WO2017045524A1 - 一种硬质砂轮以及其制备方法 - Google Patents

一种硬质砂轮以及其制备方法 Download PDF

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WO2017045524A1
WO2017045524A1 PCT/CN2016/097290 CN2016097290W WO2017045524A1 WO 2017045524 A1 WO2017045524 A1 WO 2017045524A1 CN 2016097290 W CN2016097290 W CN 2016097290W WO 2017045524 A1 WO2017045524 A1 WO 2017045524A1
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parts
grinding wheel
temperature
pressure
grinding
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PCT/CN2016/097290
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English (en)
French (fr)
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赵永海
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苏州国量量具科技有限公司
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Publication of WO2017045524A1 publication Critical patent/WO2017045524A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02—Physical 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
    • 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

Definitions

  • the invention discloses a hard grinding wheel and a preparation method thereof, and belongs to the technical field of hard molds.
  • the grinding wheel is also called a fixed abrasive.
  • the grinding wheel is a fixed abrasive with a certain strength by a bonding agent to fix a common abrasive into a certain shape (mostly round, with a through hole in the center). It is generally composed of abrasives, binders and pores, which are often referred to as the three elements of a fixed abrasive. According to the different classification of bonding agents, ceramic grinding wheels, resin grinding wheels and rubber grinding wheels are common.
  • the grinding wheel is the largest and the most widely used one. It can be coarsely ground, semi-finished and polished on the outer circle, inner circle, plane and various profiles of metal or non-metal workpieces. Fine grinding and grooving and cutting.
  • the grinding wheel is a porous body prepared by adding a binder to the abrasive, pressing, drying and calcining. Due to the different abrasives, binders and manufacturing processes, the characteristics of the grinding wheel vary greatly, which has an important influence on the processing quality, productivity and economy of the grinding. The characteristics of the grinding wheel are mainly determined by factors such as abrasive, particle size, binder, hardness, structure, shape and size.
  • Abrasives are the main raw material for the manufacture of grinding wheels, which are responsible for cutting work. Therefore, the abrasive must be sharp and have high hardness, good heat resistance and certain toughness.
  • the material used to bond the abrasive in the grinding wheel is called a bonding agent.
  • the strength, impact resistance, heat resistance and corrosion resistance of the grinding wheel are mainly determined by the properties of the bonding agent.
  • Commonly used bonding agents are: ceramics (heat resistance, corrosion resistance, porosity, easy to maintain contour, poor elasticity), widely used, suitable for various forming grinding, grinding gears, grinding of V ⁇ 35m/s Threads, etc.
  • the rubber has higher strength and elasticity, small porosity, poor heat resistance, easy to fall off the abrasive grains, suitable for grinding wheels and guide wheels without centering, slotted and cut thin grinding wheels, polishing wheels, and the like.
  • the hardness of the grinding wheel refers to the difficulty of the abrasive grains on the surface of the grinding wheel falling off under the action of the grinding force.
  • the hardness of the grinding wheel is soft, which means that the abrasive grains of the grinding wheel are easy to fall off, and the hardness of the grinding wheel is hard, indicating that the abrasive grains are difficult to fall off.
  • the hardness of the grinding wheel and the hardness of the abrasive are two different concepts. The same kind of abrasive can be made into grinding wheels of different hardness. It is mainly determined by the performance and quantity of the bonding agent and the manufacturing process of the grinding wheel. The significant difference between grinding and cutting is that the grinding wheel has “self-sharpness” and the hardness of the grinding wheel is selected. It is to choose the self-sharpness of the grinding wheel.
  • the organization of the grinding wheel refers to the proportional relationship between the three parts of the abrasive grains, binders and pores of the grinding wheel. It is usually graded as a percentage of the volume of the grinding wheel occupied by the abrasive particles.
  • the outer diameter of the grinding wheel should be selected as large as possible to increase the peripheral speed of the grinding wheel, which is advantageous for improving the grinding processing productivity and surface roughness.
  • the productivity and roughness can be improved.
  • the width of the grinding wheel is appropriately reduced.
  • the invention provides a hard grinding wheel with low cost, simple preparation method and wear resistance.
  • the weight percentage of each of the above components is:
  • the invention uses copper powder, single crystal corundum and cubic boron nitride as abrasive, phenolic resin and epoxy resin as binder, molybdenum disulfide, potassium fluoroaluminate, ferric oxide, zinc oxide and aluminum oxide as additives, increasing Ceramic glaze to improve the wear resistance of the grinding wheel.
