技术领域：Technical field:
本发明涉及一种基于孔模板技术的多种磨料协同排布工艺，其属于超硬磨料工具制造领域。The invention relates to a collaborative arrangement process of various abrasive materials based on hole template technology, which belongs to the field of superhard abrasive tool manufacturing.
背景技术：Background technique:
传统的固结磨料工具按照结合剂不同可分为树脂结合剂、陶瓷结合剂、金属结合剂(包括电镀及烧结)、金刚石工具等几类，这些金刚石工具在生产中的大量应用，极大提升了加工业的总体水平和能力，也改变了加工业的原有面貌，但不论是单层电镀的还是多层烧结(热固化)的金刚石固结磨料工具，磨料只是被机械包埋镶嵌在镀层或胎体金属中，其界面缺乏结合力，在负荷较重的高效磨削作业中，砂轮磨粒或镀层易脱落，为增加把持力就必须增加结合剂层厚度，其结果又会带来磨粒裸露高度和容屑空间减小，工具容易堵塞等问题。Traditional bonded abrasive tools can be divided into resin bonds, vitrified bonds, metal bonds (including electroplating and sintering), diamond tools, etc. according to different bonds. The extensive application of these diamond tools in production has greatly improved The overall level and ability of the processing industry has also changed the original appearance of the processing industry, but whether it is a single-layer electroplated or multi-layer sintered (heat-cured) diamond-bonded abrasive tool, the abrasive is only mechanically embedded in the coating. Or in the carcass metal, the interface lacks bonding force. In the high-efficiency grinding operation with heavy load, the abrasive grains or coating of the grinding wheel are easy to fall off. In order to increase the holding force, the thickness of the bonding agent layer must be increased, which will result in grinding. The exposed height of grains and the chip space are reduced, and the tools are easy to block and other problems.
为了从根本上提高磨粒、结合剂、基体三者间的结合强度，国内外在上世纪90年代初期开始着力研究用高温钎焊技术替代电镀开发单层金刚石磨料工具，研究结果表明，高温钎焊可以实现金刚石磨粒和基体高的结合强度，在重负荷磨削加工过程中，高温钎焊金刚石工具可以有效避免磨粒、结合剂层的脱落与剥落，磨粒的利用更加充分，砂轮寿命更高。此外，由于高的界面结合强度，结合剂层厚度只需维持在磨粒高度的30％左右就能够牢固地把持住磨粒，这样钎焊砂轮极大扩展了其容屑空间。相对于传统砂轮，钎焊砂轮的这些优异性能所显示出的加工优越性是非常明显的。In order to fundamentally improve the bonding strength between the abrasive grains, the bonding agent and the matrix, in the early 1990s at home and abroad, efforts were made to study the use of high-temperature brazing technology instead of electroplating to develop single-layer diamond abrasive tools. The research results show that high-temperature brazing Brazing can achieve high bonding strength between diamond abrasive grains and the matrix. During heavy-duty grinding, high-temperature brazing diamond tools can effectively prevent the abrasive grains and bond layer from falling off and peeling off. The abrasive grains are more fully utilized and the life of the grinding wheel higher. In addition, due to the high interface bonding strength, the thickness of the bond layer only needs to be maintained at about 30% of the height of the abrasive grains to firmly hold the abrasive grains, so that the brazed grinding wheel greatly expands its chip space. Compared with traditional grinding wheels, the processing superiority shown by these excellent properties of brazed grinding wheels is very obvious.
