CN113999654B - Superhard abrasive cluster and manufacturing method thereof - Google Patents
Superhard abrasive cluster and manufacturing method thereof Download PDFInfo
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- CN113999654B CN113999654B CN202111409382.XA CN202111409382A CN113999654B CN 113999654 B CN113999654 B CN 113999654B CN 202111409382 A CN202111409382 A CN 202111409382A CN 113999654 B CN113999654 B CN 113999654B
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- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
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- C09K3/1436—Composite particles, e.g. coated particles
Abstract
The invention discloses a superhard abrasive cluster and a manufacturing method thereof, belonging to the field of superhard materials, and the manufacturing process comprises the following steps: (1) dissolving a styrene monomer, BPO and a superhard abrasive in deionized water, and uniformly stirring at room temperature; (2) dissolving polyvinyl alcohol in deionized water, and stirring at room temperature for 10-30 min; (3) adding the materials in the steps (1) and (2) into a reaction kettle, and starting a system for condensation under the protection of nitrogen; (4) reacting the system in the step (3) according to a temperature control curve until the reaction is finished; (5) carrying out vacuum filtration on the product obtained in the step (4) until all the solvent is discharged; (6) drying the product obtained in the step (5) to constant weight; (7) and (5) sieving the dried substance obtained in the step (6) to obtain the product. The superhard abrasive cluster manufactured by the formula of the polystyrene based abrasive cluster and the related process can meet the requirement of efficient passivation of the cutting edge of the cutter, and the cutting edge of the cutter is smooth and mellow and has no notches and sawteeth.
Description
Technical Field
The invention belongs to the field of superhard materials, and particularly relates to a superhard abrasive cluster and a manufacturing method thereof.
Background
In the field of machining, materials with strong tendency to spontaneously oxidize, such as stainless steel, heat-resistant alloy, and the like, generally need to be subjected to surface plating (such as nickel plating), and in order to avoid the problem of poor bonding between a metal material and a plating layer, the metal material generally needs to be subjected to passivation treatment before plating; the cutter of high-speed steel, hard alloy, metal ceramic and the like is easy to generate defects such as microscopic gaps and the like on the cutting edge after being ground, the defects are easy to expand, the abrasion and the damage of the cutter are accelerated, and the cutting performance and the service life of the cutter are seriously influenced, so the cutter in the field is also generally subjected to passivation treatment; before coating, the tool containing the coating, namely the hard alloy and the metal ceramic tool, needs to be passivated so as to enhance the bonding capacity of the coating and the tool and ensure the firmness and the service life of the coating.
The traditional passivation of the cutter mostly adopts a high-efficiency mechanical passivation method. For example, the selected abrasive is super-hard abrasive such as diamond or Cubic Boron Nitride (CBN), or common abrasive such as chrome corundum, green silicon carbide, walnut shell, or a mixture thereof. However, the coarse superhard abrasive particles are not favorable for process setting and easily cause damage to tooling fixtures, and the fine superhard abrasive particles are difficult to realize efficient passivation work; due to the reasons of high granularity control difficulty, low self hardness and the like, the adoption of the grinding materials such as the chrome corundum, the green silicon carbide or the walnut shell cannot greatly improve the passivation effect, and the microscopic gaps and the saw teeth of the cutting edge of the cutter cannot be completely eliminated. And the consumption of the common grinding material is high when the common grinding material is used for passivation, so that dust pollution is easily caused.
Therefore, the superhard cluster abrasive is designed, and an effective manufacturing method is provided, so that the passivation of the cutter can be completed efficiently and in high quality, the quality of the cutting edge of the cutter is improved, the edge breakage is greatly reduced, and the method has important significance for improving the strength of the cutting edge of the cutter, prolonging the service life of the cutter and reducing the machining cost.
Disclosure of Invention
The invention designs a cluster abrasive which can efficiently remove the defects of the cutting edge, achieve smooth and flat cutting edge and enable the cutter to be firm and durable, based on the current situation that the cutter has microscopic gaps (micro tipping and sawteeth) with different degrees after grinding the cutting edge and can not meet the requirements of high strength and high stability of the cutting edge of the cutter in machining. The cluster abrasive contains fine-grained superabrasive (diamond or CBN) as a highly effective passivating body; the resin microspheres are used as a substrate to retain the elasticity of the abrasive clusters so as to avoid the risk that coarse-grained super-hard abrasive easily causes new defects to the cutting edge. And the method for manufacturing the abrasive clusters with different grain diameters is further deepened so as to meet the different requirements of passivating different specifications and different types of cutters on the grain diameters of the abrasive clusters.
