CN116117704A - 兼具打磨及开槽功能的金刚石磨轮开槽片及其制备方法 - Google Patents
兼具打磨及开槽功能的金刚石磨轮开槽片及其制备方法 Download PDFInfo
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 32
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Abstract
本发明公开了一种兼具打磨及开槽功能的金刚石磨轮开槽片,属于金刚石工具技术领域。该磨轮开槽片包括圆片状基体和设于基体外周上的金刚石刀头,所述金刚石刀头为多个,均匀布置于圆片状基体的环形外边缘;所述圆片状基体的中心位置设有用于固定所述磨轮开槽片的轴孔;所述金刚石刀头厚度为8‑12mm,圆片状基体的厚度为3‑4.5mm,刀头的厚度与基体的厚度之差大于等于5mm。本发明利用基体与刀头厚度差可使原本薄的刀头通过排布位置达到加厚加宽切缝宽度的效果,原材料由优质铜,铁,锡,镍,钨铁合金等金属粉以及高品质金刚石等组成的原材料,通过设计成可以打磨的磨轮形状,又可以进行开槽切割的形状。
Description
技术领域
本发明涉及金刚石工具技术领域,具体涉及一种兼具打磨及开槽功能的金刚石磨轮开槽片及其制备方法。
背景技术
在当今以经济建设为中心的大环境里,高效节能是提高产品市场竞争力的主要方法之一。随着用工成本不断攀升,高效节能的产品更受市场的认可。工人在户外作业时很多情况不仅需要打磨,还需要切割修整,本发明即可满足此类复杂的施工情况,同时该产品生产工艺流程简易,相对制造成本更低,降低焊材、电能、钢材的消耗。
发明内容
本发明的目的在于提供一种兼具打磨及开槽功能的金刚石磨轮开槽片及其制备方法,所制备的金刚石磨轮开槽片其刀头强韧性好,刀头与磨轮基体结合强度高,能够同时实现高效打磨及开槽作业。
为实现上述目的,本发明所采用的技术方案如下:
一种兼具打磨及开槽功能的金刚石磨轮开槽片,包括圆片状基体和设于基体外周上的金刚石刀头,所述金刚石刀头为多个,均匀布置于圆片状基体的环形外边缘;所述圆片状基体的中心位置设有用于固定所述磨轮开槽片的轴孔;所述金刚石刀头为箭头状结构,相邻金刚石刀头之间形成箭头状槽口,箭头方向与打磨方向一致,有利于磨削废料的排出。
所述金刚石刀头厚度为8-12mm,圆片状基体的厚度为3-4.5mm,刀头的厚度与基体的厚度之差大于等于5mm。
所述圆片状基体上在刀头与轴孔之间开设多个环形散热孔,环形散热孔的直径5-10mm,轴孔直径20-25mm,基体直径80-100mm,多个金刚石刀头环绕基体外周排布所形成的环形平面的宽度为15-25mm。
所述圆片状基体的材质为65Mn钢,
所述兼具打磨及开槽功能的金刚石磨轮开槽片的制备方法,包括如下步骤:
(1)基体加工:根据图纸要求,车加工,切割所需基体;
(2)金刚石刀头的无压烧结成型:
将金刚石刀头的各制备原料按比例称量并混合3小时左右,然后放入模具中冷压成型,再进行无压烧结成型,即得到所述金刚石刀头;
(3)金刚石刀头与基体的钎焊连接:
将金刚石刀头与银焊片一起放在相应的基体位置上,调整好焊接位置加热融化银焊片,使刀头和基体焊接在一起,然后以600N/mm2强度标准对每个金刚石刀头进行焊接强度检测;
(4)焊接后的磨轮开槽片先将其刀头内侧面抛丸喷砂,然后用砂轮打磨金刚石刀头的工作面,并使金刚石暴露出来,将焊接后一种无压烧结磨轮开槽片用磨光机打磨基体表面光亮,然后以600N/mm2强度标准对每个金刚石刀头部分进行安全焊接强度检测,不合格返工,合格则进行表面喷漆,烘干,以防止表面生锈,最后丝印,激光打标,包装,入库。
