CN106891271A - 一种不锈钢切割砂轮及其制备方法 - Google Patents
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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
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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
- B24D18/0009—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
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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
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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
- B24D3/20—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 and being essentially organic
- B24D3/28—Resins or natural or synthetic macromolecular compounds
- B24D3/32—Resins or natural or synthetic macromolecular compounds for porous or cellular structure
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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
- B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
- B24D3/342—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties incorporated in the bonding agent
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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
- B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
- B24D3/346—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties utilised during polishing, or grinding operation
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Abstract
一种不锈钢切割砂轮，其特征在于，该切割砂轮原料包括混合磨粒、填料、造孔剂、树脂、增强材料组成。所述混合磨粒为黑碳化硅、单晶刚玉、棕刚玉、棕刚玉‑氧化铈核/壳复合磨粒、铁尖晶石，所述填料为沸石、碳化硅微粉，树脂为腰果酚改性的酚醛树脂，增强材料为含有石墨的玻璃纤维网。本发明的优点在于：1、磨具孔隙率大，便于容屑；2、磨削区温度低不会导致工件烧伤；3、氧化铈的化学机械抛光原理，从而改善切割加工表面的微观状况，降低粗糙度；4、由于混合磨粒采用了不同硬度的不同种类的磨粒搭配，切削效率高；5、切割刀口窄，切割面平整，节约昂贵的被切割材料；6、采用了磨削层和非磨削层设计降低了成本；7、不含氟化物，减少了环境污染。
Description
技术领域
本发明属机械加工领域，具体涉及一种不锈钢切割砂轮及其制备方法。
背景技术
不锈钢以其优良的耐腐蚀性能，良好的力学性能和加工性能及较好的焊接性能，成为被广泛选用的工程材料。同时，通过不同的抛光加工方法，可以使各种不锈钢板材、管材、棒材、异型材的表面具有不同等级的表面光洁度，大大改善了不锈钢的外观，使之达到美学效果，增加了对消费者的吸引力，给人们以美的享受。但是, 从钢厂购来的耐热不锈钢长杆要落成短料，用剪切方法导致模具大量损坏, 且剪切后的材料纵向有微小裂纹存在，用普通砂轮切断,其砂轮的磨损较大，且刀口消耗不锈钢量大，这严重影响着产品质量和劳动生产效率，也造成极大地浪费。
发明内容
本发明的目的正是针对现有技术中所存在的问题而提供的一种切削效率高、耐磨性好、表面光洁度高的不锈钢切割专用砂轮。
本发明的目的是通过以下技术方案来实现的：
本发明的新型不锈钢切割砂轮，原料包括混合磨粒、填料、造孔剂、树脂、增强材料组成。所述混合磨粒为黑碳化硅、单晶刚玉、棕刚玉、棕刚玉-氧化铈核/壳复合磨粒、铁尖晶石，所述填料为沸石、碳化硅微粉，树脂为腰果酚改性的酚醛树脂，增强材料为含有石墨的玻璃纤维网。各原料的重量百分比为：混合磨粒75％～85％，填料3％～7％，造孔剂1％～3％，树脂10％～15％。
具体制备方法为：
本发明的切割砂轮的制造方法具体步骤如下：
a、混合磨粒→润湿剂→混合→填料→混合→树脂粉→混合均匀为成型料；
b、玻璃纤维网浸润一层含有石墨且经硫酸钙晶须原位聚合而成腰果酚改性的酚醛树脂；
