CN113277837A - Preparation method of high-performance black corundum abrasive - Google Patents
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Abstract
The invention discloses a preparation method of a high-performance black corundum abrasive, which comprises the following steps: (1) the raw materials are proportioned, 43-51 parts of high-alumina bauxite, 48-56 parts of high-iron bauxite and 1-2 parts of magnesium oxide are selected as raw materials, the selected raw materials are respectively crushed, and then the raw materials are mixed by an automatic proportioning system, so that the mixed raw materials meet the proportioning; (2) performing electric smelting, namely adding the raw materials mixed in the step (1) into an electric arc furnace for electric smelting to prepare liquid black corundum, and then cooling to obtain a blocky black corundum semi-finished product; (3) and (3) crushing, impurity removing, cleaning and sorting the block-shaped black corundum semi-finished product subjected to electric melting in the step (2) by using a jaw crusher and a ball mill to obtain a black corundum abrasive finished product. The invention solves the technical problem of increasing the performance of the common-grade black corundum abrasive within limited cost, breaks through the traditional technical idea in the field, and greatly improves the internal performance of the common-grade black corundum product.
Description
Technical Field
The invention relates to the technical field of black corundum production, and particularly relates to a preparation method of a high-performance black corundum abrasive.
Background
The black corundum is a gray black crystal obtained by smelting bauxite as a raw material in an electric arc furnace. The black corundum abrasive has the advantages of strong cutting force, high toughness, good hardness and softness, good wear resistance and the like, is mainly used for sand blasting of stainless steel, metal products, optical glass and bamboo and wood products, and is also a novel abrasive for manufacturing resin grinding wheels, cutting sheets and abrasive cloth.
The grade and the performance of the current black corundum abrasive are as follows: the common grade (such as ZZ65 type) is a main product in the market, and has large demand, wide application range and lower production cost; fine grades (e.g. TS series) have high performance and are commonly used in some special fields, but their production costs are also very high.
The alumina crystal in the black corundum abrasive mainly plays a grinding role, the content of the alumina in the common-grade black corundum abrasive is about 62%, the silicon oxide mainly plays a bonding role, and the content of the silicon oxide in the common-grade black corundum abrasive is about 20%; when the sharp edges and corners of an alumina crystal are ground off, the alumina crystal falls off to expose a new alumina crystal at the inner layer, the new alumina crystal continues to play a grinding role, and the property of the black corundum is called self-sharpening. The alumina content in the black corundum product determines the hardness and the wear resistance of the abrasive; the content of silicon oxide and the phase composition of the crystalline part of the silicon oxide determine the toughness (crushing resistance) of the abrasive, and the toughness of a common grade black corundum abrasive product is generally about 17 percent.
In some fields, the use of the black corundum abrasive requires higher toughness, but the production cost cannot bear the fine-grade black corundum product, and only the common-grade black corundum product can be adopted, so that the technical problem that how to improve the performance of the common-grade black corundum abrasive product and the production cost of the black corundum product cannot be greatly improved is difficult to overcome in the field.
The chemical composition of the black corundum is mainly Al2O3、Fe2O3、SiO2、TiO2(ii) a The main mineral phase comprises about 63% of alpha-aluminum oxide, about 18% of glass phase and about 3% of ilmenite; the microstructure is alpha-Al with the size of 10-100 mu m playing the main grinding and polishing function2O3The particles are filled with a glass phase, and ilmenite is contained in the middle of the glass phase; alpha-Al in the process of polishing and grinding workpieces by using black corundum as abrasive2O3With time of contact of particles with the workIncrease, increase of friction, alpha-Al2O3The particles will fall off from the glass phase with lower strength, alpha-Al2O3The particles fall off to take away the heat on the surface of the workpiece, and a new tough opening appears, so that the workpiece has high self-sharpening performance; the internal mechanism that the workpiece is not easy to burn when the black corundum abrasive is used for polishing and grinding the workpiece and the self-sharpening property is good is realized; alpha-Al2O3The particle determines the hardness of the abrasive, and the overall strength of the glass phase containing ilmenite determines the toughness, i.e., durability, of the black corundum abrasive; the inherent mechanism that the black corundum is not easy to burn workpieces and has good self-sharpening property can know that if the strength of the whole glass phase is too low, the durability of the black corundum abrasive is greatly reduced; according to the invention, through proper raw material selection and proportion, the raw materials and the components in the original black corundum form a new phase, and the new phase and the original ilmenite phase are both present in the middle of the glass phase, so that the strength of the new integral glass phase is improved to a proper degree, the advantages of no burn of the workpiece by the black corundum and good self-sharpening performance are both maintained, and the durability of the black corundum is improved.
