CN115896641A - Low-cost circular saw blade and manufacturing method thereof - Google Patents
Low-cost circular saw blade and manufacturing method thereof Download PDFInfo
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- CN115896641A CN115896641A CN202211405711.8A CN202211405711A CN115896641A CN 115896641 A CN115896641 A CN 115896641A CN 202211405711 A CN202211405711 A CN 202211405711A CN 115896641 A CN115896641 A CN 115896641A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 33
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 87
- 239000010432 diamond Substances 0.000 claims abstract description 63
- 229910003460 diamond Inorganic materials 0.000 claims abstract description 59
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 36
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 35
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 35
- 239000011701 zinc Substances 0.000 claims abstract description 35
- 239000011159 matrix material Substances 0.000 claims abstract description 32
- 239000000463 material Substances 0.000 claims abstract description 21
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 18
- 239000000843 powder Substances 0.000 claims description 96
- 238000002156 mixing Methods 0.000 claims description 34
- 238000005245 sintering Methods 0.000 claims description 31
- 238000000034 method Methods 0.000 claims description 28
- 239000002245 particle Substances 0.000 claims description 24
- 230000008569 process Effects 0.000 claims description 22
- 230000009467 reduction Effects 0.000 claims description 15
- 230000000630 rising effect Effects 0.000 claims description 15
- 238000000498 ball milling Methods 0.000 claims description 12
- 239000011812 mixed powder Substances 0.000 claims description 12
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 11
- 239000002994 raw material Substances 0.000 claims description 10
- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 claims description 9
- 238000004321 preservation Methods 0.000 claims description 9
- 239000007789 gas Substances 0.000 claims description 8
- 229910000831 Steel Inorganic materials 0.000 claims description 7
- 229940057995 liquid paraffin Drugs 0.000 claims description 7
- 230000001681 protective effect Effects 0.000 claims description 7
- 239000010959 steel Substances 0.000 claims description 7
- 238000007688 edging Methods 0.000 claims description 6
- 239000001257 hydrogen Substances 0.000 claims description 6
- 229910052739 hydrogen Inorganic materials 0.000 claims description 6
- 238000005498 polishing Methods 0.000 claims description 6
- 239000000047 product Substances 0.000 claims description 6
- 238000005096 rolling process Methods 0.000 claims description 6
- 239000004576 sand Substances 0.000 claims description 6
- 238000003756 stirring Methods 0.000 claims description 6
- 238000003466 welding Methods 0.000 claims description 6
- 239000011265 semifinished product Substances 0.000 claims description 5
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 4
- 238000001816 cooling Methods 0.000 claims description 4
- 229910001873 dinitrogen Inorganic materials 0.000 claims description 3
- 230000035484 reaction time Effects 0.000 claims description 2
- 238000000465 moulding Methods 0.000 claims 1
- 238000002203 pretreatment Methods 0.000 claims 1
- 229910052742 iron Inorganic materials 0.000 abstract description 11
- 238000005520 cutting process Methods 0.000 abstract description 7
- 239000000758 substrate Substances 0.000 abstract description 3
- 230000001568 sexual effect Effects 0.000 abstract description 2
- 239000000126 substance Substances 0.000 description 11
- 238000002474 experimental method Methods 0.000 description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 6
- 238000011049 filling Methods 0.000 description 5
- 229910002804 graphite Inorganic materials 0.000 description 5
- 239000010439 graphite Substances 0.000 description 5
- 239000012188 paraffin wax Substances 0.000 description 5
- 238000003825 pressing Methods 0.000 description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 4
- 229910052802 copper Inorganic materials 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000000227 grinding Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 229910052757 nitrogen Inorganic materials 0.000 description 4
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 description 3
- 230000008859 change Effects 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 238000009472 formulation Methods 0.000 description 3
- 150000002431 hydrogen Chemical class 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 238000005204 segregation Methods 0.000 description 2
- 239000004575 stone Substances 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- 229910000906 Bronze Inorganic materials 0.000 description 1
- 229910000617 Mangalloy Inorganic materials 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 230000003044 adaptive effect Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910001566 austenite Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 239000010974 bronze Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000003763 carbonization Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
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Abstract
The application relates to the technical field of diamond saw blades, in particular to a low-cost circular saw blade and a manufacturing method thereof. The saw blade comprises a substrate and a cutter head, wherein the components of the cutter head comprise 10-35 parts of diamond, 42-83 parts of iron element, 2-6 parts of nickel element and 5-17 parts of zinc element in parts by weight. This application is through only introducing zinc and nickel element in the iron-based matrix, guarantees tool bit intensity and tool bit to the diamond greatly reduced tool bit's the cost of manufacture on raw and other materials when controlling the power, has further promoted the sharpness of iron-based matrix class tool bit, and the sexual valence relative altitude is extensively applicable to various cutting.
