EP0095055B1 - Method of manufacturing an abrasive body - Google Patents

Method of manufacturing an abrasive body Download PDF

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Publication number
EP0095055B1
EP0095055B1 EP83104209A EP83104209A EP0095055B1 EP 0095055 B1 EP0095055 B1 EP 0095055B1 EP 83104209 A EP83104209 A EP 83104209A EP 83104209 A EP83104209 A EP 83104209A EP 0095055 B1 EP0095055 B1 EP 0095055B1
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EP
European Patent Office
Prior art keywords
abrasive
grinding
layer
centrifuge
support layer
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
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EP83104209A
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German (de)
French (fr)
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EP0095055A2 (en
EP0095055A3 (en
Inventor
Rainer Augustin
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DR. ELBEL SCHLEIFMITTEL GMBH
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Dr Elbel Schleifmittel GmbH
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Priority to AT83104209T priority Critical patent/ATE33106T1/en
Publication of EP0095055A2 publication Critical patent/EP0095055A2/en
Publication of EP0095055A3 publication Critical patent/EP0095055A3/en
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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D13/00—Wheels having flexibly-acting working parts, e.g. buffing wheels; Mountings therefor
    • B24D13/02—Wheels having flexibly-acting working parts, e.g. buffing wheels; Mountings therefor acting by their periphery

Definitions

  • the invention relates to a method for producing an abrasive body with an abrasive, consisting of a binder-abrasive grain mixture and an abrasive grain-free, elastomeric carrier layer, the latter carrier layer being foamed under the action of a centrifugal force in a centrifuge onto the active grinding layer located in the centrifuge.
  • a grinding wheel according to the type mentioned has grinding wheels which are statistically distributed in an elastomeric and mostly foamed binder.
  • the individual abrasive grain evades the grinding pressure exerted by the machined workpiece due to its elastically yielding substrate, no tangible cutting performance can be achieved with such abrasive bodies, which is why they are mainly used for finishing work for which they are excellently suited.
  • the two components for forming the elastomeric support layer and the abrasive grain layer are mixed and simultaneously introduced into the centrifuge, whereupon the heavier abrasive grains are separated radially from the lighter support layer as a result of the centrifugal force effect.
  • the grinding wheels are produced exclusively by entering the necessary components into the centrifuge.
  • a controlled shaping of the grinding-active surface that is, an exact spatial definition of individual grinding-body conglomerates with regard to their dimensions and with regard to the space between them is not provided in this previously known method, rather the grinding-grain bodies 19 shown in FIG. 10 protrude in a statistically irregular manner from the elastomer carrier layer out.
  • the essential effect of this arrangement is precisely the avoidance or tilting away from the grinding pressure exerted by the workpiece, as mentioned above, such grinding bodies cannot achieve satisfactory cutting performance.
  • US Pat. No. 2,001,911 describes grinding wheels which can be produced using negative molds.
  • the choice of the negative form thus makes it possible to define and assign abrasive grains to abrasive grain conglomerates, but these abrasive grain conglomerates are placed directly on a carrier layer connecting them or bonded to them and are then applied individually or continuously to a core 11.
  • the thin carrier layer for example paper or fabric
  • the object of the invention is therefore to provide a simple method for producing elastic grinding wheels for all industrial applications, which has a more favorable ratio between service life (service life) and production costs (production costs) than the previously known solutions.
  • the grinding active layer is produced in an elastic, flat negative form with the formation of islands as a whole, is brought together with the elastic negative form into an annular shape, both are placed in the centrifuge, and the elastomeric carrier layer on the not yet cured grinding active layer is foamed.
  • elastic grinding bodies can be produced in the practically required geometrical shapes, for example in the form of disks (disk grinding disks) or wheel shape.
  • the abrasive body shown in sectional views in FIGS. 1 and 2 consists of a layer 11 of a hardened binder-abrasive grain mixture, a backing layer 12 formed of a foamed elastomer and a further layer 13 made of fabric, in particular textile fiber fabric.
  • the layer 11 of the binder-abrasive grain mixture has cutouts 11 in such a way that the layer 11 in the form of islands 11 b rests on the elastomer carrier layer 12.
  • All known hard materials such as corundum, silicon carbide, boron carbide and other carbides, garnet, natural sandpaper, glass powder, etc., can be used as the grinding grain for the layer 11 in order to support the grinding effect in various respects and to achieve a sufficient chip gap volume in the grinding-active surface , the installation of grinding aids such as pyrite, hollow corundum, marble powder, cryolite etc. is recommended, the density of which should be at least 2g / cm '.
  • Cold-curing types e.g. Polyurethanes curing at room temperature.
  • High-quality elastomers that cure warm can also be used for difficult grinding tasks.
  • thermosetting polyurethanes, thiocols and other liquid prepolymers of elastomers can be used.
  • the thickness of the binder abrasive grain layer 11 depends on the surface of the abrasive grain islands 11b and is 10-50% of the maximum extension (edge length, diameter) of the abrasive grain islands 11b.
  • the thickness of the elastomer carrier layer 12 is at least 5 mm, for most applications 10-20 mm are provided.
  • the width and number of the cutouts 11a are chosen so that the area ratio of grain islands 11b to cutouts 11a is in the range 50:50 to 95: 5.
  • soft, foaming polyurethane types or foaming thiocols can be used for the carrier layer 12.
  • binder formulations namely a harder, non-foaming formulation for the abrasive grain layer 11 and a softer setting and / or foaming formulation for the elastomer layer 12.