随着钎焊金刚石工具的进一步工业化应用，遇到了一系列加工应用难题，主要是针对不同的加工材料，单一粒度的磨料适应范围低，难以在一个较广的加工范围内均表面优异。以国家高铁建设中所用到的轨道板切削为例。博格板承接钢轨处需要磨削加工，两侧面出露的螺纹钢头及混凝土部分必须切除，传统金刚石锯片在使用过程中暴露出锯片寿命低、加工效率低的问题。后期制备的单层钎焊金刚石锯片样品进行试切割时，在切割初期时，单层钎焊金刚石工具的优势非常明显，切割效率较快，切割平稳，锯片不烧伤，切口平直，负载小，性能优异。但随着切割的进行，部分混凝土粉末及切削产生的切屑粘附于锯片之上，造成磨粒出露降低，切割效率下降，进一步损伤金刚石磨粒，使锯片温度升高，磨粒石墨化，形成恶性循环，导致锯片负载过大无法继续使用。实例说明，单一类型的磨粒工具在应用时难以发挥出长效、稳定的特点，需要新型的制备理论及制备方法来提高钎焊工具的性能。With the further industrial application of brazed diamond tools, a series of processing and application problems have been encountered, mainly for different processing materials, the single-grain abrasive has a low adaptability range, and it is difficult to achieve a uniform surface in a wide processing range. Take the track slab cutting used in the construction of the national high-speed railway as an example. The part where the Bourg plate is connected to the rail needs to be ground, and the exposed rebar heads and concrete parts on both sides must be cut off. The traditional diamond saw blade has problems of low blade life and low processing efficiency during use. When the sample of the single-layer brazed diamond saw blade prepared in the later stage is used for trial cutting, the advantages of the single-layer brazed diamond tool are very obvious at the initial stage of cutting, the cutting efficiency is fast, the cutting is stable, the saw blade does not burn, the incision is straight, and the load Small, great performance. However, as the cutting progresses, part of the concrete powder and cutting chips adhere to the saw blade, resulting in a decrease in the exposure of the abrasive grains, a decrease in cutting efficiency, further damage to the diamond abrasive grains, and an increase in the temperature of the saw blade. , forming a vicious circle, causing the saw blade to be overloaded and unable to continue to use. The examples show that it is difficult for a single type of abrasive tool to exert long-term and stable characteristics in application, and a new preparation theory and preparation method are needed to improve the performance of brazed tools.
而随着研究的深入发现，对于难加工的黑色金属材料，传统的单一类型磨料工具难以有效加工，钎焊金刚石工具加工黑色金属材料时散热性能好，但因容易高温石墨化难以高效快速加工；而钎焊CBN(立方氮化硼)工具虽然具有较好的加工黑色金属的性能，但在加工中遇到高温时易与水发生反应，降低其性能，而多数情况下加工条件中都会用到冷却液。碳化硅及三氧化二铝磨料虽然磨料锋利，加工表面质量较高，但磨损量大，消耗快，不适于高端机床加工。目前，钎焊工具的研究主要集中在金刚石磨料的钎焊，金刚石磨料、立方氮化硼磨料、碳化硅磨料、三氧化二铝磨料等多种磨料的同时钎焊以制作寿命更长、加工效率更高的工具的研究尚未涉及。此外，目前市场上还会遇到多种复合材料、混合结构材料等加工新问题，传统的单一类型工具，无论是烧结工具还是钎焊、电镀工具都难以进行。With the in-depth research, it is found that for ferrous metal materials that are difficult to process, traditional single-type abrasive tools are difficult to process effectively. Brazed diamond tools have good heat dissipation performance when processing ferrous metal materials, but they are difficult to process efficiently and quickly because they are prone to high-temperature graphitization; Although brazed CBN (cubic boron nitride) tools have good performance in processing ferrous metals, they are prone to react with water when they encounter high temperatures during processing, reducing their performance. In most cases, they will be used in processing conditions. Coolant. Although silicon carbide and aluminum oxide abrasives are sharp and have high surface quality, they are not suitable for high-end machine tools due to their high wear and fast consumption. At present, the research on brazing tools is mainly focused on the brazing of diamond abrasives, and the simultaneous brazing of various abrasives such as diamond abrasives, cubic boron nitride abrasives, silicon carbide abrasives, and aluminum oxide abrasives to produce longer life and higher processing efficiency. Studies of higher tools have not been covered. In addition, the current market will encounter new processing problems such as a variety of composite materials and mixed structural materials. Traditional single-type tools, whether it is sintering tools, brazing tools, or electroplating tools, are difficult to process.
将多种磨料协同排布于同一个单层钎焊工具中具有较大的困难，这是由于每一种磨料的几何外形是不一致的，常规的排布技术难以将磨料均匀排布，且在多种磨料协同排布时，每一种磨料的粒度不一致，难以做到每种磨料的均匀分布，有可能出现大粒度与小粒度磨料不能均匀分布的现象。传统的磨料排布工艺多集中于单种磨料的有序或者多层结构设计，所针对磨料规格与形状要求较为一致，对于多种磨料的不同形状具有一定的困难。It is very difficult to arrange multiple abrasives in the same single-layer brazed tool, because the geometric shape of each abrasive is inconsistent, and it is difficult to arrange the abrasives uniformly by conventional arrangement technology, and in the When a variety of abrasives are arranged cooperatively, the particle size of each abrasive is inconsistent, and it is difficult to achieve uniform distribution of each abrasive, and there may be a phenomenon that the large-sized and small-sized abrasives cannot be evenly distributed. The traditional abrasive arrangement process mostly focuses on the orderly or multi-layer structure design of a single abrasive, and the requirements for abrasive specifications and shapes are relatively consistent, and it has certain difficulties for different shapes of various abrasives.
