CN113649957A - Steel rail cutting grinding wheel and preparation method thereof - Google Patents
Steel rail cutting grinding wheel and preparation method thereof Download PDFInfo
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- 238000000227 grinding Methods 0.000 title claims abstract description 179
- 238000005520 cutting process Methods 0.000 title claims abstract description 63
- 229910000831 Steel Inorganic materials 0.000 title claims description 48
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- 238000002360 preparation method Methods 0.000 title abstract description 14
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- 238000001816 cooling Methods 0.000 claims abstract description 37
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- 238000000034 method Methods 0.000 claims abstract description 30
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- 229910052700 potassium Inorganic materials 0.000 claims description 15
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/20—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
- B24D3/285—Reaction products obtained from aldehydes or ketones
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
- B24D18/0009—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
-
- 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
- B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
- B24D3/342—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties incorporated in the bonding agent
- B24D3/344—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties incorporated in the bonding agent the bonding agent being organic
-
- 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
- B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
- B24D3/346—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties utilised during polishing, or grinding operation
-
- 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
- B24D5/12—Cut-off wheels
Abstract
The invention provides a rail cutting grinding wheel and a preparation method thereof, and relates to the technical field of grinding wheels, wherein the grinding wheel mainly adopts a pretreated alumina nano ceramic material, and is matched with grinding materials such as brown corundum, silicon carbide, monocrystalline corundum, white corundum, blue corundum and the like as grinding basic particles, phenolic resin liquid, phenolic resin powder and auxiliary filling materials are used for firmly bonding the grinding material particles, the grinding material particles are reinforced by a glass fiber net and are processed under special process conditions, and the surface of the grinding wheel is subjected to coating treatment after solidification, so that a layer of special cooling material is obtained on the surface of the grinding wheel, and the rail cutting grinding wheel with high strength, good sharpness and no burn injury is obtained; meanwhile, due to the inherent characteristics of the alumina nano material, the nano particles are not easy to break and fall off in the grinding process, and the service life of the grinding wheel is prolonged.
Description
Technical Field
The invention relates to the technical field of grinding wheels, in particular to a steel rail cutting grinding wheel with a surface coating and a preparation method thereof.
Background
Based on the requirements of the development and market of the existing railways in China, a large number of steel rail cutting grinding wheels are needed for the construction, the maintenance and the repair of the railways, and the demand of the grinding wheels is increasing day by day. However, the steel rail cutting grinding wheel which is circulated and used in the market at present has the problems of non-sharp cutting, burnt cutting surfaces, uneven cuts, poor durability, dust splashing in the cutting process and the like, and the working efficiency and the working environment are seriously influenced. Therefore, the rail cutting grinding wheel which can realize sharp cutting, does not cause burning of a cutting surface, has flat cut and good durability is developed.
Disclosure of Invention
Technical problem to be solved
Aiming at the defects of the prior art, the invention provides the steel rail cutting grinding wheel and the preparation method thereof, and the grinding wheel prepared by the invention can completely achieve the technical effects of sharpness, no damage to the steel rail, flat cut and good durability when cutting the steel rail.
(II) technical scheme
In order to achieve the purpose, the invention is realized by the following technical scheme:
in one aspect, the invention provides a steel rail cutting grinding wheel, which is made of the following raw materials: the cooling material comprises grinding materials, phenolic resin liquid, phenolic resin powder, a cooling material, an auxiliary filling material, a surface coating cooling material, a coloring agent and a glass fiber net; wherein the phenolic resin liquid accounts for 5-9% of the mass fraction of the grinding material, the phenolic resin powder accounts for 9-16% of the mass fraction of the grinding material, the cooling material accounts for 5-12% of the mass fraction of the grinding material, the auxiliary filling material accounts for 4-16% of the mass fraction of the grinding material, the surface coating adhesive accounts for 0.2-3.5% of the mass fraction of the grinding material, the surface coating cooling material accounts for 0.4-6% of the mass fraction of the grinding material, the colorant accounts for 0-0.5% of the mass fraction of the grinding material, and the glass fiber net accounts for 2-3 pieces.
Further, as the optimization of the steel rail cutting grinding wheel, each 100 parts of the grinding material is composed of the following raw materials in parts by weight: 5-45 parts of pretreated alumina nano ceramic abrasive, 25-55 parts of brown corundum, 0-25 parts of silicon carbide, 0-30 parts of monocrystalline corundum, 0-25 parts of white corundum and 0-30 parts of blue fused alumina.
Further, as the optimization of the steel rail cutting grinding wheel, the grain diameters of the components of the grinding material are respectively as follows: the pretreated alumina nano ceramic abrasive material 425-.