  • the abrasive has a particle size of 20 to 40 ⁇ m.
  • the cubic structure of boron nitride has a molecular formula of BN, its crystal structure is similar to diamond, and its hardness is slightly lower than that of diamond. It is HV72000 ⁇ 98000 MPa, and is often used as abrasive and tool materials.
  • Cubic boron nitride abrasives have excellent grinding performance, which not only can handle the processing of difficult-to-grind materials, improve productivity, but also help to strictly control the shape and dimensional accuracy of the workpiece, and can effectively improve the grinding quality of the workpiece and significantly improve the grinding.
  • the surface integrity of the rear workpiece increases the fatigue strength of the part, prolongs service life and increases reliability.
  • Phenolic resin is also known as bakelite, bakelite powder. Originally a colorless or yellow-brown transparent material, the market often adds coloring agents and is red, yellow, black, green, brown, blue and other colors, and has particles and powders. Resistant to weak acids and weak bases, decomposes in the presence of strong acids, and corrodes in the presence of strong bases. Do not dissolve in water, soluble in organic solvents such as acetone and alcohol. A polycondensation of phenol aldehyde or a derivative thereof. The invention selects an alkaline phenolic resin, and the basic phenolic resin mainly serves as a casting binder.
  • Phenolic resins are multifunctional and compatible with a wide variety of organic and inorganic flavors.
  • the heat treatment increases the glass transition temperature of the cured resin, and the properties of the resin can be further improved.
  • the glass transition temperature is similar to that of a crystalline solid such as polypropylene.
  • Epoxy resin refers to an organic compound containing two or more epoxy groups in a molecule, and their relative molecular masses are not high except for a few.
  • the molecular structure of the epoxy resin is characterized by the presence of an active epoxy group in the molecular chain, and the epoxy group may be located at the end, in the middle or in a ring structure of the molecular chain. Since the molecular structure contains an active epoxy group, they can be cross-linked with various types of curing agents to form an insoluble polymer having a three-dimensional network structure.
  • a polymer compound containing an epoxy group in a molecular structure is collectively referred to as an epoxy resin.
  • the cured epoxy resin has good physical and chemical properties. It has excellent bonding strength to the surface of metal and non-metal materials, good dielectric properties, small set shrinkage, good dimensional stability and high hardness. It has good flexibility and is stable to alkali and most solvents.
  • Molybdenum disulfide is an important solid lubricant and is especially suitable for high temperature and high pressure.
  • the main function of molybdenum disulfide for friction materials is to reduce friction at low temperature, increase friction at high temperature, and reduce ignition loss, which is volatile in friction materials.
  • Molybdenum disulfide is obtained by a comprehensive chemical purification reaction, and its pH is 7-8, which is slightly alkaline. It covers the surface of the friction material and protects other materials from oxidation. In particular, other materials are not easily peeled off and the adhesion is enhanced.
  • the particle size of the abrasive is primarily related to the surface roughness and productivity of the machined surface.
  • the grinding allowance is large, and the required surface roughness value is large, and coarser abrasive grains should be selected. Because the abrasive grains are coarse, the pores are large, and the grinding depth is large, the grinding wheel is not easy to block and generate heat.
  • fine grinding the margin is small, the roughness value is required to be low, and finer abrasive grains can be selected. In general, the finer the abrasive grains, the better the surface roughness of the grinding.
  • the abrasives of the above-described particle sizes of the present invention are suitable for fine grinding, superfinishing, thread milling and honing.
  • the concentration of the above-mentioned ceramic glaze is 68 to 70 Baume, and the specific gravity of the glaze is 1.83 to 1.88 Kg/L.
  • the above-mentioned grinding wheel of the present invention has a grain-gravity ratio of 61 to 63%, and is applied to fine grinding and profile grinding.
  • Another object of the present invention is to provide a method for preparing the above grinding wheel:
  • the temperature is raised from room temperature to 200 to 350 ° C and pressurized to 2 to 5 MPa, and the holding pressure is maintained for 2 to 5 minutes; then the temperature is raised to 680 to 720 ° C, wherein the pressure is raised to 10 ⁇ 15MPa, keep warm for 1 ⁇ 2 hours, then cool down to 100 ⁇ 140°C, reduce pressure to 2 ⁇ 5MPa, then heat up to 700 ⁇ 800°C, keep pressure at 11 ⁇ 13 MPa, keep this temperature and pressure for 20 ⁇ 40min; finally reduce the temperature and pressure until the temperature is room temperature, and the pressure is adjusted to the standard atmospheric pressure.
