CN114367926B - Special fiber reinforced resin abrasive cutting wheel for cutting railway steel rail and manufacturing method thereof - Google Patents
Special fiber reinforced resin abrasive cutting wheel for cutting railway steel rail and manufacturing method thereof Download PDFInfo
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- CN114367926B CN114367926B CN202210009467.7A CN202210009467A CN114367926B CN 114367926 B CN114367926 B CN 114367926B CN 202210009467 A CN202210009467 A CN 202210009467A CN 114367926 B CN114367926 B CN 114367926B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
- B24D5/12—Cut-off wheels
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- 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
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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
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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
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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
- B24D3/34—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
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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
- B24D3/34—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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
- B24D5/02—Wheels in one piece
- B24D5/04—Wheels in one piece with reinforcing means
Abstract
A fiber reinforced resin abrasive cutting wheel special for cutting railway rails and a manufacturing method thereof belong to the technical field of railway rail cutting, and the abrasive cutting wheel comprises the following components in parts by mass: 30-60 parts of high-temperature calcined brown corundum, 20-50 parts of ceramic coated white corundum, 10-20 parts of monocrystalline corundum, 10-30 parts of silicon carbide, 17-25 parts of high-strength phenolic resin, 4-12 parts of lithopone, 2-8 parts of zinc sulfide, 5-9 parts of cryolite and 0.5-0.8 part of iron oxide red; the preparation method comprises the steps of premixing, mixing, sieving, naturally drying, secondarily sieving, forming, hardening and the like. The density of the grinding wheel can reach 2.30g/cm 3 ～2.35g/cm 3 The cutting of 80# steel rail can be finished within 2 minutes, the cutting of 60# steel rail can be finished within 2 minutes, and the cut is guaranteed to be bright and straight, so that the requirement of the minimum tolerance of steel rail cutting machining is met.
Description
Technical Field
The invention belongs to the technical field of railway steel rail cutting, and particularly relates to a special fiber reinforced resin abrasive cutting wheel for railway steel rail cutting and a manufacturing method thereof.
Background
With the rapid development of economy in China, railway transportation and high-speed train operation have very important positions in economic development strategies in China. Therefore, the cutting process of the railway rail is more developed in the direction of high efficiency and high precision. The material hardness and toughness of the railway steel rail are higher, and the cutting difficulty is higher. The cutting equipment and the cutting pieces of the early railway steel rail are mostly used by matching the cutting equipment of the whole imported internal combustion engine with the imported cutting pieces, and the cutting equipment and the cutting pieces of the early railway steel rail are expensive in price, long in supply period, low in cost performance and lack of competitive independent production research and development core technology. Therefore, the use cost is always high.
The imported cutting blade has the use characteristics that the product density is high, the service life is long, and the linear speed needs to be improved to improve the cutting efficiency of the product, so that the linear speed of 100m/s is mainly used, nowadays, domestic common steel rail cutting equipment is matched and assembled on the basis of a HONDA internal combustion engine, and the designed linear speed of the use is mostly below 80 m/s. The steel rail cutting operation environment is mostly field operation on a transportation line, a cutting machine and a cutting blade are often required to be transported to a place far away from a fixed unit for use, the protection measures are poor, and great potential safety hazards also exist for users.
With the upgrade of the manufacturing industry and the development of abrasive tools in China, domestic cutting blades also start to replace imported products with high-end abrasives, but the expensive raw material price of the cutting blades also brings higher use cost, and the cutting blades produced by common abrasives cannot meet the higher service life, so that the cutting blades are frequently replaced in the cutting process, and therefore, the use cost cannot be reduced, the operation efficiency is influenced, and even the use safety is influenced.
The cutting requirements for high hardness and high toughness railway rails present even greater challenges to the cutting ability, cutting efficiency, service life, and safety of fully self-made cutting blade products.
Disclosure of Invention
Aiming at the problems of low hardness, low cutting efficiency, short service life, poor safety, high manufacturing cost and the like of the railway steel rail cutting blade in the prior art, the invention provides the special fiber reinforced resin cutting grinding wheel for cutting the railway steel rail and the manufacturing method thereof. The specific technical scheme is as follows:
the special fiber reinforced resin abrasive cutting wheel for cutting the railway steel rail comprises the following components in parts by mass: 30-60 parts of high-temperature calcined brown corundum, 20-50 parts of ceramic coated white corundum, 10-20 parts of monocrystalline corundum, 10-30 parts of silicon carbide, 17-25 parts of high-strength phenolic resin, 4-12 parts of lithopone, 2-8 parts of zinc sulfide, 5-9 parts of cryolite and 0.5-0.8 part of iron oxide red;
the high-strength phenolic resin comprises phenolic resin liquid and phenolic resin powder, and the mass ratio is that the phenolic resin liquid: phenolic resin powder = (30 to 40): (60-70);
the density of the grinding wheel is 2.30g/cm 3 ～2.35g/cm 3 ；
The high-temperature calcined brown corundum is brown corundum calcined at 800-1300 ℃ for 2-4 h;
the ceramic coating white corundum is calcined at 800-1300 ℃ for 2-4h, and then ceramic coating is carried out;
the ceramic coating is high-pressure spray coating by using iron oxide red and a ceramic bonding agent;
the thickness of the ceramic plating coat is less than 0.2 mm;
the granularity of the high-temperature calcined brown corundum, the ceramic coated white corundum, the monocrystalline corundum and the silicon carbide is 22-46 meshes;
the granularity of the lithopone, the zinc sulfide and the cryolite is 80 to 325 meshes;
the type of the phenolic resin liquid is PF2559;
the model of the phenolic resin powder is PF2898ASS;
the particle sizes of the phenolic resin powder and the iron oxide red are 280-325 meshes;
the manufacturing method of the special fiber reinforced resin abrasive cutoff wheel for cutting the railway steel rail comprises the following steps:
step 1, premixing:
(1) According to the component proportion of the grinding wheel, mixing the high-temperature calcined brown corundum, the ceramic coating white corundum, the monocrystalline corundum and the silicon carbide, and preparing an abrasive component A after uniformly mixing;
(2) Mixing lithopone, zinc sulfide and cryolite according to the component proportion of the grinding wheel, and preparing an auxiliary material component B after uniformly mixing;
(3) Adding phenolic resin powder into the auxiliary material component B according to the component proportion of the grinding wheel, mixing, and uniformly mixing to obtain a mixture C;
step 2, mixing:
adding the phenolic resin liquid into the grinding material component A according to the component proportion of the grinding wheel, uniformly mixing, then adding iron oxide red, continuously and uniformly mixing, then adding the mixture C, further mixing, and uniformly mixing to obtain a grinding wheel blank D;
and step 3, sieving and naturally airing:
sieving the grinding wheel blank D, then placing the grinding wheel blank D in a storage room with constant temperature and constant humidity, and standing for 24-26 h for later use;
and 4, secondary sieving:
sieving the static grinding wheel blank D for the second time to obtain a uniform and loose molding material E;
step 5, forming:
the temperature of a mould is raised to 30-60 ℃ in advance, a glass fiber reinforced net is laid in the mould, then a forming material E is filled in the mould, the material is spread for two times, and the forming material E is fully spread and scraped evenly; laying a glass fiber reinforced mesh on the flattened molding material E, placing a label and a steel ring, and pressing to obtain a grinding wheel;
step 6, hardening:
(1) Penetrating 15-30 grinding wheels into the penetrating rod, placing two V-shaped dragon partition nets and an aluminum partition plate between every two adjacent grinding wheels, covering a steel plate on the uppermost grinding wheel, and clamping by using a spring to form a string of grinding wheels;
(2) Placing the grinding wheels clamped into a string in a hot air hardening furnace, neatly and uniformly placing the grinding wheels into the furnace, and hardening at high temperature;
and 7, checking:
taking out the hardened and cooled grinding wheel, and inspecting to obtain a finished grinding wheel, wherein the density of the finished grinding wheel reaches 2.30g/cm 3 ～2.35g/cm 3 。
According to the technical scheme, in the step 1, the mixing time of the high-temperature calcined brown corundum, the ceramic coated white corundum, the monocrystalline corundum and the silicon carbide is 1-4 min; mixing the lithopone, the zinc sulfide and the cryolite for 1-10 min; the mixing time of the phenolic resin powder and the auxiliary material component B is 1-5 min;
in the technical scheme, in the step 2, the mixing time of the phenolic resin liquid and the abrasive component A is 2-12 min; the time for continuously and uniformly mixing the added iron oxide red is 1-5 min, and the time for further mixing the added mixture C is 2-10 min.