  • a harder, non-foaming formulation for the abrasive grain layer 11 and a softer setting and / or foaming formulation for the elastomer layer 12.
  • the difference in hardness between grain layer 11 and elastomer layer 12 results solely from the grain content. Even when using the same formulation for the binder of the grain layer 11 and the elastomer layer 12, the difference in hardness is therefore 10-20 Shore A points.
  • an elastic abrasive body can be produced, which is used on the workpieces to be machined in all industrial application areas with regard to stability and shape sequence properties can.
  • the insert 23 is used to hold a filled negative mold, as explained below.
  • the size of the centrifugal force and thus the The speed of rotation of the centrifuge depends on the viscosity and the open time as well as the foaming pressure of the elastomer used.
  • accelerations in the order of magnitude of 3 ,6800 g, essentially in the range of 150-2500 g, are required to produce the grinding wheel according to the invention.
  • an axially displaceable filler neck 21 is embedded, with which the necessary amount of the grain-free elastomer (later backing layer) can advantageously be injected by an automatic metering machine with a mixing head.
  • the process for producing the grinding wheels according to the invention is based on a flat negative mold which corresponds to the development of the finished grinding wheel: the width of the mold corresponds to the width of the grinding wheel to be produced, the length of its circumference.
  • this negative form consists of an elastomeric impression material, for example of silicone rubber.
  • corresponding mold cavities of this form are filled with a highly viscous and / or thixotropic abrasive grain binder mixture and wiped off.
  • the mold is then rolled into a circle and placed in the centrifuge. Then, while rotating, the grain-free elastomer mixture is back-poured or back-foamed and cured.
  • the binder containing the abrasive grain can have the same composition as the grain-free elastomer mixture used to produce the backing layer, but without the former, the latter with foaming agent. Also, for example, by adding the crosslinker, the binder containing the abrasive grain (for producing the layer 11) can be made harder, in order to increase the chip removal rate.
  • the grain-free elastomer mixture is advantageously applied to the negative mold with the grain-binder mixture which has not yet hardened. This not only simplifies the manufacture of the grinding wheels according to the invention, it also achieves a smooth and stress-free hard transition from the layer 11 containing the abrasive grain to the grain-free and softer elastomer layer 12, which is further supported by the centrifugal force gradient decreasing towards the center of rotation of the centrifuge.
  • the mixtures introduced in this way need not be cured to their full extent or at all under the action of the acceleration until they can be removed from the mold.
  • the acceleration can be reduced after a certain time from, for example, 153-2446 g to 2.7-153 g, in which the process is continued until the mixture is still sticky but sufficiently firm is.
  • the mold can then be removed and the abrasive body in the molded part, if necessary, further cured under the influence of heat.
  • the method according to the invention opens up the possibility of designing the inner ring 24 as a reusable core made of any hard material, the peripheral surface of which is freshly ground and optionally roughened and / or provided with an adhesion-promoting primer.
  • the inner ring 24 designed in this way is then provided with a roll of open-mesh and optionally provided with adhesion promoter glass fiber fabric 13 before the centrifuge is filled, so that this fabric wrap, which can also be low-stretch fabric, fleece, etc. made of other textile fibers, is an integral part Part of the grinding wheel produced.
  • the excess foam of the elastomer protrudes as a bead over the mold edge and can easily be cut off with a knife before the mass is removed from the mold and finally hardened .
  • the grinding wheel according to the invention and a method for its production have been described above using the exemplary embodiment of a wheel-shaped grinding wheel, but grinding wheels in other shapes can also be produced, for example in the form of disks or plates.
  • the required shapes are rotatably suspended in the centrifuge, whereby the centrifugal force then also acts in the axial direction of the grinding wheel.
  • the foaming of the grain-free elastomer towards the pivot point can also be limited, but for the simplicity of the device one can also let it foam freely.
  • the grinding wheel must then be ground flat. Double-sided adhesive film can then be used to fasten the grinding plates thus obtained to a base.
  • the mixtures used do not need to be cured until they can be removed from the mold or under full acceleration, depending on the size of the grinding wheel, acceleration value, viscosity, open time and other parameters, 30-180 seconds of centrifuging time are sufficient until the distribution is complete has stabilized in the pane structure so that the shape can be removed. It must be horizontal until the binder has sufficiently hardened be discontinued, with simultaneous or subsequent heat treatment for final curing.
  • a variant of the described method is based on a rigid negative form.
  • a metal is conceivable as the molding material, but it is expedient to use a material which allows such molds to be produced more cheaply. Plaster, concrete, epoxy, polyester resin, deep-drawn foils or the like can be used.
  • the mold cavities provided with a release agent are in turn filled with the abrasive grain / binder mixture until this mass is flush with the mold surface.
  • a carrier material of the appropriate dimensions is placed on top. Possible carrier materials are e.g. Paper, foils, nonwovens, fabrics, knitted fabrics, etc.
  • the backing material must bond firmly to the abrasive grain binder mixture in the mold nests.
  • the backing material can be coated accordingly, provided the inherent adhesive strength of the abrasive grain binder mixture in the mold nests is not sufficient for this.
  • the carrier material with the firmly adhering grinding knobs is pulled off the mold and then, with knobs facing outwards, inserted into the ring mold and, as already described , back-poured or back-foamed.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