Disclosure of Invention
The invention aims to provide a preparation method of a high-performance black corundum abrasive, which can improve the performance of a common-grade black corundum product within limited production cost and solve the technical problem in the field.
In order to solve the technical problems, the invention adopts the following technical scheme:
the preparation method of the high-performance black corundum abrasive is designed, and comprises the following steps:
(1) raw material ratio
Selecting the following raw materials in parts by weight: 48-51 parts of high-iron bauxite, 48-51 parts of high-iron bauxite and 1-2 parts of magnesium oxide, wherein the content of aluminum oxide in the high-iron bauxite is 63% -69%, the content of silicon oxide is less than 25%, the content of aluminum oxide in the high-iron bauxite is 55% -61%, the content of iron oxide is 20.0% -30.0%, and the purity of the magnesium oxide is more than 93.0%;
respectively crushing the selected raw materials, and then mixing the raw materials by an automatic proportioning system to make the mixed raw materials accord with the proportion;
(2) electric melting
Adding the raw materials mixed in the step (1) into an electric arc furnace for electric smelting to prepare liquid black corundum; pouring the liquid black corundum into a special container, after the solution is cooled in the special container at normal temperature for 12 hours, when the solution reaches a solidification state, overturning the solidified black corundum out of the container, and then pouring by using spray water until the temperature is reduced to normal temperature to obtain a blocky black corundum semi-finished product;
(3) finished product
And (3) crushing, impurity removing, cleaning and sorting the fused massive black corundum semi-finished product in the step (2) by using a jaw crusher and a ball mill to obtain black corundum granularity sand products with different specifications, and obtaining a black corundum abrasive finished product after the physical and chemical indexes are qualified.
Preferably, the black corundum semi-finished product prepared in the step (2) contains 61-68% of aluminum oxide, 9.0-14.0% of ferric oxide, 15.0-25.0% of silicon oxide and 0.5-1.0% of magnesium oxide.
The invention has the beneficial effects that:
the invention has strengthened the bonding strength of the abrasive material, has increased the binding capacity of the crystalline part of the silicon oxide, has improved the toughness of the ordinary grade abrasive material, adopt the scheme of the invention, can promote the toughness of the black corundum abrasive material of the ordinary grade to 23% -24% from about 17% (improve 37% than the toughness of the existing black corundum abrasive material of the same grade), even 1 ton of black corundum that produces using the invention is equivalent to not using the black corundum more than 1.35 tons of produced of the invention, and can guarantee the new product uses the performance advantage of this product effect except durability unchanged; meanwhile, compared with the existing black corundum abrasive material with the same grade, the production cost is only increased by about 1 percent. Solves the technical problem of increasing the performance of the common-grade black corundum abrasive within limited cost.
