CN113788680B - 一种纳米陶瓷结合剂cBN气孔砂轮及其制备方法 - Google Patents

一种纳米陶瓷结合剂cBN气孔砂轮及其制备方法 Download PDF

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CN113788680B
CN113788680B CN202111163398.7A CN202111163398A CN113788680B CN 113788680 B CN113788680 B CN 113788680B CN 202111163398 A CN202111163398 A CN 202111163398A CN 113788680 B CN113788680 B CN 113788680B
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刘振波
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Jiangsu Saiyang Precision Tools Technology Co ltd
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Abstract

本发明公开了一种纳米陶瓷结合剂cBN气孔砂轮及其制备方法，将cBN磨料、填料、无机组合物及亚克力微球加入丙酮或者酒精等溶液中，混合、干燥后得到陶瓷粉料；然后将陶瓷粉料填充至金属模具后冷压压平，最后将金属模具置于热压机腔内保压后得到陶瓷素坯；然后将砂轮素坯烧结，得到纳米陶瓷结合剂cBN气孔砂轮。本发明创造性地在砂轮制备中使用亚克力微球进行造孔并通过热压固化工艺解决砂轮变形、开裂等问题，烧结后制得的砂轮锥度小、气孔孔径尺寸一致、分布均匀；本发明制备纳米陶瓷cbn气孔砂轮的方法未见近似报道。