步骤(2)中,所述金刚石刀头的制备原料由铜、铁、锡、镍、钨铁合金、液体石蜡和金刚石组成,其中金刚石粒度为30/40、40/45或45/50,金刚石抗压强度 20-30kg;所述钨铁合金中钨含量为70-80wt.%,其余为铁;所述金刚石刀头按重量份数计的制备原料如下:
铜15-35份、铁32-46份、镍2-11份、锡1-9份、钨铁合金27-40份、液体石蜡1.0-2.0份、金刚石1.1-2.8份。
所述金刚石刀头按重量百分比计的制备原料优选如下:
铜21-33份、铁27-40份、镍4-10份、锡2-7份、钨铁合金30-38份、液体石蜡1.0-2.0份、金刚石1.6-2.5份。
步骤(2)中,所述无压烧结成型过程在氢气保护气氛下进行,压力为常压,烧结温度为820~930℃(优选880~920℃),烧结时间1-4小时,氢气流量0.3m3/h。
步骤(2)中,保温结束后,停止加热自然冷却到500℃出炉风冷,氢气保持畅通直到冷却到100℃以下停止通氢气。
步骤(3)中,钎焊工艺参数为:钎焊温度800-820℃,钎焊时间10-15秒。
本发明具有如下优点和有益效果:
1、本发明磨轮开槽片中,将基体与刀头的厚度差设计为大于等于5mm,可以形成打磨的间隙,从而满足了公路路牙打磨直角边沿的需要。
2、本发明磨轮开槽片中,将刀头侧面之间设计成箭头槽形状,使用时排屑方向和打磨方向一致,排屑更通畅,对刀头散热效果越好,并且刀头分布的很多的槽口可以进一步降低切割接触面积,有利于开槽切割时降低切割阻力,提高切割锋利度。
3、本发明在刀头的制备原料中,通过在特定量的铜、镍、铁、锡中添加规定量钨铁合金粉进一步提高配方胎体的整体耐热度,从而可以在无水打磨时保持磨轮开槽片的锋利度不衰减。钨铁合金钨在刀头中能和同其它元素协同作用提高刀头的耐热度、耐磨性和冲击强度。
4、本发明磨轮开槽片的基体中散热孔的设计可以形成循环风流,有利于打磨时灰尘从基体孔中排走带走刀头上打磨切割时的瞬间热量,提高散热能力,有利于提高磨轮开槽片锋利度。
附图说明
图1为本发明金刚石磨轮开槽片结构俯视图。
图2为本发明金刚石磨轮开槽片结构剖视图。
图中:1-基体;2-金刚石刀头;3-散热孔;4-轴孔;5-槽口。
具体实施方式
以下结合附图及实施例详述本发明。
本发明提供一种兼具打磨及开槽功能的金刚石磨轮开槽片,如图1-2所示。该磨轮开槽片包括圆片状基体1和设于基体外周上的金刚石刀头2,所述金刚石刀头2为多个,均匀布置于圆片状基体的环形外边缘;所述圆片状基体的中心位置设有用于固定所述磨轮开槽片的轴孔4。
所述圆片状基体上在刀头与轴孔之间开设多个环形散热孔3,环形散热孔的直径5-10mm,轴孔直径20-25mm,基体直径80-100mm,多个金刚石刀头环绕基体外周排布所形成的环形平面的宽度为15-25mm。
所述金刚石刀头厚度为8-12mm,圆片状基体的厚度为3-4.5mm,刀头的厚度与基体的厚度之差大于等于5mm。所述金刚石刀头为箭头状结构,相邻金刚石刀头之间形成箭头状槽口5,箭头方向与打磨方向一致,有利于磨削废料的排出。
本发明利用基体与刀头厚度差可使原本薄的刀头通过排布位置达到加厚加宽切缝宽度的效果,原材料由优质铜,铁,锡,镍,钨铁合金等金属粉以及高品质金刚石等组成,本发明采用铜,铁,锡,镍,钨铁合金粉末为基础而混合的原材料,通过设计成可以打磨的磨轮形状,又可以进行开槽切割的形状.