An elastic grinding element for form-true grinding including a supporting layer of elastomer material and an adhesive grit layer bound to the supporting layer and having an active grinding surface made of a hardened mixture of binder and abrasive grit. The process for making the grinding element includes providing a mold having a shape constructed to produce a desired shape for the grinding element, putting the mixture of binder and abrasive grit and the elastomer material in the mold, and accelerating the mixture of binder and abrasive grit and the elastomer material while in the mold.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines Schleifkörpers mit einer schleifaktiven, aus einem Bindemittel-Schleifkorn-Gemisch bestehenden und einer schleifkornfreien, elastomeren Trägerschicht, wobei letztere Trägerschicht unter Einwirkung einer Zentrifugalkraft in einer Zentrifuge auf die in der Zentrifuge befindliche schleifaktive Schicht aufgeschäumt wird.The invention relates to a method for producing an abrasive body with an abrasive, consisting of a binder-abrasive grain mixture and an abrasive grain-free, elastomeric carrier layer, the latter carrier layer being foamed under the action of a centrifugal force in a centrifuge onto the active grinding layer located in the centrifuge.

Ein Schleifkörper gemäß der genannten Gattung weist statistisch in einem elastomeren und meist geschäumten Bindemittel verteilte Schleifkörper auf. Da das einzelne Schleifkorn infolge seines elastisch nachgebenden Untergrundes durch Dreh- und Kippbewegungen dem vom bearbeiteten Werkstück ausgeübten Schleifdruck aber ausweicht, lassen sich mit derartigen Schleifkörpern keine fühlbaren Zerspanleistungen erreichen, sie werden deswegen hauptsächlich für die Finishbearbeitung eingesetzt, für die sie sich vorzüglich eignen.A grinding wheel according to the type mentioned has grinding wheels which are statistically distributed in an elastomeric and mostly foamed binder. However, since the individual abrasive grain evades the grinding pressure exerted by the machined workpiece due to its elastically yielding substrate, no tangible cutting performance can be achieved with such abrasive bodies, which is why they are mainly used for finishing work for which they are excellently suited.

Eine Verbesserung dieser Schleifkörper ist dadurch erreicht worden, daß das Schleifkorn nicht mehr "individuell", sondern in hart gebundenen Verbänden, Konglomeraten von 3-5 mm Dicke, eingebettet ist. Diese Konglomerate "schwimmen" mit Abstand voneinander in dem elastischen Material. Infolge ihrer größeren Abmessungen und ihrer geometrischen Gestaltung wird das Ausweichen oder Wegkippen gegenüber dem vom Werkstück ausgeübten Schleifdruck verhindert. Derartige Schleifkörper haben schleiftechnisch erhebliche Vorteile, sind in der Herstellung jedoch sehr aufwendig und damit teuer und eignen sich auch nicht für das Schleifen mit ölhaltigen Kühlmitteln, da das Elastomer als verwendetes elastisches Material zwischen den Konglomeraten zu quellen beginnt. Auch mit reinem Wasser oder vollsynthetischen Kühlmitteln quellen diese Elastomere im Feinstkornbereich wegen der hier sehr geringen Zerspanung und damit geringen Abnutzung der Schleifkörper.An improvement of this abrasive body has been achieved in that the abrasive grain is no longer embedded "individually", but in hard-bonded dressings, conglomerates of 3-5 mm in thickness. These conglomerates "float" in the elastic material at a distance from one another. Due to their larger dimensions and their geometrical design, the avoidance or tilting away from the grinding pressure exerted by the workpiece is prevented. Such grinding wheels have considerable advantages in terms of grinding technology, but are very complex to manufacture and therefore expensive and are also unsuitable for grinding with oil-containing coolants, since the elastomer, as the elastic material used, begins to swell between the conglomerates. Even with pure water or fully synthetic coolants, these elastomers swell in the finest grain area due to the very low machining and therefore low wear of the grinding wheels.

Aus der US―PS 3,850,589 ist ein gattungsgemäßes Verfahren bekannt. Hierbei sind zwei Möglichkeiten vorgesehen: Entweder wird zunächst die elastomere Trägerschicht in die Zentrifuge eingebracht, diese dann beschleunigt bis die äußere Hälfte der Zentrifugalform gleichmäßig mit der Trägerschicht bedeckt ist. Danach wird dann in die rotierende Zentrifuge die Schleifkornmischung eingegeben, die unter dem Einfluß der Zentrifugalkraft die elastomere Trägerschicht durchwandert und so zum Umfangsbereich der Zentrifuge gelangt, wo eine mehr oder weniger homogene Schleifkornschicht sich bildet, zwischen denen kleine Zwischenräume der Trägerschicht verbleiben. Schließlich kann dann noch zusätzliches Trägermaterial eingeschäumt werden. Oder die beiden Komponenten zur Bildung zur elastomeren Trägerschicht und der Schleifkornschicht werden vermischt und gleichzeitig in die Zentrifuge eingegeben, worauf wiederum eine radiale Separierung der schwereren Schleifkörner von der leichteren Trägerschicht infolge der Zentrifugalkraftwirkung erfolgt.A generic method is known from US Pat. No. 3,850,589. Two options are provided for this: either the elastomeric carrier layer is first introduced into the centrifuge, which is then accelerated until the outer half of the centrifugal shape is evenly covered with the carrier layer. Then the abrasive grain mixture is then introduced into the rotating centrifuge, which moves under the influence of the centrifugal force through the elastomeric carrier layer and thus reaches the peripheral region of the centrifuge, where a more or less homogeneous abrasive grain layer forms, between which small gaps in the carrier layer remain. Finally, additional carrier material can then be foamed. Or the two components for forming the elastomeric support layer and the abrasive grain layer are mixed and simultaneously introduced into the centrifuge, whereupon the heavier abrasive grains are separated radially from the lighter support layer as a result of the centrifugal force effect.

Grundsätzlich erfolgt bei diesem vorbekannten Verfahren die Herstellung der Schleifkörper jedoch ausschließlich durch Eingabe der erforderlichen Komponenten in die Zentrifuge.Basically, in this previously known method, the grinding wheels are produced exclusively by entering the necessary components into the centrifuge.

Damit lassen sich Schleifkörper herstellen (Figur 10 der US―PS 3,850,589), die, wie oben angedeutet, statistisch verteilt in dem elastomeren geschäumten Bindemittel sitzen.This makes it possible to produce grinding wheels (FIG. 10 of US Pat. No. 3,850,589) which, as indicated above, are randomly distributed in the elastomeric foamed binder.

Eine kontrollierte Formgebung der schleifaktiven Oberfläche, d.h., eine exakte räumliche Definition einzelner Schleifkörper-Konglomerate hinsichtlich ihrer Abmessungen und hinsichtlich des zwischen ihnen befindlichen Zwischenraums ist bei diesem vorbekannten Verfahren nicht vorgesehen, vielmehr ragen die in Figur 10 dargestellten Schleifkornkörper 19 in statistisch unregelmäßiger Weise aus der elastomeren Trägerschicht heraus. Der wesentliche Effekt dieser Anordnung ist gerade das Ausweichen oder Wegkippen gegenüber dem vom Werkstück ausgeübten Schleifdruck, wie oben erwähnt, lassen sich mit derartigen Schleifkörpern keine zufriedenstellenden Zerspanleistungen erreichen.A controlled shaping of the grinding-active surface, that is, an exact spatial definition of individual grinding-body conglomerates with regard to their dimensions and with regard to the space between them is not provided in this previously known method, rather the grinding-grain bodies 19 shown in FIG. 10 protrude in a statistically irregular manner from the elastomer carrier layer out. The essential effect of this arrangement is precisely the avoidance or tilting away from the grinding pressure exerted by the workpiece, as mentioned above, such grinding bodies cannot achieve satisfactory cutting performance.

