CN115256251A - 一种树脂基复合结合剂磨盘及其制备方法 - Google Patents
一种树脂基复合结合剂磨盘及其制备方法 Download PDFInfo
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Abstract
本发明属于树脂磨具技术领域,涉及一种树脂基复合结合剂磨盘及其制备方法。将磨料、金属粉、金属氧化物粉、树脂粉混合成型后烧结,然后破碎,得到磨料物;再将树脂粉、添加剂与磨料物混合后热压成型,然后硬化,得到磨削体;再将磨削体与基体复合,得到树脂基复合结合剂磨盘。本发明采用与现有技术不同的思路,从磨盘配方以及制备工艺着手,先将磨料、金属粉、金属氧化物粉、树脂粉混合成型后烧结,然后破碎,得到磨料物,与现有制备磨盘的方法不同,得到的产品研磨能力很强,磨削比很高,磨削过程中磨耗较小,磨削过程中修整和更换磨具次数低于现有磨具,还具有较长的使用寿命,并节约了修整和更换磨具所需的时间,生产效率大幅提升。
Description
技术领域
本发明属于树脂磨具技术领域,涉及一种树脂基复合结合剂磨盘及其制备方法。
背景技术
随着工业技术的快速发展,超硬磨盘被广泛地应用汽车、航天航空、电子行业、3C行业等。技术的不断更新,对工件要求越来越高,因此对磨盘的要求也越来越高,不仅要有高的研磨效率,还需被加工工件有好的表面粗糙度。传统的超硬磨盘,采用金刚石或者CBN磨料制备而成。若使用粗粒度磨料,磨盘有相对好的切削效率,但磨削工件的粗糙度较差;若采用细粒度磨料,磨盘磨削加工的工件有较好的粗糙度,但加工效率会相对较差。因此,传统的磨盘制备工艺不能满足这种相互矛盾的要求。双端面研磨加工一般速度只有几十转,属于低速冷磨削,而在这样的加工条件下,要解决同时具有高加工效率和低表面粗糙度这一矛盾要求,明显增加对现有超硬双端磨盘设计的难度。因此,针对以上现状及技术需求,设计一种既具有高加工效率,又能获得好加工粗糙度的磨盘显得颇为急切。
发明内容
本发明的目的是提供一种加工工件时能实现大磨削余量,又能获得微粉磨料磨盘才能达到的表面粗糙度的树脂基复合结合剂磨盘及其制备方法。
为实现上述目的,本发明采用以下技术方案:
一种树脂基复合结合剂磨盘,其制备方法为,将磨料、金属粉、金属氧化物粉、树脂粉混合成型后烧结,然后破碎,得到磨料物;再将树脂粉、添加剂与磨料物混合后热压成型,然后硬化,得到磨削体;再将磨削体与基体复合,得到树脂基复合结合剂磨盘。
本发明中,先将磨料、金属粉、金属氧化物粉、树脂粉混合成型后烧结,然后破碎,得到磨料物,与现有制备磨盘的方法不同,得到的产品研磨能力很强,磨削比很高,磨削过程中磨耗较小,磨削过程中修整和更换磨具次数低于现有磨具,还具有较长的使用寿命,并节约了修整和更换磨具所需的时间,生产效率大幅提升。
本发明中,将磨料、金属粉、金属氧化物粉、树脂粉混合后热压成型后烧结,然后破碎、过筛,得到磨料物;磨料物的粒度为8#~200#,优选为10#~50#,进一步优选为15#~30#。热压为预热后加热加压,优选的,热压的工艺为:180℃预热5min,然后升温至250℃同时加压30MPa压制50min;烧结为250℃保温10h。
本发明中,树脂粉可以是酚醛树脂粉或聚酰亚胺树脂粉或者聚氨酯树脂等。
本发明中,添加剂包括碳化硅、碳粉、金属粉、金属氧化物粉中的一种或几种;金属粉为铜粉;金属氧化物粉为氧化锌粉或氧化镁粉。
本发明中,制备磨料物时,树脂粉、金属粉、金属氧化物粉、磨料的质量比为(15~20)∶(50~55)∶(1~5)∶(25~30),优选为(16~20)∶(50~53)∶(2~5)∶(25~28)。
本发明中,以磨削体的质量为100%,树脂粉、碳化硅、碳粉、金属氧化物粉、金属粉、磨料物的质量百分数分别为15~20%、20~25%、7~10%、1~3%、3~5%、余量;优选为18~20%、22~25%、7~9%、1~3%、3~5%、余量。
本发明中,将树脂粉、添加剂与磨料物混合后170℃、10MPa热压成型,然后于170℃硬化10h,得到磨削体。