  • the temperature increase rate from room temperature to 200 to 350 ° C is 5 to 10 ° C / min.
  • the temperature increase rate from the temperature of 200 to 350 ° C to 680 to 720 ° C is 3 to 7 ° C / min.
  • the temperature decreasing rate from the temperature of 680 to 720 ° C to 100 to 140 ° C is 5 to 7 ° C / min.
  • the temperature increase rate from the temperature of 100 to 140 ° C to 700 to 800 ° C is 3 to 7 ° C / min.
  • the temperature decreasing rate from the temperature of 700 to 800 ° C to room temperature is 3 to 6 ° C / min.
  • the slow temperature rise and slow temperature drop as well as the pressurization and pressure reduction operations of the above step 2) are to make the mixture into a grinding wheel more compact, so that the wear resistance of the prepared grinding wheel is enhanced.
  • the density is cooled to 2.50-2.55 g/cm3 of the forming grinding wheel.
  • the above steps of preparing the grinding wheel of the invention effectively improve the self-sharp performance of the grinding wheel, reduce the weight of the grinding wheel, facilitate installation and setting adjustment, and improve the uniformity and balance performance of the grinding wheel.
  • the hard grinding wheel of the present application is a high-hard abrasive-cubic boron nitride, and its hardness is 8000 ⁇ 9000HV, its hardness is second only to diamond, wear resistance and electrical conductivity are good, heat generation is small; grinding hard alloy, stainless steel, Difficult to machine materials such as high alloy steel.
  • the bonding agent adopts ceramic material; the grinding wheel can be easily deformed, the heat resistance is good, and the wear resistance is high; the bonding property of various ceramic materials is good, the crack can be effectively prevented, and the heat resistance of the existing grinding wheel is poorly solved. , the problem of easy deformation.
  • the addition of ceramic glaze solves the problem that the existing grinding wheel has poor bonding performance and the abrasive is easy to fall off.
  • the invention adds copper powder metal powder, which not only improves the thermal conductivity of the grinding wheel, but also has the advantages of quick heat dissipation, low grinding temperature, increased hardness and strength of the grinding wheel, reduced crack formed by rigid grinding, grinding efficiency and service life. Far more than traditional grinding wheels.
  • Raw materials for preparing grinding wheel 50 parts of copper powder, 15 parts of single crystal corundum, 9 parts of cubic boron nitride, 15 parts of phenolic resin, 12 parts of epoxy resin, 1.5 parts of molybdenum disulfide, fluoroaluminate 4 parts of potassium, 5 parts of ferric oxide, 3 parts of zinc oxide, 2 parts of alumina, and 12 parts of ceramic glaze.
  • the ceramic glaze has a Baume degree of 68.
  • the components of the above composition by weight are charged into a mixer, and stirred at a stirring speed of 500 to 600 rpm for 1 hour to form a mixture; after stirring, the mixture is flattened, and the template is pressed to a thickness of 5 cm to raise the temperature.
  • the temperature is 3 ° C / min, the temperature is raised to 240 ° C and pressurized to 4 MPa, and the holding pressure is kept for 4 min; then the temperature is raised to 700 ° C at a heating rate of 5 ° C / min, wherein the pressure is also raised to 14 MPa, and the holding pressure is maintained for 1.2 hours, then The temperature is lowered to 10 ° C / min to 110 ° C, while the pressure is reduced to 3 MPa, and then the temperature is raised to 7 ° C / min to 780 ° C, while maintaining the pressure of 12 MPa, maintaining this temperature and pressure for 30 min; The temperature was reduced to a temperature of room temperature, and the pressure was adjusted to a standard atmospheric pressure. Finally, the diameter of the grinding wheel prepared according to the above process was 15 cm.
  • Nickel-chromium steel is a hard-to-grind material, and the grinding wheel prepared by the present invention is subjected to a grinding test. At the table speeds of 150 mm/min and 200 mm/min, the grinding wheels all exhibit high wheel wear rates. At the same time, as the depth of cut increases, the grinding wheel still has a lower grinding energy.