Description

一种纳米陶瓷结合剂cBN气孔砂轮及其制备方法
技术领域
本发明属于陶瓷cBN砂轮制备技术领域，具体涉及一种纳米陶瓷结合剂cBN气孔砂轮及其制备方法，可用于加工轴承套圈内孔。
背景技术
现代机械加工技术正加速向高速高效高精加工方向发展。在加工技术各要素中，高性能磨具是实现高速高效高精加工的关键和保证。立方氮化硼由于其硬度很高，轻度很高，用其制造的磨削工具磨削能力很强，磨削效率高，磨具磨损小，形状保持性好，使用寿命长，所以其在磨加工方面显示了很大的优势。
且实践证明：若将磨削速度由35提高到50-60时，一般生产效率可提高30%-60%，对砂轮的耐用度提高约0.7-1倍，工件表面粗擦度参数值降低50%左右。目前国内轴承厂商大部分采用刚玉、微晶刚玉等普通砂轮，存在加工效率低、修整频繁、加工工件品质稳定性低等一系列问题，严重限制了轴承高端化的发展进程，如果能够通过改造、引进使用cBN磨具，一方面可以改善提高工件加工品质、保障产品稳定性，另一方面可以极大提升磨削加工时的进给速度提高生产效率且避免由于使用普通磨具时由于砂轮磨损带来的粉尘影响。
发明内容
本发明的目的是提供一种制备纳米陶瓷结合剂cBN气孔砂轮的方法及产品，制得的cBN砂轮坯体烧结后砂轮气孔孔径尺寸近似、分布均匀、锥度<0.1mm，砂轮可广泛用于轴承套圈件的内孔高速磨削。
为实现上述目的，本发明采用的技术方案如下：
一种纳米陶瓷结合剂cBN气孔砂轮，由cBN磨料、填料、无机组合物及高分子树脂球制备；以cBN磨料、填料、无机组合物及高分子树脂球的重量和为100%，cBN磨料的重量为60～75wt%，填料的重量为1～10wt%，高分子树脂球的重量为2～8wt%，余量为无机组合物，优选的，cBN磨料的重量为65～72wt%，填料的重量为4～7wt%，高分子树脂球的重量为3～6wt%，余量为无机组合物。
本发明中，无机组合物包括二氧化硅、氧化硼、氧化钠以及氧化锌；优选的，无机组合物由二氧化硅、氧化硼、氧化钠以及氧化锌组成；无机组合物中，各组分重量百分数为，二氧化硅65%～75%、氧化硼10～25%、氧化钠2～5%、氧化锌余量；填料可以为氧化铝、碳化硅、玻璃珠等；高分子树脂球为亚克力微球即PMMA微球。
本发明公开了上述纳米陶瓷结合剂cBN气孔砂轮在加工轴承套圈内孔中的应用。本发明公开的纳米陶瓷结合剂cBN气孔砂轮用于轴承加工时，一方面可以改善提高工件加工品质、保障产品稳定性，另一方面可以极大提升磨削加工时的进给速度提高生产效率且避免由于使用现有磨具时由于砂轮磨损带来的粉尘影响。
本发明公开了上述纳米陶瓷结合剂cBN气孔砂轮的制备方法，包括如下步骤：将cBN磨料、填料、无机组合物及高分子树脂球混合得到陶瓷粉料；所述陶瓷粉料依次经过冷压、热压、烧结，得到纳米陶瓷结合剂cBN气孔砂轮。
本发明中，将cBN磨料、填料、无机组合物及高分子树脂球加入溶剂中，混合后去除溶剂，得到陶瓷粉料；热压的温度为150～180℃、时间为10～30min，压力为80～180KN；烧结为分段式升温至800～960℃，保温2～3h，比如烧结为空气气氛下，2～3.5小时从室温升至450～550℃，再保温2.5～3.5h，然后2.5～3小时升至650～750℃，再保温2～2.5h，然后2～3.5小时升至800～960℃，再保温2～3h，最后随炉冷却。
本发明中，溶剂为丙酮、酒精等；通过旋转蒸发去除溶剂后得到陶瓷粉料；然后将陶瓷粉料填充至金属模具后冷压压平，再将金属模具置于热压机腔内保压后得到陶瓷素坯；最后将砂轮素坯烧结，得到纳米陶瓷cBN气孔砂轮。进一步的，旋转蒸发的时间为30～45分钟、温度的为60～80℃、真空度为-0.090～-0.15Mpa。
本发明中，cBN磨料的粒径为微米级，比如40～100微米；填料的粒径为50～100微米；无机组合物的粒径为10～50纳米，比如10～20纳米；高分子树脂球的粒径为1～50微米，比如5～15微米。原料都是本领域制备砂轮的常规原料。
本发明与现有技术相比，具有如下优点：
砂轮中具有适量的气孔可以在磨削的过程中起良好的冷却、容屑排屑及促使砂轮自锐的作用，作为常识，造孔剂的种类与用量对结合剂强度及砂轮性能的影响大，指出氧化铝空心球及空心玻璃微球造出的气孔比较均匀, 兼顾了砂轮的强度与锋利性。本发明克服了现有技术偏见，纳米陶瓷cBN气孔砂轮中首次使用PMMA球造孔、制备方法稳定，国内外未见相关报道。本发明通过PMMA球的合理使用制得的纳米陶瓷cBN气孔砂轮使用价值较大，其气孔尺径一致性、分布均匀性远大于现有添加其他造孔剂制得的cBN砂轮。
本发明制备砂轮具备潜在的环保价值，可用于替代轴承套圈内孔加工的普通砂轮，大大降低磨削中粉尘的产生。本发明中所涉及的原料都是市购产品，比如氧化铝微球、为现有产品，市场有售，符合国家标准。
附图说明
图1为本发明实施例一纳米陶瓷cBN气孔砂轮的显微照片；
图2为使用聚苯乙烯微球造孔剂砂轮的显微照片；
图3为本发明纳米陶瓷气孔砂轮加工工件后的效果图；
图4为现有市售砂轮在同样的设备上加工同样的工件后的效果图。
具体实施方式
