EP3231558A1 - Corps vert, meule et procédé de fabrication d'au moins un corps vert - Google Patents

Corps vert, meule et procédé de fabrication d'au moins un corps vert Download PDF

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Publication number
EP3231558A1
EP3231558A1 EP16164700.3A EP16164700A EP3231558A1 EP 3231558 A1 EP3231558 A1 EP 3231558A1 EP 16164700 A EP16164700 A EP 16164700A EP 3231558 A1 EP3231558 A1 EP 3231558A1
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EP
European Patent Office
Prior art keywords
volume
green body
amount
powder composition
grit
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EP16164700.3A
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German (de)
English (en)
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EP3231558B1 (fr
Inventor
Marijke VAN DER MEER
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3M Innovative Properties Co
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3M Innovative Properties Co
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Priority to EP19208783.1A priority Critical patent/EP3666462A1/fr
Priority to EP16164700.3A priority patent/EP3231558B1/fr
Publication of EP3231558A1 publication Critical patent/EP3231558A1/fr
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • B24D3/04Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
    • B24D3/14Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic ceramic, i.e. vitrified bondings
    • B24D3/18Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic ceramic, i.e. vitrified bondings for porous or cellular structure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B24D18/0009Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses

Definitions

  • the present invention relates to a green body, a grinding wheel and a method for manufacturing at least a green body, particularly a green body with high environmental compatibility and handling stability.
  • Gum arabic also known as aracia gum, chaar gund, char goond, or meska, is a natural gum made of the hardened sap of various species of the acacia tree. Gum arabic can be collected from the species Senegalia (Acacia) and Vachellia (Acacia) seyal of the acacia tree.
  • temporary binders In the production of grinding segments for grinding wheels, usually temporary binders are used.
  • the temporary binder is necessary as pressing aid for pressing the grinding segments and to improve the mechanical stability of the grinding segments after pressing.
  • the common temporary binders for example phenolic resins or other polymers, need typically special furnaces with exhaustion systems are necessary.
  • Gum arabic as temporary binder which burns out of the finished product during the sintering process is especially advantageous due to its typical characteristic namely high environmental compatibility.
  • One of the ideas on which the present invention is based is to use gum arabic as additive for grinding wheel production to improve the pressing process and handling stability of the green part prior to the sintering process.
  • gum arabic is an organic temporary binder it burns out during sintering process without any combustion residues or dangerous emissions. Further, an application of gum arabic is easier and more homogeneous than with other established polysaccharides like sugar solutions or food starch. Due to its eco-friendly and manufacturing conditions optimizing properties the utilization of gum arabic in vitrified grinding tools is a forward looking technology.
  • EP 2 175 002 A1 relates to an abrasive composition.
  • a green body Before sintering, a green body is usually very sensitive and has no good stability, which makes handling of the green body slow and difficult. This leads to low manufactured parts output rates. Additionally inaccuracies occur with respect to geometrical shape. Edge breakouts and material loss are further disadvantages. Theses aspects can be counteracted with the here described gum arabic as temporary binder. Productivity, accuracy as well as product manipulation are improved on an environmentally friendly resources saving manner.
  • the features of the green body are also disclosed for the method for manufacturing at least a green body and vice versa.
  • a first aspect of the disclosure pertains to a green body comprising a primary grit in an amount of 5% to 40% by volume, preferably in an amount of 10% to 35% by volume, and more preferably in an amount of 15% to 25% by volume, based on 100% by volume of the green body; a vitrified bond in an amount of 20% to 60% by volume; preferably in an amount of 25% to 40% by volume, based on 100% by volume of the green body; a gum arabic in an amount of 5% to 20% by volume; preferably in an amount of 7% to 17% by volume; and more preferably in an amount of 8% to 12% by volume, based on 100% by volume of the green body; a pore forming material in an amount of 0% to 20% by volume; preferably in an amount of 0% to 15% by volume, based on 100% by volume of the green body and a secondary grit in an amount of 0% to an amount sufficient to bring the green body to 100% by volume.