以下实施例中,所述圆片状基体的材质为65Mn钢,所述金刚石刀头的制备原料由铜、铁、锡、镍、钨铁合金、液体石蜡和金刚石组成,其中金刚石粒度为30/40、 40/45或45/50,金刚石抗压强度20-30kg;所述钨铁合金中钨含量为78wt.%,其余为铁。金刚石刀头中的原料中各组份均为重量份。
实施例1:
本实施例兼具打磨及开槽功能的金刚石磨轮开槽片的制备方法,包括如下步骤:
(1)基体加工:根据图纸要求,车加工,切割所需基体;
(2)将金刚石刀头中的原料按照:铜26份、铁27份、镍7份、锡6份、钨铁合金34份、液体石蜡1.5份的比例,放入混料桶中混50分钟左右,再加入金刚石1.9份,继续混料2小时后,将粉料灌入模具中然后进行冷压成型,冷压机吨位 200吨;冷压后进行无压烧结成型。
所述无压烧结成型过程在氢气保护气氛下进行,压力为常压,烧结温度为890℃,烧结时间3小时,氢气流量0.3m3/h;保温结束后,停止加热自然冷却到500℃出炉风冷,氢气保持畅通直到冷却到100℃以下停止通氢气。
(3)金刚石刀头与基体的钎焊连接:
将金刚石刀头与银焊片一起放在相应的基体位置上,调整好焊接位置加热融化银焊片,使刀头和基体焊接在一起,钎焊温度805℃,钎焊时间10-15秒。所用银焊片化学成分为(wt.%):银12.0%,铜31.2%,磷4.8%,锡1.5%,钛1.0%和余量锌。钎焊后以600N/mm2强度标准对每个金刚石刀头进行焊接强度检测,均合格。
(4)焊接后的磨轮开槽片先将其刀头内侧面抛丸喷砂,然后用砂轮打磨金刚石刀头的工作面,并使金刚石暴露出来,将焊接后一种无压烧结磨轮开槽片用磨光机打磨基体表面光亮,然后以600N/mm2强度标准对每个金刚石刀头部分进行安全焊接强度检测,均合格。然后进行表面喷漆,烘干,以防止表面生锈,最后丝印,激光打标,包装,入库。
实施例2:
本实施例兼具打磨及开槽功能的金刚石磨轮开槽片的制备方法,包括如下步骤:
(1)基体加工:根据图纸要求,车加工,切割所需基体;
(2)将金刚石刀头中的原料按照:铜25份、铁30份、镍6份、锡5份、钨铁合金35份、液体石蜡1.5份的比例,放入混料桶中混50分钟左右,再加入金刚石1.9份,继续混料2小时后,将粉料灌入模具中然后进行冷压成型,冷压机吨位 200吨;冷压后进行无压烧结成型。
所述无压烧结成型过程在氢气保护气氛下进行,压力为常压,烧结温度为900℃,烧结时间3小时,氢气流量0.3m3/h;保温结束后,停止加热自然冷却到500℃出炉风冷,氢气保持畅通直到冷却到100℃以下停止通氢气。
(3)金刚石刀头与基体的钎焊连接:
将金刚石刀头与银焊片一起放在相应的基体位置上,调整好焊接位置加热融化银焊片,使刀头和基体焊接在一起,钎焊温度805℃,钎焊时间10-15秒。所用银焊片化学成分为(wt.%):银12.0%,铜31.2%,磷4.8%,锡1.5%,钛1.0%和余量锌。钎焊后以600N/mm2强度标准对每个金刚石刀头进行焊接强度检测,均合格。
(4)焊接后的磨轮开槽片先将其刀头内侧面抛丸喷砂,然后用砂轮打磨金刚石刀头的工作面,并使金刚石暴露出来,将焊接后一种无压烧结磨轮开槽片用磨光机打磨基体表面光亮,然后以600N/mm2强度标准对每个金刚石刀头部分进行安全焊接强度检测,均合格。然后进行表面喷漆,烘干,以防止表面生锈,最后丝印,激光打标,包装,入库。
实施例3:
本实施例兼具打磨及开槽功能的金刚石磨轮开槽片的制备方法,包括如下步骤:
(1)基体加工:根据图纸要求,车加工,切割所需基体;
(2)将金刚石刀头中的原料按照:铜26份、铁30份、镍7份、锡5份、钨铁合金36份、液体石蜡1.5份的比例,放入混料桶中混50分钟左右,再加入金刚石2.0份,继续混料2小时后,将粉料灌入模具中然后进行冷压成型,冷压机吨位 200吨;冷压后进行无压烧结成型。
所述无压烧结成型过程在氢气保护气氛下进行,压力为常压,烧结温度为900℃,烧结时间3小时,氢气流量0.3m3/h;保温结束后,停止加热自然冷却到500℃出炉风冷,氢气保持畅通直到冷却到100℃以下停止通氢气。
(3)金刚石刀头与基体的钎焊连接:
将金刚石刀头与银焊片一起放在相应的基体位置上,调整好焊接位置加热融化银焊片,使刀头和基体焊接在一起,钎焊温度805℃,钎焊时间10-15秒。所用银焊片化学成分为(wt.%):银12.0%,铜31.2%,磷4.8%,锡1.5%,钛1.0%和余量锌。钎焊后以600N/mm2强度标准对每个金刚石刀头进行焊接强度检测,均合格。