c、将成型料投入已加热至85℃的模具中，中间加入玻璃纤维网，温热成型；
d、投料时非磨削层和磨削层同时投，第一道非磨削层80g，磨削层180g,第二道非磨削层180g，磨削层280g；
e、非磨削层配方为：30#棕刚玉20%，36#石榴石30%，40#尖晶石20%，石膏15%，树脂15%；
f、采用梯度固化工艺。
本发明的有益效果是：
1、采用黑碳化硅、单晶刚玉、棕刚玉、棕刚玉-氧化铈核/壳复合磨粒、铁尖晶石五种磨粒混合，形成硬度梯度，能发挥各自的优点，使得切割效率高，切割面光洁度好，工件不烧伤；
2、沸石的加入既有利于增加结合强度，又便于排屑；
3、碳化硅微粉和石墨的加入有利于导热，使得磨削区温度不至于积累过高烧伤工件。
造孔剂选用经高温煅烧过的硅藻土颗粒，由于其具有多孔性和不可压缩性，其孔隙率可达90%，密度小，经表面封孔，使得硅藻土在砂轮中结合强度高，磨削时保持了高孔隙率，有利于排削和散热，降低磨削区温度。
具体实施方式
实施例1
混合磨粒质量百分比：黑碳化硅5%、单晶刚玉20%、棕刚玉45%、棕刚玉-氧化铈核/壳复合磨粒20%、铁尖晶石10%。
本实施例中的不锈钢切割砂轮是按温热压制成型工艺制作，按1把组分A混合磨料和B树脂液充分混合，2再与组分C填料沸石和组分D碳化硅微粉充分混合，3再与E造孔剂硅藻土充分混合，4再与组分F树脂粉充分混合，过筛，过筛后放置于恒温恒湿车间放置72h，过筛即为磨削层成型料。
将棕刚玉、石榴石、尖晶石和树脂液混匀，加入石膏混匀，加入树脂粉混匀，过筛，即为非磨削层成型料。
将成型料分别投入到已加热至85℃的模具中；中间加入玻璃纤维网（已浸润一层含有石墨的腰果酚改性的酚醛树脂），温热成型。采用梯度固化工艺固化，最高固化温度为185℃。不锈钢切割砂轮各原料组分重量比例为：混合磨粒24﹟：15.98； 混合磨粒30﹟：35.96；混合磨粒36﹟：11.99 ；混合磨粒46﹟：14.86；沸石：3.81；造孔剂：1.12；碳化硅微粉0.5µm:2.56；树脂液：4.73；树脂粉：8.99。
实施例2
本实施例中的不锈钢切割砂轮是按温热压制成型工艺制作，按1把组分A混合磨粒及棕刚玉磨粒和B树脂液充分混合，2再与组分C填料沸石和组分D碳化硅微粉充分混合，3再与E造孔剂硅藻土充分混合，4再与组分F树脂粉充分混合，过筛，过筛后放置于恒温恒湿车间放置96h，过筛即为磨削层成型料。
将棕刚玉、石榴石、尖晶石和树脂液混匀，加入石膏混匀，加入树脂粉混匀，过筛，即为非磨削层成型料。
将成型料投入到已加热至85℃的模具中；中间加入玻璃纤维网（已浸润一层含有石墨的腰果酚改性的酚醛树脂），温热成型。采用梯度固化工艺固化，最高固化温度为185℃。不锈钢切割砂轮各原料组分重量比例为：混合磨粒24﹟：15.98； 棕刚玉磨粒30﹟：40.96；混合磨粒36﹟：11.99 ；混合磨粒46﹟：13.71；沸石：1.66；造孔剂：1.12；碳化硅微粉0.5µm:0.36；树脂液：4.73；树脂粉：9.49。
实施例3
本实施例中的不锈钢切割砂轮是按温热压制成型工艺制作，按1把组分A混合磨料及棕刚玉磨粒和B树脂液充分混合，2再与组分C填料沸石和组分D碳化硅微粉充分混合，3再与E造孔剂硅藻土充分混合，4再与组分F树脂粉充分混合，过筛，过筛后放置于恒温恒湿车间放置120h，过筛即为磨削层成型料。
将棕刚玉、石榴石、尖晶石和树脂液混匀，加入石膏混匀，加入树脂粉混匀，过筛，即为非磨削层成型料。
将成型料投入到已加热至85℃的模具中；中间加入玻璃纤维网（已浸润一层含有石墨的腰果酚改性的酚醛树脂），温热成型。采用梯度固化工艺固化，最高固化温度为185℃。不锈钢切割砂轮各原料组分重量比例为：混合磨粒24﹟：15.98；混合磨粒 30﹟：35.96；棕刚玉磨粒36﹟：11.99 ；混合磨粒46﹟：14.86；沸石：3.81；造孔剂：1.12；碳化硅微粉0.5µm:2.56；树脂液：4.73；树脂粉：8.99。
本发明和现市面质量较好品牌切割砂轮的切割实验比较
Claims (6)
1.一种不锈钢切割砂轮，其特征在于，该切割砂轮原料包括混合磨粒、填料、造孔剂、树脂、增强材料组成；所述混合磨粒为黑碳化硅、单晶刚玉、棕刚玉、棕刚玉-氧化铈核/壳复合磨粒、铁尖晶石，所述填料为沸石、碳化硅微粉，树脂为腰果酚改性的酚醛树脂，增强材料为含有石墨的玻璃纤维网；所述腰果酚改性的酚醛树脂是经硫酸钙晶须原位聚合而成；各原料的重量百分比为：混合磨粒75％～85％，填料3％～7％，造孔剂1％～3％，树脂10％～15％。
2.根据权利要求1所述的不锈钢切割砂轮，其特征在于：混合磨粒中黑碳化硅、单晶刚玉、棕刚玉、棕刚玉-氧化铈核/壳复合磨粒、铁尖晶石重量百分比分别为黑碳化硅5%、单晶刚玉20%、棕刚玉45%、棕刚玉-氧化铈核/壳复合磨粒20%、铁尖晶石10%。
3.根据权利要求1所述的不锈钢切割砂轮，其特征在于：混合磨粒的粒度为24# -46# ，含有石墨的玻璃纤维网浸含有经硫酸钙晶须原位聚合而成的腰果酚改性的酚醛树脂。
4.根据权利要求1所述的不锈钢切割砂轮，其特征在于： 造孔剂是由煅烧硅藻土组成的，且硅藻土是经树脂表面封孔而成。
5.根据权利要求1所述的不锈钢切割砂轮，其特征在于：砂轮是由内外两层组成，外层是磨削层，内层是非磨削层。
6.根据权利要求1所述的不锈钢切割砂轮，其特征在于：制备砂轮的成型料混好后经过恒温恒湿（温度25℃，湿度65%），浸润72-100h。
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