The invention breaks through the traditional concept of improving the internal performance of the black corundum product: the original methods for improving the durability of the black corundum product mainly comprise two methods, firstly, a high-quality raw material with higher alumina content is selected, so that the full utilization of mineral deposits is not facilitated, the raw material cost is greatly increased, and the production cost of the product is greatly increased; secondly, raw materials with low alumina content are still used, a part of reducing agent is added by changing the electric melting process, and the alumina content in the product is improved by increasing the reducing atmosphere in the electric melting process, but the cost of the raw materials is increased by adding the reducing agent in the method, and the electric energy consumption is greatly increased by the reducing atmosphere, so that the cost is greatly increased; the product durability is improved after the product performance is improved by the traditional concept, but the performance price ratio advantage of the black corundum product is reduced. The invention creatively solves the technical problem in the field, breaks through the traditional technical idea in the field and greatly improves the internal performance of the common-grade black corundum product.
Detailed Description
The following examples are given to illustrate specific embodiments of the present invention, but are not intended to limit the scope of the present invention in any way. The apparatus elements referred to in the following examples are, unless otherwise specified, conventional apparatus elements; the industrial raw materials are all conventional industrial raw materials which are sold on the market, if not specifically mentioned.
Example 1: a preparation method of a high-performance black corundum abrasive comprises the following steps:
(1) raw material ratio
Selecting the following raw materials in parts by weight: 48-51 parts of high-iron bauxite, 48-51 parts of high-iron bauxite and 1-2 parts of magnesium oxide, wherein the content of aluminum oxide in the high-iron bauxite is 63% -69%, the content of silicon oxide is less than 25%, the content of aluminum oxide in the high-iron bauxite is 55% -61%, the content of iron oxide is 20.0% -30.0%, and the purity of the magnesium oxide is more than 93.0%;
respectively crushing the selected raw materials, and then mixing the raw materials by an automatic proportioning system to make the mixed raw materials accord with the proportion;
(2) electric melting
Adding the raw materials mixed in the step (1) into an electric arc furnace for electric smelting to prepare liquid black corundum; pouring the liquid black corundum into a special container, after the solution is cooled in the special container at normal temperature for 12 hours, when the solution reaches a solidification state, overturning the solidified black corundum out of the container, and then pouring by using spray water until the temperature is reduced to normal temperature to obtain a blocky black corundum semi-finished product;
(3) finished product
And (3) crushing, impurity removing, cleaning and sorting the fused massive black corundum semi-finished product in the step (2) by using a jaw crusher and a ball mill to obtain black corundum granularity sand products with different specifications, and obtaining a black corundum abrasive finished product after the physical and chemical indexes are qualified.
Wherein, the black corundum semi-finished product prepared in the step (2) contains 61-68% of alumina, 9.0-14.0% of ferric oxide, 15.0-25.0% of silicon oxide and 0.5-1.0% of magnesium oxide.
Example 2: a preparation method of a high-performance black corundum abrasive comprises the following steps:
(1) raw material ratio
Selecting the following raw materials in parts by weight: 43-47 parts of high-iron bauxite, 52-56 parts of high-iron bauxite and 1-2 parts of magnesium oxide, wherein the content of aluminum oxide in the high-iron bauxite is 65-72%, the content of silicon oxide is less than 25%, the content of aluminum oxide in the high-iron bauxite is 55-61%, the content of iron oxide is 15.0-25.0%, and the purity of the magnesium oxide is more than 93.0%;
respectively crushing the selected raw materials, and then mixing the raw materials by an automatic proportioning system to make the mixed raw materials accord with the proportion;
(2) electric melting
Adding the raw materials mixed in the step (1) into an electric arc furnace for electric smelting to prepare liquid black corundum; pouring the liquid black corundum into a special container, after the solution is cooled in the special container at normal temperature for 12 hours, when the solution reaches a solidification state, overturning the solidified black corundum out of the container, and then pouring by using spray water until the temperature is reduced to normal temperature to obtain a blocky black corundum semi-finished product;
(3) finished product
And (3) crushing, impurity removing, cleaning and sorting the fused massive black corundum semi-finished product in the step (2) by using a jaw crusher and a ball mill to obtain black corundum granularity sand products with different specifications, and obtaining a black corundum abrasive finished product after the physical and chemical indexes are qualified.