In the technical scheme, in the step 3, the mesh number of the sieve for sieving the grinding wheel blank D is 14-22 meshes; the temperature of the storage chamber is 22-25 ℃, and the humidity is 25-40%;
in the above technical scheme, in the step 4, the mesh number of the screen for the second sieving is 16-20 meshes.
In the technical scheme, in the step 5, the specification of the glass fiber reinforced mesh is 280 g of 5 meshes; the pressing pressure is 60-200 kg/cm 2 And keeping the pressure for 15-20 s.
In the above technical scheme, in step 6, the thickness of the aluminum separator is 10mm; the thickness of the steel plate is 20mm; the high-temperature hardening parameters are that the temperature rise process is 30-32 hours, the highest temperature is 185 +/-5 ℃, the temperature is kept for 10-12 hours, and the temperature reduction process is 8-10 hours.
Compared with the prior art, the special fiber reinforced resin abrasive cutting wheel for cutting the railway steel rail and the manufacturing method thereof have the beneficial effects that:
1. the technological formula for producing the steel rail cutting sheet products in China mostly takes semi-brittle corundum, zirconium corundum and single-crystal corundum as main abrasive systems and ordinary brown corundum and white corundum as main abrasive systems, and partial main and auxiliary materials need to be imported. The semi-brittle corundum has excellent performance, but the domestic semi-brittle corundum is difficult to meet the performance requirement, is still best in import and is expensive. The zirconia alumina is corundum abrasive with the best wear resistance and impact resistance, domestic autonomous products can also meet the use requirements, many enterprises add the zirconia alumina in the formula to improve the wear resistance and impact resistance of the product, but the wear resistance and impact resistance of the product are mainly determined by the overall strength generated by the formula and the structural design of the product besides the performance of the abrasive, and the zirconia alumina has poor sharpness, is not suitable for rail cutting, is the same as semi-brittle corundum, and is expensive. The monocrystalline corundum is an excellent abrasive which gives consideration to sharpness and wear resistance, and although the price of the monocrystalline corundum is not as high as that of the zirconium corundum and the semi-brittle corundum, the price of the monocrystalline corundum is still high, and the cost performance is not high at the same time. The brown corundum has the characteristics of better toughness and wide applicability, while the white corundum has larger brittleness and higher sharpness, and has a more ideal use effect if the white corundum and the white corundum are reasonably matched, and the white corundum is low in price compared with the three grinding materials and is the most common grinding material, but is difficult to simultaneously meet the requirements of higher cutting efficiency, longer service life and higher safety of users when being used for cutting steel rails.
According to the grinding wheel, the high-temperature calcined brown corundum and the ceramic coated white corundum are used as main grinding materials, the common brown corundum has good toughness, wide applicability and high cost performance, and the purity and the hydrophilicity of the grinding materials are improved by using the high-temperature calcination technology on the basis of utilizing the brown corundum when the brown corundum is calcined, so that the service life of the materials is prolonged; the white corundum has good sharpness, the cutting efficiency of a product can be improved, the coated white corundum is formed by coating a ceramic material on the surface of the white corundum on the basis of high-temperature calcination, the original sharpness of the white corundum is guaranteed, the service life of the white corundum is further prolonged, and the combination of the two abrasives mainly improves the purity, toughness and hydrophilicity of the abrasives and improves the bonding strength of the abrasives and a bonding agent by using high-temperature calcination and coating technologies.
The grinding wheel uses high-temperature calcined brown corundum (namely brown corundum calcined for 2-4h at 800-1300 ℃), and combines with ceramic coated white corundum (white corundum calcined for 2-4h at 800-1300 ℃) to carry out ceramic coating, wherein the thickness of the ceramic coating is less than 0.2 mm); the grinding material is calcined to play two roles, firstly, the grinding material is sintered at high temperature due to microcracks formed by multiple impacts in the granulating process, so that the strength of single particles is increased due to sintering in the manufacturing process of the grinding material; and secondly, the capillary action of the abrasive is increased, the hydrophilicity of the abrasive is increased, and the adsorption effect of the abrasive particles on the binder is improved, so that the abrasive particles are adhered to the matrix by virtue of the binder. Compared with the brown corundum and the white corundum which are not calcined, the micro-hardness of the calcined brown corundum and white corundum abrasive can be improved by 10-15%, the toughness is improved by 10-15%, the hydrophilicity is improved by 3-4 times, the grinding amount is improved by 3-5%, and the durability is improved by 30-50%.
2. The white corundum after calcination is plated with iron oxide red and ceramic bonding agent, and according to the specific surface area of abrasive grains, the iron oxide red and the ceramic bonding agent are added according to a certain proportion and uniformly stirred, and then the ceramic coating is uniformly coated on the surface of the abrasive by a high-pressure spraying device and heated in the spraying process to be quickly cured so as to achieve thin and uniform coating, and the thickness of the white corundum coating used in the invention is less than 0.2mm, and an excessively thick coating can play an opposite role. The coated monocrystalline corundum has good sharpness and wear resistance, and the sharpness and wear resistance of the product can be further improved by adding a certain amount of monocrystalline corundum.
3. The high-strength phenolic resin adopted by the invention comprises phenolic resin liquid and phenolic resin powder, and the mass ratio of the phenolic resin liquid to the phenolic resin powder is as follows: phenolic resin powder = (30 to 40): (60-70); the strength of the phenolic resin is mainly reflected in the improvement of the service life and the rotary crushing strength of the grinding wheel after the grinding wheel product is prepared, and the improvement range is 25-50%.
4. The carborundum of this emery wheel has good heat conduction heat dispersion, can also promote the cutting efficiency of product simultaneously, reduces the burn.
5. The invention limits the granularity of each component, which is a core technology, and the granularity can directly influence the yield, the wear resistance, the sharpness and the service life of a grinding wheel product. The four grinding materials of the high-temperature calcined brown corundum, the ceramic coated white corundum, the monocrystalline corundum and the silicon carbide are mixed for use, and under the condition of proper component proportion, the good service life and the cutting efficiency of the product can be considered at the same time, and the high manufacturing cost cannot be caused.
6. Compared with the common phenolic resin, the high molecular weight phenolic resin can generate better associativity with four mixed abrasives, so that the service life of the product is prolonged, and the safety is improved by 15-25% compared with the common phenolic resin.
7. The auxiliary materials in the grinding wheel are lithopone, zinc sulfide, cryolite and iron oxide red, and the composite auxiliary material is mainly used for prolonging the service life of a product, improving the cutting and grinding efficiency, promoting the material combination efficiency, increasing the combination strength and safety and the like; the high-temperature calcined brown fused alumina and the ceramic coating white fused alumina are used as main abrasive materials and matched with high-molecular-weight phenolic resin, so that the service life of the product is ensured, and the auxiliary materials are mainly selected to improve the cutting efficiency of the product.
The common auxiliary materials for increasing sharpness mainly comprise iron sulfide mineral powder of metal sulfide, artificially synthesized cryolite and the like. The effect of lubricant and heat-dissipating agent is formed on the surface of the grinding wheel by utilizing the reaction between the sulfur component in the iron powder and the fluorine component in the cryolite and the workpiece in the cutting process. The sulfur in the iron powder is usually trivalent sulfur, and the cutting process generates larger pungent odor and has certain pollution to the environment, so the lithopone with sulfur content compounds and zinc sulfide are selected in the product to improve the defects, and the product is more environment-friendly.