作为常识,破碎、过筛都为常规技术,只要得到粒度为8#~200#的磨料物即可;磨削体与基体复合为常规技术,使得两者粘接得到磨盘即可;进一步的,磨削体用改性环氧胶粘接在基体上后,进行常规机加工,得到树脂基复合结合剂磨盘成品。
针对超硬磨盘的特殊应用,为了提高现有磨盘的加工效率以及加工效果,现有技术研究很多方法,大都从结构着手,比如现有技术公开了一种超硬磨盘,包括放置板、限制板、支撑板、连接槽和调节机构,所述调节机构包括螺纹套、螺纹杆、轴承和滑槽,所述限制板内壁表面开设滑槽,所述滑槽内壁表面滑动连接支撑板,所述支撑板外壁表面顶端固定连接轴承,所述轴承中部固定连接螺纹杆,所述螺纹杆外壁表面转动连接螺纹套,所述螺纹套外壁表面固定连接放置板;通过旋转螺纹杆沿着螺纹套和底端的支撑板内部的轴承转动,且便于使支撑板沿着滑槽移动,且便于根据需要调节合适的磨盘对材料进行打磨,且避免材料不同所需的磨盘硬度不同跟换磨盘,且导致打磨的效率较低。现有技术公开了一种树脂合剂超硬磨盘结构,套在电机轴连接柱上,其中固定圆盘位于超硬磨盘一端,所述固定圆盘位于电机轴连接柱外端,其中电机轴连接柱一端套有焊接连接的定位块,所述电机轴连接柱一端设置焊接连接的套入杆,所述超硬磨盘一端开设定位槽,其中定位槽内部放置有定位块,所述超硬磨盘另一端均匀开设对接槽,可使得超硬磨盘可以被快速简易的固定,这样不仅可以给工作人员固定磨盘作业带来便利,还可以有效的对超硬磨盘进行双重固定,有效保证超硬磨盘进行正常工作。结构的变化对于推动产业发展作用有限,因为为了匹配新的结构,需要对现有加工设备进行改造,这不仅导致客户成本、工作量陡增,关键是针对一种结构就需要改造一次设备,显然不符合实际生产需求。本发明采用与现有技术不同的思路,从磨盘配方以及制备工艺着手,先将磨料、金属粉、金属氧化物粉、树脂粉混合成型后烧结,然后破碎,得到磨料物,与现有制备磨盘的方法不同,得到的产品研磨能力很强,磨削比很高,磨削过程中磨耗较小,磨削过程中修整和更换磨具次数低于现有磨具,还具有较长的使用寿命,并节约了修整和更换磨具所需的时间,生产效率大幅提升。实际加工生产显示,加工软碳,余量0.2mm,加工时间1min/load,工件粗糙度Ra0.1,修整间隔长达100loads,工件无划伤、无断裂现象,整体使用下来,完全满足客户对工件表面质量和加工效率的要求。
附图说明
图1为树脂基复合结合剂双端面磨盘成品图。
图2为树脂基复合结合剂双端面磨盘的局部放大图。
具体实施方式
下面结合具体的实施案列对本发明做出进一步的说明。本发明涉及的原料为磨具制备常规原料,符合磨盘用的常规原料要求,其中磨料粒度可以200#~5000#。本发明实施例采用的具体制备操作以及性能测试为本领域常规技术。作为常识,破碎、过筛都为常规技术,只要得到粒度为8#~200#的磨料物即可;磨削体与基体复合为常规技术,使得两者粘接即可,可采用本领域常规的改性环氧胶粘接;进一步的,磨削体用改性环氧胶粘接在基体上后,进行常规机加工,得到树脂基复合结合剂磨盘成品。
实施例一 一种加工碳材料的树脂基复合结合剂双端面磨盘
具体制备步骤为:
(1)将聚酰亚胺树脂粉、铜粉、氧化锌粉以及金刚石磨料(1000#)常规混合后热压成型,再烧结;热压工艺为:180℃预热5min,然后2分钟升温至250℃同时加压30MPa压制50min,然后卸压,在250℃保温10h,进行烧结,最后自然降温,得到烧结物;其中,聚酰亚胺树脂粉18wt%、铜粉52wt%、ZnO粉 3wt%、金刚石27wt%;
(2)将烧结物常规破碎、过18#和24#筛网,取18#以细24#以粗的部分作为磨料物;
(3)将酚醛树脂粉、碳化硅粉、碳粉、氧化镁粉、铜粉、磨料物按表1的比例混合,得到5Kg成型料;将成型料加入常规模具中在170℃、10MPa下热压15分钟,卸压后再保温10h进行硬化,得到磨削体;然后将磨削体采用市售改性环氧胶粘接在常规钢基体上,得到磨盘半成品。