In der US-PS 2,001,911 sind Schleifkörper beschrieben, die mit Hilfe von Negativformen hergestellt werden können. Durch die Wahl der Negativform ist somit eine Definition und Zuordnung von Schleifkörnern zu Schleifkornkonglomeraten möglich, jedoch sind diese Schleifkornkonglomerate unmittelbar auf einer sie verbindenden Trägerschicht aufgesetzt bzw. mit dieser verklebt und werden dann einzeln oder zusammenhängend auf einen Kern 11 aufgebracht. Es versteht sich von selbst, daß die dünne Trägerschicht (beispielsweise Papier oder Gewebe) nicht die gewünschte "schwimmende" Lagerung der Schleifkörperkonglomerate erreicht wird.US Pat. No. 2,001,911 describes grinding wheels which can be produced using negative molds. The choice of the negative form thus makes it possible to define and assign abrasive grains to abrasive grain conglomerates, but these abrasive grain conglomerates are placed directly on a carrier layer connecting them or bonded to them and are then applied individually or continuously to a core 11. It goes without saying that the thin carrier layer (for example paper or fabric) does not achieve the desired "floating" mounting of the abrasive conglomerates.

Die Aufgabe der Erfindung besteht daher in der Schaffung eines einfachen Verfahrens zur Herstellung von elastischen Schleifkörpern für alle industriellen Anwendungsbereiche, die ein günstigeres Verhältnis zwischen Standzeit (Gebrauchsdauer) und Herstellungsaufwand (Gestehungskosten) als die bisher bekannten Lösungen aufweist.The object of the invention is therefore to provide a simple method for producing elastic grinding wheels for all industrial applications, which has a more favorable ratio between service life (service life) and production costs (production costs) than the previously known solutions.

Dies löst die Erfindung dadurch, daß die Schleifaktive Schicht in einer elastischen, ebenen Negativform unter Bildung von Inseln als Ganzes hergestellt wird, zusammen mit der elastischen Negativform in eine ringförmige Gestalt gebracht wird, beide in die Zentrifuge eingelegt werden, und die elastomere Trägerschicht auf die noch nicht ausgehärtete schleifaktive Schicht aufgeschäumt wird.This solves the invention in that the grinding active layer is produced in an elastic, flat negative form with the formation of islands as a whole, is brought together with the elastic negative form into an annular shape, both are placed in the centrifuge, and the elastomeric carrier layer on the not yet cured grinding active layer is foamed.

Mit diesem Verfahrfen ergeben sich hinsichtlich der Produktionskosten wesentliche Vorteile:

  • Die Negativformen mit den fest anhaftenden Schleifnoppen können auf Lager gefertigt und später entsprechend dem Kundenwunsch mehr oder weniger hart bzw. elastisch hintergossen bzw. hinterschäumt werden, so daß eine Art "Bausatzsystem" durch Wahl bzw. Zuordnung verschiedener Schleifnoppen zu verschiedenem Trägermaterial ermöglicht wird. Die ebene Negativform ist im übrigen kostengünstig herzustellen.
With this method, there are significant advantages in terms of production costs:
  • The negative molds with the firmly adhering grinding knobs can be made in stock and later, according to the customer's wishes, back-molded or back-foamed more or less hard or elastically, so that a kind of "kit system" is made possible by choosing or assigning different grinding knobs to different carrier material. The flat negative mold is otherwise inexpensive to manufacture.

Die Vorteile in bezug auf die Erhöhung der Schleifleistung ergeben sich aus der Tatsache, daß beim erfindungsgemäßen Verfahren beispielsweise auch Phenolharz als Bindemittel für die Schleifschicht verwendet werden kann, die für ihre hohen Abtragsleistungen pro Zeiteinheit bekannt sind.The advantages with regard to increasing the grinding performance result from the fact that, for example, phenolic resin, which is known for its high removal rates per unit of time, can also be used as a binder for the grinding layer in the process according to the invention.

Durch geeignete konstruktive Ausgestaltung der verwendeten Zentrifugen lassen sich elastische Schleifkörper in den praktisch erforderlichen geometrischen Formen herstellen, beispielsweise in Scheibenform (Tellerschleifscheiben) oder auch Radform.By means of a suitable design of the centrifuges used, elastic grinding bodies can be produced in the practically required geometrical shapes, for example in the form of disks (disk grinding disks) or wheel shape.

Ein Ausführungsbeispiel eines Schleifkörpers und dessen Herstellungsverfahren werden nun anhand von Zeichnungen näher erläutert, es zeigen:

  • Figur 1: einen Querschnitt durch einen elastischen Schleifkörper in der Ebene A-B der Figur 2,
  • Figur 2: einen Querschnitt durch die eine Hälfte des elastischen Schleifkörpers senkrecht zur Ebene A-B,
  • Figuren 3―6: einen Ausschnitt aus Oberflächenansichten des Schleifkörpers gemäß den
  • Figuren 1 bis 2 mit verschiedenen Gestaltungen der schleifaktiven Oberfläche,
  • Figur 7: eine teilweise aufgebrochene Seitenansicht einer Zentrifuge zur Druchführung des erfindungsgemäßen Verfahrens zur Herstellung eines Schleifkörpers gemäß den Figuren 1-6 und
  • Figur 8: die Einzelheit X der Figur 7 in einer Querschnittsdarstellung..
An embodiment of a grinding wheel and its manufacturing process will now be explained in more detail with reference to drawings, in which:
  • FIG. 1: a cross section through an elastic grinding body in the plane AB of FIG. 2,
  • FIG. 2 shows a cross section through one half of the elastic grinding body perpendicular to the plane AB,
  • Figures 3―6: a section of surface views of the grinding wheel according to the
  • FIGS. 1 to 2 with different designs of the active grinding surface,
  • 7 shows a partially broken side view of a centrifuge for carrying out the method according to the invention for producing an abrasive wheel according to FIGS. 1-6 and
  • Figure 8: the detail X of Figure 7 in a cross-sectional view ..