Further, as the optimization of the steel rail cutting grinding wheel, the cooling material is one or two of high molecular ratio sodium fluoroaluminate and potassium fluoroaluminate powder with the grain diameter of 38-48 mu m; one or more of iron sulfide, potassium sulfate, barite and gypsum powder are filled in the auxiliary filling position; the surface coating adhesive is phenolic resin liquid with the viscosity range of 300-1000 cps; the surface coating cooling material is one or more of potassium fluoborate, potassium fluoaluminate and sodium hexafluoroaluminate powder with the grain diameter of 18-25 mu m; the colorant is a dye or a pigment.
On the other hand, the invention also provides a preparation method of the steel rail cutting grinding wheel, and the grinding wheel is prepared according to the following steps:
(1) pre-mixing the abrasive: every 100 parts of abrasive material is weighed according to the following parts by weight: 5-45 parts of pretreated alumina nano ceramic abrasive, 25-55 parts of brown corundum, 0-25 parts of silicon carbide, 0-30 parts of monocrystalline corundum, 0-25 parts of white corundum and 0-30 parts of blue fused alumina; fully and uniformly mixing the raw materials, adding phenolic resin liquid accounting for 5-9% of the mass fraction of the grinding materials, and mixing and stirring for 10-15 minutes to obtain a mixture 1;
(2) premixing powder materials: weighing 5-12% of cooling material, 4-16% of auxiliary filler and 9-16% of phenolic resin powder, mixing and stirring for 1-5 minutes to obtain a mixture 2;
(3) integral mixing: adding the mixture 1 obtained in the step (1) into the mixture 2 obtained in the step (2), fully mixing and stirring for 10-15 minutes, and sieving by using an 8-mesh sieve to obtain a mixture 3;
(4) soaking and placing: soaking the mixture 3 and standing for 12-24 hours;
(5) hot-press molding: pressing the soaked mixture 3 into a grinding wheel blank by using a hot-press forming grinding tool;
(6) and (3) pressurizing and curing: and (3) pressurizing and curing the prepared grinding wheel blank, wherein the curing temperature is set as follows: the temperature is increased from room temperature to the maximum temperature of 185 ℃ at the rate of 10 ℃/h, wherein the holding temperature and holding time are as follows: keeping the temperature at 80 ℃, 125 ℃ and 140 ℃ for 90 minutes at each temperature, keeping the temperature at the maximum temperature of 185 ℃ for 420 minutes, then naturally cooling after the heat preservation at the maximum temperature is finished, and discharging the product at the temperature lower than 60 ℃;
(7) coating on the surface: weighing 0.2-3.5% of surface coating adhesive, 0.4-6% of surface coating cooling material and 0-0.5% of coloring agent, fully mixing to prepare slurry, and then preparing for later use, wherein the grinding wheel blank is taken out of a furnace and subjected to surface coating by using the slurry in one of a roller coating mode, a blade coating mode or a spraying mode;
(8) and (3) drying: after the surface coating is manufactured, putting the grinding wheel with the dry surface into a curing oven for drying, wherein the drying temperature is set as: and (3) preserving heat for 3 hours at the temperature of 60 ℃, preserving heat for 3 hours at the temperature of 90 ℃, preserving heat for 2 hours at the temperature of 110 ℃, preserving heat for 3 hours at the temperature of 130 ℃, preserving heat for 3 hours at the temperature of 160 ℃, then naturally cooling after the heat preservation at the highest temperature is finished, and discharging the steel rail cutting grinding wheel at the temperature lower than 60 ℃ to obtain the steel rail cutting grinding wheel.
Further, as an optimization of the preparation method of the steel rail cutting grinding wheel, the specific preparation method of the grinding wheel blank in the step (5) is as follows: two glass fiber webs were used for the production process: placing a glass fiber net, baking the net, pressing the net, putting the soaked mixture 3, placing another glass fiber net, and pressing by using a hot-press forming die; three glass fiber webs were used for the production process: placing a glass fiber net, baking the net, pressing the net, putting the soaked mixture 3, then placing a glass fiber net, baking the net, pressing the net, putting the soaked mixture 3, placing the last glass fiber net, and pressing by using a hot-press forming die; the requirements of the glass fiber net are not lower than the requirements of the net cloth specified by 6 x 6-230/1400 in the mechanical industry standard JB/T11432 of the people's republic of China.
Further, as an optimization of the preparation method of the steel rail cutting grinding wheel, the hot-press forming die in the step (5) adopts an upper elastic pressing plate and a lower elastic pressing plate, and the pressure per unit area is not less than 1700 pa.
Further, as an optimization of the preparation method of the steel rail cutting grinding wheel, the specific operation method of the roller coating in the step (7) is as follows: adjusting the viscosity of the slurry within the range of 10000-30000cps, and then using a conical roller glue spreader with the surface Shore hardness of 30-36 degrees to roll the slurry on the outer side surface of a grinding wheel used for cutting.