8. The method of the invention performs step-by-step mixing according to the density and granularity characteristics of various raw materials, and the mixing uniformity is better. The cutting and grinding performance and the service life of the product are determined by the uniform and high abrasive components, the glass fiber net plays a role similar to a beam in reinforced concrete in the product, and the glass fiber net and the binding agent can greatly improve the product strength of the grinding wheel product, so that the glass fiber net is an important guarantee for the safety of the grinding wheel product and can further improve the service life; the uniform auxiliary material components are mainly used for further improving the product performance.
9. The method of the invention screens and trays the grinding wheel blank, places the grinding wheel blank in a storage room with constant temperature and humidity for 24 to 26 hours, and screens the blank again before forming to prepare a forming material with moderate humidity, uniformity and looseness, which can improve the forming quality and reduce the rejection rate.
10. The forming process of the invention is to press the weight and the thickness of the product into a specified shape and size according to the designed density of the grinding wheel, and the designed density of the product is 2.30g/cm 3 ～2.35g/cm 3 Is larger than the common grinding wheel. The requirements for forming, pressing and hardening are higher, and the process is more complicated than that of the conventional product. The method comprises the steps of raising the temperature of a mold to 20-60 ℃ in advance, placing a high-strength glass fiber reinforced net which is processed to be flat in advance in the mold, then putting a forming material, spreading the forming material twice, fully and uniformly spreading and scraping the forming material, and then placing another glass fiber net, wherein the two glass fiber nets can increase the safety to a greater extent so as to meet the forming process parameter of a high-hardness grinding wheel, namely the pressure of 60-200 kg/cm 2 Pressure maintaining time of 15-20 s, pressureThe thickness is set, so that the compactness, uniformity and safe processing are ensured.
The conventional forming process is a pressing process which is one-time material scraping, has low density, is low in safety when a glass fiber reinforced net is placed, and can only support the pressure maintaining time of 1-2 s.
11. In the hardening process, 15-30 grinding wheels penetrate into the penetrating rod, and two V-shaped isolating nets are placed between the two grinding wheels, so that the grinding wheels are prevented from being adhered in the hardening process, and heat transfer and exhaust are facilitated; then an aluminum partition plate with the thickness of 10mm is placed, so that the grinding wheel is fully and uniformly heated in the hardening process. A steel plate with the thickness of 20mm is covered on the grinding wheel and is clamped by a high-strength spring, so that the probability of thickness rebound deformation in the hardening process of the grinding wheel is reduced, and the consistency of the product and the designed density is ensured.
The conventional grinding wheel hardening clamp is characterized in that 4-10 grinding wheels are placed on an aluminum partition plate, the number of the aluminum partition plates is small, the heat transfer effect is poor, a spring is not used for clamping, and each grinding wheel is unevenly heated and has uneven quality.
12. According to the high-temperature reaction mechanism of the phenolic resin, the hardening process curve of 30-32 hours is compiled, the maximum temperature is 185 +/-5 ℃, the temperature is kept for 10-12 hours, and the temperature is reduced for 8-10 hours, so that the product has sufficient hardening reaction and maximization of bonding strength under the condition of not depending on other auxiliary materials for increasing the toughness and the bonding strength.
13. At present, the cutting efficiency of the 60-type steel rail cutting blade produced in China is mostly about 2 minutes and 30 seconds per cutter, and the cutting efficiency of the 80# steel rail is about 3 minutes per cutter.
Through continuous development, trial and improvement, the density of the grinding wheel can reach 2.35g/cm 3 The cutting of 80# steel rail can be completed within 2 minutes, the cutting of 60# steel rail can be completed within 2 minutes, and the cut is guaranteed to be bright and straight, so that the requirement of the minimum tolerance of steel rail cutting machining is met.
14. The service life of the railway steel rail cutting blade is required to be not less than 3 cutters for cutting 60# steel rail by each grinding wheel, not less than 2.5 cutters for cutting 80# steel rail by each grinding wheel, the service life of the grinding wheel for cutting 60# steel rail can reach 6.5 cutters for cutting 60# steel rail, and the service life of the grinding wheel for cutting 80# steel rail can reach 5.5 cutters for cutting 80# steel rail is greatly prolonged.
Detailed Description
The present invention will be further described with reference to specific examples, but the present invention is not limited to these examples.
Example 1
The special fiber reinforced resin abrasive cutting wheel for cutting the railway steel rail comprises the following components in parts by mass: 45 parts of high-temperature calcined brown corundum, 35 parts of ceramic coated white corundum, 15 parts of monocrystalline corundum, 20 parts of silicon carbide, 21 parts of high-strength phenolic resin, 8 parts of lithopone, 5 parts of zinc sulfide, 7 parts of cryolite and 0.6 part of iron oxide red;
the high-strength phenolic resin comprises phenolic resin liquid and phenolic resin powder, and the mass ratio is that the phenolic resin liquid: phenolic resin powder =35:65;
the high-temperature calcined brown corundum is brown corundum calcined at 1000 ℃ for 3 hours;
the ceramic coating white corundum is calcined at 1000 ℃ for 3 hours and then is subjected to ceramic coating;
the ceramic coating is high-pressure spray coating by using iron oxide red and a ceramic bonding agent; the thickness of the ceramic plating coat is 0.1mm;
the granularity of the high-temperature calcined brown corundum, the ceramic coated white corundum, the monocrystalline corundum and the silicon carbide is 24 meshes;
the granularity of the lithopone, the zinc sulfide and the cryolite is 200 meshes;
the type of the phenolic resin liquid is PF2559;
the model of the phenolic resin powder is PF2898ASS;
the particle sizes of the phenolic resin powder and the iron oxide red are 325 meshes;
the manufacturing method of the special fiber reinforced resin abrasive cutoff wheel for cutting the railway steel rail comprises the following steps:
step 1, premixing:
(1) Mixing the high-temperature calcined brown corundum, the ceramic coating white corundum, the monocrystalline corundum and the silicon carbide for 2min according to the component proportion of the grinding wheel, and preparing an abrasive component A after uniform mixing;
(2) Mixing lithopone, zinc sulfide and cryolite for 3min according to the component proportion of the grinding wheel, and preparing an auxiliary material component B after uniformly mixing;
(3) Adding phenolic resin powder into the auxiliary material component B according to the component proportion of the grinding wheel, mixing for 3min, and uniformly mixing to obtain a mixture C;
step 2, mixing:
adding the phenolic resin liquid into the abrasive component A according to the component proportion of the grinding wheel, mixing for 10min, then adding iron oxide red, continuously and uniformly mixing for 3min, then adding the mixture C, further mixing for 7min, and uniformly mixing to obtain a grinding wheel blank D;
and step 3, sieving and naturally airing:
sieving the grinding wheel blank D, wherein the mesh number of a screen is 20 meshes, then placing the grinding wheel blank D in a constant-temperature and constant-humidity storage room, keeping the temperature at 23 ℃ and the humidity at 30%, and standing for 24 hours for later use;
and 4, secondary sieving:
sieving the blank D of the grinding wheel after standing for the second time, wherein the mesh number of a sieve is 20 meshes, and obtaining a uniform and loose molding material E;
step 5, forming:
the temperature of a mould is raised to 40 ℃ in advance, a pretreated and flat glass fiber reinforced mesh with the size of 5 meshes and the weight of 280 grams is laid in the mould, then a forming material E is filled in the mould, the material spreading is carried out twice, and the forming material E is fully spread and scraped evenly; then laying a 5-mesh 280 g glass fiber reinforced net on the flattened molding material E, finally placing a label and a steel ring, and pressing under the pressure of 120kg/cm 2 Maintaining the pressure for 15s to prepare the grinding wheel;
step 6, hardening:
(1) Penetrating 20 grinding wheels into a penetrating rod, placing two V-shaped dragon partition nets between every two adjacent grinding wheels, placing an aluminum partition plate with the thickness of 10mm, and finally covering a steel plate with the thickness of 20mm on the uppermost grinding wheel and tightly clamping the steel plate by using a spring to form a grinding wheel which is clamped into a string;
(2) Placing the grinding wheels clamped into a string in a hot air hardening furnace, neatly and uniformly placing the grinding wheels into the furnace, and hardening at high temperature; the high-temperature hardening parameters are that the temperature rise process is 30 hours, the maximum temperature is 185 ℃, the temperature is kept for 10 hours, and the temperature reduction process is 8 hours;
and 7, checking:
and taking out the hardened and cooled grinding wheel, and inspecting to obtain a finished grinding wheel.