The invention adopts the following technical scheme to realize the purpose: selecting a micro-powder super-hard abrasive (diamond or CBN) with a proper granularity so as to be convenient for passivating objects of different materials; reasonable polymer monomers are optimized, and a polymer polymerization reaction process suitable for intervention of micropowder super-hard grinding materials is designed, so that the super-hard grinding materials can be uniformly and effectively combined with polymers serving as a cluster grinding material base material, and the controllable particle size of a grinding material cluster is ensured.
Specifically, the method for manufacturing the super-hard abrasive cluster comprises the following steps:
(1) dispersing styrene monomer, BPO and super-hard abrasive in deionized water, and uniformly stirring at 30 +/-5 ℃;
(2) dissolving polyvinyl alcohol in deionized water, and stirring at room temperature for 10-30 min;
(3) adding the materials obtained in the steps (1) and (2) into a reaction kettle together, keeping nitrogen protection and simultaneously starting a system for condensation, and keeping the temperature at 40 +/-5 ℃;
(4) reacting the system in the step (3) according to a specific temperature control curve until the reaction is finished;
(5) carrying out vacuum filtration on the product obtained in the step (4) until all the solvent is discharged;
(6) drying the product obtained in the step (5) by suction filtration to constant weight;
(7) and (4) sieving the dried substance obtained in the step (6) to obtain the product.
Furthermore, the mass ratio of the styrene monomer to the super-hard abrasive to the BPO is 1 (0.05-0.2) to 0.04-0.08, and the addition amount of the polyvinyl alcohol is 0.45-0.5% of the mass of the styrene monomer.
Further, the specific process of the temperature control curve is as follows: heating to 80 deg.C for 30min, maintaining for 5min, heating to 90 deg.C for 10min, maintaining for 90min, and naturally cooling to room temperature.
Further, the concentration of polyvinyl alcohol was 3wt%, the degree of polymerization was 1700, and the degree of alcoholysis was 88%.
Further, the super-hard abrasive is diamond micropowder or CBN, and the particle size is M6/8 (namely the particle size is 6-8 μ M).
The drying is carried out in a 40 ℃ forced air oven.
The superhard abrasive cluster prepared by the method.
In order to ensure that the styrene monomer can form microspheres with uniform particle size through suspension polymerization, the styrene monomer, Benzoyl Peroxide (BPO) and super-hard abrasive micro powder are firstly dissolved in deionized water and continuously stirred uniformly; then adding PVA dissolved in deionized water into a styrene reaction system.
In order to satisfy the synergistic effect of physical embedding and chemical bond combination between polystyrene microspheres produced by suspension polymerization and superhard abrasive materials, a reaction system is required to be carried out in a reaction kettle capable of only controlling temperature, and the polystyrene microspheres containing the superhard abrasive materials are prepared by a certain temperature rise curve.
On one hand, the invention designs the superhard cluster abrasive material and the formula system which can meet the requirements of high efficiency and high quality; on the other hand, a feasible manufacturing process with controllable cluster abrasive grain size is developed to meet the passivation requirements of different types.
The invention has the beneficial effects that: tests prove that the superhard abrasive cluster manufactured by the formula of the polystyrene-based abrasive cluster and the related process can meet the requirement of efficient passivation of the cutting edge of the cutter, and the cutting edge of the cutter is smooth and mellow and has no notched sawteeth. The scheme is economical and reliable, and has the potential of wide popularization.
Drawings
FIG. 1 is an electron microscope (magnification:. times.400) photomicrograph (superabrasive bonded condition) of a superabrasive cluster made in example 1 of the present invention;
FIG. 2 is an electron microscope (x 200) micrograph of a superabrasive cluster made in example 1 of the present invention (abrasive cluster uniformity);
FIG. 3 is a view of one of the numerically controlled tools to be treated by the sand blasting process-a numerically controlled blade;
FIG. 4 optical (x 50) photomicrograph of a conventional abrasive blasting passivated blade corner;
figure 5 is an optical (x 50) micrograph of the corners of a superabrasive cluster grit blasted passivated insert made using example 1 of the present invention.