Further, as an optimization of the preparation method of the steel rail cutting grinding wheel, the knife coating operation method in the step (7) comprises the following specific steps: adjusting the viscosity of the slurry within the range of 5000-.
Further, as an optimization of the preparation method of the steel rail cutting grinding wheel, the specific operation method of spraying in the step (7) is as follows: the viscosity of the slurry is adjusted to be in the range of 1100-5000cps, and then the slurry is sprayed to the outer side surface of the grinding wheel by a spray gun under the pressure of 0.3-0.65MPa when cutting.
Further, as an optimization of the preparation method of the steel rail cutting grinding wheel, the dry material amount of the coating slurry in the step (7) is controlled to be 0.5-4g/dm2。
(III) advantageous effects
The invention provides a steel rail cutting grinding wheel and a preparation method thereof. The grinding wheel mainly adopts a pretreated alumina nano ceramic material, abrasive materials such as brown corundum, silicon carbide, monocrystalline corundum, white corundum, blue fire corundum and the like are used as grinding basic particles, the abrasive material particles are firmly bonded by phenolic resin liquid, phenolic resin powder and auxiliary filling materials, the glass fiber mesh is used for reinforcing, the processing is carried out under special process conditions, and the surface of the grinding wheel is subjected to coating treatment after solidification, so that a layer of special cooling material is obtained on the surface of the grinding wheel, and the steel rail cutting grinding wheel with high strength, good sharpness and no burning injury is obtained; meanwhile, due to the inherent characteristics of the alumina nano material, nano-scale particles are not easy to break and fall off in the grinding process, and the service life of the grinding wheel is prolonged.
Drawings
FIG. 1: schematic side structure of grinding wheel
101: grinding wheel, 102: glass fiber web, 103: coating;
FIG. 2 schematic view of a conical applicator
201: a grinding wheel body; 202: rubber sheets; 203: a rotation shaft; 204 rotating shaft transition plates; 205: the steel body is rotated in a conical shape.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are some embodiments of the present invention, but not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Examples all produced 400 x 4 x 32 rail grinding wheel
Example 1
A steel rail cutting grinding wheel is prepared according to the following steps:
(1) wetting by using mixed abrasive: each 100 parts of abrasive material by weight comprises the following raw materials by weight: the pretreated alumina nano ceramic abrasive material comprises the following steps: 30 parts of (1); 30 parts of brown corundum, 20 parts of silicon carbide, 10 parts of white corundum and 10 parts of blue fused alumina; putting the mixture into a mixer, fully mixing the prepared grinding materials for 3 minutes, then adding phenolic resin liquid accounting for 7 percent of the weight of the grinding materials, and mixing for 12 minutes to obtain a mixture 1;
wherein the grain size range of each component of the grinding material is as follows: the pretreated alumina nano ceramic abrasive material comprises the following steps: 550-700 μm; brown corundum: 550-830 μm; silicon carbide: 550-700 μm; white corundum: 700 to 830 μm; blue fire corundum: 425 to 700 μm;
(2) mixing powder, namely mixing a cooling material accounting for 8 percent of the weight of the grinding material: high molecular weight sodium fluoroaluminate, and an auxiliary filler accounting for 12 percent of the grinding material by mass percent: mixing iron sulfide, potassium sulfate, barite and gypsum powder, wherein phenolic resin powder accounting for 12% of the weight of the grinding materials is mixed for 3 minutes to obtain a mixture 2;
wherein the particle size range of the high molecular sodium fluoroaluminate is 38-48 mu m; the particle size range of the iron sulfide is 250-425 mu m; the grain size range of the potassium sulfate is 48-62 mu m; the particle size range of barite and gypsum is 38-48 μm;
(3) integral mixing: adding the mixture 1 into the mixture 2, and mixing for 12 minutes to obtain a mixture 3; the purpose is to fully mix the moistened grinding material and the powder;
(4) soaking and placing: the mixture 3 is soaked and placed for 14 hours after passing through an 8-mesh screen; the mixed materials are used for realizing the purpose of material waking, and the function is to be fused and fully infiltrated;
(5) hot-press molding: after the infiltration and the placement, pressing a grinding wheel blank, wherein the process is as follows:
flow when 2 glass fiber nets: placing a glass fiber net, baking the net, pressing the net, putting the soaked mixture 3, placing another glass fiber net, and pressing by using a hot-press forming die to obtain a grinding wheel blank; the hot-press forming die adopts an upper elastic pressing plate and a lower elastic pressing plate, and the unit area pressure is 17 Mpa; the amount of mixture 3 charged was 1050 g.