Description
Technical Field
The application relates to the technical field of diamond saw blades, in particular to a low-cost circular saw blade and a manufacturing method thereof.
Background
The diamond saw blade is a cutting tool, mainly composed of a base body and a tool bit, and is widely applied to processing of hard and brittle materials such as concrete, refractory materials, stones, ceramics and the like. In the existing tool bit, a high copper formula is mostly selected, although the high copper formula has good sintering performance, the high copper formula is expensive, has large deformability and poor holding force on diamond, while the high iron formula is low in price, low-melting-point metal in a matrix is easy to run off, so that the sharpness is not enough, and under the background that the manufacturing cost is greatly increased, the direction of manufacturing a saw blade which is cheap and has various performances is an important research direction.
Disclosure of Invention
Additional features and advantages of the present application will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the present application. The objectives and other advantages of the application may be realized and attained by the structure particularly pointed out in the written description.
The circular saw blade and the manufacturing method thereof have the advantages of being low in cost, easy to sinter, good in sharpness, high in cost performance and wide in universality.
In a first aspect, the present application provides a low cost circular saw blade comprising a base body and a cutting head. The components of the tool bit comprise, by weight, 10-35 parts of diamond, 42-83 parts of iron element, 2-6 parts of nickel element and 5-17 parts of zinc element.
In the tool bit of this application, only adopt 4 compositions just can satisfy the requirement to tool bit intensity and tool bit diamond holding power, adopt low-melting substances such as zinc substitution bronze, tin, brass in this application, greatly reduced raw and other materials cost when bonding other metal powder and diamond, further make the matrix embrittled, promote the sharpness of product.
In some embodiments, the source of elemental nickel comprises an iron-nickel prealloyed powder having an average particle size of 15-22 μm. The iron-nickel prealloying powder with small granularity is high in activity and bending strength, and the nickel element is introduced to be matched with the iron base in a mode of adding the iron-nickel prealloying powder, so that the wear resistance of the high-iron-base cutter head is improved, and the deformability of the high-iron-base cutter head is reduced.
In some embodiments, the source of elemental iron comprises reduced iron powder having an average particle size of 30-40 μm. The reduced iron is low in price, but after the reduced iron powder is specially treated, the sintering temperature is reduced, so that the good wettability with diamond is still kept in the sintering process, the strength of the diamond is not influenced by slight etching of the diamond, and the holding force of the diamond in a matrix is improved.
In some embodiments, the source of elemental zinc comprises elemental zinc having an average particle size of 10-15 μm. The connection performance of the cutter head can be improved by only adding the simple substance zinc, so that the tire body is embrittled, and the sharpness of the cutter head is improved.
In a second aspect, the present application provides a method for manufacturing a circular saw blade with low cost, which is used for manufacturing the circular saw blade, and comprises the following steps:
pre-mixing matrix powder: preparing raw materials according to the proportion, mixing all components except diamond in a mixer, adding steel balls, setting the ball-to-material ratio to be 3.
Premixing diamond: and (3) independently mixing the diamond for 0.2-0.3h, then adding liquid paraffin, and uniformly stirring again to obtain the pretreated diamond powder.
Integral mixing: and putting the matrix powder and the pretreated diamond powder into a mixer to be uniformly mixed for 0.5-1.5 hours to obtain the prefabricated mixed powder.
And (3) forming a cutter head: and (4) compacting, die filling and sintering the prefabricated mixed powder to obtain the semi-finished tool bit.
Saw blade forming: and (4) performing sand rolling, welding, edging, detecting, polishing and marking on the semi-finished product cutter head to obtain the finished product circular saw blade.
Wherein, the temperature and the pressure are changed in a trend of rising firstly and then falling in the sintering process, and the rising process comprises at least three stages of heat preservation and pressure maintaining: keeping the temperature and the pressure at 550 ℃ and 10-20MPa for 10-30S; keeping the temperature and the pressure at 730-750 ℃ and 20-30MPa for 10-30S; keeping the temperature and pressure at 820-860 deg.C and 40-60MPa for 1.5-3.0min.
