy also be in acceptable level.The effect of the high material material removal rate of the no surface damage that is obtained on ceramic workpiece by instrument of the present invention comes the grinding ceramic material all can not realize by the abrasive wheel of in the market various bonding types.
Example 4
Prepare a cup-shaped abrasive wheel, and on " the thorough moral of Blanc (blanchard) type " lathe of a vertical shaft, carry out sapphire grinding test.
Adopt with the ground section of the abrasive wheel #6 identical component of example 1 and make a cup-shaped abrasive wheel (diameter=250mm), wherein (1) adamantine granularity is 45 microns (Unite States Standard 270/325 orders), and the ratio in ground section is 12.5vol.% (50 concentration); (2) ground section is of a size of: chord length 133.1mm, width 4.76mm, thickness 5.84mm.These ground section are bonding along the periphery of the side of a cup-shaped steel core wheel with central shaft hole.On this side of core wheel, has the groove that forms along its periphery, the recess that these grooves have formed is discrete, shallow, width and length are equal to ground section.In these recesses, add epoxy resin binder (available from the Technodyne of Japanese Taoka HT-18 adhesive), and each ground section is put into recess, adhesive is solidified.The final abrasive wheel that forms as shown in Figure 2.
Utilize this cup-shaped abrasive wheel to come the surface of grinding one workpiece material (diameter is the sapphire solid cylinder of 100mm), can all comparatively obtain acceptable surface smoothness under the ideal situation at grinding conditions such as G ratio, MRR and energy consumptions.
Example 5
Utilize the ground section shown in the following table 3 to prepare the cup-shaped abrasive wheel of 2A2 type (diameter is 280mm), this abrasive wheel is suitable for grinding or back of the body mill AlTiC or silica chip.Unless point out in addition hereinafter, otherwise the size of ground section is circumferential lengths 139.3mm that width is 3.23mm, thickness is 5.84mm.Utilization can be by U.S.'s mesh 140/170 the weighing of screen cloth after, the component that stirs, prepare the diamond abrasive that contains bonding material with ratio listed in the table 3, so that fully mixing back 16 ground section of preparation on each abrasive wheel.The powder in addition weighing required to each ground section, and be introduced into a graphite jig, leveling and compacting.The graphite jig that will be used for ground section is at 3000psi (2073N/cm 2) pressure heating 15 minutes down and under 405 ℃ temperature.After cooling, ground section is taken out from mould.
As described in the example 1, each ground section is bonded on the mach 7075 T6 aluminium cores and form an abrasive wheel.Ground section is carried out degrease, sandblast and applying adhesive, and put it into and be processed to meet in the die cavity of abrasive wheel peripheral shape.After adhesive solidifies, abrasive wheel is machined to required size, and carries out balance and velocity test.
Table 3
The bonding material composition
Weight % volume %Sample Cu Sn P graphite C u Sn P graphite tester 49.47 50.01 0.52 0.00 43.71 54.03 2.26 0.00 (Ex.1) (1) 46.50 47.01 0.49 6.00 35.70 44.14 1.86 18.307.5/2040 (2) 46.50 47.01 0.49 6.00 35.70 44.14 1.86 18.307.5/2040 (3) 45.76 46.26 0.48 7.50 34.02 42.07 1.75 22.167.5/2051 (4) 46.50 47.01 0.49 6.00 35.70 44.14 1.86 18.305/2040 (5) 43.53 44.01 0.46 12.00 29.55 36.54 1.53 32.3725/2052
Table 4
Ground section composition Vol%Sample bonding material graphite diamond aPorosity bTester＞80 0.00 18.75＜5, (Ex.1), (75 concentration), (1)＞80 17.93 1.88＜57.5/2040, (7.5 concentration), (2)＞80 17.93 1.88＜57.5/2040, (7.5 concentration), (3)＞75 21.72 1.88＜57.5/2051, (7.5 concentration), (4)＞80 18.07 1.25＜55/2040, (5 concentration), (5)＞63 30.35 6.25＜525/2052, (25 concentration)
A. the granularity of all diamond particles that adopted in each ground section all is 325 orders (49 microns), and just wherein the granularity of sample (1) is 270 orders (57 microns).Diamond concentration is given as and is lower than adamantine percent by volume.
B. porosity is to estimate by the observation to the microstructure of each ground section.Owing to formed the alloy of intermetallic, thereby the density of tested sample often is higher than the theoretical density of the material that adopts in the ground section.