  • Raw materials for preparing grinding wheel 62 parts by weight of copper powder, 19 parts of single crystal corundum, 12 parts of cubic boron nitride, 20 parts of phenolic resin, 15 parts of epoxy resin, 2 parts of molybdenum disulfide, fluoroaluminate 5 parts of potassium, 4 parts of ferric oxide, 2.5 parts of zinc oxide, 3 parts of alumina, and 13 parts of ceramic glaze.
  • the ceramic glaze has a Baume degree of 70.
  • the components of the above composition by weight are charged into a mixer, and stirred at a stirring speed of 800 to 1000 rpm for 0.5 hour to form a mixture; after stirring, the mixture is flattened, and the template is pressed to a thickness of 6 cm to raise the temperature.
  • the temperature is 4 ° C / min, the temperature is raised to 300 ° C and pressurized to 3.5 MPa, and the holding pressure is maintained for 3 min; then the temperature is raised to 720 ° C at a heating rate of 6 ° C / min, wherein the pressure is also raised to 15 MPa, and the holding pressure is maintained for 1.5 hours. Then, the temperature is lowered to 100 ° C at a cooling rate of 5 ° C / min, while the pressure is reduced to 4 MPa, and then the temperature is raised to 750 ° C at a heating rate of 6 ° C / min, while the pressure is maintained at 11 MPa, keep this temperature and pressure for 25 min; finally cool down to a temperature of room temperature, and adjust the pressure to standard atmospheric pressure. Finally, the diameter of the grinding wheel prepared according to the above process was 18 cm.
  • the hardness of the grinding wheel prepared by the above formula composition and process is Q grade, and the abrasive grain size is 40 ⁇ m.
  • Raw materials for preparing grinding wheel 65 parts by weight of copper powder, 25 parts of single crystal corundum, 12 parts of cubic boron nitride, 25 parts of phenolic resin, 12 parts of epoxy resin, 1.5 parts of molybdenum disulfide, fluoroaluminate 4 parts of potassium, 3 parts of ferric oxide, 2.5 parts of zinc oxide, 2.5 parts of alumina, and 12 parts of ceramic glaze.
  • the ceramic glaze has a Baume degree of 70.
  • the components of the above composition by weight are charged into a mixer, and stirred at a stirring speed of 900 to 1200 rpm for 0.5 hour to form a mixture; after stirring, the mixture is flattened, and the template is pressed to a thickness of 7 cm to raise the temperature.
  • the temperature is 6 ° C / min, the temperature is raised to 300 ° C and pressurized to 4.5 MPa, and the holding pressure is kept for 4 min; then the temperature is raised to 700 ° C at a heating rate of 7 ° C / min, wherein the pressure is also raised to 14 MPa, and the holding pressure is maintained for 1.0 hour. Then, the temperature is lowered to 120 ° C at a cooling rate of 5 ° C / min, while the pressure is reduced to 4.0 MPa, and then the temperature is raised to 750 ° C at a heating rate of 5 ° C / min, while the pressure is maintained at 12 MPa, maintaining this temperature and pressure for 30 min. Finally, the temperature is lowered to a temperature of room temperature, and the pressure is adjusted to a standard atmospheric pressure. Finally, the diameter of the grinding wheel prepared according to the above process was 20 cm.
  • the hardness of the grinding wheel prepared by the above formula composition and process is Q grade, and the particle size of the above abrasive is 30 ⁇ m.