  • the green body is based on a powder composition, wherein the powder composition can be
  • the gum arabic can be applied as powder with a particle size of about 10 ⁇ m to 250 ⁇ m.
  • the gum arabic can be delivered from Caesar & Loretz GmbH (Germany) (Gummi Arabicum, Arts endeavor 512).
  • a method for manufacturing at least a green body, particularly a green body to the first aspect of the disclosure comprises a step A of providing a powder composition comprising a primary grit in an amount of 5% to 40% by volume, preferably in an amount of 10% to 35% by volume; and more preferably in an amount of 15% to 25% by volume, based on 100% by volume of the powder composition, a vitrified bond in an amount of 20% to 60% by volume, preferably in an amount of 25% to 40% by volume, based on 100% by volume of the powder composition, a gum arabic in an amount of 5% to 20% by volume, preferably in an amount of 7% to 17% by volume; and more preferably in an amount of 8% to 12% by volume, based on 100% by volume of the powder composition, a pore forming material in an amount of 0% to 20% by volume, preferably in an amount of 0% to 15% by volume, based on 100% by volume of the powder composition and a secondary grit in an amount of
  • step A For providing the powder composition of step A, an exact weighing of each component of the powder composition is performed. Depending on the geometry and the material of a workpiece to be grinded, the shape, the dimensions and the ingredients of the grinding segment have to be defined.
  • the amount of components is defined by the volume of the grinding segments, which results from the dimensions of the grinding segment.
  • the composition of the powder composition is defined by percentage of volume and the corresponding densities. All components in form of a dry powder of the powder composition can be mixed. By mixing the components a homogeneous distribution of the components can be obtained.
  • the mixed powder composition can be portioned and formed into at least one green body in the corresponding further method step (step B).
  • a grinding wheel comprises grinding segments, wherein the grinding segments are obtained by sintering the green body and are positioned and glued onto a blank.
  • gum arabic as an organic temporary binder for the production of grinding wheels with vitrified bond type. Due to its eco-friendly and manufacturing conditions optimizing properties the utilization of gum arabic in vitrified grinding tools is a forward looking technology. Gum Arabic can be used to improve handling stability of a green body prior to the sintering process. A bonding type of corresponding grinding wheels can be a vitrified bonding type.
  • the primary grit comprises super abrasive grits with a mean grit size from 2 ⁇ m to 300 ⁇ m; preferably 3 ⁇ m to 200 ⁇ m; and more preferably 45 ⁇ m to 130 ⁇ m.
  • the grit size can depend on the operational area of the grinding wheel.
  • Super abrasive grits can be made up of diamond or CBN (Cubic Boron Nitride).
  • Super abrasive grits are applied from different suppliers like Element Six Ltd. (Ireland), Sandvik Hyperion (Germany), EID Ltd. (United Kingdom), Duratec Hartstoffe GmbH (Germany), L.M. van Moppes & Sons SA (Switzerland) or WorldWide Superabrasives LLC (USA) in differing types from blocky to splintery or from amber to black versions.
  • Examples for diamond and CBN products are ABN, PDA (from Element Six Ltd.); CBN Type I, RVG, SP1 S (from Sandvik Hyperion); EBN, ERD(from EID Ltd.); BBN-J (from Duratec Hartstoffe GmbH); FRD(from van Moppes & Sohn SA); and BMI(from WorldWide Superabrasives LLC).
  • the vitrified bond comprises at least one glass frit.
  • the vitrified bond different glass frits in powder form from Reimbold & Strick (Germany) (A4015 P Bindefritte Gem.), Ferro GmbH (Germany) (DSCE K 2247 Transparent - 1376714, VK6327(90158), Heraeus Schauer GmbH (Austria) (IS FTR90741 F Frit farblos - Spezialglas TGF2584AF) or Prince Minerals LLC (USA) (Ceramic Bond for CBN Grit - 872063-25, Ceramic Bond - 865060-25, Ceramic Bond Modifier - 872064-1) can be used.