Detailed Description
The invention is described in further detail below with reference to the accompanying drawings:
in order to make the superhard abrasive cluster smoothly made, the suspension polymerization in the high-molecular polymerization reaction is selected as a synthesis process. Suspension polymerization is a common polymerization method for industrial production. The suspension polymerization is essentially a bulk polymerization in which a water-insoluble monomer is dispersed in a medium by the action of a relatively strong stirring and suspending agent, and the monomer is dispersed in the form of small droplets having a diameter of 0.01 to 5 mm. The particle size of the monomer during the synthesis of the polymer can be controlled by changing the conditions in the synthesis reaction process, so that the particle size of the superabrasive cluster can be conveniently controlled.
In order to enable the superhard abrasive cluster to have certain elasticity, styrene is selected as a monomer, and polystyrene microspheres are generated through suspension polymerization. The polystyrene has good impact resistance due to the aggregation structure of the polystyrene and can show considerable elasticity when stressed. The superhard abrasive cluster made of polystyrene serving as a base material can meet the technical requirement of high-efficiency passivation.
In order to ensure that the superhard abrasive cluster can complete the passivation of the cutter with high efficiency and high quality, improve the cutting edge quality of the cutter and greatly reduce tipping, the superhard abrasive (diamond or CBN) micropowder is selected as a main abrasive. Compared with common abrasive materials such as chrome corundum, green silicon carbide, walnut shells and the like, the cutting capability of the super-hard abrasive material in the field of cast metal or powder metallurgy has strength and sharpness which are difficult to achieve by the common abrasive material. In addition, the micro powder is selected instead of the coarse-particle super-hard abrasive for passivation, so that the realization of a passivation process is facilitated, and the equipment maintenance and the passivation effect are facilitated.
In the invention, the initiator BPO exists in the ball in the form of functional groups in suspension polymerization (the addition amount is small), and the redundant initiator is discharged along with the suction filtration of a medium; the suspending agent polyvinyl alcohol is arranged in the middle of the interface of the styrene and the aqueous medium in the reaction process, and is also removed along with the aqueous medium by suction filtration after the reaction is finished.
The proposal of the idea and the existence of the formula components can ensure that the superhard abrasive cluster designed by the invention has the capability of passivating cutters with high efficiency and high quality, can ensure the passivation of the cutting edges of different types of cutters, and can meet the passivation requirements of various types of products.
Styrene monomer (CAS number: 100-42-5) from Thermo Fisher in the following examples; diamond micropowder (M6/8) was purchased from Yalong superhard materials, Inc., Henan province.
Example 1
A method for manufacturing a superhard abrasive cluster comprises the following specific preparation process:
(1) 17.572g of styrene monomer, 0.701g of BPO and 1.757g of diamond micro powder (particle size: M6/8) are dissolved in 70mL of deionized water and stirred at the rotating speed of 380rpm under the condition of 30 ℃;
(2) dissolving 2.8mL of 3wt% polyvinyl alcohol (17-88, polymerization degree 1700 and alcoholysis degree 88%) in 30mL of deionized water, and stirring at 380rpm for 15min at 30 ℃;
(3) adding the step (1) and the step (2) into a reaction kettle together, keeping nitrogen protection, starting a system for condensation, and keeping the temperature at 40 ℃;
(4) reacting the system in the step (3) according to a specific temperature control curve (heating for 30min to 80 ℃, maintaining for 5min, heating for 10min to 90 ℃, and maintaining for 90 min) until the reaction is finished;
(5) carrying out vacuum filtration on the product obtained in the step (4) until all the solvent is discharged;
(6) drying the product obtained in the step (5) in a blast oven at 40 ℃ until the weight is constant;
(7) and (4) sieving the dried product obtained in the step (6), and taking the product under a 30-mesh sieve and the product over a 50-mesh sieve to obtain the product. Micrographs of the prepared superabrasive cluster are shown in fig. 1 and fig. 2, in fig. 1, the sphere is polystyrene microsphere, and the surface is attached with superabrasive micropowder, and the picture can prove that the superabrasive micropowder participates in suspension polymerization of styrene and is embedded on the surface of the polystyrene microsphere, so that sandblasting passivation of a cutter can be realized. As can be seen from FIG. 2, the superabrasive clusters have a particle size of 0.3mm to 0.5mm and are uniformly distributed.