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

Abstract

一种硬质砂轮及其制备方法，该砂轮由以下重量份的组分组成：铜粉50-70份、单晶刚玉10-25份、立方氮化硼7-15份、酚醛树脂10-25份、环氧树脂10-17份、二氧化硫0.5-2.5份、氟铝酸钾2.5-6份、三氧化二铁2.5-6份、氧化锌1.5-4份、氧化铝1.5-4份、陶瓷釉8-15份。将上述组分混合均匀后、刮平、压模，然后进行热处理和压力变化处理以得到所需尺寸的砂轮。由上述方法制备得到的砂轮不易变形、耐热性好，很高的耐磨性，加入金属粉末导热快，砂轮的强度和硬度高，适合精磨、超精磨、螺纹磨和珩磨。

Description

一种硬质砂轮以及其制备方法 一种硬质砂轮以及其制备方法
技术领域
本发明公开一种硬质砂轮及其制备方法，属于硬质模具技术领域。
背景技术
砂轮又称固结磨具，砂轮是由结合剂将普通磨料固结成一定形状(多数为圆形，中央有通孔)，并具有一定强度的固结磨具。其一般由磨料、结合剂和气孔构成，这三部分常称为固结磨具的三要素。按照结合剂的不同分类，常见的有陶瓷砂轮、树脂砂轮、橡胶砂轮。砂轮是磨具中用量最大、使用面最广的一种，使用时高速旋转，可对金属或非金属工件的外圆、内圆、平面和各种型面等进行粗磨、半精磨和精磨以及开槽和切断等。
砂轮是在磨料中加入结合剂，经压坯、干燥和焙烧而制成的多孔体。由于磨料、结合剂及制造工艺不同，砂轮的特性差别很大，因此对磨削的加工质量、生产率和经济性有着重要影响。砂轮的特性主要是由磨料、粒度、结合剂、硬度、组织、形状和尺寸等因素决定。
磨料是制造砂轮的主要原料，它担负着切削工作。因此，磨料必须锋利，并具备高的硬度、良好的耐热性和一定的韧性。砂轮中用以粘结磨料的物质称为结合剂，砂轮的强度、抗冲击性、耐热性及抗腐蚀能力主要决定于结合剂的性能。常用的结合剂有：陶瓷(耐热性、耐腐蚀性好、气孔率大、易保持轮廓、弹性差)，应用广泛，适用于V＜35m/s的各种成形磨削、磨齿轮、磨螺纹等。树脂强度高、弹性大、耐冲击、坚固性和耐热性差、气孔率小；适用于V＞50m/s，可制成薄片砂轮，用于磨槽、切割等。橡胶的强度和弹性更高、气孔率小、耐热性差、磨粒易脱落；适用于无心磨的砂轮和导轮、开槽和切割的薄片砂轮、抛光砂轮等。
砂轮的硬度是指砂轮表面上的磨粒在磨削力作用下脱落的难以程度。砂轮的硬度软，表示砂轮的磨粒容易脱落，砂轮的硬度硬，表示磨粒较难脱落。砂轮的硬度和磨料的硬度是两个不同的概念。同一种磨料可以做成不同硬度的砂轮，它主要决定于结合剂的性能、数量以及砂轮制造的工艺、磨削与切削的显著差别是砂轮具有“自锐性”，选择砂轮的硬度，实际上就是选择砂轮的自锐性。
砂轮的组织是指组成砂轮的磨粒、结合剂、气孔三部分体积的比例关系。通常以磨粒所占砂轮体积的百分比来分级。
砂轮的外径应尽可能选择大一些，以提高砂轮的圆周速度，这样对提高磨削加工生产率与表面粗糙度有利。此外，在机床刚度及功率许可的条件下，如选用宽度较大的砂轮，同样能收到提高生产率和降低粗糙度的效果，但是在磨削热敏性高的材料时，为避免工件表面的烧伤和产生裂纹，砂轮的宽度适当减小。
发明内容：
本发明提供一种成本低、制备方法简便且耐磨的硬质砂轮。
上述硬质砂轮中各组分的重量份比：
铜粉 50~70份
单晶刚玉 10~25份
立方氮化硼 7~15份
酚醛树脂 10~25份
环氧树脂 10~17份
二硫化钼 0.5~2.5份
氟铝酸钾 2.5~6份
三氧化二铁 2.5~6份
氧化锌 1.5~4份
氧化铝 1.5~4份
陶瓷釉 8~15份。
优选的，上述各组分的重量百分比为：
铜粉 66份
单晶刚玉 17份
立方氮化硼 12份
酚醛树脂 18份
环氧树脂 12份
二硫化钼 1.5份
氟铝酸钾 4份
三氧化二铁 5份
氧化锌 2.5份
氧化铝 3份
陶瓷釉 12份。
本发明以铜粉、单晶刚玉和立方氮化硼为磨料，酚醛树脂和环氧树脂为结合剂，二硫化钼、氟铝酸钾、三氧化二铁、氧化锌和氧化铝为添加剂，增加陶瓷釉以提高砂轮的耐磨性。
具体地，上述磨料的粒度为20~40μm。