  • the pore forming material comprises graphite or glass bubbles.
  • pore forming material also "porosity generating substances” can be understood.
  • the pore forming material can be delivered from 3M Company (USA), Omega Minerals Germany GmbH (Germany) or Tokai Carbon Europe GmbH (Germany).
  • the secondary grit comprises aluminum oxide, silicon carbide, boron carbide or boron nitride.
  • the grit size of the secondary grit can be chosen dependent on the grit size of the primary grit.
  • the grit size of the secondary grit can be the same size as the primary grit or the grit size of the secondary grit can be one size smaller than the primary grit, with grit sizes according to FEPA Standard.
  • the secondary grit can be delivered from 3M Company (USA), Imerys Fused Minerals Villach GmbH (Austria) or Saint Gobain Ceramics Materials (Germany).
  • a grinding segment is provided by sintering the green body.
  • the gum arabic burns out of the green body.
  • vitrified bonds can be developed within the green body and the at least one grinding segment can be manufactured.
  • the powder composition is provided by weighting and mixing the primary grit, the vitrified bond, the gum arabic, the pore forming material and the secondary grit in a shaker mixer.
  • the shape, the dimensions and the composition of the grinding segment has to be selected.
  • the composition of the powder composition is defined by percentage of the volume of each component and the corresponding densities. All components in form of a dry powder of the powder composition can be mixed. By mixing the components a homogeneous distribution of the here described components can be obtained and the powder composition can be portioned in the corresponding further method step (process step B).
  • the components in form of a dry powder of the powder composition can be mixed in a shaker mixer for example type T2F from Willy A. Bachofen AG - Maschinenfabrik (Switzerland) with a rotational speed from 23rpm to 101 rpm and a mixing duration from 15min to 4 hours depending on a weight of the powder composition and the grit size of the primary grit from 2 ⁇ m to 300 ⁇ m.
  • a shaker mixer for example type T2F from Willy A. Bachofen AG - Maschinenfabrik (Switzerland) with a rotational speed from 23rpm to 101 rpm and a mixing duration from 15min to 4 hours depending on a weight of the powder composition and the grit size of the primary grit from 2 ⁇ m to 300 ⁇ m.
  • the mixing can be interrupted from time to time and a container of the shaker mixer can be tapped. Ceramic balls and chain parts can be added to the container to increase the homogeneity.
  • the components can be sieved through sieves with applied grit size depending mesh opening.
  • All handling tools for the components like containers, scoops, hoppers, brushes are grit size depending multifold existing, so that basically no grit carryover with impurity of products can take place.
  • the portioning of the powder composition into at least one green body is conducted with containers.
  • the containers are emptied into a mold with at least one cavity. That is to say that the mixed and sieved raw material can be portioned in a further process step by a weighing automat type DWA 11 from Dr. Fritsch GmbH (Germany).
  • the powder composition can be filled in constant portions into containers.
  • the portioned powder composition is formed into a green body.
  • the forming can be done by pressing in a mold.
  • the pressing process can be semi-automatic bi-directional with a specific pressure of 25 kN/cm 2 for example.
  • a pressing velocity can be adapted, if necessary dwell times can be included.
  • the green body can be transported manually with the aid of a spatula onto a tray made up of Cordierite 128 (Steuler-KCH GmbH, Germany) covered with sand (pink aluminum oxide mesh 80), for example.
  • the sands on the tray can prevent the green body from adhering on the tray during or after the sintering of the green body. So, the sintered green body or grinding segment can be easily removed from the tray after sintering.
  • the gum arabic burns out of the at least one green body such that the at least one grinding segment is produced.
  • the at least one grinding segment can be used for manufacturing a grinding wheel.
  • the sintering can be conducted with an averaged heating rate of about 20°C to 120°C per hour, preferably of 50°C to 70°C per hour.
  • the at least one tray or a plurality of trays can be put on top of each other with cordierite spacers in between into a furnace.