Controlling the temperature to be 550 ℃ in the sintering process, and keeping the temperature for 10-30 seconds, so that zinc fully flows into gaps of pressed compacts under the condition of liquid, and the uniform distribution of zinc is realized; the temperature is kept at 730-750 ℃ for 10-30S, so that the reduced iron powder is conveniently converted into austenite, the powder has a particle rearrangement phenomenon, the adaptive temperature rise speed is controlled, the manufacturing time is reasonably controlled, the manufacturing time is shortened, and the manufacturing cost is reduced.
In some embodiments, the ramp rate is 2.0-3.0 ℃/S as the temperature is increased; when the temperature is reduced, the temperature reduction speed is 3.0-4.0 ℃/S. Reasonable temperature rising and reducing speed is controlled, and the influence on the hardness and the strength of the cutter head caused by temperature change is reduced.
In some embodiments, the reduced iron powder is subjected to a pretreatment including a ball milling treatment and a reduction treatment before the carcass powder is premixed. The pretreatment is carried out before the reaction of reduced iron, so that the iron-based sintering activity is improved, and the sintering temperature of the tool bit is reduced.
In some embodiments, the ball milling process is to add the reduced iron powder into a ball mill, fill nitrogen as a protective gas, set the ball-to-material ratio in the drum to be 15: 1, and mill for 10-15 hours. The average particle size of the reduced iron powder was reduced in a ball mill, and the ball mill was filled with nitrogen gas as a protective gas. And filling protective gas to prevent the reduced iron from being oxidized in the ball milling process.
In some embodiments, the liquid paraffin is added in an amount of 0.1ml to 0.2ml per 1kg of matrix powder during the diamond premixing process. And paraffin is coated on the surface of the diamond, so that the diamond can be primarily bonded with partial carcass powder, the density difference between the diamond powder and the carcass powder is reduced, and the segregation degree of the diamond is reduced.
In some examples, the reduction treatment is to put the ball-milled reduced iron powder into a reduction furnace into which hydrogen is introduced, set the temperature in the furnace at 650 to 750 ℃, and react for 0.5 to 1 hour, and because the ball milling causes the reduced iron powder to harden, it is necessary to further reduce and eliminate work hardening, reduce the carbon content, and improve the quality of the iron powder.
Through adopting foretell technical scheme, the beneficial effect of this application is:
1. this application only introduces zinc and nickel element through in the iron-based matrix, alright in order to guarantee tool bit intensity and tool bit to the diamond to the accuse power, the material cost of greatly reduced tool bit on raw and other materials simultaneously effectively reduces sintering temperature in the manufacturing process and reduces the cost of manufacture, has further promoted the sharpness of iron-based matrix class tool bit, and the sexual valence relative altitude is extensively applicable to the cutting of various materials.
2. According to the method, the reduced iron is selected as the raw material, ball milling and hydrogen reduction treatment are carried out on the reduced iron before matrix powder premixing, the average particle size of the reduced iron is reduced, the sintering activity of the iron powder is improved, and the problem that the reduced iron powder is difficult to sinter is solved.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure.
Clearly, such objects and other objects of the present application will become more apparent as the description of preferred embodiments thereof proceeds.
These and other objects, features and advantages of the present application will become more apparent from the following detailed description of one or more preferred embodiments, which is to be read in connection with the accompanying drawings.
Detailed Description
The following detailed description will be given with reference to the embodiments, so as to fully understand and implement the technical effects of the present application by applying technical means to solve the technical problems. It should be noted that, as long as there is no conflict, the embodiments and the features of the embodiments in the present application may be combined with each other, and the technical solutions formed are all within the scope of the present application.
In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the present application. It will be apparent, however, to one skilled in the art that the present application may be practiced without some of the specific details or with other methods described herein.
In a first aspect, the present application provides a low cost circular saw blade comprising a base body and a blade head.
The tool bit comprises 10-35 parts of diamond, 42-83 parts of iron element, 2-6 parts of nickel element and 5-17 parts of zinc element by weight.
The diamond may be present in 10 parts, 15 parts, 16 parts, 17 parts, 18 parts, 19 parts, 20 parts, 21 parts, 22 parts, 23 parts, 24 parts, 25 parts, 26 parts, 27 parts, 28 parts, 29 parts, 30 parts, 31 parts, 32 parts, 33 parts, 34 parts, 35 parts in parts or a value in a range where any two of the above values are combined.