The density of the grinding wheel prepared by the embodiment reaches 2.35g/cm 3 The 80# steel rail can be cut once in 130s, the 60# steel rail can be cut once in 100s, and the cut is guaranteed to be bright and straight, so that the requirement of the minimum tolerance of the steel rail cutting machining is met. When the grinding wheel cutting device is used for cutting, the 60# steel rail can reach 6.5 cutters, and the 80# steel rail can reach 5.5 cutters, so that the steel rail can be scrapped and replaced, and the service life is greatly prolonged.
Example 2
The special fiber reinforced resin abrasive cutting wheel for cutting the railway steel rail comprises the following components in parts by mass: 30 parts of high-temperature calcined brown corundum, 20 parts of ceramic coated white corundum, 10 parts of monocrystalline corundum, 10 parts of silicon carbide, 17 parts of high-strength phenolic resin, 4 parts of lithopone, 2 parts of zinc sulfide, 5 parts of cryolite and 0.5 part of iron oxide red;
the high-strength phenolic resin comprises phenolic resin liquid and phenolic resin powder, and the mass ratio is that the phenolic resin liquid: phenolic resin powder =30:70;
the high-temperature calcined brown corundum is brown corundum calcined at 800 ℃ for 4 hours;
the ceramic coating white corundum is calcined at 800 ℃ for 4 hours and then is subjected to ceramic coating;
the ceramic coating is high-pressure spray coating by using iron oxide red and a ceramic bonding agent; the thickness of the ceramic plating coat is 0.08mm;
the granularity of the high-temperature calcined brown corundum, the ceramic coating white corundum, the monocrystalline corundum and the silicon carbide is 35 meshes;
the granularity of the lithopone, the zinc sulfide and the cryolite is 270 meshes of sieve;
the type of the phenolic resin liquid is PF2559;
the model of the phenolic resin powder is PF2898ASS;
the particle sizes of the phenolic resin powder and the iron oxide red are 325 meshes;
the manufacturing method of the special fiber reinforced resin abrasive cutoff wheel for cutting the railway steel rail comprises the following steps:
step 1, premixing:
(1) According to the component proportion of the grinding wheel, mixing the high-temperature calcined brown corundum, the ceramic coating white corundum, the monocrystalline corundum and the silicon carbide for 3min, and preparing an abrasive component A after uniformly mixing;
(2) Mixing lithopone, zinc sulfide and cryolite for 6min according to the component proportion of the grinding wheel, and preparing an auxiliary material component B after uniformly mixing;
(3) Adding phenolic resin powder into the auxiliary material component B according to the component proportion of the grinding wheel, mixing for 3min, and uniformly mixing to obtain a mixture C;
step 2, mixing:
adding the phenolic resin liquid into the abrasive component A according to the component proportion of the grinding wheel, mixing for 10min, then adding iron oxide red, continuously and uniformly mixing for 4min, then adding the mixture C, further mixing for 10min, and uniformly mixing to obtain a grinding wheel blank D;
and step 3, sieving and naturally airing:
sieving the grinding wheel blank D, wherein the mesh number of the sieve is 16 meshes, then placing the grinding wheel blank D in a constant-temperature constant-humidity storage chamber, keeping the temperature at 22 ℃ and the humidity at 32%, and standing for 25 hours for later use;
and 4, secondary sieving:
sieving the sand wheel blank D after standing for the second time, wherein the mesh number of a screen is 20 meshes to obtain a uniform and loose molding material E;
step 5, forming:
the temperature of a mould is raised to 45 ℃ in advance, a pretreated and flat glass fiber reinforced net with the size of 5 meshes and the weight of 280 grams is laid in the mould, then a forming material E is filled in the mould, the material is spread for two times, and the forming material E is fully spread and scraped evenly; then laying a 5-mesh 280 g glass fiber reinforced net on the flattened molding material E, finally placing a label and a steel ring, and pressing under the pressure of 80kg/cm 2 Maintaining the pressure for 20s to prepare the sandA wheel;
step 6, hardening:
(1) Penetrating 10 grinding wheels into the penetrating rod, placing two V-shaped dragon partition nets between every two adjacent grinding wheels, placing an aluminum partition plate with the thickness of 10mm, and finally covering a steel plate with the thickness of 20mm on the uppermost grinding wheel and clamping the steel plate by using a spring to form a grinding wheel clamped into a string;
(2) Placing the grinding wheels clamped into a string in a hot air hardening furnace, neatly and uniformly placing the grinding wheels into the furnace, and hardening at high temperature; the high-temperature hardening parameters are that the temperature rising process is 31 hours, the highest temperature is 180 ℃, the temperature is kept for 10 hours, and the temperature reduction process is 9 hours;
and 7, checking:
and taking out the hardened and cooled grinding wheel, and inspecting to obtain a finished grinding wheel.
The density of the grinding wheel prepared by the embodiment reaches 2.35g/cm 3 The method has the advantages that the 80# steel rail can be cut once within 140s, the 60# steel rail can be cut once within 110s, and the cut is bright and straight, so that the requirement of minimum tolerance of steel rail cutting machining is met. When the grinding wheel is used for cutting, the 60# steel rail cut by the grinding wheel can reach 6.5 cutters, and the 80# steel rail can reach 5.5 cutters and can be scrapped and replaced, so that the service life is greatly prolonged.
Example 3
The special fiber reinforced resin abrasive cutting wheel for cutting the railway steel rail comprises the following components in parts by mass: 60 parts of high-temperature calcined brown corundum, 50 parts of ceramic coated white corundum, 20 parts of monocrystalline corundum, 30 parts of silicon carbide, 25 parts of high-strength phenolic resin, 12 parts of lithopone, 8 parts of zinc sulfide, 9 parts of cryolite and 0.8 part of iron oxide red;
the high-strength phenolic resin comprises phenolic resin liquid and phenolic resin powder, and the mass ratio is that the phenolic resin liquid: phenolic resin powder =40:60, adding a solvent to the mixture;
the high-temperature calcined brown corundum is brown corundum calcined at 1300 ℃ for 2 hours;
the ceramic coating white corundum is obtained by calcining at 1300 ℃ for 2 hours and then performing ceramic coating;
the ceramic coating is high-pressure spray coating by using iron oxide red and a ceramic bonding agent; the thickness of the ceramic plating coat is 0.11mm;
the granularity of the high-temperature calcined brown corundum, the ceramic coated white corundum, the monocrystalline corundum and the silicon carbide is 40 meshes;
the granularity of the lithopone, the zinc sulfide and the cryolite is 250 meshes;
the type of the phenolic resin liquid is PF2559;
the model of the phenolic resin powder is PF2898ASS;
the particle sizes of the phenolic resin powder and the iron oxide red are 325 meshes;
the manufacturing method of the special fiber reinforced resin abrasive cutoff wheel for cutting the railway steel rail comprises the following steps:
step 1, premixing:
(1) Mixing the high-temperature calcined brown corundum, the ceramic coated white corundum, the monocrystalline corundum and the silicon carbide for 2min according to the component proportion of the grinding wheel, and preparing an abrasive component A after uniformly mixing;
(2) Mixing lithopone, zinc sulfide and cryolite for 8min according to the component ratio of the grinding wheel, and preparing an auxiliary material component B after uniformly mixing;
(3) Adding phenolic resin powder into the auxiliary material component B according to the component proportion of the grinding wheel, mixing for 3min, and uniformly mixing to obtain a mixture C;
step 2, mixing:
adding the phenolic resin liquid into the abrasive component A according to the component proportion of the grinding wheel, mixing for 12min, then adding iron oxide red, continuously and uniformly mixing for 5min, then adding the mixture C, further mixing for 6min, and uniformly mixing to obtain a grinding wheel blank D;
and step 3, sieving and naturally airing:
sieving the grinding wheel blank D, wherein the mesh number of the sieve is 16 meshes, then placing the grinding wheel blank D in a constant-temperature constant-humidity storage chamber, keeping the temperature at 25 ℃ and the humidity at 40%, and standing for 26 hours for later use;
and 4, secondary sieving:
sieving the blank D of the grinding wheel after standing for the second time, wherein the mesh number of a sieve is 20 meshes, and obtaining a uniform and loose molding material E;
step 5, forming:
the temperature of a mould is raised to 50 ℃ in advance, a pretreated and flat glass fiber reinforced net with the size of 5 meshes and the weight of 280 grams is laid in the mould, then a forming material E is filled in the mould, the material is spread for two times, and the forming material E is fully spread and scraped evenly; then laying a 5-mesh 280 g glass fiber reinforced net on the flattened section material E, finally placing a label and a steel ring, and pressing under the pressure of 180kg/cm 2 Maintaining the pressure for 15s to prepare the grinding wheel;
step 6, hardening:
(1) Penetrating 8 grinding wheels into the penetrating rod, placing two V-shaped dragon partition nets between every two adjacent grinding wheels, placing an aluminum partition plate with the thickness of 10mm, and finally covering a steel plate with the thickness of 20mm on the uppermost grinding wheel and clamping the steel plate by using a spring to form a grinding wheel clamped into a string;
(2) Placing the grinding wheels clamped into a string in a hot air hardening furnace, neatly and uniformly placing the grinding wheels into the furnace, and hardening at high temperature; the high-temperature hardening parameters are that the temperature rise process is 32h, the maximum temperature is 190 ℃, the heat preservation is 10h, and the temperature reduction process is 10h;
and 7, checking:
and taking out the hardened and cooled grinding wheel, and inspecting to obtain a finished grinding wheel.