  • the furnace can be a model ST 68 HD BW from PYROTEC.
  • the furnace is heated with an averaged heating rate of about 20°C to 120°C per hour, preferably of 50°C to 70°C degrees per hour and a maximum temperature between 600°C and 1100°C. This maximum temperature can then be held for up to an hour or longer before the furnace is cooled down again.
  • the cool down procedure can take place with maximum cooling rate.
  • the at least one grinding segment is deburred with a tumble vibratory grinder.
  • a tumble vibratory grinder can be from Raytech Industries (USA).
  • the at least one grinding segment can be machined to a defined height. This machining can be realized with a double disc grinder. This grinding machine can be from Hahn+Kolbificat GmbH (Germany).
  • the at least one grinding segment is cleaned via an ultrasonic bath.
  • the at least one grinding segments can be cleaned via a ultrasonic bath for example for 15 min at 55°C and dried in a drying furnace, for example at 150°C for one hour.
  • the ultrasonic bath can be an ultrasonic bath from HGH GmbH & Co. KG (Germany) and the drying unit can be a furnace from Nabertherm GmbH (Germany).
  • the at least one grinding segment can be inspected for quality control for example.
  • the quality of each batch can be documented via a lot of 50 grinding segments for example in respect of dimensions with digital measuring slide of Mitutoyo Corporation (Japan), density by a balance produced of Kern&Sohn GmbH (Germany) and young modulus measured frequency based nondestructively via a ZVUK 130 measuring device from Abrasive A.S. (Czech Republic) before the grinding segment is glued onto the blank.
  • the at least one grinding segment is positioned and glued onto the blank such that the grinding wheel is produced.
  • the at least one grinding segment is glued onto the blank with two component glue. Differing types of two component glue can be used depending on the application field, for example Scotch type 460 from 3M Company (USA). Therefore the grinding segment can be time efficiently assembled on the blank.
  • the blank comprises a diameter between 120 mm and 1800 mm.
  • the blank can be made of steel, aluminum or any other suitable material.
  • the segments are positioned onto a blank. It is possible that the grinding wheel comprises grinding segments of various shapes for example of hexagonal, rectangular, round, triangular or pie-shapes.
  • the grinding segments can be arranged and fixed in a clockwise direction onto the blank, for example.
  • the grinding wheel which is assembled by a plurality of grinding segments, can be trimmed and be supplied with customized coolant bores, slots or grooves by water jet cutting.
  • the water jet cutting machine can be supplied by Maximator Jet GmbH (Germany).
  • the glued grinding segments of the grinding wheel are brought by lapping on a lapping machine towards an aimed topography, parallelism and flatness.
  • the lapping machine can be supplied by Lapmaster Wolters GmbH (Germany).
  • Lapmaster Wolters GmbH Germany
  • the parallelism and the flatness can be measured.
  • standard tools like steel rulers, slip gauges, dial indicators and roughness measuring devices can be used. This device for roughness measuring can be supplied by Jenopitk (Germany).
  • Fig. 1 schematically illustrates a pie chart of a powder composition for a green body and alternatively of a portioned green body according to an embodiment of the invention.
  • Fig. 1 shows a possible composition for the powder composition 11, wherein by portioning the powder composition 11 the green body 10 can be manufactured.
  • the composition of the powder composition 11 and the green body 10 is the same with the difference that for manufacturing the green body 10 the powder composition 11 can be portioned formed or pressed into a certain geometrical shape.
  • the green body 10 and the powder composition 11 comprises a primary grit 1 in an amount of 12% by volume, a vitrified bond 2 in an amount by 40% by volume, a gum arabic 3 in an amount of 10% by volume, a pore forming material 4 in an amount of 3% and a secondary grit 5 in an amount of 35% by volume.
  • the here described amounts of percentage by volume are based on 100% by volume of the green body 10 and the powder composition 11.
  • the primary grit 1 comprises super abrasive grits with a mean grit size of 2 ⁇ m to 300 ⁇ m.