The iron element may be present in 42 parts, 44 parts, 46 parts, 48 parts, 50 parts, 52 parts, 54 parts, 56 parts, 58 parts, 60 parts, 62 parts, 64 parts, 66 parts, 68 parts, 70 parts, 72 parts, 74 parts, 76 parts, 78 parts, 80 parts, 82 parts, 83 parts in parts or any combination thereof.
The nickel element may be present in an amount of 2 parts, 2.2 parts, 2.4 parts, 2.6 parts, 2.8 parts, 3 parts, 3.2 parts, 3.4 parts, 3.6 parts, 3.8 parts, 4 parts, 4.2 parts, 4.4 parts, 4.6 parts, 4.8 parts, 5 parts, 5.2 parts, 5.4 parts, 5.6 parts, 5.8 parts, 6 parts, or any combination thereof.
The zinc element may be present in amounts of 5 parts, 5.5 parts, 6 parts, 6.5 parts, 7 parts, 7.5 parts, 8 parts, 8.5 parts, 9 parts, 9.5 parts, 10 parts, 10.5 parts, 11 parts, 11.5 parts, 12 parts, 12.5 parts, 13 parts, 13.5 parts, 14 parts, 15 parts, 16 parts, 17 parts, or any combination thereof.
The substrate can be any substrate material, and preferably comprises 65 manganese steel and 75Cr1 steel.
According to some embodiments of the present application, optionally, the source of nickel elements comprises an iron-nickel prealloyed powder having an average particle size of 15-22 μm.
The iron-nickel alloy powder is Hunan Kelvin powder F2M1021, the powder has a bending strength in the range of 1800-2000MPa, and the average particle size may be 15.5 μ M, 16 μ M, 16.5 μ M, 17 μ M, 17.5 μ M, 18 μ M, 18.5 μ M, 19 μ M, 19.5 μ M, 20 μ M, 20.5 μ M, 21 μ M, 21.5 μ M, 22 μ M or a value in a range obtained by combining any two of the above values.
According to some embodiments of the application, optionally, the iron-nickel prealloy is Fe82Ni18.
Further, fe82Ni18 represents an atomic mass fraction of iron and an atomic mass fraction of nickel in the alloy powder of 82% and 18%, respectively.
According to some embodiments of the present application, optionally, the source of elemental iron comprises reduced iron powder having an average particle size of 30-40 μm.
Further, the reduced iron is sponge iron powder prepared by reducing iron oxide with a solid or gaseous reducing agent, has strong reducibility, is easy to undergo oxidation reaction, and has an average particle diameter of 30 μm, 31 μm, 32 μm, 33 μm, 34 μm, 35 μm, 36 μm, 37 μm, 38 μm, 39 μm, 40 μm or a value within a range obtained by combining any two of the above values.
According to some embodiments of the application, optionally, the source of zinc element comprises elemental zinc, and the elemental zinc has an average particle size of 10-15 μm.
The average particle size of the zinc element may be 10 μm, 10.5 μm, 11 μm, 11.5 μm, 12 μm, 12.5 μm, 13 μm, 13.5 μm, 14 μm, 14.5 μm, 15 μm or a value thereof within a range obtained by combining any two of the above values.
In a second aspect, the present application provides a method for manufacturing a low-cost circular saw blade, which is used for manufacturing the above-mentioned low-cost circular saw blade, and comprises the following specific manufacturing steps:
pre-mixing matrix powder: preparing raw materials according to the proportion, mixing all components except diamond in a three-dimensional mixer, adding steel balls, setting the ball-to-material ratio to be 3.
Pre-mixing diamond: and independently mixing the diamond for 0.2-0.3h, then adding liquid paraffin, and uniformly stirring again to obtain the pretreated diamond powder.
Integral mixing: and putting the matrix powder and the pretreated diamond powder into a mixer to be uniformly mixed for 0.5-1.5 hours to obtain the prefabricated mixed powder.
And (3) forming a cutter head: and pouring the prefabricated mixed powder into a briquetting machine, pressing into a required shape and size, assembling a graphite mold according to the shape of the blank, putting the blank into the mold, setting a sintering temperature and a pressure variation curve, and sintering to obtain a semi-finished cutter head.