Der in Figur 1 und 2 in Schnittdarstellungen dargestellte Schleifkörper besteht aus einer Schicht 11 eines gehärteten Bindemittel-Schleifkorn-Gemisches, einer aus einem geschäumten Elastomer gebildeten Trägerschicht 12 und einer weiteren Schicht 13 aus Gewebe, insbesondere textilem Fasergewebe.The abrasive body shown in sectional views in FIGS. 1 and 2 consists of a layer 11 of a hardened binder-abrasive grain mixture, a backing layer 12 formed of a foamed elastomer and a further layer 13 made of fabric, in particular textile fiber fabric.

Die Schicht 11 des Bindemittel-Schleifkorn-Gemisches weist dabei Aussparungen 11 derart auf, daß die Schicht 11 in Form von Inseln 11 b auf der Elastomer-Trägerschicht 12 aufsitzt.The layer 11 of the binder-abrasive grain mixture has cutouts 11 in such a way that the layer 11 in the form of islands 11 b rests on the elastomer carrier layer 12.

Als Schleifkörnung für die Schicht 11 können alle bekannten Hartstoffe verwendet werden, wie beispielsweise Korunde, Siliziumcarbid, Borcarbid und andere Carbide, Granat, Naturschmirgel, Glasmehl usw. Um die Schleifwirkung in verschiedener Hinsicht zu unterstützen und um ein ausreichendes Spanlückenvolumen in der schleifaktiven Oberfläche zu erzielen, empfiehlt sich außerdem der Einbau von Schleifhilsmitteln wie beispielsweise Pyrit, Hohlkugelkorund, Marmormehl, Kryolith usw., deren Dichte mindestens 2g/ cm' betragen soll.All known hard materials, such as corundum, silicon carbide, boron carbide and other carbides, garnet, natural sandpaper, glass powder, etc., can be used as the grinding grain for the layer 11 in order to support the grinding effect in various respects and to achieve a sufficient chip gap volume in the grinding-active surface , the installation of grinding aids such as pyrite, hollow corundum, marble powder, cryolite etc. is recommended, the density of which should be at least 2g / cm '.

Als Bindemittel dienen vorzugsweise kalthärtende Typen z.B. bei Raumtemperatur härtende Polyurethane. Für schwierige Schleifaufgaben können auch höher-wertige Elastomere eingesetzt werden, die warm aushärten, hier sind beispielsweise warmhärtende Polyurethane, Thiokole und andere flüssige Präpolymere von Elastomeren verwendbar.Cold-curing types, e.g. Polyurethanes curing at room temperature. High-quality elastomers that cure warm can also be used for difficult grinding tasks. Here, for example, thermosetting polyurethanes, thiocols and other liquid prepolymers of elastomers can be used.

Die Dicke der Bindemittel-Schleifkorn-Schicht 11 richtet sich nach der Oberfläche der Schleifkorninseln 11b und beträgt 10-50% der maximalen Ausdehnung (Kantenlänge, Durchmesser) der Schleifkorninseln 11b.The thickness of the binder abrasive grain layer 11 depends on the surface of the abrasive grain islands 11b and is 10-50% of the maximum extension (edge length, diameter) of the abrasive grain islands 11b.

Um dem erfindungsgemäßen Schleifkörper eine ausreichende Hintergrundelastizität zu geben, beträgt die Dicke der Elastomer-Trägerschicht 12 mindestens 5 mm, für die meisten Anwendungsfälle sind 10-20 mm vorgesehen.In order to give the grinding wheel according to the invention sufficient background elasticity, the thickness of the elastomer carrier layer 12 is at least 5 mm, for most applications 10-20 mm are provided.

Breite und Anzahl der Aussparungen 11a werden so gewählt, daß das Flächenverhältnis von Korninseln 11b zu Aussparungen 11a im Bereich 50:50 bis 95:5 liegt.The width and number of the cutouts 11a are chosen so that the area ratio of grain islands 11b to cutouts 11a is in the range 50:50 to 95: 5.

Für die Trägerschicht 12 lassen sich beispielsweise weiche, schäumende Polyurethan-Typen verwenden, oder auch shäumende Thiokole.For example, soft, foaming polyurethane types or foaming thiocols can be used for the carrier layer 12.

Um den Aufbau des Schleifkörpers auf den jeweiligen Verwendungszweck besser einstellen zu können, empfiehlt sich die Verwendung unterschiedlicher Bindemittelrezepturen, nämlich einer härteren, nicht schäumenden für die Schleifkorn- schicht 11 und einer weicher eingestellten und/ oder schäumenden Rezeptur für die Elastomerschicht 12. Zweckmäßigerweise geht man beim unten erläuterten Zentrifugenverfahren von gleichen oder verwandten Rohstoffen aus, beispielsweise einer harten, nicht schäumenden und einer weicheren, schäumenden Polyurethan-Rezeptur. Entsprechendes gilt für Thiokole, die für ihre Verwendung in der Schleifkornschicht 11 ungeschäumt mit Epoxidharzen härter eingestellt werden.In order to be able to better adjust the structure of the grinding wheel to the respective intended use, it is recommended to use different binder formulations, namely a harder, non-foaming formulation for the abrasive grain layer 11 and a softer setting and / or foaming formulation for the elastomer layer 12. Appropriately, one goes in the centrifuge process explained below from the same or related raw materials, for example a hard, non-foaming and a softer, foaming polyurethane formulation. The same applies to thiocols, which are made unfoamed with epoxy resins for their use in the abrasive grain layer 11.