  • the grit size can depend on the operational area of the grinding wheel.
  • Super abrasive grits can be made up of diamond or CBN (Cubic Boron Nitride).
  • the vitrified bond 2 comprises at least one glass frit.
  • the pore forming material 3 comprises graphite or glass bubbles.
  • the secondary grit comprises aluminum oxide, silicon carbide, boron carbide or boron nitride.
  • Fig. 2 schematically illustrates different geometrical shapes of a green body or a grinding segment after sintering of the green body according to an embodiment of the invention.
  • the green body 10 can in general have different geometrical shapes, such as hexagonal, rectangular, round, triangular or pie-shaped. For special applications also an individual geometrical shape is conceivable.
  • the corresponding grinding segment 20 with vitrified bonds is manufactured.
  • the gum arabic 3 burns out of the green body 10 such that the grinding segment 20 is provided.
  • the gum arabic as a temporary binder supports a handling of the green body before sintering and vitrified bonds are created within the grinding segment 20 after the sintering.
  • the geometrical shape of the grinding segments 20 depends on their application as parts of a grinding wheel 30 (see Fig. 3 ) as well as on a size of a blank 6 on which the grinding segments 20 are positioned and glued on to manufacture the grinding wheel 30.
  • the grinding segments 20 can comprise a thickness of greater than 6 mm, preferably between 3 mm to 6 mm. It is also possible to provide customized grinding segments 20 with a specific thickness.
  • Fig. 3 schematically illustrates a grinding wheel according to an embodiment of the invention.
  • the grinding segments 20 having hexagonal shape are positioned and glued onto a blank 6.
  • the grinding segments 20 can be glued onto the blank 6 with a two component glue.
  • the blank 6 comprises steel, aluminium or other suitable material with a diameter between 120 mm and 1800 mm.
  • the grinding segments 20 having a distance d to each other.
  • the grinding wheel 30 which is assembled by a plurality of grinding segments 20, can be trimmed and be supplied with customized coolant bores, slots or grooves by water jet cutting.
  • the distance d can be greater than 5 mm, preferably between 1 mm to 5 mm. It is also possible to provide customized grinding wheels 30 with tailored distance d. By the distance d between the pluralities of grinding segments 20 a coolant can be efficiently transported to the outside during operation.
  • Fig. 4 schematically illustrates a grinding wheel according to another embodiment of the invention.
  • the grinding wheel 30 as can be seen in the drawing of Fig. 4 is based on Fig. 3 with the difference that the plurality of grinding segments 20 comprises a triangular shape or pie-shape, respectively.
  • the triangular shape or pie-shape can be applied for a grinding wheel 30 with a diameter of 120 mm to 1800 mm, for example.
  • the blank 6 is fully covered by the plurality of grinding segments 20 (indicated by the round arrow), wherein the grinding segments 20 having the distance d to each other.
  • the pie-shaped grinding segments 20 can be arranged and fixed in a clockwise direction onto the blank 6, for example.
  • the grinding wheel 30, which is assembled by a plurality of grinding segments 20, can be trimmed and be supplied with customized coolant bores, slots or grooves by water jet cutting. In other words the grinding segments 20 do not have contact to each other. By the distance d between the pluralities of grinding segments 20 the coolant can be efficiently transported to the outside during operation.
  • Fig. 5 schematically illustrates stages of a method for manufacturing at least a green body and at least a grinding segment according to an embodiment of the invention.
  • the powder composition 11 comprising a primary grit 1 in an amount of 5% to 40% by volume; preferably in an amount of 10% to 35% by volume; and more preferably in an amount of 15% to 25% by volume, based on 100% by volume of the powder composition 11 a vitrified bond 2 in an amount of 25% to 60% by volume, based on 100% by volume of the powder composition 11, a gum arabic 3 in an amount of 5% to 20% by volume; preferably in an amount of 7% to 17% by volume; and more preferably in an amount of 8% to 12% by volume, based on 100% by volume of the powder composition 11, a pore forming material 4 in an amount of 0% to 20% by volume; preferably in an amount of 0% to 15% by volume, based on 100% by volume of the powder composition 11 and a secondary grit 5 in an amount of 0% to an amount sufficient to bring the powder composition to 100% by volume, is provided.