Saw blade forming: carrying out sand rolling, welding, edging, detecting, polishing and marking on the semi-finished tool bit to obtain a finished circular saw;
wherein, the temperature and the pressure are changed in a trend of rising first and then falling in the sintering process, and the rising process comprises at least three heat preservation and pressure maintaining stages: keeping the temperature and the pressure at 550 ℃ and 10-20MPa for 10-30S; keeping the temperature and the pressure at 730-750 ℃ and 20-30MPa for 10-30S; keeping the temperature and the pressure at 820-860 ℃ and 40-60MPa for 1.5-3.0min.
According to some embodiments of the present application, optionally, the temperature rise rate is 2.0-3.0 ℃/S; when the temperature is reduced, the temperature reduction speed is 3.0-4.0 ℃/S.
According to some embodiments of the present application, the fine reduced iron is optionally subjected to a pretreatment including a ball milling treatment and a reduction treatment before the addition.
According to some embodiments of the present application, the ball milling process is optionally performed by adding the reduced iron powder into a ball mill, filling nitrogen gas as a shielding gas, setting a ratio of balls to materials in the drum to be 15: 1, filling the reduced iron powder in an amount to slightly cover the surfaces of the balls by filling the gaps between the balls, and performing a milling process for 10 to 15 hours.
According to some embodiments of the application, optionally, in the diamond premixing process, the addition amount of the liquid paraffin is 0.1ml-0.2ml added per 1kg of the matrix powder, the paraffin is coated on the surface of the diamond powder and used for adhering part of the matrix powder, the density difference between the diamond and the matrix powder is reduced, diamond segregation caused by floating of the diamond in the mixing process is prevented, meanwhile, dust raising is reduced, the pressing formability is improved, and the paraffin is volatile through high-temperature heating and is not easy to remain in the cutter head.
According to some embodiments of the present application, the reduction treatment is optionally performed by placing the ball-milled reduced iron powder in a reaction furnace into which hydrogen gas is introduced, and setting the temperature in the furnace to 650 to 750 ℃ and the reaction time to 0.5 to 1 hour.
Example 1
The present embodiment provides a low-cost circular saw blade including a base body and a blade. The components of the tool bit comprise 10 parts of diamond, 83 parts of iron element, 2 parts of nickel element and 5 parts of zinc element according to parts of components.
The source of the nickel element comprises an iron-nickel prealloyed powder, preferably Fe82Ni18, having an average particle size of 15 μm.
The source of the iron element includes reduced iron powder having an average particle size of 30 μm.
The zinc element source comprises a zinc simple substance, and the average particle size of the zinc simple substance is 10 mu m.
The embodiment also provides a manufacturing method of the low-cost circular saw blade, which is used for manufacturing the low-cost circular saw blade and comprises the following specific manufacturing steps:
ball milling treatment of reduced iron powder: the reduced iron powder is charged into a ball mill, a protective gas, preferably nitrogen, is filled, the ball-to-material ratio in the drum is set to 15: 1, the amount of the charged reduced iron powder is such that the gaps between the balls are filled up to slightly cover the surface of the balls, and the grinding time is 10 hours.
Reduction treatment of reduced iron powder: and (3) putting the ball-milled reduced iron powder into a reducing furnace filled with hydrogen, setting the temperature in the furnace to be 650 ℃, and reacting for 0.5 hour.
Pre-mixing matrix powder: preparing raw materials according to the proportion, mixing all the components except diamond in a three-dimensional mixer, adding steel balls, setting the ball-material ratio to be 3:1, and mixing for 0.5 hour to obtain matrix powder.
Pre-mixing diamond: and (3) independently mixing the diamonds for 0.2h, adding 0.1ml of liquid paraffin into each 1kg of matrix powder, and uniformly stirring again to obtain the pretreated diamond powder.
Integral mixing: and (3) putting the matrix powder and the pretreated diamond powder into a mixer to be uniformly mixed for 0.5 hour to obtain the prefabricated mixed powder.
And (3) forming a cutter head: and pouring the prefabricated mixed powder into a briquetting machine, pressing into a required shape and size, assembling a graphite mold according to the shape of the blank, putting the blank into the mold, setting a sintering temperature and a pressure variation curve, and sintering to obtain a semi-finished cutter head.
Saw blade forming: and (4) performing sand rolling, welding, edging, detecting, polishing and marking on the semi-finished product cutter head to obtain the finished product circular saw blade.