(6) And (3) pressurizing and curing: in order to maintain the flatness of the grinding wheel; and (3) pressurizing and curing the prepared grinding wheel blank, wherein the curing temperature is set as follows: the temperature is increased from room temperature to the maximum temperature of 185 ℃ at the rate of 10 ℃/h, wherein the holding temperature and holding time are as follows: keeping the temperature at 80 ℃, 125 ℃ and 140 ℃ for 90 minutes at each temperature, keeping the temperature at the maximum temperature of 185 ℃ for 420 minutes, then naturally cooling after the heat preservation at the maximum temperature is finished, and discharging the product at the temperature lower than 60 ℃;
(7) after the cured product is discharged from the furnace, the surface coating is prepared by the following method:
roller coating; weighing the following raw materials in parts by weight: 100 parts of potassium fluoborate, 20 parts of phenolic resin liquid and 0.25 part of red dye, and the components are uniformly mixed and adjusted to slurry with the viscosity of 28000cps by water; then, roller coating is carried out on the outer surface of the grinding wheel by using a Shore 32 degree conical roller; the diameter range of the roller coating grinding wheel is 230-400 mm; wherein the total sizing amount of the two sides of the grinding wheel is 27.83g
(8) And (3) drying: after the surface coating is manufactured, the grinding wheel with the dry surface is put into a curing oven for drying, the temperature is preserved for 3 hours at 60 ℃, 3 hours at 90 ℃, 2 hours at 110 ℃, 3 hours at 130 ℃ and 3 hours at 160 ℃, and the temperature rise rate in the process is 4 DEG/min; stopping the furnace, cooling to 60 ℃, and discharging; thus obtaining the steel rail cutting grinding wheel.
The grinding wheel structure prepared in example 1 is shown in fig. 1-2, a grinding wheel 101 is made of an abrasive, a phenolic resin liquid, phenolic resin powder, a cooling material, an auxiliary filler, a surface coating cooling material, a colorant and a glass fiber net, the middle of the grinding wheel 101 is provided with the glass fiber net 102, and the outer side of the grinding wheel 101 is coated with a coating 103; when the grinding wheel is coated with the coating 103, a special device is adopted for uniformly coating, the device comprises a rubber sheet 202, an automatic rotating shaft 203, a rotating shaft transition plate 204 and a conical rotating rigid body, the automatic rotating shaft 203 is rotatably connected with the rotating shaft transition plate 204, the conical rotating steel body 205 is arranged on the automatic rotating shaft 203, and the rubber sheet 202 is arranged on the side surface of the conical rotating rigid body. When the grinding wheel 101 rotates, the grinding wheel 101 drives the conical rotating steel bodies 205 to rotate, and the coating 103 of the grinding wheel 101 is coated in the rotating process of the grinding wheel 101.
Example 2
This example differs from example 1 in that:
in the step (7), the surface coating is manufactured by adopting the following method:
blade coating; weighing the following raw materials in parts by weight: 100 parts of potassium fluoborate, 20 parts of phenolic resin liquid and 0.25 part of red dye, and the components are uniformly mixed and adjusted to slurry with the viscosity of 28000cps by water; then coating the outer surface of the grinding wheel by using a scraper; the diameter range of the blade coating grinding wheel is 230-400 mm; wherein the total sizing amount of the double surfaces of the grinding wheel is 26.20 g.
Example 3
A steel rail cutting grinding wheel is prepared according to the following steps:
(1) wetting by using mixed abrasive: each 100 parts of abrasive material by weight comprises the following raw materials by weight: the pretreated alumina nano ceramic abrasive material comprises the following steps: 20 parts of (1); 30 parts of brown corundum, 20 parts of monocrystalline corundum, 10 parts of white corundum and 20 parts of blue fused alumina; putting the mixture into a mixer, fully mixing the prepared grinding materials for 3 minutes, then adding phenolic resin liquid accounting for 7 percent of the weight of the grinding materials, and mixing for 12 minutes to obtain a mixture 1;
wherein the grain size range of each component of the grinding material is as follows: the pretreated alumina nano ceramic abrasive material comprises the following steps: 550-700 μm; brown corundum: 550-830 μm; silicon carbide: 550-700 μm; white corundum: 700 to 830 μm; blue fire corundum: 425 to 700 μm;
(2) mixing powder, namely mixing a cooling material accounting for 8 percent of the weight of the grinding material: potassium fluoroaluminate, and an auxiliary filler accounting for 12 percent of the abrasive by mass: mixing iron sulfide, potassium sulfate, barite and gypsum powder, wherein phenolic resin powder accounting for 12% of the weight of the grinding materials is mixed for 3 minutes to obtain a mixture 2;
wherein the particle size range of the potassium fluoborate is 38-48 mu m; the particle size range of the iron sulfide is 250-425 mu m; the grain size range of the potassium sulfate is 48-62 mu m; the particle size range of barite and gypsum is 38-48 μm;
(3) integral mixing: adding the mixture 1 into the mixture 2, and mixing for 12 minutes to obtain a mixture 3;
(4) soaking and placing: the mixture 3 is soaked and placed for 14 hours after passing through an 8-mesh screen; (5) hot-press molding: after the infiltration and the placement, pressing a grinding wheel blank, wherein the process is as follows:
three glass fiber net manufacturing processes: placing a glass fiber net, baking the net, pressing the net, putting in the mixture 3 after being soaked and placed by 45%, then placing a glass fiber net, baking the net, pressing the net, putting in the mixture 3 after being soaked and placed by 55%, placing the last glass fiber net, and pressing by using a hot-press forming die; the hot-press forming die adopts an upper elastic pressing plate and a lower elastic pressing plate, and the unit area pressure is 17 Mpa; the amount of mixture 3 charged was 1050 g.