此外对于多种磨料排布的单层工具的钎焊制备工艺目前尚未有报道涉及，主要是由于目前单种磨料排布技术尚在发展之中，并且对实际生产问题的科学转化尚有一定的滞后，多种磨料排布理论及工艺尚处于理论提出和完善阶段。In addition, there is no report on the brazing preparation process of single-layer tools with multiple abrasive arrangements, mainly because the current single abrasive arrangement technology is still under development, and there is still a certain degree of scientific transformation of actual production problems. Lag, a variety of abrasive arrangement theory and technology is still in the stage of theoretical proposal and improvement.
综上可知，为了进一步提高超硬磨料工具行业的应用水平，需要一种新的磨料磨具制备理论，即利用多种磨料的优势，并利用合理的制造工艺及制备方法，将其集合于一种工具中，制备出一种新型的磨料工具，使其能够在一些新型领域发挥更大更广泛的作用。In summary, in order to further improve the application level of the superabrasive tool industry, a new theory of abrasive tool preparation is needed, that is, to use the advantages of various abrasive materials, and use reasonable manufacturing processes and preparation methods to integrate them into one Among these tools, a new type of abrasive tool is prepared, which enables it to play a larger and wider role in some new fields.
发明内容：Invention content:
本发明基于孔模板技术的多种磨料协同排布工艺是基于传统钎焊单层超硬磨料工具的制备特点提出的新型超硬磨料工具磨料排布技术，多种磨料的协同排布，通过粒度与磨料种类的不同，形成三维空间结构，实现持续加工效果，并且由于多种磨料的使用，充分有效地利用多种磨料的特点，利用特定的孔模板技术，将其统一地综合到一种加工工具中去，扩大了传统加工工具的应用范围。The multi-abrasive synergistic arrangement technology based on the hole template technology of the present invention is a new superhard abrasive tool abrasive arrangement technology based on the preparation characteristics of traditional brazed single-layer superabrasive tools. Different from the types of abrasives, it forms a three-dimensional space structure to achieve continuous processing effects, and due to the use of various abrasives, it can fully and effectively use the characteristics of various abrasives, and use specific hole template technology to integrate them into one processing In the tool, the application range of traditional processing tools has been expanded.
本发明采用如下技术方案：一种基于孔模板技术的多种磨料协同排布工艺，其步骤如下：The present invention adopts the following technical scheme: a collaborative arrangement process of multiple abrasives based on hole template technology, the steps of which are as follows:
(1)根据加工要求确定磨料参数，所述磨料包括负责主要加工作用的主要磨料，及起辅助作用的辅助磨料，其中主要磨料包括一种或者多种磨料种类，辅助磨料亦包括一种或者多种磨料种类；(1) Determine the abrasive parameters according to the processing requirements, the abrasive includes the main abrasive responsible for the main processing function, and the auxiliary abrasive that plays an auxiliary role, wherein the main abrasive includes one or more abrasive types, and the auxiliary abrasive also includes one or more A type of abrasive;
(2)将超硬工具基体表面清理；(2) cleaning the surface of the superhard tool substrate;
(3)在超硬工具基体表面上排布磨料部位刷粘结剂；(3) Brush the adhesive on the abrasive parts arranged on the surface of the superhard tool substrate;
(4)将孔模板粘贴于超硬工具基体表面；(4) Paste the hole template on the surface of the superhard tool substrate;
(5)将步骤(1)中所确定的多种磨料根据粒度大小进行严格过筛，将过筛后的多种磨料按照磨粒粒度大小从大到小先后利用孔模板排布磨料；(5) Strictly sieve the various abrasives determined in step (1) according to the particle size, and arrange the abrasives by using the hole template successively according to the particle size of the sieved various abrasives;
(6)揭去孔模板，将钎料排布于磨料的空隙、超硬工具基体表面的表面空白处，高温加热后熔化，钎料中的元素成分与负责主要加工作用的主要磨料同时发生冶金化学结合。(6) Remove the hole template, arrange the solder in the gap of the abrasive material and the blank space on the surface of the superhard tool substrate, heat it at a high temperature and melt it, and the elemental composition in the solder and the main abrasive material responsible for the main processing will be metallurgically at the same time chemical bond.