The density of the grinding wheel prepared by the embodiment reaches 2.34g/cm 3 The method has the advantages that the 80# steel rail can be cut once in 120s, the 60# steel rail can be cut once in 115s, and the cut is guaranteed to be bright and straight, so that the requirement of the minimum tolerance of steel rail cutting machining is met. When the grinding wheel cutting device is used for cutting, the 60# steel rail can reach 6.5 cutters, and the 80# steel rail can reach 5.5 cutters, so that the steel rail can be scrapped and replaced, and the service life is greatly prolonged.
Example 4
The special fiber reinforced resin abrasive cutting wheel for cutting the railway steel rail comprises the following components in parts by mass: 35 parts of high-temperature calcined brown corundum, 25 parts of ceramic coated white corundum, 13 parts of monocrystalline corundum, 14 parts of silicon carbide, 18 parts of high-strength phenolic resin, 10 parts of lithopone, 4 parts of zinc sulfide, 7 parts of cryolite and 0.7 part of iron oxide red;
the high-strength phenolic resin comprises phenolic resin liquid and phenolic resin powder, and the mass ratio is that the phenolic resin liquid: phenolic resin powder =32:68;
the high-temperature calcined brown corundum is brown corundum calcined at 1200 ℃ for 2.5 hours;
the ceramic coating white corundum is calcined at 1200 ℃ for 2.5 hours and then subjected to ceramic coating;
the ceramic coating is high-pressure spray coating by using iron oxide red and a ceramic bonding agent; the thickness of the ceramic plating coat is 0.08mm;
the granularity of the high-temperature calcined brown corundum, the ceramic coating white corundum, the single crystal corundum and the silicon carbide is 32 meshes;
the granularity of the lithopone, the zinc sulfide and the cryolite is 180 meshes;
the type of the phenolic resin liquid is PF2559;
the model of the phenolic resin powder is PF2898ASS;
the particle sizes of the phenolic resin powder and the iron oxide red are 325 meshes;
the manufacturing method of the special fiber reinforced resin abrasive cutoff wheel for cutting the railway steel rail comprises the following steps:
step 1, premixing:
(1) According to the component proportion of the grinding wheel, mixing the high-temperature calcined brown corundum, the ceramic coating white corundum, the monocrystalline corundum and the silicon carbide for 2.5min, and preparing an abrasive component A after uniformly mixing;
(2) Mixing lithopone, zinc sulfide and cryolite for 3.5min according to the component proportion of the grinding wheel, and preparing an auxiliary material component B after uniformly mixing;
(3) Adding phenolic resin powder into the auxiliary material component B according to the component proportion of the grinding wheel, mixing for 5min, and uniformly mixing to obtain a mixture C;
step 2, mixing:
adding the phenolic resin liquid into the abrasive component A according to the component proportion of the grinding wheel, mixing for 8min, then adding iron oxide red, continuously and uniformly mixing for 2min, then adding the mixture C, further mixing for 5min, and uniformly mixing to obtain a grinding wheel blank D;
and step 3, sieving and naturally airing:
sieving the grinding wheel blank D, wherein the mesh number of the sieve is 16 meshes, then placing the grinding wheel blank D in a constant-temperature constant-humidity storage chamber, keeping the temperature at 24 ℃ and the humidity at 38%, and standing for 25 hours for later use;
and 4, secondary sieving:
sieving the blank D of the grinding wheel after standing for the second time, wherein the mesh number of a sieve is 20 meshes, and obtaining a uniform and loose molding material E;
step 5, forming:
the temperature of a mould is raised to 55 ℃ in advance, a pretreated and flat glass fiber reinforced net with the size of 5 meshes and the weight of 280 grams is laid in the mould, then a forming material E is filled in the mould, the material is spread for two times, and the forming material E is fully spread and scraped evenly; then laying a 5-mesh 280-gram glass fiber reinforced net on the flattened section material E, finally placing a label and a steel ring, and pressing under the pressure of 80kg/cm 2 Maintaining the pressure for 15s to prepare the grinding wheel;
step 6, hardening:
(1) Penetrating 5 grinding wheels into a penetrating rod, placing two V-shaped dragon partition nets between every two adjacent grinding wheels, placing an aluminum partition plate with the thickness of 10mm, and finally covering a steel plate with the thickness of 20mm on the uppermost grinding wheel and tightly clamping the steel plate by using a spring to form a grinding wheel which is clamped into a string;
(2) Placing the grinding wheels clamped into a string in a hot air hardening furnace, neatly and uniformly placing the grinding wheels into the furnace, and hardening at high temperature; the high-temperature hardening parameters are that the temperature rising process is 30 hours, the highest temperature is 185 ℃, the temperature is kept for 11 hours, and the temperature reduction process is 8.5 hours;
and 7, checking:
and taking out the hardened and cooled grinding wheel, and inspecting to obtain a finished grinding wheel.
The density of the grinding wheel prepared by the embodiment reaches 2.34g/cm 3 The 80# steel rail can be cut once in 125s, the 60# steel rail can be cut once in 105s, and the cut is guaranteed to be bright and straight, so that the requirement of the minimum tolerance of the steel rail cutting machining is met. When the grinding wheel is used for cutting, the grinding wheel can cut the 60# steel rail by 6.5 knives, and the grinding wheel can cut the 80# steel rail by 5.5 knives, so that the steel can be reportedThe waste replacement greatly prolongs the service life.