(4)焊接后的磨轮开槽片先将其刀头内侧面抛丸喷砂,然后用砂轮打磨金刚石刀头的工作面,并使金刚石暴露出来,将焊接后一种无压烧结磨轮开槽片用磨光机打磨基体表面光亮,然后以600N/mm2强度标准对每个金刚石刀头部分进行安全焊接强度检测,均合格。然后进行表面喷漆,烘干,以防止表面生锈,最后丝印,激光打标,包装,入库。
Claims (10)
1.一种兼具打磨及开槽功能的金刚石磨轮开槽片,其特征在于:该磨轮开槽片包括圆片状基体和设于基体外周上的金刚石刀头,所述金刚石刀头为多个,均匀布置于圆片状基体的环形外边缘;所述圆片状基体的中心位置设有用于固定所述磨轮开槽片的轴孔;所述金刚石刀头为箭头状结构,相邻金刚石刀头之间形成箭头状槽口,箭头方向与打磨方向一致,有利于磨削废料的排出。
2.根据权利要求1所述的兼具打磨及开槽功能的金刚石磨轮开槽片,其特征在于:所述金刚石刀头厚度为8-12mm,圆片状基体的厚度为3-4.5mm,刀头的厚度与基体的厚度之差大于等于5mm。
3.根据权利要求1所述的兼具打磨及开槽功能的金刚石磨轮开槽片,其特征在于:所述圆片状基体上在刀头与轴孔之间开设多个环形散热孔,环形散热孔的直径5-10mm,轴孔直径20-25mm,基体直径80-100mm,多个金刚石刀头环绕基体外周排布所形成的环形平面的宽度为15-25mm。
4.根据权利要求1所述的兼具打磨及开槽功能的金刚石磨轮开槽片,其特征在于:所述圆片状基体的材质为65Mn钢。
5.根据权利要求1-4任一所述的兼具打磨及开槽功能的金刚石磨轮开槽片的制备方法,其特征在于:该制备方法包括如下步骤:
(1)基体加工:根据图纸要求,车加工,切割所需基体;
(2)金刚石刀头的无压烧结成型:
将金刚石刀头的各制备原料按比例称量并混合3小时左右,然后放入模具中冷压成型,再进行无压烧结成型,即得到所述金刚石刀头;
(3))金刚石刀头与基体的钎焊连接:
将金刚石刀头与银焊片一起放在相应的基体位置上,调整好焊接位置加热融化银焊片,使刀头和基体焊接在一起,然后以600N/mm2强度标准对每个金刚石刀头进行焊接强度检测;
(4)焊接后的磨轮开槽片先将其刀头内侧面抛丸喷砂,然后用砂轮打磨金刚石刀头的工作面,并使金刚石暴露出来,将焊接后一种无压烧结磨轮开槽片用磨光机打磨基体表面光亮,然后以600N/mm2强度标准对每个金刚石刀头部分进行安全焊接强度检测,不合格返工,合格则进行表面喷漆,烘干,以防止表面生锈,最后丝印,激光打标,包装,入库。
6.根据权利要求5所述的兼具打磨及开槽功能的金刚石磨轮开槽片的制备方法,其特征在于:步骤(2)中,所述金刚石刀头的制备原料由铜、铁、锡、镍、钨铁合金、液体石蜡和金刚石组成,其中金刚石粒度为30/40、40/45或45/50,金刚石抗压强度20-30kg;所述钨铁合金中钨含量为70-80wt.%,其余为铁;所述金刚石刀头按重量份数计的制备原料如下:
铜15-35份、铁32-46份、镍2-11份、锡1-9份、钨铁合金27-40份、液体石蜡1.0-2.0份、金刚石1.1-2.8份。
7.根据权利要求6所述的兼具打磨及开槽功能的金刚石磨轮开槽片的制备方法,其特征在于:所述金刚石刀头按重量百分比计的制备原料如下:
铜21-33份、铁27-40份、镍4-10份、锡2-7份、钨铁合金30-38份、液体石蜡1.0-2.0份、金刚石1.6-2.5份。
8.根据权利要求6所述的兼具打磨及开槽功能的金刚石磨轮开槽片的制备方法,其特征在于:步骤(2)中,所述无压烧结成型过程在氢气保护气氛下进行,压力为常压,烧结温度为820~930℃,烧结时间1-4小时,氢气流量0.3m3/h。
9.根据权利要求6所述的兼具打磨及开槽功能的金刚石磨轮开槽片的制备方法,其特征在于:步骤(2)中,保温结束后,停止加热自然冷却到500℃出炉风冷,氢气保持畅通直到冷却到100℃以下停止通氢气。
10.根据权利要求6所述的兼具打磨及开槽功能的金刚石磨轮开槽片的制备方法,其特征在于:步骤(3)中,钎焊工艺参数为:钎焊温度800-820℃,钎焊时间10-15秒。
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