(6) And (3) pressurizing and curing: in order to maintain the flatness of the grinding wheel; and (3) pressurizing and curing the prepared grinding wheel blank, wherein the curing temperature is set as follows: the temperature is increased from room temperature to the maximum temperature of 185 ℃ at the rate of 10 ℃/h, wherein the holding temperature and holding time are as follows: keeping the temperature at 80 ℃, 125 ℃ and 140 ℃ for 90 minutes at each temperature, keeping the temperature at the maximum temperature of 185 ℃ for 420 minutes, then naturally cooling after the heat preservation at the maximum temperature is finished, and discharging the product at the temperature lower than 60 ℃;
(7) after the solidification is discharged from the furnace, the surface coating is manufactured by adopting the following method:
blade coating; weighing the following raw materials in parts by weight: 100 parts of potassium fluoborate, 20 parts of phenolic resin liquid and 0.3 part of phenol blue dye, which are uniformly mixed and adjusted to slurry with the viscosity of 22600cps by water; then coating the outer surface of the grinding wheel by using a scraper; the diameter range of the blade coating grinding wheel is 230-400 mm; wherein the total sizing amount of the double surfaces of the grinding wheel is 23.32 g.
(8) And (3) drying: after the surface coating is manufactured, the grinding wheel with the dry surface is put into a curing oven for drying, the temperature is preserved for 3 hours at 60 ℃, 3 hours at 90 ℃, 2 hours at 110 ℃, 3 hours at 130 ℃ and 3 hours at 160 ℃, and the temperature rise rate in the process is 4 DEG/min; stopping the furnace, cooling to 60 ℃, and discharging; thus obtaining the steel rail cutting grinding wheel.
Example 4
(1) Wetting by using mixed abrasive: each 100 parts of abrasive material by weight comprises the following raw materials by weight: the pretreated alumina nano ceramic abrasive material comprises the following steps: 30 parts of (1); 30 parts of brown corundum, 10 parts of silicon carbide, 10 parts of monocrystalline corundum, 10 parts of white corundum and 10 parts of blue fused alumina; fully mixing the prepared grinding materials for 3 minutes, then adding phenolic resin liquid accounting for 7 percent of the weight of the grinding materials, and mixing for 12 minutes to obtain a mixture 1;
wherein the grain size range of each component of the grinding material is as follows: the pretreated alumina nano ceramic abrasive material comprises the following steps: 550-700 μm; brown corundum: 550-830 μm; silicon carbide: 550-700 μm; white corundum: 700 to 830 μm; blue fire corundum: 425 to 700 μm;
(2) mixing powder, namely mixing a cooling material accounting for 8 percent of the weight of the grinding material: high molecular weight sodium fluoroaluminate, and an auxiliary filler accounting for 12 percent of the grinding material by mass percent: mixing iron sulfide, potassium sulfate, barite and gypsum powder, wherein phenolic resin powder accounting for 12% of the weight of the grinding materials is mixed for 3 minutes to obtain a mixture 2;
wherein the particle size range of the potassium fluoborate is 38-48 mu m; the particle size range of the iron sulfide is 250-425 mu m; the grain size range of the potassium sulfate is 48-62 mu m; the particle size range of barite and gypsum is 38-48 μm;
(3) integral mixing: adding the mixture 1 into the mixture 2, and mixing for 12 minutes to obtain a mixture 3;
(4) soaking and placing: the mixture 3 is soaked and placed for 14 hours after passing through an 8-mesh screen; (5) hot-press molding: after the infiltration and the placement, pressing a grinding wheel blank, wherein the process is as follows: flow when 2 glass fiber nets: placing a glass fiber net, baking the net, pressing the net, putting the soaked mixture 3, placing another glass fiber net, and pressing by using a hot-press forming die to obtain a grinding wheel blank; the hot-press forming die adopts an upper elastic pressing plate and a lower elastic pressing plate, and the unit area pressure is 17 Mpa; the amount of mixture 3 charged was 1050 g.