Die Härtedifferenz zwischen Kornschicht 11 und Elastomerschicht 12 ergibt sich allein schon aus dem Korngehalt. Selbst bei Verwendung der gleichen Rezeptur für das Bindemittel der Kornschicht 11 und die Elastomerschicht 12 beträgt daher der Härteunterschied 10-20 Shore-A-Punkte.The difference in hardness between grain layer 11 and elastomer layer 12 results solely from the grain content. Even when using the same formulation for the binder of the grain layer 11 and the elastomer layer 12, the difference in hardness is therefore 10-20 Shore A points.

Durch Auswahl geeigneter Schleifkörnungen und Bindemittelrezepturen einerseits und durch Dimensionierung der relativen Größe der Schleifkorninseln 11b im Verhältnis zu den Aussparungen 11a in der Schleifschicht 11 andererseits läßt sich ein elastischer Schleifkörper herstellen, der hinsichtlich Standfestigkeit und Formfolgeeigenschaften auf die zu bearbeitenden Werkstücke in allen industriellen Anwendungsbereichen eingesetzt werden kann.By selecting suitable abrasive grains and binder formulations on the one hand and by dimensioning the relative size of the abrasive grain islands 11b in relation to the recesses 11a in the abrasive layer 11 on the other hand, an elastic abrasive body can be produced, which is used on the workpieces to be machined in all industrial application areas with regard to stability and shape sequence properties can.

Im folgenden soll nun das erfindungsgemäße Verfahren zur Herstellung eines Schleifkörpers erläutert werden:

  • Zur Durchführung des Verfahrens schlägt die Erfindung eine Vorrichtung vor, wie sie in den Figuren 7 und 8 dargestllt ist:
  • Diese Vorrichtung besteht aus einer Zentrifuge, bei der innerhalb einer Schutzhaube 25 mit Deckel 22 ein Einsatz 23 zur Aufnahme der Mischungsbestandteile des Schleifkörpers rotiert. Durch einen Innenring 24 wird das Schleifkörpervolumen nach innen hin begrenzt.
The method according to the invention for producing an abrasive body will now be explained below:
  • To carry out the method, the invention proposes a device such as that shown in FIGS. 7 and 8:
  • This device consists of a centrifuge in which an insert 23 for receiving the mixture components of the grinding wheel rotates within a protective hood 25 with a cover 22. The inside volume of the grinding wheel volume is limited by an inner ring 24.

Der Einsatz 23 dient zur Aufnahme einer befüllten Negativform, wie weiter unten erläutert.The insert 23 is used to hold a filled negative mold, as explained below.

Die Größe der Zentrifugalkraft und damit der Rotationsgeschwindigkeit der Zentrifuge hängt dabei von der Viskosität und der offenen Zeit sowie dem Schäumdruck des verwendeten Elastomers ab. Je nach Art und Zusammensetzung des Gemischs sind zur Erzeugung des erfindungsgemäßen Schleifkörpers Beschleunigungen in der Größenordnung von 3―6800 g, im wesentlichen im Bereich von 150-2500 g erfordlich.The size of the centrifugal force and thus the The speed of rotation of the centrifuge depends on the viscosity and the open time as well as the foaming pressure of the elastomer used. Depending on the type and composition of the mixture, accelerations in the order of magnitude of 3 ,6800 g, essentially in the range of 150-2500 g, are required to produce the grinding wheel according to the invention.

In dem zur Bildung des Schleifkörpers vorgesehenen Hohlraum zwischen dem Einsatz 23 und dem Innenring 24 ist ein axial verschiebbarer Füllstutzen 21 eingelassen, mit dem vorteilhafterweise durch eine automatische Dosiermaschine mit Mischkopf die notwendige Menge des kornfreien Elastomers (spätere Trägerschicht) eingespritzt werden kann.In the cavity provided between the insert 23 and the inner ring 24 to form the grinding wheel, an axially displaceable filler neck 21 is embedded, with which the necessary amount of the grain-free elastomer (later backing layer) can advantageously be injected by an automatic metering machine with a mixing head.

Das Verfahren zur Herstellung der erfindungsgemäßen Schleifkörper geht von einer ebenen Negativform aus, die der Abwicklung des fertigen Schleifrades entspricht: Die Breite der Form entspricht dabei der Breite des herzustellenden Schleifrades, die Länge dessen Umfang.The process for producing the grinding wheels according to the invention is based on a flat negative mold which corresponds to the development of the finished grinding wheel: the width of the mold corresponds to the width of the grinding wheel to be produced, the length of its circumference.

Im einfachsten Falle besteht diese Negativform aus einem elastomeren Abformmaterial, beispielsweise aus Silikonkautschuk. Zur Herstellung der erfindungsgemäßen Schleifkörper in Form der Inseln 11 werden entsprechende Formnester dieser Form mit einem hoch-viskosen und/oder thixotropen Schleifkorn-Bindemittelgemisch gefüllt und abgestrichen.In the simplest case, this negative form consists of an elastomeric impression material, for example of silicone rubber. To produce the abrasive articles according to the invention in the form of the islands 11, corresponding mold cavities of this form are filled with a highly viscous and / or thixotropic abrasive grain binder mixture and wiped off.

Anschließend wird die Form zum Kreis gerollt und in die Zentrifuge eingelegt. Unter Rotation wird anschließend mit der kornfreien Elastomer-mischung hintergossen bzw. hinterschäumt und ausgehärtet.The mold is then rolled into a circle and placed in the centrifuge. Then, while rotating, the grain-free elastomer mixture is back-poured or back-foamed and cured.

Dabei kann das das Schleifkorn enthaltende Bindemittel prinzipiell die gleiche Zusammensetzung wie die zur Erzeugung der Trägerschicht verwendete kornfreie Elastomer-Mischung aufweisen, erstere jedoch ohne, letztere mit Schäumemittel. Auch kann zum Beispiel durch Vernetzer-Zugabe das Schleifkorn enthaltende Bindemittel (zur Erzeugung der Schicht 11) härter eingestellt werden, um so die Spanleistung zu erhöhen.In principle, the binder containing the abrasive grain can have the same composition as the grain-free elastomer mixture used to produce the backing layer, but without the former, the latter with foaming agent. Also, for example, by adding the crosslinker, the binder containing the abrasive grain (for producing the layer 11) can be made harder, in order to increase the chip removal rate.