进一步地，所述主要磨料和辅助磨料均为莫氏硬度大于5的磨料。Further, both the main abrasive and the auxiliary abrasive have a Mohs hardness greater than 5.
进一步地，所述主要磨料包括天然金刚石、人造金刚石、立方氮化硼、聚晶金刚石、聚晶立方氮化硼等，所述主要磨料的粒度范围1目～300目。Further, the main abrasives include natural diamond, artificial diamond, cubic boron nitride, polycrystalline diamond, polycrystalline cubic boron nitride, etc., and the particle size of the main abrasives ranges from 1 mesh to 300 mesh.
进一步地，所述辅助磨料包括碳化硅、氧化铝等，所述辅助磨料的粒度范围1目～300目。Further, the auxiliary abrasive includes silicon carbide, aluminum oxide, etc., and the particle size of the auxiliary abrasive ranges from 1 mesh to 300 mesh.
进一步地，所述孔模板上孔洞的大小与多种磨料的粒度一致。Further, the size of the holes on the hole template is consistent with the particle size of various abrasives.
进一步地，所述孔模板为单层孔模板或者复合层孔模板。Further, the hole template is a single-layer hole template or a composite layer hole template.
进一步地，所述多种磨料中所选用的单种磨料平均粒径差范围在10％以内。Further, the average particle size difference of a single abrasive selected from the multiple abrasives is within 10%.
进一步地，所述超硬工具基体表面为钻头、锯片、异形磨轮、磨盘具有简单几何型面以及复杂曲面的工具的表面。Further, the superhard tool base surface is the surface of tools with simple geometric profiles and complex curved surfaces such as drill bits, saw blades, special-shaped grinding wheels, and grinding discs.
本发明具有如下有益效果：The present invention has following beneficial effects:
(1).应用范围广，不仅可以应用于传统材料的加工，还可以应用于黑色金属、复合材料、混合材料等难加工材料以及新兴材料的加工，对加工材料的适合性好；(1). It has a wide range of applications, not only can be applied to the processing of traditional materials, but also can be applied to the processing of difficult-to-process materials such as ferrous metals, composite materials, mixed materials, and emerging materials, and has good suitability for processing materials;
(2).工具综合加工性能优异，通过本发明的工艺可以发挥各种磨粒的优点，使产品稳定、高效；(2). The comprehensive processing performance of the tool is excellent, and the advantages of various abrasive grains can be brought into play through the process of the present invention, so that the product is stable and efficient;
(3).磨粒出露效果佳，具有持续加工能力，即具有一定的多层钎焊加工能力，极大提高了工具寿命；(3). The effect of abrasive particle exposure is good, and it has continuous processing ability, that is, it has a certain multi-layer brazing processing ability, which greatly improves the tool life;
(4).宜于工业化生产，结合布料设备，本发明可以进行连续操作，适合工业化生产操作；(4). Suitable for industrialized production, combined with material distribution equipment, the present invention can carry out continuous operation, suitable for industrialized production operation;
(5).本发明所采用的制备工艺与方法工艺简单稳定，易于操作并进行工业化生产，能够有效地扩大钎焊超硬磨料工具的应用范围和工具性能，具有较高的经济效益。(5). The preparation process and method adopted in the present invention are simple and stable, easy to operate and carry out industrial production, can effectively expand the application range and tool performance of brazed superabrasive tools, and have high economic benefits.
附图说明：Description of drawings:
图1为多种磨料磨损阶段。Figure 1 shows various stages of abrasive wear.
图2为不同粒度磨料排布。Figure 2 shows the arrangement of abrasives with different particle sizes.
图3为相同粒度磨料排布。Figure 3 shows the arrangement of abrasives with the same particle size.