本发明公开的纳米陶瓷结合剂cBN气孔砂轮的制备方法如下：将cBN磨料、辅助填料、亚克力微球及无机组合物加入溶剂中，旋转蒸发后得到陶瓷粉料；然后将陶瓷粉料填充至金属模具中冷压压平，最后将金属模具置于热压机腔内保压后出模得到陶瓷素坯；然后将砂轮素坯烧结，得到纳米陶瓷cBN气孔砂轮。本发明通过配方的选择，获得的纳米陶瓷cBN气孔砂轮气孔分布均匀、尺径一致，烧结后砂轮变形量小、锥度≤0.1mm，由其制备的纳米陶瓷cBN气孔砂轮使用价值较大，其锋利性、稳定性远大于现有轴承套圈内孔加工用普通磨料砂轮。
本发明涉及的砂轮加工以及工件加工都是在根据现有方法进行，砂轮的性能表征比如锥度、气孔分布、气孔孔径、气孔率（阿基米德排水法）的测试方法都是本领域常规方法。cBN磨料的粒径为微米级，比如70微米；填料的粒径为80微米；无机组合物的粒径为15纳米；亚克力微球的粒径为10微米。
实施例一
称量50g cBN磨料、填料SiC 3.6g、亚克力微球3.6g、14.3g无机组合物，以酒精为溶剂常规混合后置于旋转蒸发仪中，在60℃、-0.12Mpa下旋转蒸发25min后陶瓷粉料，然后将陶瓷粉料填充入现有金属模具中并常规冷压压平，然后将金属模具置于170℃的热压机腔内120KN保温30min后脱模得到cBN砂轮素坯；将取出的砂轮素坯置于高温电阻炉内进行分段式升温烧结，最后随炉冷却得到纳米陶瓷气孔砂轮，用于加工轴承套圈内孔，砂轮外径为47mm，内孔为38mm，高度为24mm；上述无机组合物的重量组成为二氧化硅73%、氧化硼20%、氧化钠3%、氧化锌余量；上述烧结为空气气氛下，烧结工艺为3小时从室温升至500℃，再保温3h，然后3小时从500℃升至700℃，再保温2h，然后3小时从700℃升至930℃，再保温2h，最后随炉冷却。附图1为上述纳米陶瓷气孔砂轮的显微照片，可以看出本发明制备的砂轮气孔规则、分布均匀。
在实施例一的基础上，将亚克力树脂球替换为同大小的聚苯乙烯微球，其余不变，得到纳米陶瓷气孔砂轮，显微照片参见图2，气孔规则度、分布均匀度都较差。
以现有市售加工轴承套圈内孔的砂轮（砂轮外径为47mm，内孔为38mm，高度为24mm，其为目前工业应用效果好的砂轮之一）为对比，采用现有设备加工轴承套圈内孔，参见下表所示，为本发明纳米陶瓷气孔砂轮和现有市售砂轮的部分加工性能参数对比：
Figure 276653DEST_PATH_IMAGE001
附图3、附图4分别为本发明上述纳米陶瓷气孔砂轮和现有市售砂轮在同样的设备上加工同样的工件后的效果图，可以看出本发明砂轮加工工件的表面磨削纹路非常细腻规则。
实施例二
称量37g cBN磨料、填料氧化铝1.15g、亚克力微球2.3g以及9.2g无机组合物；将其加入酒精溶液中混合后置于旋转蒸发仪中，在80℃、-0.09Mpa下旋转蒸发30min后陶瓷粉料，然后将陶瓷粉料填充入表面喷有脱模剂的金属模具中并冷压压平，最后将金属模具置于180℃的热压机腔内100KN保温15min后脱模得到cBN砂轮素坯；将取出、的砂轮素坯置于高温电阻炉内对砂轮坯体进行分段式升温烧结，最高温度为960℃，保温3h，最后随炉冷却得到纳米陶瓷气孔砂轮，用于加工轴承套圈内孔，砂轮外径为36mm，内孔为27mm，高度为33mm；上述无机组合物的组成为二氧化硅68%、氧化硼25%、氧化钠4%、氧化锌余量；上述烧结为空气气氛下，烧结工艺为3小时从室温升至500℃，再保温3h，然后3小时从500℃升至700℃，再保温2h，然后3小时从700℃升至960℃，再保温3h，最后随炉冷却。
实施例三
称量28g cBN磨料、SiC 4.6g、亚克力微球2.8g以及11.2g无机组合物；将其加入酒精溶液混合后置于旋转蒸发仪中，在70℃、-0.15Mpa下旋转蒸发40min后陶瓷粉料，然后将陶瓷粉料填充入表面喷有脱模剂的金属模具中并冷压压平，最后将金属模具置于160℃的热压机腔内150KN保温30min后脱模得到cBN砂轮素坯；将取出、的砂轮素坯置于高温电阻炉内对砂轮坯体进行分段式升温烧结，最高温度为930℃，保温2h，最后随炉冷却得到纳米陶瓷气孔砂轮，用于加工轴承套圈内孔，砂轮外径为28mm，内孔为23mm，高度为23mm；上述无机组合物的组成为二氧化硅73%、氧化硼20%、氧化钠3%、氧化锌余量；上述烧结为空气气氛下，烧结工艺为3小时从室温升至500℃，再保温3h，然后3小时从500℃升至700℃，再保温2h，然后3小时从700℃升至930℃，再保温2h，最后随炉冷却。
对比例一
在实施例一的基础上，将旋转蒸发工艺替换为鼓风干燥，即置于鼓风干燥箱中，在60℃下干燥30min得到陶瓷粉料；其余不变，得到砂轮，锥度0.39mm。
对比例二
在实施例一的基础上，将氧化钠替换为氧化钙，其余不变，得到砂轮，进行实施例一同样的加工测试，进给速度为80μm/s。
在实施例一的基础上，将氧化锌替换为氧化钾，其余不变，得到砂轮，进行实施例一同样的加工测试，修整间隔为95。
在实施例一的基础上，将填料SiC的用量从3.6g增加到9g，其余不变，得到砂轮，进行实施例一同样的加工测试，修整间隔为80。
在实施例一的基础上，冷压后烧结，省略热压步骤，其余不变，得到的砂轮出现开裂，无法应用。
本发明制备纳米陶瓷cBN气孔砂轮时，创造性地采用纳米无机材料原料混合并使用旋转蒸发的方式将亚克力微球均匀分散在陶瓷原料的无机组分中，并且通过热压固化的方式将亚克力微球稳定在陶瓷素坯当中，消除了烧结时因温度升高的影响造成的砂轮锥度过大、表面裂纹等一系列问题，烧结后制得的砂轮锥度小、气孔孔径尺寸一致、分布均匀；本发明制备纳米陶瓷cBN气孔砂轮的方法未见近似报道。