Wherein, the black corundum semi-finished product prepared in the step (2) contains 61-68% of alumina, 9.0-14.0% of ferric oxide, 15.0-25.0% of silicon oxide and 0.5-1.0% of magnesium oxide.
The chemical composition of the black corundum is mainly Al2O3、Fe2O3、SiO2、TiO2(ii) a The main mineral phase comprises about 63% of alpha-aluminum oxide, about 18% of glass phase and about 3% of ilmenite; the microstructure is alpha-Al with the size of 10-100 mu m playing the main grinding and polishing function2O3The particles are filled with a glass phase, and ilmenite is contained in the middle of the glass phase; alpha-Al in the process of polishing and grinding workpieces by using black corundum as abrasive2O3The friction of the particles increases with the contact time with the workpiece, alpha-Al2O3The particles will fall off from the glass phase with lower strength, alpha-Al2O3The particles fall off to take away the heat on the surface of the workpiece, and a new tough opening appears, so that the workpiece has high self-sharpening performance; the internal mechanism that the workpiece is not easy to burn when the black corundum abrasive is used for polishing and grinding the workpiece and the self-sharpening property is good is realized; alpha-Al2O3The particle determines the hardness of the abrasive, and the overall strength of the glass phase containing ilmenite determines the toughness, i.e., durability, of the black corundum abrasive; the inherent mechanism that the black corundum is not easy to burn workpieces and has good self-sharpening property can know that if the strength of the whole glass phase is too low, the durability of the black corundum abrasive is greatly reduced; according to the invention, by adding a proper amount of magnesium oxide, the magnesium oxide and the components in the original black corundum form a new phase, and the new phase and the original ilmenite phase are both present in the middle of the glass phase, so that the strength of the new integral glass phase is improved to a proper degree, the advantages of no burn of the workpiece by the black corundum and good self-sharpening performance are both maintained, and the durability of the black corundum is improved.
The black corundum product prepared by the method has the following mineral phases: about 62 percent of corundum phase (alpha-aluminum oxide), about 20 percent of glass phase, about 13 percent of hercynite phase and about 5 percent of other minerals, and the crystal size of the corundum phase is 10-100 microns. Because the hardness of the glass phase is far lower than that of the corundum phase, when the corundum phase is used as an abrasive, the corundum phase plays a main grinding role, the corundum phase crystals are filled with weaker glass phase, and along with the increase of the grinding time of the corundum phase and the increase of the friction force, the corundum phase crystals can fall off from the adjacent weaker glass phase positions to take away the grinding heat, so that a new cutting edge is formed, and the excellent performances of good self-sharpening property of black corundum and difficulty in burning workpieces are shown.
The mineral phases of the complex phase corundum product in the prior art are as follows: 72-82% of corundum phase, 15-25% of magnesium spinel, 1-5% of other minerals, and the hardness of the corundum and magnesium spinel in the complex phase corundum-mineral phase is relatively close to that of the magnesium spinel, and when the composite corundum-mineral phase is used as an abrasive, the two minerals simultaneously play a main grinding role.
Therefore, compared with the complex phase corundum in the prior art, the black corundum product prepared by the invention has larger phase difference, so that the grinding mechanism of the black corundum product and the complex phase corundum is very different, and the grinding effect is also very different. In addition, the production mode in the preparation method is melting, the prepared product is corundum, glass and hercynite composite mineral phase, and the performance of the product is better.
Performance detection test:
during batching, the high bauxite and the high iron bauxite are subjected to chemical component detection, batching is carried out according to the proportion that the alumina content is 61% +/-2% and the ferric oxide content is 13% +/-2% after mixing, 1%, 1.5% and 2.0% by weight of magnesium oxide are uniformly added into the mixture respectively, the electric melting process is kept unchanged, tests are carried out for three times, and the detected toughness values of samples prepared by the tests for three times are respectively as follows: 19.63%, 23.38%, 23.18%; experiments show that the effect is better when 1.5 percent of magnesium oxide is added. The toughness of the test sample reaches 23.38%, and the toughness is increased by 37.05% compared with the toughness detection value fluctuation of the product being produced from 2017 to 2020, and the average value is 17.06%.