(6) Pressurizing and curing to maintain the flatness of the grinding wheel; and (3) pressurizing and curing the prepared grinding wheel blank, wherein the curing temperature is set as follows: the temperature is increased from room temperature to the maximum temperature of 185 ℃ at the rate of 10 ℃/h, wherein the holding temperature and holding time are as follows: keeping the temperature at 80 ℃, 125 ℃ and 140 ℃ for 90 minutes at each temperature, keeping the temperature at the maximum temperature of 185 ℃ for 420 minutes, then naturally cooling after the heat preservation at the maximum temperature is finished, and discharging the product at the temperature lower than 60 ℃;
(7) after the solidification is discharged from the furnace, the surface coating is manufactured by adopting the following method:
blade coating; weighing the following raw materials in parts by weight: 100 parts of potassium fluoborate, 20 parts of phenolic resin liquid and 0.3 part of black dye, and the components are uniformly mixed and adjusted to slurry with the viscosity of 25500cps by water; then coating the outer surface of the grinding wheel by using a scraper; the diameter range of the blade coating grinding wheel is 230-400 mm; wherein the total sizing amount of the double surfaces of the grinding wheel is 24.56 g.
(8) And (3) drying: after the surface coating is manufactured, the grinding wheel with the dry surface is put into a curing oven for drying, the temperature is preserved for 3 hours at 60 ℃, 3 hours at 90 ℃, 2 hours at 110 ℃, 3 hours at 130 ℃ and 3 hours at 160 ℃, and the temperature rise rate in the process is 4 DEG/min; stopping the furnace, cooling to 60 ℃, and discharging; thus obtaining the steel rail cutting grinding wheel.
Example 5
This example differs from example 4 in that:
in the step (7), the surface coating is manufactured by adopting the following method:
spraying; weighing the following raw materials in parts by weight: 100 parts of potassium fluoborate and 20 parts of phenolic resin liquid are uniformly mixed and adjusted to slurry with the viscosity of 2000cps by water; then spraying the slurry to the outer surface of the grinding wheel by using a spray gun under the air pressure of 0.42 MPa; the diameter range of the spraying grinding wheel is 230-400 mm; wherein the total sizing amount of the double surfaces of the grinding wheel is 23.50 g.
Using the cured tap product of example 4, surface coating was made using the following method:
spraying, wherein the spraying is carried out in a semi-closed space, and the included angle between a nozzle and the surface of the grinding wheel is about 75 degrees;
adding 100 parts of potassium fluoborate, adding 20 parts of phenolic resin liquid, and adjusting the viscosity to 2000cps by using water; then spraying the slurry to the outer surface of the grinding wheel by using a spray gun under the air pressure of 0.42 MPa; the diameter range of the spraying grinding wheel is 230-400 mm;
comparative example: the formula is as follows: 50 parts of white corundum, 50 parts of brown corundum, and the balance of bonding agent, filler and coolant are the same as those in the embodiment 1, and the manufacturing method is also the same as that in the embodiment one, but no surface coating is formed.
Comparative example
A rail cutting grinding wheel without surface coating is prepared according to the following steps:
(1) wetting by using mixed abrasive: each 100 parts of abrasive material by weight comprises the following raw materials by weight: 50 parts of brown corundum and 50 parts of white corundum; putting the mixture into a mixer, fully mixing the prepared grinding materials for 3 minutes, then adding phenolic resin liquid accounting for 7 percent of the weight of the grinding materials, and mixing for 12 minutes to obtain a mixture 1;
wherein the grain size range of each component of the grinding material is as follows: brown corundum: 550-830 μm; white corundum: 700 to 830 μm;
(2) mixing powder, namely mixing a cooling material accounting for 8 percent of the weight of the grinding material: high molecular weight sodium fluoroaluminate, and an auxiliary filler accounting for 12 percent of the grinding material by mass percent: mixing iron sulfide, potassium sulfate, barite and gypsum powder, wherein phenolic resin powder accounting for 12% of the weight of the grinding materials is mixed for 3 minutes to obtain a mixture 2;
wherein the particle size range of the high molecular sodium fluoroaluminate is 38-48 mu m; the particle size range of the iron sulfide is 250-425 mu m; the grain size range of the potassium sulfate is 48-62 mu m; the particle size range of barite and gypsum is 38-48 μm;
(3) integral mixing: adding the mixture 1 into the mixture 2, and mixing for 12 minutes to obtain a mixture 3; the purpose is to fully mix the moistened grinding material and the powder;
(4) soaking and placing: the mixture 3 is soaked and placed for 14 hours after passing through an 8-mesh screen; the mixed materials are used for realizing the purpose of material waking, and the function is to be fused and fully infiltrated;
(5) hot-press molding: after the infiltration and the placement, pressing a grinding wheel blank, wherein the process is as follows:
flow when 2 glass fiber nets: placing a glass fiber net, baking the net, pressing the net, putting the soaked mixture 3, placing another glass fiber net, and pressing by using a hot-press forming die to obtain a grinding wheel blank; the hot-press forming die adopts an upper elastic pressing plate and a lower elastic pressing plate, and the unit area pressure is 17 Mpa; the amount of mixture 3 charged was 1050 g.