Example 6
The assessment of grinding performance:
To carrying out the test of grinding performance according to the low diamond concentration of example 5 preparations, the sample (diameter 280mm, thickness 29.3mm, centre bore are 228.6mm, promptly 11 inches * 1.155 inches * 9 inches) that the buck of graphite filling is taken turns.The performance of these samples and the contrast in the example 5 are made comparisons with back of the body emery wheel, and the latter is according to the high concentration of example 1 (abrasive wheel #6) (75 concentration) and does not have the metal grinding segment components of graphite packing to make.
Carry out the grinding more than 70 times at the AlTiC workpiece (210 grades of AlTiC that can buy from Minnesotan 3M company) that is of a size of 4.5 inches (114.3 mm) or 6.0 inches (152.4mm) square, each grinding is that 114.3mm (4.5 inches) is wide, 1.42mm (0.056 inch) is dark, writes down worn blank micron number and normal grinding force.The condition of grinding is:
The grinding test condition:
Lathe: Strasbaugh grinding machine, model 7AF
Grinding method: vertical shaft crush grinding
Abrasive wheel specification: diameter 280mm, thickness 29.3mm, aperture 229mm.
Wheel speed: 1,200rpm
Work speed: 19rpm
Cooling agent: deionized water
The material material removal rate: variation, from the little meter per second of 1.0 little meter per seconds to 5.0
Utilization can be repaired and dressing for 6 inches (152.4mm) dressing pads of 38A240-HVS from the specification that the Norton of Massachusetts Worcester has bought.After initial job, when the feeding plastics change, can periodically repair as required and dressing.
Listed the result's (blank amount of normal force-excision) who the sample in the example 52,4 and 1 is carried out the grinding test among following table 5 and Fig. 3.
Table 5
The worn amount of normal grinding force-blank Abrasive wheelTester tester tester 2a 2a 2b 4 Sample(Ex.1) (Ex.1) (Ex.1) MRRThe total base of 1351222 (μ/second) Normal grinding force 1bs (Kg) ( μ ) 25 6 ( 2.7 ) 8 ( 3.6 ) 11 ( 5.0 ) 11 ( 5.0 ) 50 16 ( 7.3 ) 20 ( 9.1 ) 23 ( 10.4 ) 6 ( 2.7 ) 7 ( 3.2 ) 19 ( 8.6 ) 20 ( 9.1 ) 75 12 ( 5.4 ) 7 ( 3.2 ) 23 ( 10.4 ) 22 ( 10.0 ) 100 24 ( 10.9 ) 34 ( 15.4 ) 40 ( 18.2 ) 17 ( 7.7 ) 7 ( 3.2 ) 27 ( 12.3 ) 28 ( 12.7 ) 150 27 ( 12.3 ) 45 ( 20.4 ) 50 ( 22.7 ) 22 ( 10.0 ) 7 ( 3.2 ) 31 ( 14.1 ) 32 ( 14.5 ) 200 33 ( 15.0 ) 50 ( 22.7 ) 59 ( 26.8 ) 28 ( 12.7 ) 21 ( 9.5 ) 34 ( 15.4 ) 36 ( 16.3 ) 250 37 ( 16.8 ) 53 ( 24.1 ) 60 ( 27.2 ) 31 ( 14.1 ) 30 ( 13.6 ) 38 ( 17.3 ) 38 ( 17.3 ) 300 40 ( 18.7 ) 57 ( 25.9 ) 63 ( 28.6 ) 33 ( 15.0 ) 35 ( 15.9 ) 40 ( 18.2 ) 36 ( 16.3 ) 350 36 ( 16.3 ) 39 ( 17.7 ) 42 ( 19.1 ) 38 ( 17.3 ) 400 39 ( 17.7 ) 41 ( 18.6 ) 40 ( 18.2 ) 33 ( 15.0 ) 450 42 ( 19.1 ) 42 ( 19.1 ) 40 ( 18.2 ) 34 ( 15.4 ) 500 42 ( 19.1 ) 45 ( 20.4 ) 41 ( 18.6 ) 34 ( 15.9 ) 550 43 ( 19.5 ) 46 ( 20.9 ) 43 ( 19.5 ) 35 ( 15.9 ) 600 46 ( 20.9 ) 46 ( 20.9 ) 39 ( 17.7 ) 31 ( 14.1 )
A. 2a is the sample 2 in the table 3, and the edge width of its ground section is 3.13mm.
B. 2b is the sample 2 in the table 3, and the edge width of its ground section is 2.03mm.
These results show: when being that 75 contrast abrasive wheel is when carrying out surfacing by not having graphite packing and diamond abrasive concentration, under the situation of higher MRR (from the MRR of the little meter per second of 1-3 to 5), normal force need be improved the blank of much removing a greater number.And low diamond concentration of the present invention, fill graphite, much smaller according to the abrasive wheel (sample 2a, 2b and 4) of example 3 normal force required in grinding process.Abrasive wheel of the present invention equals to contrast with abrasive wheel sample required power under the MRR of 1 little meter per second situation in the required power of worn equivalent blank under the MRR of the 2 little meter per seconds situation.