立方结构的氮化硼，分子式为BN，其晶体结构类似金刚石，硬度略低于金刚石，为HV72000～98000兆帕，常用作磨料和刀具材料。
立方氮化硼磨具的磨削性能十分优异，不仅能胜任难磨材料的加工，提高生产率，且有利于严格控制工件的形状和尺寸精度，还能有效提高工件的磨削质量，显著提高磨后工件的表面完整性，因而提高了零件的疲劳强度，延长了使用寿命，增加了可靠性。
酚醛树脂又称电木，电木粉。原为无色或黄褐色透明物，市场销售往往加着色剂而呈红、黄、黑、绿、棕、蓝等颜色，有颗粒、粉末状。耐弱酸和弱碱，遇强酸发生分解，遇强碱发生腐蚀。不溶于水，溶于丙酮、酒精等有机溶剂中。苯酚醛或其衍生物缩聚而得。本发明选用碱性酚醛树脂，碱性酚醛树脂主要做铸造黏结剂。酚醛树脂最重要的特征就是耐高温，即使在非常高的温度下，也能保持其结构的整体性和尺寸的稳定性。酚醛树脂是一种多功能，与各种各样的有机和无机调料都能相容的物质。热处理会提高固化树脂的玻璃化温度，可以进一步改善树脂的各项性能。玻璃化温度与结晶固体如聚丙烯的熔化状态相似。
环氧树脂是泛指分子中含有两个或两个以上环氧基团的有机化合物，除个别外，它们的相对分子质量都不高。环氧树脂的分子结构是以分子链中含有活泼的环氧基团为其特征，环氧基团可以位于分子链的末端、中间或成环状结构。由于分子结构中含有活泼的环氧基团，使它们可与多种类型的固化剂发生交联反应而形成不溶的具有三向网状结构的高聚物。凡分子结构中含有环氧基团的高分子化合物统称为环氧树脂。固化后的环氧树脂具有良好的物理、化学性能，它对金属和非金属材料的表面具有优异的粘接强度，介电性能良好，变定收缩率小，制品尺寸稳定性好，硬度高，柔韧性较好，对碱及大部分溶剂稳定。
二硫化钼是重要的固体润滑剂，特别适用于高温高压下。二硫化钼用于摩擦材料主要功能是低温时减摩，高温时增摩，烧失量小，在摩擦材料中易挥发。二硫化钼是经过化学提纯综合反应而得，其pH值为7-8，略显碱性。它覆盖在摩擦材料的表面，能保护其他材料，防止它们被氧化，尤其是使其他材料不易脱落，贴附力增强。
磨料的粒度主要与加工表面粗糙度和生产率有关。粗磨时，磨削余量大，要求的表面粗糙度值较大，应选用较粗的磨粒。因为磨粒粗、气孔大，磨削深度较大，砂轮不易阻塞和发热。精磨时，余量较小，要求粗糙度值较低，可选取较细磨粒。一般而言，磨粒越细、磨削表面粗糙度越好。
本发明上述粒度的磨料适合的范围为精磨、超精磨、螺纹磨和珩磨。
上述加入陶瓷釉的浓度为68~70波美，其中釉的比重为1.83~1.88Kg/L。
本发明的上述砂轮的磨粒率为61~63%，应用于精磨和成型磨。
本发明的另一个目的是提供了上述砂轮的制备方法：
1)按照上述配方将各组分装入混料机中，混合1-2小时，充分混匀以形成混合物；
2)混合物搅拌均匀后刮平，盖上模板后压制到所需厚度；然后进行热处理和压力变化处理。
进一步地，将混料压制成所需的厚度后，先由室温升温至200~350℃并加压至2~5MPa，保温保压2~5min；然后升温680~720℃，其中压力升至10~15MPa，保温保压1~2小时，然后降温至100~140℃，同时压力减压至2~5MPa，然后升温至700~800℃，压力保持为11~13 MPa，保持此温度和压力下20~40min；最后降温减压至温度为室温，压力调整至标准大气压。
具体地，上述由室温升温至200~350℃的升温速率为5~10℃/min。
具体地，上述由温度为200~350℃升温至680~720℃的升温速率为3~7℃/min。
具体地，上述由温度为680~720℃降温至100~140℃的降温速率为5~7℃/min。
具体地，上述由温度为100~140℃升温至700~800℃的升温速率为3~7℃/min。
具体地，上述由温度为700~800℃降温至室温的降温速率为3~6℃/min。
上述步骤2）的缓慢升温与缓慢降温以及加压和减压操作是为了使得混合物成型为砂轮更加密实、使得制备得到的砂轮的耐磨性增强。
热压完毕后冷却至成型砂轮的密度2.50-2.55g/cm3。
本发明上述制备砂轮的步骤有效提高了砂轮的自锐性能，减轻了砂轮重量，便于安装和设定调整，提高了砂轮的组织均匀性和平衡性能。