Wherein, the temperature and the pressure change in a trend of rising and then falling in the sintering process, when the temperature is between room temperature and 860 ℃, the temperature integrally rises in a trend, and the temperature rising speed is 2.0 ℃/S; when the temperature is between 860 and 600 ℃, the temperature is wholly reduced, and the cooling speed is 3.0 ℃/S. The raising process comprises at least three stages of heat preservation and pressure maintaining: at 550 ℃, the pressure is 10MPa, and the heat preservation and pressure maintaining time is 30S; at 730 ℃, the pressure is 20MPa, and the heat preservation and pressure maintaining time is 30S; maintaining the temperature and pressure at 820 deg.C and 40MPa for 3.0min.
Example 2
The present embodiment provides a low-cost circular saw blade including a base body and a cutter head. The tool bit comprises 22.5 parts of diamond, 62.5 parts of iron element, 4 parts of nickel element and 11 parts of zinc element by weight.
The source of the nickel element comprises an iron-nickel prealloyed powder, preferably Fe82Ni18, having an average particle size of 18 μm.
The source of the elemental iron comprises reduced iron powder having an average particle size of 35 μm.
The zinc element source comprises a zinc simple substance, and the average particle size of the zinc simple substance is 12 mu m.
The embodiment also provides a manufacturing method of the low-cost circular saw blade, which is used for manufacturing the low-cost circular saw blade and comprises the following specific manufacturing steps:
ball milling treatment of reduced iron powder: the reduced iron powder is charged into a ball mill, a protective gas, preferably nitrogen, is filled, the ball-to-material ratio in the roller is set to 15: 1, the amount of the charged reduced iron powder is such that the gaps between the balls are filled up to slightly cover the surfaces of the balls, and the grinding time is 12 hours.
Reduction treatment of reduced iron powder: and putting the ball-milled reduced iron powder into a reduction furnace filled with hydrogen, setting the temperature in the furnace to be 700 ℃, and reacting for 0.75 hour.
Pre-mixing matrix powder: preparing raw materials according to the proportion, mixing all components except diamond in a three-dimensional mixer, adding steel balls, setting the ball-material ratio to be 4: 1, and mixing for 1 hour to obtain matrix powder.
Pre-mixing diamond: and (3) independently mixing the diamonds for 0.25h, then adding 0.15ml of paraffin into each 1kg of matrix powder, and uniformly stirring again to obtain the pretreated diamond powder.
Integral mixing: and (3) putting the matrix powder and the pretreated diamond powder into a mixer to be uniformly mixed for 1 hour to obtain the prefabricated mixed powder.
And (3) forming a cutter head: and pouring the prefabricated mixed powder into a briquetting machine, pressing into a required shape and size, assembling a graphite mold according to the shape of the blank, putting the blank into the mold, setting a sintering temperature and a pressure variation curve, and sintering to obtain a semi-finished cutter head.
Saw blade forming: and (4) performing sand rolling, welding, edging, detecting, polishing and marking on the semi-finished product cutter head to obtain the finished product circular saw blade.
Wherein, the temperature and the pressure change in a trend of rising and then falling in the sintering process, when the temperature is between room temperature and 860 ℃, the temperature integrally rises in a trend, and the temperature rising speed is 2.5 ℃/S; when the temperature is 860-600 ℃, the temperature is wholly reduced, and the cooling speed is 3.5 ℃/S. The raising process comprises at least three stages of heat preservation and pressure maintaining: at 550 ℃, under the pressure of 15MPa, keeping the temperature and the pressure for 15S; keeping the temperature and the pressure at 740 ℃ and 25MPa for 15S; keeping the temperature and the pressure at 840 ℃ and 50MPa for 2.25min.
Example 3
The present embodiment provides a low-cost circular saw blade including a base body and a cutter head. The tool bit consists of 35 parts of diamond, 42 parts of iron element, 6 parts of nickel element and 17 parts of zinc element according to parts of components.
The source of the nickel element comprises an iron-nickel prealloyed powder, preferably Fe82Ni18, having an average particle size of 22 μm.
The source of the iron element includes reduced iron powder having an average particle size of 40 μm.
The zinc element source comprises a zinc simple substance, and the average particle size of the zinc simple substance is 35 mu m.