Vorteilhafterweise wird dabei die kornfreie Elastomermischung auf die Negativform mit der noch nicht ausgehärteten Korn-Bindemittelmischung aufgebracht. Dadurch ist nicht nur die Herstellung der erfindungsgemäßen Schleifkörper vereinfacht, erreicht wird auch ein fließender und spannungsfreier Harteübergang von der Schleifkorn enthaltenden Schicht 11 zu der kornfreien und weicheren Elastomerschicht 12, der außerdem nocht durch das zum Drehpunkt der Zentrifuge abnehmende Zentrifugalkraftgefälle unterstützt wird.The grain-free elastomer mixture is advantageously applied to the negative mold with the grain-binder mixture which has not yet hardened. This not only simplifies the manufacture of the grinding wheels according to the invention, it also achieves a smooth and stress-free hard transition from the layer 11 containing the abrasive grain to the grain-free and softer elastomer layer 12, which is further supported by the centrifugal force gradient decreasing towards the center of rotation of the centrifuge.

Die Aushärtung der derart eingebrachten Mischungen braucht nicht bis zur Entformbarkeit unter der Einwirkung der Beschleunigung in voller Höhe oder überhaupt zu erfolgen. Bei den im Ausführungsbeispiel dargestellten Schleifkörperformen (Rad) kann nach einem gewissen Zeit die Beschleunigung von beispielsweise 153-2446 g auf 2,7-153 g gesenkt werden, bei der dann so lange weitergeschieudert wird, bis das Gemisch zwar noch klebrig, aber ausreichend fest ist. Dann kann die Form entnommen und der Schleifkörper im Formteil gegebenenfalls unter Wärmeeinfluß weiter zu Ende gehärtet werden.The mixtures introduced in this way need not be cured to their full extent or at all under the action of the acceleration until they can be removed from the mold. In the grinding wheel shapes (wheel) shown in the exemplary embodiment, the acceleration can be reduced after a certain time from, for example, 153-2446 g to 2.7-153 g, in which the process is continued until the mixture is still sticky but sufficiently firm is. The mold can then be removed and the abrasive body in the molded part, if necessary, further cured under the influence of heat.

Das erfindungsgemäße Verfahren eröffnet die Möglichkeit, den Innenring 24 als wiederverwendbaren Kern aus beliebigem hartem Material auszugestalten, dessen Umfangsfläche frisch geschliffen und gegebenenfalls gerauht und/oder mit einem haftungsvermittelnden Primer versehen ist.The method according to the invention opens up the possibility of designing the inner ring 24 as a reusable core made of any hard material, the peripheral surface of which is freshly ground and optionally roughened and / or provided with an adhesion-promoting primer.

Der derart ausgestaltete Innenring 24 wird dann vor der Befüllung der Zentrifuge mit einem Wickel offenmaschigen und gegebenenfalls mit Haftvermittler versehenen Glasseidengewebes 13 versehen, so daß dieser Gewebewickel, es kann sich hier auch um dehnungsarmes Gewebe, Vlies usw. aus anderen textilen Fasern handeln, ein integraler Bestandteil des hergestellten Schleifkörpers wird.The inner ring 24 designed in this way is then provided with a roll of open-mesh and optionally provided with adhesion promoter glass fiber fabric 13 before the centrifuge is filled, so that this fabric wrap, which can also be low-stretch fabric, fleece, etc. made of other textile fibers, is an integral part Part of the grinding wheel produced.

So besteht die Möglichkeit, derartige Schleifkörper in Radform auf beim Anwender vorhandenen geeigneten Vorrichtungen zu spannen, ohne daß sich beim Arbeiten der Schleifkörperring dehnt oder zerbirst.There is the possibility of clamping such grinding wheels in wheel form on suitable devices available to the user, without the grinding wheel ring stretching or bursting when working.

Bei der Herstellung von Schleifköpern in Radform, wie in den Figuren dargestellt, steht bei der Herstellung der überschüssige Schaum des Elastomers als Wulst über den Formrand hervor und kann leicht mit einem Messer abgeschnitten werden, bevor die Masse aus der Form entnommen und zu Ende gehärtet wird.In the manufacture of grinding wheels in wheel form, as shown in the figures, the excess foam of the elastomer protrudes as a bead over the mold edge and can easily be cut off with a knife before the mass is removed from the mold and finally hardened .

Der erfindungsgemäße Schleifkörper und ein Verfahren zu seiner Herstellung sind oben am Ausführungsbeispiel eines Schleifkörpers in Radform beschrieben worden, es lassen sich jedoch auch Schleifkörper in anderen Formen herstellen, beispielsweise in Scheiben- oder Teller-form. Im letzteren Fall werden die erforderlichen Formen in der Zentrifuge drehbar aufgehängt, wodurch die Zentrifugalkraft dann ebenfalls in axialer Richtung des Schleifkörpers wirkt.The grinding wheel according to the invention and a method for its production have been described above using the exemplary embodiment of a wheel-shaped grinding wheel, but grinding wheels in other shapes can also be produced, for example in the form of disks or plates. In the latter case, the required shapes are rotatably suspended in the centrifuge, whereby the centrifugal force then also acts in the axial direction of the grinding wheel.

Bei der Herstellung von Schleifkörpern in Tellerform läßt sich die Schäumung des kornfreien Elastomers zum Drehpunkt hin zwar auch begrenzen, der Einfachheit der Vorrichtung wegen kann man jedoch auch frei schäumen lassen. In diesem Falle muß anschließend der Schleifkörper plan geschliffen werden. Zur Befestigung der so erhaltenen Schleifteller auf einer Unterlage kann dann doppelseitige Klebefolie verwendet werden.In the manufacture of abrasive discs in the form of a plate, the foaming of the grain-free elastomer towards the pivot point can also be limited, but for the simplicity of the device one can also let it foam freely. In this case, the grinding wheel must then be ground flat. Double-sided adhesive film can then be used to fasten the grinding plates thus obtained to a base.