Example 5
The special fiber reinforced resin abrasive cutting wheel for cutting the railway steel rail comprises the following components in parts by mass: 55 parts of high-temperature calcined brown corundum, 45 parts of ceramic coated white corundum, 18 parts of monocrystalline corundum, 24 parts of silicon carbide, 21 parts of high-strength phenolic resin, 10 parts of lithopone, 7 parts of zinc sulfide, 8 parts of cryolite and 0.7 part of iron oxide red;
the high-strength phenolic resin comprises phenolic resin liquid and phenolic resin powder, and the mass ratio is that the phenolic resin liquid: phenolic resin powder =38:62, a first step of mixing;
the high-temperature calcined brown corundum is brown corundum calcined at 1050 ℃ for 4 hours;
the ceramic coating white corundum is calcined at 1050 ℃ for 3 hours and then subjected to ceramic coating;
the ceramic coating is high-pressure spray coating by using iron oxide red and a ceramic bonding agent; the thickness of the ceramic plating coat is 0.15mm;
the granularity of the high-temperature calcined brown corundum, the ceramic coated white corundum, the monocrystalline corundum and the silicon carbide is 35 meshes;
the granularity of the lithopone, the zinc sulfide and the cryolite is 270 meshes;
the type of the phenolic resin liquid is PF2559;
the model of the phenolic resin powder is PF2898ASS;
the particle sizes of the phenolic resin powder and the iron oxide red are 325 meshes;
the manufacturing method of the special fiber reinforced resin abrasive cutoff wheel for cutting the railway steel rail comprises the following steps:
step 1, premixing:
(1) Mixing the high-temperature calcined brown corundum, the ceramic coating white corundum, the monocrystalline corundum and the silicon carbide for 2min according to the component proportion of the grinding wheel, and preparing an abrasive component A after uniform mixing;
(2) Mixing lithopone, zinc sulfide and cryolite for 4min according to the component proportion of the grinding wheel, and preparing an auxiliary material component B after uniformly mixing;
(3) Adding phenolic resin powder into the auxiliary material component B according to the component proportion of the grinding wheel, mixing for 3min, and uniformly mixing to obtain a mixture C;
step 2, mixing:
adding the phenolic resin liquid into the abrasive component A according to the component proportion of the grinding wheel, mixing for 8min, then adding iron oxide red, continuously and uniformly mixing for 4min, then adding the mixture C, further mixing for 8min, and uniformly mixing to obtain a grinding wheel blank D;
and step 3, sieving and naturally airing:
sieving the grinding wheel blank D, wherein the mesh number of the sieve is 20 meshes, then placing the grinding wheel blank D in a constant-temperature constant-humidity storage chamber, keeping the temperature at 23 ℃ and the humidity at 32%, and standing for 25.5 hours for later use;
and 4, secondary sieving:
sieving the blank D of the grinding wheel after standing for the second time, wherein the mesh number of a sieve is 20 meshes, and obtaining a uniform and loose molding material E;
step 5, forming:
the temperature of a mould is raised to 60 ℃ in advance, a pretreated and flat glass fiber reinforced mesh with the size of 5 meshes and the weight of 280 grams is laid in the mould, then a forming material E is filled in the mould, the material spreading is carried out twice, and the forming material E is fully spread and scraped evenly; then, a 5-mesh 280 g glass fiber reinforced net is laid on the flattened molding material E, and finally, a label and a steel ring are placed on the net for pressing, wherein the pressure is 170kg/cm 2 Maintaining the pressure for 15s to prepare the grinding wheel;
step 6, hardening:
(1) Penetrating 8 grinding wheels into the penetrating rod, placing two V-shaped dragon partition nets between every two adjacent grinding wheels, placing an aluminum partition plate with the thickness of 10mm, and finally covering a steel plate with the thickness of 20mm on the uppermost grinding wheel and clamping the steel plate by using a spring to form a grinding wheel clamped into a string;
(2) Placing the grinding wheels which are clamped into a string in a hot air hardening furnace, neatly and uniformly placing the grinding wheels into the furnace, and performing high-temperature hardening; the high-temperature hardening parameters are that the temperature rising process is 32 hours, the maximum temperature is 185 ℃, the temperature is kept for 12 hours, and the temperature reduction process is 8.5 hours;
and 7, checking:
and taking out the hardened and cooled grinding wheel, and inspecting to obtain a finished grinding wheel.
The density of the grinding wheel prepared by the embodiment reaches 2.33g/cm 3 The 80# steel rail can be cut once in 140s, the 60# steel rail can be cut once in 100s, and the cut is guaranteed to be bright and straight, so that the requirement of the minimum tolerance of the steel rail cutting machining is met. When the grinding wheel is used for cutting, the 60# steel rail cut by the grinding wheel can reach 6.5 cutters, and the 80# steel rail can reach 5.5 cutters and can be scrapped and replaced, so that the service life is greatly prolonged.
Example 6
The special fiber reinforced resin abrasive cutting wheel for cutting the railway steel rail comprises the following components in parts by mass: 50 parts of high-temperature calcined brown corundum, 45 parts of ceramic coated white corundum, 18 parts of monocrystalline corundum, 12 parts of silicon carbide, 21 parts of high-strength phenolic resin, 9 parts of lithopone, 3 parts of zinc sulfide, 6 parts of cryolite and 0.6 part of iron oxide red;
the high-strength phenolic resin comprises phenolic resin liquid and phenolic resin powder, and the mass ratio is that the phenolic resin liquid: phenolic resin powder =34:66;
the high-temperature calcined brown corundum is brown corundum calcined at 1100 ℃ for 3 hours;
the ceramic coating white corundum is calcined at 1100 ℃ for 4 hours and then is subjected to ceramic coating;
the ceramic coating is high-pressure spray coating by using iron oxide red and a ceramic bonding agent; the thickness of the ceramic plating coat is less than 0.07 mm;
the granularity of the high-temperature calcined brown corundum, the ceramic coated white corundum, the monocrystalline corundum and the silicon carbide is 27 meshes;
the granularity of the lithopone, the zinc sulfide and the cryolite is 110 meshes;
the type of the phenolic resin liquid is PF2559;
the model of the phenolic resin powder is PF2898ASS;
the particle sizes of the phenolic resin powder and the iron oxide red are 325 meshes;
the manufacturing method of the special fiber reinforced resin abrasive cutoff wheel for cutting the railway steel rail comprises the following steps:
step 1, premixing:
(1) According to the component proportion of the grinding wheel, mixing the high-temperature calcined brown corundum, the ceramic coating white corundum, the monocrystalline corundum and the silicon carbide for 1min, and preparing an abrasive component A after uniformly mixing;
(2) Mixing lithopone, zinc sulfide and cryolite for 10min according to the component proportion of the grinding wheel, and preparing an auxiliary material component B after uniformly mixing;
(3) Adding phenolic resin powder into the auxiliary material component B according to the component proportion of the grinding wheel, mixing for 4min, and uniformly mixing to obtain a mixture C;
step 2, mixing:
adding the phenolic resin liquid into the grinding material component A according to the component ratio of the grinding wheel, mixing for 11min, then adding iron oxide red, continuing to uniformly mix for 5min, then adding the mixture C, further mixing for 2min, and uniformly mixing to obtain a grinding wheel blank D;
and step 3, sieving and naturally airing:
sieving the grinding wheel blank D, wherein the mesh number of the sieve is 20 meshes, then placing the grinding wheel blank D in a constant-temperature constant-humidity storage chamber, keeping the temperature at 21 ℃ and the humidity at 27%, and standing for 24 hours for later use;
and 4, secondary sieving:
sieving the sand wheel blank D after standing for the second time, wherein the mesh number of a screen is 20 meshes to obtain a uniform and loose molding material E;
step 5, forming:
the temperature of a mould is raised to 30 ℃ in advance, a pretreated and flat glass fiber reinforced net with the size of 5 meshes and the weight of 280 grams is laid in the mould, then a forming material E is filled in the mould, the material is spread for two times, and the forming material E is fully spread and scraped evenly; then laying a 5-mesh 280 g glass fiber reinforced net on the flattened molding material E, finally placing a label and a steel ring, and pressing under the pressure of 95kg/cm 2 Maintaining the pressure for 17s to prepare the grinding wheel;
step 6, hardening:
(1) Penetrating 10 grinding wheels into the penetrating rod, placing two V-shaped dragon partition nets between every two adjacent grinding wheels, placing an aluminum partition plate with the thickness of 10mm, and finally covering a steel plate with the thickness of 20mm on the uppermost grinding wheel and clamping the steel plate by using a spring to form a grinding wheel clamped into a string;
(2) Placing the grinding wheels clamped into a string in a hot air hardening furnace, neatly and uniformly placing the grinding wheels into the furnace, and hardening at high temperature; the high-temperature hardening parameters are that the temperature rise process is 32 hours, the maximum temperature is 185 ℃, the heat preservation is 12 hours, and the temperature reduction process is 8 hours;
and 7, checking:
and taking out the hardened and cooled grinding wheel, and inspecting to obtain a finished grinding wheel.