The conventional abrasive materials are mostly chrome corundum, green silicon carbide, walnut shells and the like for carrying out sand blasting passivation on the cutter, the numerical control cutter (as shown in figure 3) in figure 3 is passivated by special sand blasting equipment under the action of a strong airflow spray gun, and the sand blasting process is generally that firstly, the sand blasting pressure is controlled to be 0.6-0.8 MPa; ② the air supply is more than or equal to 5m for cultivation/min; thirdly, the sand flow is kept at 300-500 Kg/h; fourthly, the distance between the spray gun head and the cutter is 60-100 mm; when the tool (the tool of fig. 3) was passivated by sandblasting using the above-described conventional abrasive, the passivation results are shown in fig. 4. The superhard abrasive cluster prepared by the method is used for passivating a numerical control cutter (the cutter in figure 3), and the passivation result is shown in figure 5. As can be seen from FIG. 4, the conventional chrome corundum abrasive (grain size 0.3mm-0.8 mm) is easy to generate edge defects when the tool is passivated by sandblasting under the condition of sandblasting amount 300 Kg/h; as can be seen from FIG. 5, the superabrasive clusters of the present invention have smooth and defect-free cutting edges when the tool is passivated by sandblasting under the condition of sandblasting amount of 300 Kg/h.
Example 2
A method for manufacturing a superhard abrasive cluster comprises the following specific preparation process:
(1) 17.572g of styrene monomer, 0.701g of BPO and 3.514g of diamond micro powder (particle size: M6/8) are dissolved in 70mL of deionized water and stirred at the rotating speed of 760rpm under the condition of 30 ℃;
(2) dissolving 2.8mL of 3wt% polyvinyl alcohol (17-88, polymerization degree 1700 and alcoholysis degree 88%) in 30mL of deionized water, and stirring at 380rpm for 15min at 30 ℃;
(3) adding the materials obtained in the steps (1) and (2) into a reaction kettle together, keeping nitrogen protection, starting a system for condensation, and keeping the temperature at 40 ℃;
(4) reacting the system in the step (3) according to a specific temperature control curve (heating for 30min to 80 ℃, maintaining for 5min, heating for 10min to 90 ℃, and maintaining for 90 min) until the reaction is finished;
(5) carrying out vacuum filtration on the product obtained in the step (4) until all the solvent is discharged;
(6) drying the product obtained in the step (5) in a blast oven at 40 ℃ until the weight is constant;
(7) and (5) sieving the dried substance obtained in the step (6), and taking substances below a 50-mesh sieve and above a 70-mesh sieve to obtain the product. The grain diameter of the super-hard abrasive cluster is 0.2mm-0.35mm, and the super-hard abrasive cluster is uniformly distributed.
Example 3
A method for manufacturing a superhard abrasive cluster comprises the following specific preparation process:
(1) 17.572g of styrene monomer, 1.40g of BPO and 0.88g of diamond micropowder (particle size: M6/8) are dissolved in 70mL of deionized water and stirred at the rotating speed of 200rpm under the condition of 30 ℃;
(2) dissolving 2.8mL of 3wt% polyvinyl alcohol (17-88, polymerization degree 1700 and alcoholysis degree 88%) in 30mL of deionized water, and stirring at 380rpm for 15min at 30 ℃;
(3) adding the materials obtained in the steps (1) and (2) into a reaction kettle together, keeping nitrogen protection, starting a system for condensation, and keeping the temperature at 40 ℃;
(4) reacting the system in the step (3) according to a specific temperature control curve (heating for 30min to 80 ℃, maintaining for 5min, heating for 10min to 90 ℃, and maintaining for 90 min) until the reaction is finished;
(5) carrying out vacuum filtration on the product obtained in the step (4) until all the solvent is discharged;
(6) drying the product obtained in the step (5) in a blast oven at 40 ℃ until the weight is constant;
(7) and (4) sieving the dried product obtained in the step (6), and taking the product under a 20-mesh sieve and the product on a 30-mesh sieve to obtain the product. The grain diameter of the super-hard abrasive cluster is 0.5mm-0.7mm, and the super-hard abrasive cluster is uniformly distributed.