其中：in:
1-大粒度磨粒；2-中等粒度磨粒；3-小粒度磨粒；4-磨损后的大粒度磨粒；5-开始磨损的中粒度磨粒；6-磨损后的中等粒度磨粒；7-大孔洞；8-小孔洞；9-重合孔；10-剩余孔。1-Large-grained abrasive grains; 2-Medium-grained abrasive grains; 3-Small-grained abrasive grains; 4-Large-grained abrasive grains after wear; 5-Medium-grained abrasive grains that started to wear; 6-Medium-sized abrasive grains after wear ; 7-large hole; 8-small hole; 9-coincident hole; 10-remaining hole.
具体实施方式：detailed description:
请参照图1至图3所示，本发明基于孔模板技术的多种磨料协同排布工艺的步骤如下：Please refer to Fig. 1 to Fig. 3, the steps of the multi-abrasive collaborative arrangement process based on hole template technology in the present invention are as follows:
(1)根据加工要求确定磨料参数，包括(类型、品级、粒度、比例)，所述磨料包括负责主要加工作用的主要磨料，及起辅助作用的辅助磨料，其中主要磨料包括一种或者多种磨料种类，辅助磨料亦包括一种或者多种磨料种类；(1) Determine the abrasive parameters according to the processing requirements, including (type, grade, particle size, ratio), the abrasive includes the main abrasive responsible for the main processing function, and the auxiliary abrasive that plays an auxiliary role, wherein the main abrasive includes one or more Types of abrasives, auxiliary abrasives also include one or more types of abrasives;
(2)将超硬工具基体表面清理；(2) cleaning the surface of the superhard tool substrate;
(3)在超硬工具基体表面上排布磨料部位刷粘结剂；(3) Brush the adhesive on the abrasive parts arranged on the surface of the superhard tool substrate;
(4)将孔模板粘贴于超硬工具基体表面；(4) Paste the hole template on the surface of the superhard tool substrate;
(5)将步骤(1)中所确定的多种磨料根据粒度大小进行严格过筛，将过筛后的多种磨料按照磨粒粒度大小从大到小先后利用孔模板排布磨料；(5) Strictly sieve the various abrasives determined in step (1) according to the particle size, and arrange the abrasives by using the hole template successively according to the particle size of the sieved various abrasives;
(6)揭去孔模板，将钎料排布于磨料的空隙、超硬工具基体表面的表面空白处，高温加热后熔化，钎料中的元素成分与负责主要加工作用的主要磨料同时发生冶金化学结合。(6) Remove the hole template, arrange the solder in the gap of the abrasive material and the blank space on the surface of the superhard tool substrate, heat it at a high temperature and melt it, and the elemental composition in the solder and the main abrasive material responsible for the main processing will be metallurgically at the same time chemical bond.
其中磨料参数包括(类型、品级、粒度、比例)的确定可根据加工要求进行确定，这个确定可根据加工条件进行计算推出，亦可通过模拟试验得出，亦可通过经验法估算得出。主要是用来确定适合于特定加工材料与加工条件下的磨料参数，并且适合于多种磨料协同排布的单层钎焊工具的制备工艺。Among them, the determination of abrasive parameters including (type, grade, particle size, ratio) can be determined according to processing requirements. This determination can be calculated and deduced according to processing conditions, or obtained through simulation tests, or estimated by empirical methods. It is mainly used to determine the abrasive parameters suitable for specific processing materials and processing conditions, and is suitable for the preparation process of single-layer brazing tools with multiple abrasives arranged cooperatively.
主要磨料和辅助磨料选择为莫氏硬度大于5的磨料，其中主要磨料主要包括天然金刚石、人造金刚石、立方氮化硼(CBN)、聚晶金刚石、聚晶立方氮化硼等，且主要磨料的粒度范围1目～300目，辅助磨料主要包括碳化硅、氧化铝等，且辅助磨料的粒度范围1目～300目。The main abrasives and auxiliary abrasives are abrasives with a Mohs hardness greater than 5. The main abrasives mainly include natural diamond, artificial diamond, cubic boron nitride (CBN), polycrystalline diamond, polycrystalline cubic boron nitride, etc., and the main abrasive The particle size range is 1 mesh to 300 mesh, and the auxiliary abrasive mainly includes silicon carbide, aluminum oxide, etc., and the particle size range of the auxiliary abrasive is 1 mesh to 300 mesh.