对上述半成品进行常规机加工,得到成品,为加工碳材料的树脂基复合结合剂双端面磨盘,成品图如图1,局部放大图如图2。
在客户处,Wolters双端面设备上加工Carbon rings OD40/20ID,此款砂轮完全满足客户的使用要求。结果:加工软碳,余量0.2mm,加工时间1min/load(载,50片),工件粗糙度Ra0.1,修整间隔长达100 loads,工件无划伤、无断裂现象。整体使用下来,完全满足客户对工件表面质量和加工效率的要求。而且仅需更换磨盘,对设备无任何改动。
客户现有使用的树脂复合结合剂磨盘的加工时间为2min/load(50片),工件粗糙度Ra0.11,修整间隔60 loads。此为目前生产上,加工Carbon rings OD40/20ID的最好效果。
采用市售粗粒度树脂金刚石(80#)磨盘会出现工件粗糙度很差的问题,无法满足工件光洁度的要求,需要分为粗加工和精加工两道工序,会增加客户的成本,且效率也会下降,目前已经被生产舍弃。
对比例一
将950g酚醛树脂粉、1150g碳化硅、400g碳粉、100g氧化镁、396g聚酰亚胺树脂粉、1344g铜粉、66g氧化锌粉以及594g金刚石磨料(1000#)混合,得到成型料;然后按照实施例一步骤(3)热压、硬化,再常规粘接与加工,得到树脂基复合结合剂双端面磨盘,然后同样加工软碳,加工余量最多到0.02mm,再大会出现磨削不动,设备震动大,声音异响的情况。
对比例二
在实施例一的基础上将铜粉调整为镍粉,其余不变,得到树脂基复合结合剂双端面磨盘,同样加工软碳,修整间隔缩短为80 loads。
现有技术为了提高加工品质,牺牲了加工效率,比如缩短修整间隔、延长加工时间,本发明采用新的技术思路,先将聚酰亚胺树脂粉、铜粉、氧化锌粉以及金刚石磨料混合后热压成型,再烧结、破碎,得到磨料物;然后将酚醛树脂粉、碳化硅粉、碳粉、氧化镁粉、铜粉、磨料物混合,常规制备磨盘,替换现有生产上的磨盘即可,无需改动设备,出乎意料的呈现较现有磨盘更好的加工效果,整体使用下来,完全满足客户对工件表面质量和加工效率的要求。
Claims (10)
1.一种树脂基复合结合剂磨盘的制备方法,其特征在于,将磨料、金属粉、金属氧化物粉、树脂粉混合成型后烧结,然后破碎,得到磨料物;再将树脂粉、添加剂与磨料物混合后热压成型,然后硬化,得到磨削体;再将磨削体与基体复合,得到树脂基复合结合剂磨盘。
2.根据权利要求1所述树脂基复合结合剂磨盘的制备方法,其特征在于,将磨料、金属粉、金属氧化物粉、树脂粉混合后热压成型,再烧结,然后破碎、过筛,得到磨料物。
3.根据权利要求2所述树脂基复合结合剂磨盘的制备方法,其特征在于,热压的工艺为:180℃预热5min,然后升温至250℃同时加压30MPa压制50min;烧结为250℃保温10h。
4.根据权利要求1所述树脂基复合结合剂磨盘的制备方法,其特征在于,树脂粉可以是酚醛树脂粉或聚酰亚胺树脂粉或者聚氨酯树脂等;磨料物的粒度为8#~200#。
5.根据权利要求1所述树脂基复合结合剂磨盘,其特征在于,添加剂包括碳化硅、碳粉、金属粉、金属氧化物粉中的一种或几种。
6.根据权利要求5所述树脂基复合结合剂磨盘的制备方法,其特征在于,金属粉为铜粉;金属氧化物粉为氧化锌粉或氧化镁粉。
7.根据权利要求6所述树脂基复合结合剂磨盘的制备方法,其特征在于,制备磨料物时,树脂粉、金属粉、金属氧化物粉、磨料的质量比为(15~20)∶(50~55)∶(1~5)∶(25~30);以磨削体的质量为100%,树脂粉、碳化硅、碳粉、金属氧化物粉、金属粉、磨料物的质量百分数分别为15~20%、20~25%、7~10%、1~3%、3~5%、余量。
8.根据权利要求1所述树脂基复合结合剂磨盘的制备方法制备的树脂基复合结合剂磨盘。
9.权利要求8所述树脂基复合结合剂磨盘在加工工件中的应用。
10.一种研磨工件的方法,其特征在于,利用权利要求8所述树脂基复合结合剂磨盘磨削工件,完成工件研磨。
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