The density of the grinding wheel prepared by the embodiment reaches 2.34g/cm 3 The 80# steel rail can be cut once in 135s, the 60# steel rail can be cut once in 112s, and the cut is guaranteed to be bright and straight, so that the requirement of the minimum tolerance of the steel rail cutting machining is met. When the grinding wheel cutting device is used for cutting, the 60# steel rail can reach 6.5 cutters, and the 80# steel rail can reach 5.5 cutters, so that the steel rail can be scrapped and replaced, and the service life is greatly prolonged.
Example 7
The special fiber reinforced resin abrasive cutting wheel for cutting the railway steel rail comprises the following components in parts by mass: 48 parts of high-temperature calcined brown corundum, 42 parts of ceramic coated white corundum, 16 parts of monocrystalline corundum, 18 parts of silicon carbide, 20 parts of high-strength phenolic resin, 9 parts of lithopone, 5 parts of zinc sulfide, 7 parts of cryolite and 0.7 part of iron oxide red;
the high-strength phenolic resin comprises phenolic resin liquid and phenolic resin powder, and the mass ratio is that the phenolic resin liquid: phenolic resin powder =37:63;
the high-temperature calcined brown corundum is brown corundum calcined at 950 ℃ for 4 hours;
the ceramic coating white corundum is calcined at 950 ℃ for 4 hours and then is subjected to ceramic coating;
the ceramic coating is high-pressure spray coating by using iron oxide red and a ceramic bonding agent; the thickness of the ceramic plating coat is less than 0.14 mm;
the granularity of the high-temperature calcined brown corundum, the ceramic coated white corundum, the monocrystalline corundum and the silicon carbide is 24 meshes;
the granularity of the lithopone, the zinc sulfide and the cryolite is 100 meshes;
the type of the phenolic resin liquid is PF2559;
the model of the phenolic resin powder is PF2898ASS;
the particle sizes of the phenolic resin powder and the iron oxide red are 325 meshes;
the manufacturing method of the special fiber reinforced resin abrasive cutoff wheel for cutting the railway steel rail comprises the following steps:
step 1, premixing:
(1) According to the component proportion of the grinding wheel, mixing the high-temperature calcined brown corundum, the ceramic coating white corundum, the monocrystalline corundum and the silicon carbide for 4min, and preparing an abrasive component A after uniformly mixing;
(2) Mixing lithopone, zinc sulfide and cryolite for 9min according to the component proportion of the grinding wheel, and preparing an auxiliary material component B after uniformly mixing;
(3) Adding phenolic resin powder into the auxiliary material component B according to the component proportion of the grinding wheel, mixing for 1min, and uniformly mixing to obtain a mixture C;
step 2, mixing:
adding the phenolic resin liquid into the abrasive component A according to the component proportion of the grinding wheel, mixing for 2min, then adding iron oxide red, continuously and uniformly mixing for 5min, then adding the mixture C, further mixing for 10min, and uniformly mixing to obtain a grinding wheel blank D;
and step 3, sieving and naturally airing:
sieving the grinding wheel blank D, wherein the mesh number of a screen is 14 meshes, then placing the grinding wheel blank D in a constant-temperature constant-humidity storage chamber, keeping the temperature at 24 ℃ and the humidity at 30%, and standing for 24 hours for later use;
and 4, secondary sieving:
sieving the blank D of the grinding wheel after standing for the second time to obtain a uniform and loose molding material E, wherein the mesh number of the sieve is 16 meshes;
step 5, forming:
the temperature of the mold is raised to 35 ℃ in advance, and a piece of glass fiber reinforcement with 280 g of 5 meshes which is processed smoothly in advance is laid in the moldNet, then filling the forming material E into the mould, spreading the material for two times, and fully spreading and scraping the forming material E; then laying a 5-mesh 280-gram glass fiber reinforced net on the flattened section material E, finally placing a label and a steel ring, and pressing under the pressure of 190kg/cm 2 Maintaining the pressure for 17s to prepare the grinding wheel;
step 6, hardening:
(1) Penetrating 10 grinding wheels into the penetrating rod, placing two V-shaped dragon partition nets between every two adjacent grinding wheels, placing an aluminum partition plate with the thickness of 10mm, and finally covering a steel plate with the thickness of 20mm on the uppermost grinding wheel and clamping the steel plate by using a spring to form a grinding wheel clamped into a string;
(2) Placing the grinding wheels clamped into a string in a hot air hardening furnace, neatly and uniformly placing the grinding wheels into the furnace, and hardening at high temperature; the high-temperature hardening parameters are that the temperature rising process is 32 hours, the highest temperature is 185 ℃, the temperature is kept for 11 hours, and the temperature reduction process is 10 hours;
and 7, checking:
and taking out the hardened and cooled grinding wheel, and inspecting to obtain a finished grinding wheel.
The density of the grinding wheel prepared by the embodiment reaches 2.31g/cm 3 The 80# steel rail can be cut once in 130s, the 60# steel rail can be cut once in 110s, and the cut is guaranteed to be bright and straight, so that the requirement of the minimum tolerance of the steel rail cutting machining is met. When the grinding wheel cutting device is used for cutting, the 60# steel rail can reach 6.5 cutters, and the 80# steel rail can reach 5.5 cutters, so that the steel rail can be scrapped and replaced, and the service life is greatly prolonged.
Example 8
The special fiber reinforced resin abrasive cutting wheel for cutting the railway steel rail comprises the following components in parts by mass: 34 parts of high-temperature calcined brown corundum, 28 parts of ceramic coated white corundum, 19 parts of monocrystalline corundum, 14 parts of silicon carbide, 21 parts of high-strength phenolic resin, 6 parts of lithopone, 5 parts of zinc sulfide, 6 parts of cryolite and 0.7 part of iron oxide red;
the high-strength phenolic resin comprises phenolic resin liquid and phenolic resin powder, and the mass ratio is that the phenolic resin liquid: phenolic resin powder =40:60, adding a solvent to the mixture;
the high-temperature calcined brown corundum is brown corundum calcined at 900 ℃ for 4 hours;
the ceramic coating white corundum is calcined at 1050 ℃ for 3 hours and then is subjected to ceramic coating;
the ceramic coating is high-pressure spray coating by using iron oxide red and a ceramic bonding agent; the thickness of the ceramic plating coat is less than 0.16 mm;
the granularity of the high-temperature calcined brown corundum, the ceramic coating white corundum, the single crystal corundum and the silicon carbide is 32 meshes;
the granularity of the lithopone, the zinc sulfide and the cryolite is 325 meshes;
the type of the phenolic resin liquid is PF2559;
the model of the phenolic resin powder is PF2898ASS;
the particle sizes of the phenolic resin powder and the iron oxide red are 325 meshes;
the manufacturing method of the special fiber reinforced resin abrasive cutoff wheel for cutting the railway steel rail comprises the following steps:
step 1, premixing:
(1) According to the component proportion of the grinding wheel, mixing the high-temperature calcined brown corundum, the ceramic coating white corundum, the monocrystalline corundum and the silicon carbide for 1min, and preparing an abrasive component A after uniformly mixing;
(2) Mixing lithopone, zinc sulfide and cryolite for 7min according to the component proportion of the grinding wheel, and preparing an auxiliary material component B after uniformly mixing;
(3) Adding phenolic resin powder into the auxiliary material component B according to the component proportion of the grinding wheel, mixing for 2min, and uniformly mixing to obtain a mixture C;
step 2, mixing:
adding the phenolic resin liquid into the abrasive component A according to the component proportion of the grinding wheel, mixing for 12min, then adding iron oxide red, continuously and uniformly mixing for 1min, then adding the mixture C, further mixing for 4min, and uniformly mixing to obtain a grinding wheel blank D;
and step 3, sieving and naturally airing:
sieving the grinding wheel blank D, wherein the mesh number of a screen is 16 meshes, then placing the grinding wheel blank D in a constant-temperature and constant-humidity storage room, keeping the temperature at 23 ℃ and the humidity at 36%, and standing for 24 hours for later use;
and 4, secondary sieving:
sieving the blank D of the grinding wheel after standing for the second time, wherein the mesh number of a sieve is 20 meshes, and obtaining a uniform and loose molding material E;
step 5, forming:
the temperature of a mould is raised to 48 ℃ in advance, a pretreated and flat glass fiber reinforced net with the size of 5 meshes and the weight of 280 grams is laid in the mould, then a forming material E is filled in the mould, the material is spread for two times, and the forming material E is fully spread and scraped evenly; then, a 5-mesh 280-gram glass fiber reinforced net is laid on the flattened molding material E, and finally, a label and a steel ring are placed on the glass fiber reinforced net for pressing under the pressure of 140kg/cm 2 Maintaining the pressure for 18s to prepare the grinding wheel;
step 6, hardening:
(1) 5 grinding wheels penetrate into the penetrating rod, two V-shaped dragon partition nets are placed between every two adjacent grinding wheels, an aluminum partition plate with the thickness of 10mm is placed, and finally a steel plate with the thickness of 20mm is covered on the uppermost grinding wheel and is clamped by a spring to form a grinding wheel which is clamped into a string;
(2) Placing the grinding wheels which are clamped into a string in a hot air hardening furnace, neatly and uniformly placing the grinding wheels into the furnace, and performing high-temperature hardening; the high-temperature hardening parameters are that the temperature rise process is 31h, the highest temperature is 180 ℃, the temperature is kept for 12h, and the temperature reduction process is 8h;
and 7, checking:
and taking out the hardened and cooled grinding wheel, and inspecting to obtain a finished grinding wheel.