多种磨料协同排布中磨粒种类的确定一般遵循高效、持续的原则，即进行排布的磨料共同实现对加工对象的高效、长久的加工。为实现此目标，必须有主要磨料实现材料去除，辅助磨料起辅助作用。所选择的主要磨料可以是一种，也可以是多种，但必须具有较好的耐磨损性，且具有一定的自锐性，常规的主要磨料选择对象为：人造金刚石、立方氮化硼，一般地，人造金刚石多用于加工脆性材料，立方氮化硼多用于加工金属材料。当对于加工难加工金属材料或者复合材料时，需要将人造金刚石与立方氮化硼混合使用，根据加工对象的难加工程度，若金属硬且韧性大，立方氮化硼的比例可适当提高；若金属易切削，切屑细小，可适当提高金刚石比例。比例高的磨料粒度应大于比例低的磨料。The determination of the types of abrasive grains in the collaborative arrangement of multiple abrasives generally follows the principle of high efficiency and continuity, that is, the arranged abrasives can jointly achieve efficient and long-term processing of the processing object. To achieve this goal, there must be a primary abrasive to achieve material removal and a secondary abrasive to play a supporting role. The selected main abrasive can be one type or multiple types, but it must have good wear resistance and certain self-sharpness. The conventional main abrasive selection objects are: artificial diamond, cubic boron nitride , generally, artificial diamond is mostly used for processing brittle materials, and cubic boron nitride is mostly used for processing metal materials. When processing difficult-to-machine metal materials or composite materials, it is necessary to mix artificial diamond and cubic boron nitride. According to the degree of difficulty of the processing object, if the metal is hard and tough, the proportion of cubic boron nitride can be appropriately increased; if The metal is easy to cut, and the chips are fine, so the proportion of diamond can be increased appropriately. The grain size of the abrasive with a high proportion should be larger than that with a low proportion.
协同排布是指多种磨粒在同一平面上依据粒度的不同形成的高低不一的加工空间排布。其中不同磨料粒度间的粒度比在1.0～1.8之间。Cooperative arrangement refers to the arrangement of various abrasive grains on the same plane with different heights and heights in the processing space according to the different particle sizes. The particle size ratio between different abrasive particle sizes is between 1.0 and 1.8.
其中超硬工具基体表面为钻头、锯片、异形磨轮、磨盘等具有简单几何型面以及复杂曲面的工具的表面。Among them, the surface of the superhard tool substrate is the surface of tools with simple geometric shapes and complex curved surfaces, such as drill bits, saw blades, special-shaped grinding wheels, and grinding discs.
基体表面的清理是多种方式的。对基体表面的清理决定了固着在表面的磨料与钎料的把持强度，因此表面的油污、杂质等必须清除干净，如通过超声清洗加碱液方式去除油污与粉末杂质，通过酒精去除表面水迹与水垢等，或者几种方式相结合。There are many ways to clean the substrate surface. The cleaning of the surface of the substrate determines the holding strength of the abrasive and solder fixed on the surface, so the oil and impurities on the surface must be cleaned, such as removing oil and powder impurities by ultrasonic cleaning and adding lye, and removing surface water by alcohol With scale, etc., or a combination of several methods.
粘结剂用于固定多种磨料与钎料。其具有粘结性，并且能在高温下迅速挥发，所挥发物质不影响钎焊焊接效果，亦不影响磨料的加工性能。Binders are used to hold a wide variety of abrasives and solders. It has cohesiveness and can volatilize rapidly at high temperature, and the volatilized substance does not affect the brazing welding effect, nor does it affect the processing performance of the abrasive.
利用孔模板法进行排布磨料时，首先应将磨料进行过筛，目的是将所选择磨料粒度精确地控制在某一范围之内，这样有利于多种磨料排布时的准确性。多种磨料中所选用的单种磨料平均粒径差范围应在10％以内。When using the hole template method to arrange abrasives, the abrasives should be sieved first, the purpose is to accurately control the particle size of the selected abrasives within a certain range, which is conducive to the accuracy of the arrangement of various abrasives. The average particle size difference range of a single abrasive selected from various abrasives should be within 10%.