The embodiment also provides a manufacturing method of the low-cost circular saw blade, which is used for manufacturing the low-cost circular saw blade and comprises the following specific manufacturing steps:
ball milling treatment of reduced iron powder: the reduced iron powder is charged into a ball mill, a protective gas, preferably nitrogen, is filled, the ball-to-material ratio in the roller is set to 15: 1, the amount of the charged reduced iron powder is such that the gaps between the balls are filled up to slightly cover the surfaces of the balls, and the grinding time is 15 hours.
Reduction treatment of reduced iron powder: and (3) putting the ball-milled reduced iron powder into a reaction furnace filled with hydrogen, setting the temperature in the furnace to be 750 ℃, and reacting for 1 hour.
Pre-mixing matrix powder: preparing raw materials according to the proportion, mixing all the components except diamond in a three-dimensional mixer, adding steel balls, setting the ball-material ratio to be 5:1, and mixing for 1.5 hours to obtain matrix powder.
Pre-mixing diamond: and (3) independently mixing the diamonds for 0.3h, adding 0.2ml of paraffin wax into each 1kg of matrix powder, and uniformly stirring again to obtain the pretreated diamond powder.
Integral mixing: and putting the matrix powder and the pretreated diamond powder into a mixer to be uniformly mixed for 1.5 hours to obtain the prefabricated mixed powder.
And (3) forming a cutter head: and pouring the prefabricated mixed powder into a briquetting machine, pressing into a required shape and size, assembling a graphite mold according to the shape of the blank, putting the blank into the mold, setting a sintering temperature and a pressure variation curve, and sintering to obtain a semi-finished cutter head.
Saw blade forming: and (4) performing sand rolling, welding, edging, detecting, polishing and marking on the semi-finished product cutter head to obtain the finished product circular saw blade.
Wherein, the temperature and the pressure are changed in a trend of rising and then falling in the sintering process, when the temperature is between room temperature and 860 ℃, the whole temperature is in a rising trend, and the temperature rising speed is 3.0 ℃/S; when the temperature is between 860 and 600 ℃, the temperature is wholly reduced, and the cooling speed is 4.0 ℃/S. The rising process comprises at least three heat preservation and pressure maintaining stages: at 550 ℃, under the pressure of 20MPa, keeping the temperature and the pressure for 10S; at 750 ℃, when the pressure is 30MPa, the heat preservation and pressure maintaining time is 10S; at 860 deg.C and 60MPa, maintaining the temperature and pressure for 1.5min.
Performance testing
Under the condition that the mass content of the diamond is 15% of the total mass content of the tool bit, the components or the component content of the tool bit are changed to carry out sintering test and cutting test (uniformly cutting stone with the thickness of 20 mm), the cost, the sharpness and the service life are calculated, and statistics are shown in table 1.
1. Three experimental groups, namely an experimental group 1, an experimental group 2 and an experimental group 3, are obtained by changing the mass contents of the pretreated reduced iron, the iron-nickel alloy and the zinc simple substance in the application.
2. The same formulation and components as those of experimental group 2 were selected, and reduced iron in the formulation was replaced with reduced iron without pretreatment as control group 1.
3. A conventional copper-containing formulation was selected as control 2.
Table 1 statistical table of performance tests
From the table, it can be seen that:
1. the experiment group 2 and the comparison group 2 are compared, so that the sintering temperature of the saw blade in the experiment group 2 is lower, the cutting power is only 5.6% lower than that of the comparison group 2, the service lives of the two groups are equivalent, the cost of the experiment group 2 is lower by nearly 50% than that of the comparison group 2, and the formula can effectively reduce the sintering temperature, reduce the cost and simultaneously obtain better sharpness.
2. The experiment group 2 and the experiment group 3 are compared, and it can be seen that the sintering temperature of the saw blade in the experiment group 3 is 20-50 ℃ higher than that of the saw blade in the experiment group 2, and the sharpness is improved by about 10%, which is enough to prove that the sharpness of the saw blade can be improved by improving the content of the simple substance zinc.
3. Compared with the control group 1, the experiment group 2 shows that the sintering temperature of the whole body sintered by taking the untreated reduced iron as the raw material is higher than that of the whole body sintered by taking the treated reduced iron as the raw material, and the service life of the whole body sintered by taking the untreated reduced iron as the raw material is short enough to show that the sintering temperature of the cutter head can be reduced and the service life of the cutter head can be prolonged by the pretreated reduced iron powder.