Bei der Herstellung von Tellerscheiben braucht ebenfalls die Aushärtung der verwendeten Gemische nicht bis zur Entformbarkeit oder unter Einwirkung der vollen Beschleunigung erfolgen, hier genügen, je nach Schleifkörpergröße, Beschleunigungswert, Viskosität, offener Zeit und weiterer Parameter 30-180 Sekunden Schleuderzeit, bis sich die Verteilung im Scheibenaufbau so stabilisiert hat, daß die Form entnommen werden kann. Sie muß bis zur ausreichenden Aushärtung der Bindemittel waagerecht abgesetzt werden, wobei gleichzeitig oder nachfolgend eine Wärmebehandlung zur abschließenden Aushärtung erfolgt.In the manufacture of disk discs, the mixtures used do not need to be cured until they can be removed from the mold or under full acceleration, depending on the size of the grinding wheel, acceleration value, viscosity, open time and other parameters, 30-180 seconds of centrifuging time are sufficient until the distribution is complete has stabilized in the pane structure so that the shape can be removed. It must be horizontal until the binder has sufficiently hardened be discontinued, with simultaneous or subsequent heat treatment for final curing.

Eine Variante des beschriebenen Verfahrens geht von einer starren Negativform aus. Als Formmaterial ist ein Metall denkbar, zweckmäßigerweise verwendet man jedoch ein Material, welches solche Formen preiswerter herzustellen gestattet. Es kommen hierfür in Frage Gips, Beton, Epoxid-, Polyesterharz, tiefgezogene Folien o.a.A variant of the described method is based on a rigid negative form. A metal is conceivable as the molding material, but it is expedient to use a material which allows such molds to be produced more cheaply. Plaster, concrete, epoxy, polyester resin, deep-drawn foils or the like can be used.

Zum Herstellung des erfindungsgemäßen Schleifkörpers in Radform werden die mit einem Trennmittel versehenen Formnester wiederum mit dem Schleifkorn-Bindemittelgemisch gefüllt, bis diese Masse bündig mit der Formoberfläche abschließt. Anschließend wird ein Trägermaterial entsprechender Abmessung aufgelegt. Als Trägermaterialien kommen in Frage z.B. Papier, Folien, Vliese, Gewebe, Gewirke o.ä.To produce the grinding wheel according to the invention in the form of a wheel, the mold cavities provided with a release agent are in turn filled with the abrasive grain / binder mixture until this mass is flush with the mold surface. Then a carrier material of the appropriate dimensions is placed on top. Possible carrier materials are e.g. Paper, foils, nonwovens, fabrics, knitted fabrics, etc.

Das Trägermaterial muß sich fest mit dem Schleifkorn-Bindemittelgemisch in den Formnestern verbinden. Zu diesem Zweck kann das Trägermaterial entsprechend beschichtet sein, sofern die Eigenklebkraft des Schleifkorn-Bindemittelgemisches in den Formnestern hierfür nicht ausreicht.The backing material must bond firmly to the abrasive grain binder mixture in the mold nests. For this purpose, the backing material can be coated accordingly, provided the inherent adhesive strength of the abrasive grain binder mixture in the mold nests is not sufficient for this.

Nach dem Aushärten des Schleifkorn-Bindemittelgemisches in den Formnestern, ggf. unter Einwirkung von Wärme, wird das Trägermaterial mit den fest anhaftenden Schleifnoppen (Inseln 11b) von der Form abgezogen und anschließend, Noppen nach außen, in die Ringform eingelegt und, wie bereits beschrieben, hintergossen bzw. hinterschäumt.After the abrasive grain / binder mixture has hardened in the mold nests, possibly under the influence of heat, the carrier material with the firmly adhering grinding knobs (islands 11b) is pulled off the mold and then, with knobs facing outwards, inserted into the ring mold and, as already described , back-poured or back-foamed.

Selbstverständlich ist es auch möglich, zuvor die Schleifkorn-Bindemittelmasse auszuhärten und anschließend das Trägermaterial aufzubringen, welches in diesem Falle natürlich entsprechend mit einem dauerhaften Kleber versehen sein muß.Of course, it is also possible to harden the abrasive grain binder mass beforehand and then to apply the backing material, which in this case must of course be provided with a permanent adhesive.

Claims (3)

1. Method of manufacturing a grinding body having an abrasive support layer, formed from a mixture of binding agents and abrasive grain, and an elastomeric support layer which is free of abrasive grain, wherein, by the action of a centrifugal force in a centrifuge, the latter support layer is expanded onto the abrasive layer situated in the centrifuge, characterised in that the abrasive layer (11) is integrally produced in a resilient, flat negative mould with the formation of clusters (11b), it is brought into an annular form together with the resilient negative mould, both layers are introduced into the centrifuge (25), and the elastomeric support layer (12) is expanded onto the abrasive layer (11) which has not yet hardened.
2. Method according to claim 1, characterised in that centrifuging is effected until such time as the elastomeric support layer (12) is sufficiently rigid, in that the remainder of the elastomeric foam, which may possibly protrude, is subsequently cut-off, the negative mould is removed from the centrifuge with the grinding body and completely hardened, and finally the resilient negative mould is removed.
3. Method according to claim 1, characterised in that an inner ring (24) is concentrically inserted into the centrifuge, prior to the introduction of the support layer, and is surrounded by a fabric wrapping (13) which becomes the integral component of the finished grinding body after centrifuging.
EP83104209A 1982-05-25 1983-04-29 Method of manufacturing an abrasive body Expired EP0095055B1 (en)

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AT83104209T ATE33106T1 (en) 1982-05-25 1983-04-29 PROCESS FOR MAKING AN ABRASIVE WHEEL.

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DE19823219567 DE3219567A1 (en) 1982-05-25 1982-05-25 ELASTIC GRINDING BODY AND METHOD FOR THE PRODUCTION THEREOF
DE3219567 1982-05-25

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US4539017A (en) 1985-09-03
EP0095055A2 (en) 1983-11-30
EP0095055A3 (en) 1984-02-22
DE3376055D1 (en) 1988-04-28
ATE33106T1 (en) 1988-04-15
DE3219567A1 (en) 1983-12-01

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