磨料的排布是按照从大粒度到小粒度进行排布的。利用模板法的原理，孔模板即为在模板上打出大小不一的孔洞，孔洞的大小与需要排布的磨粒粒度一致，不同大小的孔洞的密度与磨粒数量比例一致。模板选用具有一定弹性与柔软度的材料，通过粘结剂可以与基体表面较好的贴覆。且孔模板根据多种磨料的粒度可以用单层孔模板，亦可以用两层孔模板组成的复合层孔模板。The arrangement of abrasives is arranged from large particle size to small particle size. Using the principle of the template method, the hole template is to punch holes of different sizes on the template. The size of the holes is consistent with the size of the abrasive grains to be arranged, and the density of the holes of different sizes is consistent with the proportion of the abrasive grains. The template is made of materials with a certain degree of elasticity and softness, which can be better attached to the surface of the substrate through the adhesive. And the hole template can be a single-layer hole template according to the particle size of various abrasives, or a composite layer hole template composed of two layers of hole templates.
将孔模板置于基体表面，先将大粒度磨料排布，由于小孔洞8中大磨料无法进入，因此，小孔洞8为空，大孔洞7布满大粒度磨料。排布结束后，由于粘结剂的粘接作用，大粒度磨料是被固着于基体表面的不会脱落，然后将次粒度的磨料进行布洒，由于大孔洞7已被布满，次粒度磨料无法进入，只能进入小孔洞8，这样通过两次布料便可以将不同粒度的磨料排布于同一基体表面，当磨料种类增加时，按照上述方式依次排布，直至所有粒度排布完毕。The hole template is placed on the surface of the substrate, and the large-sized abrasives are first arranged. Since the large abrasives cannot enter the small holes 8, the small holes 8 are empty, and the large holes 7 are covered with large-sized abrasives. After the arrangement is completed, due to the bonding effect of the binder, the large-grained abrasives are fixed on the surface of the substrate and will not fall off, and then the sub-sized abrasives are sprinkled. Since the large holes 7 have been filled, the sub-sized abrasives It cannot enter, but can only enter the small hole 8, so that abrasives of different particle sizes can be arranged on the surface of the same substrate through two cloth distributions. When the types of abrasives increase, they will be arranged in the above-mentioned manner until all particle sizes are arranged.
由于在多种磨料粒度选择时磨料粒度有可能是不同的，也有可能是相同的，所选用的磨料排布方式是不相同的。当磨料粒度相同时，需要双层孔模板形成的复合孔模板来实现。复合孔模板由底层孔模板与表层孔模板构成，底层孔模板孔数与所要布料的磨料总数一致，表层孔模板孔数与先布料磨料数量一致。将复合孔模板共同贴附于基体表面时，由于表层孔数少，底层部分孔数会被表层孔模板遮挡住，未被遮挡的地方即是两孔模板重合的孔。此时先布第一种磨料，磨料便排布于重合孔10内，当第一种磨料排由完毕后，揭去表层孔模板，由于重合孔10已被填满，剩余孔9便可用来排布第二种磨料。排布结束后便可以得到多种磨料协同排布于同一表面的单层磨料结构，当磨料种类为三种时，复合孔模板的层数亦是三层，以此类推。Since the abrasive grain sizes may be different or the same when selecting multiple abrasive grain sizes, the selected abrasive grains are arranged in different ways. When the abrasive particle size is the same, a composite hole template formed by a double-layer hole template is required to achieve it. The composite hole template is composed of a bottom hole template and a surface hole template. The number of holes in the bottom hole template is consistent with the total number of abrasives to be clothed, and the number of holes in the surface hole template is consistent with the number of abrasives that are clothed first. When the composite hole template is attached to the surface of the substrate together, due to the small number of holes on the surface, the number of holes in the bottom layer will be covered by the surface hole template, and the unshielded area is the hole where the two hole templates overlap. At this time, the first type of abrasive is laid first, and the abrasive is arranged in the overlapping hole 10. After the first type of abrasive is discharged, the surface hole template is removed. Since the overlapping hole 10 has been filled, the remaining hole 9 can be used. Arrange the second abrasive. After the arrangement is completed, a single-layer abrasive structure in which multiple abrasives are coordinated and arranged on the same surface can be obtained. When there are three types of abrasives, the number of layers of the composite hole template is also three layers, and so on.