本申请的硬质砂轮为高硬磨料-立方氮化硼，其硬度为8000~9000HV，其硬度仅次于金刚石，耐磨性和导电性好，发热量小；磨销硬质合金、不锈钢、高合金钢等难加工材料。
技术效果：
本发明中结合剂采用陶瓷料；可以使砂轮不易变形，耐热性好，具有很高的耐磨性；各种陶瓷料粘结性能好，可以有效防止裂纹，解决了现有砂轮耐热性差，易变形的问题。同时加入陶瓷釉解决了现有砂轮粘结性能不佳，磨料易脱落的问题。本发明添加了铜粉金属粉末，不但提高了砂轮的导热性能，散热快，磨削温度低，而且增大了砂轮的硬度和强度，减少刚性磨削形成的裂纹，其磨削效率和使用寿命远远超过传统砂轮。
具体实施方式
以下通过具体实施例对本申请的技术方案作进一步阐述，其中所涉及的具体参数和条件不作为本申请技术方案的限定，在上述技术方案的基础上所做的任何改进和变换应属于本申请技术方案的保护范围之内。
实施例1
制备砂轮的原料：各组分的重量份为铜粉50份、单晶刚玉15份、立方氮化硼9份、酚醛树脂15份、环氧树脂12份、二硫化钼1.5份、氟铝酸钾4份、三氧化二铁5份、氧化锌3份、氧化铝2份、陶瓷釉12份。陶瓷釉的波美度为68。将上述重量份组成的组分装入混料机中，以搅拌速度为500~600转/分混合搅拌1小时，以形成混合物；搅拌后刮平，盖上模板压制到厚度为5cm，以升温速率为3℃/min先升温至240℃并加压至4MPa，保温保压4min；然后以升温速率为5℃/min升温至700℃，其中压力也升至14MPa，保温保压1.2小时，然后以降温速率为5℃/min降温至110℃，同时压力减压至3MPa，然后再以升温速率为7℃/min升温至780℃，同时压力保持为12MPa，保持此温度和压力下30min；最后降温减压至温度为室温，压力调整至标准大气压。最后按照上述工艺制备得到的砂轮的直径为15cm。
镍铬钢是一种难磨削的材料，由本发明制备得到砂轮进行磨削试验。在工作台速度为150mm/min和200mm/min时，砂轮都表现出高的砂轮磨损速率。同时在随着切削深度的提高，而砂轮仍然具有较低的磨削能。
实施例2
制备砂轮的原料：各组分的重量份为铜粉62份、单晶刚玉19份、立方氮化硼12份、酚醛树脂20份、环氧树脂15份、二硫化钼2份、氟铝酸钾5份、三氧化二铁4份、氧化锌2.5份、氧化铝3份、陶瓷釉13份。陶瓷釉的波美度为70。将上述重量份组成的组分装入混料机中，以搅拌速度为800~1000转/分混合搅拌0.5小时，以形成混合物；搅拌后刮平，盖上模板压制到厚度为6cm，以升温速率为4℃/min先升温至300℃并加压至3.5MPa，保温保压3min；然后以升温速率为6℃/min升温至720℃，其中压力也升至15MPa，保温保压1.5小时，然后以降温速率为5℃/min降温至100℃，同时压力减压至4MPa，然后再以升温速率为6℃/min升温至750℃，同时压力保持为11 MPa，保持此温度和压力下25min；最后降温减压至温度为室温，压力调整至标准大气压。最后按照上述工艺制备得到的砂轮的直径为18cm。
上述配方组成和工艺制备得到的砂轮的硬度为Q级别，磨料的粒径为40μm。
实施例3
制备砂轮的原料：各组分的重量份为铜粉65份、单晶刚玉25份、立方氮化硼12份、酚醛树脂25份、环氧树脂12份、二硫化钼1.5份、氟铝酸钾4份、三氧化二铁3份、氧化锌2.5份、氧化铝2.5份、陶瓷釉12份。陶瓷釉的波美度为70。将上述重量份组成的组分装入混料机中，以搅拌速度为900~1200转/分混合搅拌0.5小时，以形成混合物；搅拌后刮平，盖上模板压制到厚度为7cm，以升温速率为6℃/min先升温至300℃并加压至4.5MPa，保温保压4min；然后以升温速率为7℃/min升温至700℃，其中压力也升至14MPa，保温保压1.0小时，然后以降温速率为5℃/min降温至120℃，同时压力减压至4.0MPa，然后再以升温速率为5℃/min升温至750℃，同时压力保持为12MPa，保持此温度和压力下30min；最后降温减压至温度为室温，压力调整至标准大气压。最后按照上述工艺制备得到的砂轮的直径为20cm。
上述配方组成和工艺制备得到的砂轮的硬度为Q级别，上述磨料的粒径为30μm。

Claims (10)