(6) And (3) pressurizing and curing: in order to maintain the flatness of the grinding wheel; and (3) pressurizing and curing the prepared grinding wheel blank, wherein the curing temperature is set as follows: the temperature is increased from room temperature to the maximum temperature of 185 ℃ at the rate of 10 ℃/h, wherein the holding temperature and holding time are as follows: keeping the temperature at 80 ℃, 125 ℃ and 140 ℃ for 90 minutes at each temperature, keeping the temperature at the maximum temperature of 185 ℃ for 420 minutes, then naturally cooling after the heat preservation at the maximum temperature is finished, and discharging the product at the temperature lower than 60 ℃; thus obtaining the steel rail cutting grinding wheel of the comparative example.
The rail cutting grinding wheel prepared in examples 1 to 5 and comparative example was subjected to rail cutting experiments to further illustrate the excellent properties of the rail cutting grinding wheel provided by the present invention.
Test example 1
Cutting conditions 1:
test equipment: the special cutting machine for the electric steel rail has the following parameters:
an electric motor: model Y112M-2; the power is 4.0 kW; the rotating speed is 2880 r/min;
chip grinding wheel (spindle): the rotating speed of the main shaft is 3600 r/min; specification Φ 400 × 4 × Φ 32;
the grinding wheel used was: the rail cutting wheels prepared in examples 1 to 5 and comparative example, respectively;
workpiece: standard 60 rails, 176mm by 150mm, 60kg/m weight per unit.
Cutting conditions 2:
test equipment: the parameters of the NQG-6.6 type internal combustion cutting machine are as follows:
motor power: 6.6 KW;
grinding wheel linear velocity: greater than 70 m/s;
the grinding wheel used was: the rail cutting wheels prepared in examples 1 to 5 and comparative example, respectively; specification Φ 400 × 4 × Φ 32;
workpiece: standard 60 rails, 176mm by 150mm, 60kg/m weight per unit.
Tables 1 and 2 show the test parameters associated with the steel rail cutting wheels prepared in examples 1 to 5 and comparative example, respectively, for cutting steel rails without using any equipment. As can be seen from the results in tables 1 and 2, the cutter numbers of the steel rail cutting grinding wheels of the examples 1 to 5 are not the same as those of the comparative example, and the average time used is far shorter than that of the comparative example, so that the steel rail cutting grinding wheels prepared by the examples 1 to 5 are sharper and have better durability; the burn areas of the steel rails of the embodiments 1 to 5 can reach 0 percent, thereby effectively avoiding the loss of the steel rails and ensuring the safety of the steel rails in the using process; and the residual diameters after the A2 cutters are cut in the examples 1-5 are all larger than those of the comparative example, which shows that the steel rail cutting grinding wheels prepared in the examples 1-5 have better wear resistance, lighter wear degree and better durability.
TABLE 1
TABLE 2
The above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.
Claims (9)
1. A steel rail cutting grinding wheel is characterized by being prepared from the following raw materials: the cooling material comprises grinding materials, phenolic resin liquid, phenolic resin powder, a cooling material, an auxiliary filling material, a surface coating cooling material, a coloring agent and a glass fiber net; wherein the phenolic resin liquid accounts for 5-9% of the mass fraction of the grinding material, the phenolic resin powder accounts for 9-16% of the mass fraction of the grinding material, the cooling material accounts for 5-12% of the mass fraction of the grinding material, the auxiliary filling material accounts for 4-16% of the mass fraction of the grinding material, the surface coating adhesive accounts for 0.2-3.5% of the mass fraction of the grinding material, the surface coating cooling material accounts for 0.4-6% of the mass fraction of the grinding material, the colorant accounts for 0-0.5% of the mass fraction of the grinding material, and the glass fiber net accounts for 2-3 pieces.
2. A rail cutting wheel according to claim 1, wherein the abrasive material comprises the following raw materials in parts by weight per 100 parts by weight: 5-45 parts of pretreated alumina nano ceramic abrasive, 25-55 parts of brown corundum, 0-25 parts of silicon carbide, 0-30 parts of monocrystalline corundum, 0-25 parts of white corundum and 0-30 parts of blue fused alumina; the grain diameter of each component of the grinding material is as follows: the pretreated alumina nano ceramic abrasive material 425-.