The density of the grinding wheel prepared by the embodiment reaches 2.30g/cm 3 The 80# steel rail can be cut once in 135s, the 60# steel rail can be cut once in 100s, and the cut is guaranteed to be bright and straight, so that the requirement of the minimum tolerance of the steel rail cutting machining is met. When the grinding wheel is used for cutting, the 60# steel rail cut by the grinding wheel can reach 6.5 cutters, and the 80# steel rail can reach 5.5 cutters and can be scrapped and replaced, so that the service life is greatly prolonged.
Claims (7)
1. Special fiber reinforced resin cutter for cutting railway steel railsThe cutting grinding wheel is characterized in that the grinding wheel comprises the following components in parts by mass: 35-60 parts of high-temperature calcined brown corundum, 35-50 parts of ceramic coated white corundum, 10-20 parts of monocrystalline corundum, 10-30 parts of silicon carbide, 17-25 parts of high-strength phenolic resin, 4-12 parts of lithopone, 2-8 parts of zinc sulfide, 5-9 parts of cryolite and 0.5-0.8 part of iron oxide red; the high-strength phenolic resin comprises phenolic resin liquid and phenolic resin powder, and the mass ratio is that the phenolic resin liquid: phenolic resin powder = (30 to 40): (60 to 70); the density of the grinding wheel is 2.30g/cm 3 ～2.35g/cm 3 ；
The ceramic coating white corundum is prepared by calcining white corundum at 800-1300 ℃ for 2-4h and then performing ceramic coating, wherein the ceramic coating is prepared by performing high-pressure spray coating on iron oxide red and a ceramic bonding agent, and the thickness of the ceramic coating is less than 0.2 mm;
a method for manufacturing a special fiber reinforced resin abrasive cutting wheel for cutting railway steel rails comprises the following steps:
step 1, premixing:
(1) According to the component proportion of the grinding wheel, mixing the high-temperature calcined brown corundum, the ceramic coating white corundum, the monocrystalline corundum and the silicon carbide, and preparing an abrasive component A after uniformly mixing;
(2) Mixing lithopone, zinc sulfide and cryolite according to the component proportion of the grinding wheel, and preparing an auxiliary material component B after uniformly mixing;
(3) Adding phenolic resin powder into the auxiliary material component B according to the component proportion of the grinding wheel, mixing, and uniformly mixing to obtain a mixture C;
step 2, mixing:
adding the phenolic resin liquid into the grinding material component A according to the component proportion of the grinding wheel, uniformly mixing, then adding iron oxide red, continuously and uniformly mixing, then adding the mixture C, further mixing, and uniformly mixing to obtain a grinding wheel blank D;
and step 3, sieving and naturally airing:
sieving the grinding wheel blank D, then placing the grinding wheel blank D in a constant-temperature and constant-humidity storage room, and standing for 24-26 hours for later use;
and 4, secondary sieving:
sieving the static grinding wheel blank D for the second time to obtain a uniform and loose molding material E;
step 5, forming:
the temperature of a mould is raised to 30-60 ℃ in advance, a glass fiber reinforced net is laid in the mould, then a forming material E is filled in the mould, the material is spread for two times, and the forming material E is fully spread and scraped evenly; laying a glass fiber reinforced net on the flattened molding material E, placing a label and a steel ring, and pressing to obtain a grinding wheel;
step 6, hardening:
(1) Penetrating 15-30 grinding wheels into a penetrating rod, placing two V-shaped dragon partition nets and an aluminum partition plate between every two adjacent grinding wheels, covering a steel plate on the uppermost grinding wheel, and clamping by using a spring to form a grinding wheel clamped into a string;
(2) Placing the grinding wheels clamped into a string in a hot air hardening furnace, neatly and uniformly placing the grinding wheels into the furnace, and hardening at high temperature;
the thickness of the aluminum partition plate is 10mm; the thickness of the steel plate is 20mm; the high-temperature hardening parameters are that the temperature rising process is 30-32 hours, the highest temperature is 185 +/-5 ℃, the temperature is kept for 10-12 hours, and the temperature reduction process is 8-10 hours;
and 7, checking:
taking out the hardened and cooled grinding wheel, and inspecting to obtain a finished grinding wheel, wherein the density of the finished grinding wheel reaches 2.30g/cm 3 ～2.35g/cm 3 。
2. The fiber reinforced resin abrasive cutoff wheel special for cutting a railway steel rail according to claim 1, wherein the high-temperature calcined brown corundum is brown corundum calcined at 800-1300 ℃ for 2-4 hours.
3. The special fiber reinforced resin abrasive cutoff wheel for cutting railway rails according to claim 1, wherein the grain sizes of the high-temperature calcined brown corundum, the ceramic coated white corundum, the monocrystalline corundum and the silicon carbide are 22-46 meshes; the granularity of the lithopone, the zinc sulfide and the cryolite is 80 to 325 meshes; the particle sizes of the phenolic resin powder and the iron oxide red are 280-325 meshes.
4. The fiber reinforced resin abrasive cutoff wheel special for cutting a railway steel rail according to claim 1, wherein the type of the phenolic resin liquid is PF2559; the model of the phenolic resin powder is PF2898ASS.
5. The fiber reinforced resin abrasive cutoff wheel special for cutting a railway steel rail according to claim 1, wherein in step 1, the mixing time of the high-temperature calcined brown corundum, the ceramic coated white corundum, the single crystal corundum and the silicon carbide is 1-4 min; mixing the lithopone, the zinc sulfide and the cryolite for 1-10 min; the mixing time of the phenolic resin powder and the auxiliary material component B is 1-5 min;
in the step 2, the mixing time of the phenolic resin liquid and the abrasive component A is 2-12 min; the time for adding the iron oxide red and continuously and uniformly mixing is 1-5 min, and the time for adding the mixture C and further mixing is 2-10 min.
6. The fiber reinforced resin abrasive cutoff wheel special for cutting railway steel rails according to claim 1, wherein in the step 3, the mesh number of the sieved mesh of the abrasive wheel blank D is 14-22 meshes; the temperature of the storage chamber is 22-25 ℃, and the humidity is 25-40%;
in the step 4, the mesh number of the screen for the second sieving is 16-20 meshes.
7. The fiber reinforced resin abrasive cutoff wheel special for cutting railway steel rails according to claim 1, wherein in step 5, the specification of the glass fiber reinforced mesh is 280 grams of 5 meshes; the pressing pressure is 60-200 kg/cm 2 And keeping the pressure for 15-20 s.
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| CN115338784A (en) * | 2022-08-03 | 2022-11-15 | 莆田市屹立砂轮磨具有限公司 | Wear-resistant grinding wheel grinding tool and preparation process thereof |
| CN115229695A (en) * | 2022-08-09 | 2022-10-25 | 久铖高科(厦门)集团有限公司 | Mixing process for steel rail grinding wheel |
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