And (4) conclusion: the pretreated reduced iron powder can reduce the sintering temperature of the saw blade, avoid the problems of diamond carbonization and graphite grinding tool oxidation, prolong the service life of the saw blade by adding the iron-nickel alloy powder, and improve the sharpness of the saw blade by adding the zinc simple substance powder.
It is to be understood that the embodiments disclosed herein are not limited to the particular process steps or materials disclosed herein, but rather, are extended to equivalents thereof as would be understood by those ordinarily skilled in the relevant arts. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.
Reference in the specification to "an embodiment" means that a particular feature, or characteristic described in connection with the embodiment is included in at least one embodiment of the application. Thus, the appearances of the phrase or "an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment.
Furthermore, the described features or characteristics may be combined in any other suitable manner in one or more embodiments. In the above description, certain specific details are provided, such as thicknesses, amounts, etc., to provide a thorough understanding of embodiments of the present application. One skilled in the relevant art will recognize, however, that the application can be practiced without one or more of the specific details, or with other methods, components, materials, etc.
Claims (10)
1. A low-cost circular saw blade comprises a base body and a cutter head, and is characterized in that the cutter head comprises 10-35 parts by weight of diamond, 42-83 parts by weight of iron element, 2-6 parts by weight of nickel element and 5-17 parts by weight of zinc element.
2. The low cost circular saw blade as claimed in claim 1, wherein the source of nickel elements comprises iron-nickel prealloyed powder having an average particle size of 15-22 μm.
3. A low-cost circular saw blade as claimed in claim 1, wherein the source of the iron element comprises reduced iron powder having an average particle size of 30 to 40 μm.
4. A low cost circular saw blade as claimed in claim 1, wherein the source of elemental zinc comprises elemental zinc, the elemental zinc having an average particle size of from 10 to 15 μm.
5. A method for producing a low-cost circular saw blade, characterized in that, for producing a low-cost circular saw blade according to any one of claims 1 to 4, the production steps are as follows:
pre-mixing matrix powder: preparing raw materials according to the proportion, mixing all components except diamond in a mixer, adding steel balls, setting the ball-material ratio to be 3:1-5:1, and mixing for 0.5-1.5 hours to obtain matrix powder;
premixing diamond: independently mixing the diamonds for 0.2-0.3h, then adding liquid paraffin, and uniformly stirring again to obtain pretreated diamond powder;
integral mixing: putting the matrix powder and the pretreated diamond powder into a mixer to be uniformly mixed for 0.5-1.5 hours to obtain prefabricated mixed powder;
and (3) forming a cutter head: compacting, molding and sintering the prefabricated mixed powder to obtain a semi-finished tool bit;
saw blade forming: carrying out sand rolling, welding, edging, detecting, polishing and marking on the semi-finished product cutter head to obtain a finished product circular saw blade;
wherein, the temperature and the pressure are changed in a trend of rising firstly and then falling in the sintering process, and the rising process comprises at least three stages of heat preservation and pressure maintaining: keeping the temperature and the pressure at 550 ℃ and 10-20MPa for 10-30S; keeping the temperature and the pressure at 730-750 ℃ and 20-30MPa for 10-30S; keeping the temperature and the pressure at 820-860 ℃ and 40-60MPa for 1.5-3.0min.
6. A low cost circular saw blade as claimed in claim 5, wherein the temperature rise rate is 2.0-3.0 ℃/S; when the temperature is reduced, the cooling speed is 3.0-4.0 ℃/S.
7. The manufacturing method of a circular saw blade with low cost as claimed in claim 5, wherein the reduced iron powder is pre-treated before the pre-mixing of the matrix powder, and the pre-treatment comprises ball milling and reduction.
8. A low-cost circular saw blade manufacturing method as claimed in claim 7, wherein said ball milling process is to add said reduced iron powder into a ball mill, fill nitrogen gas as a protective gas, set a ball to material ratio in a drum to 15: 1, and mill for 10-15 hours.
9. The manufacturing method of a circular saw blade with low cost as claimed in claim 7, wherein the reduction treatment is to put the ball-milled reduced iron powder into a reduction furnace into which hydrogen is introduced, and the temperature in the furnace is set to 650 to 750 ℃ and the reaction time is set to 0.5 to 1 hour.
10. The manufacturing method of a circular saw blade with low cost as claimed in claim 5, wherein the liquid paraffin is added in an amount of 0.1ml to 0.2ml per 1kg of the carcass powder in the diamond premixing process.
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