3. A rail grinding wheel according to claim 1, wherein said cooling material is one or both of high molecular weight sodium fluoroaluminate and potassium fluoroaluminate powders having a particle size of 38 to 48 μm; one or more of iron sulfide, potassium sulfate, barite and gypsum powder are filled in the auxiliary filling position; the surface coating adhesive is phenolic resin liquid with the viscosity range of 300-1000 cps; the surface coating cooling material is one or more of potassium fluoborate, potassium fluoaluminate and sodium hexafluoroaluminate powder with the grain diameter of 18-25 mu m; the colorant is a dye or a pigment.
4. A method of manufacturing a rail cutting wheel according to any one of claims 1 to 3, wherein the wheel is manufactured by:
(1) pre-mixing the abrasive: every 100 parts of abrasive material is weighed according to the following parts by weight: 5-45 parts of pretreated alumina nano ceramic abrasive, 25-55 parts of brown corundum, 0-25 parts of silicon carbide, 0-30 parts of monocrystalline corundum, 0-25 parts of white corundum and 0-30 parts of blue fused alumina; fully and uniformly mixing the raw materials, adding phenolic resin liquid accounting for 5-9% of the mass fraction of the grinding materials, and mixing and stirring for 10-15 minutes to obtain a mixture 1;
(2) premixing powder materials: weighing 5-12% of cooling material, 4-16% of auxiliary filler and 9-16% of phenolic resin powder, mixing and stirring for 1-5 minutes to obtain a mixture 2;
(3) integral mixing: adding the mixture 1 obtained in the step (1) into the mixture 2 obtained in the step (2), fully mixing and stirring for 10-15 minutes, and sieving by using an 8-mesh sieve to obtain a mixture 3;
(4) soaking and placing: soaking the mixture 3 and standing for 12-24 hours;
(5) hot-press molding: pressing the soaked mixture 3 into a grinding wheel blank by using a hot-press forming grinding tool;
(6) and (3) pressurizing and curing: and (3) pressurizing and curing the prepared grinding wheel blank, wherein the curing temperature is set as follows: the temperature is increased from room temperature to the maximum temperature of 185 ℃ at the rate of 10 ℃/h, wherein the holding temperature and holding time are as follows: keeping the temperature at 80 ℃, 125 ℃ and 140 ℃ for 90 minutes at each temperature, keeping the temperature at the maximum temperature of 185 ℃ for 420 minutes, then naturally cooling after the heat preservation at the maximum temperature is finished, and discharging the product at the temperature lower than 60 ℃;
(7) coating on the surface: weighing 0.2-3.5% of surface coating adhesive, 0.4-6% of surface coating cooling material and 0-0.5% of coloring agent, fully mixing to prepare slurry, and then preparing for later use, wherein the grinding wheel blank is taken out of a furnace and subjected to surface coating by using the slurry in one of a roller coating mode, a blade coating mode or a spraying mode;
(8) and (3) drying: after the surface coating is manufactured, putting the grinding wheel with the dry surface into a curing oven for drying, wherein the drying temperature is set as: and (3) preserving heat for 3 hours at the temperature of 60 ℃, preserving heat for 3 hours at the temperature of 90 ℃, preserving heat for 2 hours at the temperature of 110 ℃, preserving heat for 3 hours at the temperature of 130 ℃, preserving heat for 3 hours at the temperature of 160 ℃, then naturally cooling after the heat preservation at the highest temperature is finished, and discharging the steel rail cutting grinding wheel at the temperature lower than 60 ℃ to obtain the steel rail cutting grinding wheel.
5. A method for preparing a steel rail grinding cut wheel according to claim 4, wherein the hot press molding die in the step (5) adopts upper and lower elastic press plates, and the pressure per unit area is not less than 1700 pa.
6. The method for preparing the steel rail cutting grinding wheel according to the claim 4, wherein the specific operation method of the roller coating in the step (7) is as follows: adjusting the viscosity of the slurry within the range of 10000-30000cps, and then using a conical roller glue spreader with the surface Shore hardness of 30-36 degrees to roll the slurry on the outer side surface of a grinding wheel used for cutting.
7. The method for preparing the steel rail cutting grinding wheel according to the claim 4, wherein the blade coating in the step (7) is carried out by the following specific operation method: adjusting the viscosity of the slurry within the range of 5000-.
8. A method for preparing a steel rail cutting grinding wheel according to claim 4, wherein the specific operation method of the spraying in the step (7) is as follows: the viscosity of the slurry is adjusted to be in the range of 1100-5000cps, and then the slurry is sprayed to the outer side surface of the grinding wheel by a spray gun under the pressure of 0.3-0.65MPa when cutting.
9. A method for preparing a rail grinding wheel according to claim 4, wherein the step (7) is carried out in the above mannerThe dry material amount of the coating slurry is controlled to be 0.5-4g/dm2。
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