Compared with the existing products of the same grade, the toughness value of the black corundum abrasive prepared by the invention is increased by 37.05%, which means that the durability of a new product is improved by 37.05%, and the black corundum abrasive has high economic and environmental protection values.
While the present invention has been described in detail with reference to the embodiments, those skilled in the art will appreciate that various changes can be made in the specific parameters of the embodiments without departing from the spirit of the present invention, and that various specific embodiments can be made, which are common variations of the present invention and will not be described in detail herein.
Claims (4)
1. The preparation method of the high-performance black corundum abrasive is characterized by comprising the following steps:
(1) raw material ratio
Selecting the following raw materials in parts by weight: 43-51 parts of high-iron bauxite, 48-56 parts of high-iron bauxite and 1-2 parts of magnesium oxide, wherein the content of aluminum oxide in the high-iron bauxite is 63% -72%, the content of silicon oxide is less than 25%, the content of aluminum oxide in the high-iron bauxite is 55% -61%, the content of iron oxide is 15.0% -30.0%, and the purity of the magnesium oxide is more than 93.0%;
respectively crushing the selected raw materials, and then mixing the raw materials by an automatic proportioning system to make the mixed raw materials accord with the proportion;
(2) electric melting
Adding the raw materials mixed in the step (1) into an electric arc furnace for electric smelting to prepare liquid black corundum; pouring the liquid black corundum into a special container, after the solution is cooled in the special container at normal temperature for 12 hours, when the solution reaches a solidification state, overturning the solidified black corundum out of the container, and then pouring by using spray water until the temperature is reduced to normal temperature to obtain a blocky black corundum semi-finished product;
(3) finished product
And (3) crushing, impurity removing, cleaning and sorting the fused massive black corundum semi-finished product in the step (2) by using a jaw crusher and a ball mill to obtain black corundum granularity sand products with different specifications, and obtaining a black corundum abrasive finished product after the physical and chemical indexes are qualified.
2. The method for preparing the high-performance black corundum abrasive according to claim 1, characterized in that the black corundum semi-finished product prepared in the step (2) contains 61-68% of alumina, 9.0-14.0% of ferric oxide, 15.0-25.0% of silicon oxide and 0.5-1.0% of magnesium oxide.
3. The preparation method of the high-performance black corundum abrasive according to claim 1, characterized in that the raw materials are selected in the step (1) according to the following parts by weight: 48-51 parts of high-iron bauxite, 48-51 parts of high-iron bauxite and 1-2 parts of magnesium oxide, wherein the content of aluminum oxide in the high-iron bauxite is 63% -69%, the content of silicon oxide is less than 25%, the content of aluminum oxide in the high-iron bauxite is 55% -61%, the content of iron oxide is 20.0% -30.0%, and the purity of the magnesium oxide is more than 93.0%.
4. The preparation method of the high-performance black corundum abrasive according to claim 1, characterized in that the raw materials are selected in the step (1) according to the following parts by weight: 43-47 parts of high-iron bauxite, 52-56 parts of high-iron bauxite and 1-2 parts of magnesium oxide, wherein the content of aluminum oxide in the high-iron bauxite is 65-72%, the content of silicon oxide is less than 25%, the content of aluminum oxide in the high-iron bauxite is 55-61%, the content of iron oxide is 15.0-25.0%, and the purity of the magnesium oxide is more than 93.0%.
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| CN115304374A (en) * | 2022-09-01 | 2022-11-08 | 郑州振中电熔新材料有限公司 | Electric melting ceramic sand and preparation method thereof |
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| CN115304374B (en) * | 2022-09-01 | 2024-01-23 | 郑州振中电熔新材料有限公司 | Electrofusion ceramic sand and preparation method thereof |
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