  1. 一种硬质砂轮，其特征在于：其由以下重量份的组分组成：铜粉50~70份、单晶刚玉10~25份、立方氮化硼7~15份、酚醛树脂10~25份、环氧树脂 10~17份、二硫化钼0.5~2.5份、氟铝酸钾2.5~6份、三氧化二铁2.5~6份、氧化锌1.5~4份、氧化铝1.5~4份、陶瓷釉8~15份。
  2. 根据权利要求1所述的一种硬质砂轮，其特征在于：其由以下重量份的组分组成：铜粉66份、单晶刚玉20份、立方氮化硼12份、酚醛树脂18份、环氧树脂12份、二硫化钼1份、氟铝酸钾5份、三氧化二铁5份、氧化锌3份、氧化铝3份、陶瓷釉11份。
  3. 根据权利要求1或2所述的一种硬质砂轮，其特征在于：上述陶瓷釉的浓度为68~70波美。
  4. 根据权利要求1所述的一种硬质砂轮的制备方法，其特征在于：其具体步骤如下：
    1)按照上述配方将各组分装入混料机中，混合1-2小时，充分混匀以形成混合物；
    2)混合物搅拌均匀后刮平，盖上模板后压制到所需厚度；然后进行热处理和压力变化处理。
  5. 根据权利要求4所述的一种硬质砂轮的制备方法，其特征在于：所述热处理和压力变化处理，是将混料压制成所需的厚度后，先由室温升温至200~350℃并加压至2~5MPa，保温保压2~5min；然后升温至680~720℃，其中压力升至10~15MPa，保温保压1~2小时，然后降温至100~140℃，同时压力减压至2~5MPa，然后升温至700~800℃，压力保持为11~13MPa，保持此温度和压力下20~40 min；最后降温至室温，同时压力调整至标准大气压。
  6. 根据权利要求5所述的一种硬质砂轮的制备方法，其特征在于：所述由室温升温至200~350℃的升温速率为5~10℃/min。
  7. 根据权利要求5所述的一种硬质砂轮的制备方法，其特征在于：所述由温度为200~350℃升温至680~720℃的升温速率为3~7℃/min。
  8. 根据权利要求5所述的一种硬质砂轮的制备方法，其特征在于：所述由温度为680~720℃降温至100~140℃的降温速率为5~7℃/min。
  9. 根据权利要求5所述的一种硬质砂轮的制备方法，其特征在于：所述由温度为100~140℃升温至700~800℃的升温速率为3~7℃/min。
  10. 根据权利要求5所述的一种硬质砂轮的制备方法，其特征在于：所述由温度为700~800℃降温至室温的降温速率为3~6℃/min。
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CN111423234B (zh) * 2020-04-29 2023-11-24 湖北省鄂州市天元砂辊有限责任公司 一种杂粮陶瓷砂辊及其制作方法
CN112405146A (zh) * 2020-11-27 2021-02-26 宝钢轧辊科技有限责任公司 磨削加工高速钢轧辊的方法
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CN114346919A (zh) * 2022-01-26 2022-04-15 江阴市方鸿超硬工具有限公司 一种超细粒度金刚石砂轮及其加工工艺
CN114800296A (zh) * 2022-03-30 2022-07-29 郑州九天工贸有限公司 一种高强度超薄切割砂轮及其制备方法
CN114800295A (zh) * 2022-03-30 2022-07-29 郑州九天工贸有限公司 一种自润滑树脂切割片及其制备方法
CN114800295B (zh) * 2022-03-30 2023-12-26 郑州九天工贸有限公司 一种自润滑树脂切割片及其制备方法
CN114800296B (zh) * 2022-03-30 2024-01-09 郑州九天工贸有限公司 一种高强度超薄切割砂轮及其制备方法
CN114656151A (zh) * 2022-05-26 2022-06-24 佛山市东鹏陶瓷发展有限公司 一种抛釉砖耐磨釉料及其制备方法

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