  • the application in the first step A may for example be performed by weighting and mixing the primary grit 1, the vitrified bond 2, the gum arabic 3, the pore forming material 4 and the secondary grit 5 in a shaker mixer.
  • the method can further comprise an exact weighing of each component of the powder composition.
  • a step B the powder composition 11 is portioned and formed into the green body 10.
  • the forming process is preferably done by pressing of the powder composition.
  • the portioning may for example be done by using a metering unit.
  • the powder composition 11 can be filled in constant portions into containers.
  • the filled containers can be taken and emptied in a mold for example manually.
  • the powder composition can be semi-automatic bi-directional pressed with a specific pressure of 25 kN/cm 2 for example.
  • a step C which is the step of sintering the green body and thereby producing the grinding segment
  • the gum arabic 3 burns out of the at least one green body 10 such that the at least one grinding segment 20 is manufactured or provided.
  • the at least one grinding segment 20 can be used for manufacturing the grinding wheel 30.
  • the sintering can be conducted with an averaged heating rate of about 20°C to 120°C per hour, preferably about 50°C to 70°C per hour.
  • the maximum sintering temperature is from 600°C to 1100°C.
  • Step C can be understood as an additional method step and is necessary for producing the grinding segment.
  • For the method for manufacturing the green body steps A and B are essential.
  • a grinding segment called 29.5-3-B10-C60-R11-V1000 is depicted as a further exemplary embodiment concerning its production.
  • the dimensions of the example segment with hexagonal shape are a wrench size of 29.5 mm with a thickness of 3 mm.
  • First step is to weigh all the ingredients according to following the recipe: Table 1: Overview for green body, in particular grinding segment, called 29.5-3-B10-C60-R11-V1000 volume in [%] weight for 1 piece in [g] material identification size wear necessary supplier remark Density in [g/cm 3 ] 15.8 1.31 CBN-B 5-10 ⁇ m Van Moppes primary grit 3.48 9.3 0.66 aluminum oxide pink 600 mesh Munk&Schmitz droughtntechnik GmbH&Co.
  • the next step is to homogenize the produced mixture via sieving with a sieve with a 0.2 mm mesh opening.
  • the mixed and sieved raw material is afterwards portioned in a further step by a Dr. Fritsch weighing automat type DWA 11.
  • the powder composition is filled in constant portions into little cups on the rotary table. In this case a portion will have a weight of 6.33 grams which equates to the sum given in the table above.
  • These single cups are filled in steel molds and pressed with 126.6 bar.
  • the received green body is placed onto a with mesh 80 pink aluminum oxide covered cordierite plate from Steuler, which is placed into a sinter furnace ST 68 HD BW from PYROTEC.
  • the sinter program in this case is as follows: heating with a heating rate of 60°C per hour onto 700°C and then maximum heating rate up to 880°C. This maximum temperature is held for one hour before the oven is cooled down again with maximum cooling rate.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
EP16164700.3A 2016-04-11 2016-04-11 Corps vert, meule et procédé de fabrication d'au moins un corps vert Active EP3231558B1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP19208783.1A EP3666462A1 (fr) 2016-04-11 2016-04-11 Corps vert, meule et procédé de fabrication d'au moins un corps vert
EP16164700.3A EP3231558B1 (fr) 2016-04-11 2016-04-11 Corps vert, meule et procédé de fabrication d'au moins un corps vert

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Application Number Priority Date Filing Date Title
EP16164700.3A EP3231558B1 (fr) 2016-04-11 2016-04-11 Corps vert, meule et procédé de fabrication d'au moins un corps vert

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JP6165388B1 (ja) 2016-02-22 2017-07-19 株式会社アライドマテリアル 砥粒工具
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