Claims (4)

1.一种纳米陶瓷结合剂cBN气孔砂轮的制备方法，其特征在于，包括如下步骤：将cBN磨料、填料、无机组合物及高分子树脂球加入溶剂中，混合后通过旋转蒸发去除溶剂，得到陶瓷粉料；所述陶瓷粉料依次经过冷压、热压、烧结，得到纳米陶瓷结合剂cBN气孔砂轮；无机组合物由二氧化硅、氧化硼、氧化钠以及氧化锌组成；填料为碳化硅；高分子树脂球为亚克力微球；以cBN磨料、填料、无机组合物及高分子树脂球的重量和为100%，cBN磨料的重量为65～72wt%，填料的重量为4～7wt%，高分子树脂球的重量为3～6wt%，余量为无机组合物；无机组合物中，各组分重量百分数为，二氧化硅65%～75%、氧化硼10～25%、氧化钠2～5%、氧化锌余量；热压的温度为150～180℃、时间为10～30min，压力为80～180KN；烧结为分段式升温至800～960℃，保温2～3h。
2.根据权利要求1所述纳米陶瓷结合剂cBN气孔砂轮的制备方法，其特征在于，溶剂为丙酮或者酒精。
3.根据权利要求1所述纳米陶瓷结合剂cBN气孔砂轮的制备方法制备的纳米陶瓷结合剂cBN气孔砂轮。
4.权利要求3所述纳米陶瓷结合剂cBN气孔砂轮在加工轴承套圈内孔中的应用。
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