In conclusion, the superhard abrasive cluster shows good passivation performance in the passivation treatment process of the cutter: the method can passivate the cutting edge of the cutter efficiently, improve the quality of the cutting edge, greatly reduce the defects of tipping or gaps and the like (as shown in figure 3), and can complete the cutter passivation work continuously, stably, safely and efficiently. The cutter manufactured by using the superhard abrasive cluster has the advantages of high passivation efficiency, good passivation quality, convenience in implementation of a passivation process and the like, and is beneficial to improvement of passivation environment and natural environment protection.
Claims (4)
1. A method for making a superabrasive cluster, comprising the steps of:
(1) dispersing styrene monomer, BPO and super-hard abrasive in deionized water, and uniformly stirring at 30 +/-5 ℃;
(2) dissolving polyvinyl alcohol in deionized water, and stirring at room temperature for 10-30 min; the mass ratio of the styrene monomer, the super-hard abrasive and the BPO is 1 (0.05-0.2) to 0.04-0.08, and the addition amount of the polyvinyl alcohol is 0.45-0.5 percent of the mass of the styrene monomer;
(3) adding the materials obtained in the steps (1) and (2) into a reaction kettle together, keeping nitrogen protection and simultaneously starting a system for condensation, and keeping the temperature at 40 +/-5 ℃;
(4) reacting the system in the step (3) according to a specific temperature control curve until the reaction is finished; the specific process of the temperature control curve is as follows: heating to 80 deg.C for 30min, maintaining for 5min, heating to 90 deg.C for 10min, maintaining for 90min, and naturally cooling to room temperature;
(5) carrying out vacuum filtration on the product obtained in the step (4) until all the solvent is discharged;
(6) drying the product obtained in the step (5) by suction filtration to constant weight;
(7) and (5) sieving the dried substance obtained in the step (6) to obtain the product.
2. The method of making a superabrasive cluster of claim 1, wherein the concentration of polyvinyl alcohol is 3wt%, the degree of polymerization is 1700, and the degree of alcoholysis is 88%.
3. The method of making a superabrasive cluster of claim 1, wherein the superabrasive is diamond micropowder or CBN with a particle size of M6/8.
4. A superabrasive cluster produced by the method of any of claims 1 to 3.
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| JPH036285A (en) * | 1989-06-02 | 1991-01-11 | Mitsui Toatsu Chem Inc | Synthetic resin abrasive |
| JPH10270400A (en) * | 1997-03-28 | 1998-10-09 | Sumitomo Chem Co Ltd | Abrasive for manufacturing semiconductor device, and manufacture of the abrasive |
| US6645624B2 (en) * | 2000-11-10 | 2003-11-11 | 3M Innovative Properties Company | Composite abrasive particles and method of manufacture |
| JP5187547B2 (en) * | 2007-03-07 | 2013-04-24 | 日立化成株式会社 | Abrasive for blasting and method for producing the same |
| WO2009128982A2 (en) * | 2008-04-18 | 2009-10-22 | Saint-Gobain Abrasives, Inc. | High porosity abrasive articles and methods of manufacturing same |
| CN101817172B (en) * | 2010-04-12 | 2012-01-25 | 南京航空航天大学 | Grinding and polishing pad for cured grinding material based on thermal initiation curing and preparation method thereof |
| CN102417811A (en) * | 2011-10-14 | 2012-04-18 | 上海施科特光电材料有限公司 | Composite grinding material for chemical mechanical polishing liquid, and preparation method and application of composite grinding material |
| CN102632453A (en) * | 2012-04-24 | 2012-08-15 | 浙江浦江敏锐精密机械科技有限公司 | Thermosetting resin grinding pad and preparation method thereof |
| KR101427883B1 (en) * | 2013-02-08 | 2014-08-07 | 주식회사 케이씨텍 | Surface-modified abrasive particle, method for preparing the same and slurry composition having the same |
| KR101465762B1 (en) * | 2013-04-25 | 2014-12-01 | 성균관대학교산학협력단 | Abrasive containing polystyrene/silica composite, and preparing method thereof |
| CN105860315B (en) * | 2016-06-14 | 2018-06-26 | 辽宁大学 | A kind of preparation method of hexagonal boron nitride/poly styrene composite material |
| CN106944937A (en) * | 2017-03-17 | 2017-07-14 | 衢州学院 | A kind of preparation method of the diamond abrasive tool pellet of use porous ceramic skeleton resin reinforcing |
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