In addition, abrasive wheel sample 2a required normal force under the MRR situation of 1 little meter per second or 2 little meter per seconds almost equates.Along with from 200 to 600 microns of the grindings of blank, as the abrasive wheel 2a of the present invention of example 5, the demand that 2b and 4 also demonstrates metastable power.This grinding performance is very favorable when back of the body mill AlTiC, and this is can make heat and mechanical damage to workpiece become minimum because of these less power, stable operating mode.
Contrast can not be tested with higher blank material removal rate (for example about 300 microns) with abrasive wheel (Ex.1); this is because utilize these abrasive wheels to carry out the normal force that can apply that the required power of grinding has surpassed grinding machine; thereby grinding machine can automatically shut down, and can not be recorded in the data under the higher blank material removal rate situation again.
Though do not wish to be fettered by a certain each specific theory, but can believe, abrasive wheel according to this low diamond concentration of the present invention, graphite filling has excellent grinding performance, promptly, on any one time point of grinding process, the abrasive particle quantity that with surface of the work contacts of ground section on unit are is fewer.Though those skilled in the art that can expect to take lower MRR under the lower situation of diamond concentration, the improvement (need not to consider trading off to MRR) aspect grinding force of the present invention is unexpected.With the ground section width is that the abrasive wheel 2a of 3.13mm compares, and the ground section width is that the abrasive wheel 2b of 2.03mm required force rate under the situation of phase same rate and blank material removal rate is less.2a compares with the abrasive wheel sample, and the surface area that contacts with surface of the work on abrasive wheel sample 2b any one time point in process of lapping is all smaller, i.e. the point of grinding is fewer.

Claims (9)

1. surfacing milling tool comprises the grinding edge that a core wheel and with circular circumference part is limited by a plurality of ground section, and the minimum specific strength parameter of described core wheel is 2.4MPa-cm 3/ g, density is 0.5-8.0g/cm 3If each ground section cumulative volume is 100 volume %, comprising the superfinishing particle that 0.05-10 volume % is arranged, the fragility filler of 10-35 volume %, the metal bonding material matrix of 55-89.95 volume %, the fracture toughness of this matrix is 1.0-3.0MPa M 1/2
2. milling tool as claimed in claim 1 is characterized in that described core wheel comprises metal material, and this metal material is selected from by aluminium, steel, titanium and bronze, their compound, alloy and the group that combination constituted.
3. milling tool as claimed in claim 1, it is characterized in that, described ground section comprises the metal bonding material matrix of 60-84.5 volume %, the abrasive grains of 0.5-5 volume % and the fragility filler of 15-35 volume %, and described metal bonding material matrix comprises the porosity that is 5 volume % to the maximum.
4. milling tool as claimed in claim 1 is characterized in that, described fragility filler is selected from by graphite, hexagonal boron nitride, hollow ceramic ball, feldspar, nepheline syenite, float stone, calcined clay and glass marble, and their group that combination constituted.
5. milling tool as claimed in claim 1 is characterized in that, described abrasive grains is selected from by diamond, cubic boron nitride and their group that combination constituted.
6. milling tool as claimed in claim 5 is characterized in that, described abrasive grains is that granularity is the diamond of 2-300 micron.
7. milling tool as claimed in claim 1, it is characterized in that, described milling tool comprises at least two ground section, that each ground section has is elongated, the shape of arc and the incurvature that matches with the circular circumference of described core wheel, each ground section all has two and is designed to the end that matches with adjacent ground section, thereby each ground section is when being bonded in described core wheel, and described grinding edge is continuous, and is very close to each other basically.
8. milling tool as claimed in claim 1, it is characterized in that described instrument is selected from by such two kinds of groups that abrasive wheel constituted, promptly, the abrasive wheel that comprises the continuous wheel rim of forming by a plurality of ground section that are adhered to a metal core wheel periphery, and cup-shaped abrasive wheel.
9. milling tool as claimed in claim 1 is characterized in that, described heat-staple bonding material is selected from by the adhesive of epoxy resin, metallurgical bond material, mechanical cohesive bond material and disperse bonding material and their group that combination constituted.
CN99804385A 1998-03-27 1999-02-04 Abrasive tools Expired - Fee Related CN1130274C (en)

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US09/049,623 US6102789A (en) 1998-03-27 1998-03-27 Abrasive tools
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