钎料(合金粉末)为Ag-Cu-Ti或Cu-Sn-Ti等含有能与起主要加工作用的主要磨料发生化学冶金结合成分(如钎料中的Ti元素、Cr元素)。钎料(合金粉末)排布于磨料的空隙、基体的表面空白处，高温加热后熔化，将多种磨料与基体牢固焊料。所用合金粉末的种类必须是能够同时与多种磨料发生化学反应的或者能形成一定的金属结合力的，目的是将主要加工用磨料牢固把持，例如对于金刚石来说铬元素、钛元素、钨元素均能与其发生化学冶金结构，对于立方氮化硼来说，氮元素、硼元素均能与钛元素结合，当两种磨料协同排布时，必须使用能使两者共同发生化学结合的含钛元素合金粉末才能将其共同钎焊。The brazing material (alloy powder) is Ag-Cu-Ti or Cu-Sn-Ti, etc., which contain chemical metallurgical bonding components (such as Ti element and Cr element in the brazing material) that can be combined with the main abrasive material that plays the main processing role. The brazing material (alloy powder) is arranged in the gaps of the abrasive and the blank space on the surface of the substrate, and melted after being heated at a high temperature, so that various abrasives and the substrate are firmly soldered. The type of alloy powder used must be able to chemically react with a variety of abrasives at the same time or form a certain metal bonding force. The purpose is to firmly hold the main processing abrasives, such as chromium, titanium, and tungsten for diamond. Both can produce chemical metallurgical structure with it. For cubic boron nitride, both nitrogen and boron elements can be combined with titanium. Elemental alloy powders are required to braze them together.
请参照图1所示，例如多种磨料中以人造金刚石磨料、立方氮化硼等为主要磨料，辅助磨料进行排屑、散热、平抑振动等作用，由于人造金刚石硬度较其它种类磨粒硬，因此选用为大粒度磨粒1，当加工一段时间磨损后，大粒度磨粒磨损，相应低硬度的中等粒度磨粒2如立方氮化硼、小粒度磨粒3如碳化硅等顺次露出，由于其刃口多，更加锋利，因此可以继续保持较高的工具锋利度，并且不影响排屑、表面质量。待中等粒度磨粒立方氮化硼磨损达到一定程度后，大粒度磨粒人造金刚石重新开始磨削，以此循环，达到了多层钎焊工具持续加工的效果。Please refer to Figure 1. For example, among various abrasives, artificial diamond abrasives, cubic boron nitride, etc. are the main abrasives, and the auxiliary abrasives perform functions such as chip removal, heat dissipation, and vibration suppression. Since the hardness of artificial diamond is harder than other types of abrasive grains, Therefore, the large-grained abrasive grain 1 is selected. After a period of wear and tear during processing, the large-grained abrasive grain wears away, and the corresponding low-hardness medium-grained abrasive grain 2 such as cubic boron nitride, and the small-grained abrasive grain 3 such as silicon carbide are sequentially exposed. Because it has more cutting edges and is sharper, it can continue to maintain a high tool sharpness without affecting chip removal and surface quality. After the medium-grained cubic boron nitride wears to a certain extent, the large-grained artificial diamond starts grinding again, and this cycle achieves the effect of continuous processing of multi-layer brazing tools.
下面通过两个具体实施例来具体阐述本发明基于孔模板技术的多种磨料协同排布工艺。In the following, two specific examples will be used to specifically illustrate the multiple abrasives cooperative arrangement process based on the orifice template technology of the present invention.
实施例一：Embodiment one:
制备应用于切割高铁轨道板边缘的锯片刀头。锯片外形尺寸：锯片刀头基体材质：30CrMo钢，刀头基体尺寸：A saw blade head for cutting the edge of a high-speed rail track slab is prepared. Saw blade dimensions: Saw blade head substrate material: 30CrMo steel, cutter head substrate size:
制备步骤如下：The preparation steps are as follows:
(1)确定三种磨料类型：金刚石磨料、立方氮化硼磨料、碳化硅磨料；三种磨料粒度：35/40目：40/45目：50/60目；体积比例按：6：3：1；(1) Determine three abrasive types: diamond abrasive, cubic boron nitride abrasive, silicon carbide abrasive; three abrasive grain sizes: 35/40 mesh: 40/45 mesh: 50/60 mesh; volume ratio: 6:3: 1;
(2)刀头基体进行喷砂，再用无水酒精清洗干净；(2) The base of the cutter head is sandblasted, and then cleaned with absolute alcohol;
(3)在刀头表面排布磨料区域刷涂粘结剂；(3) Brush the adhesive on the area where the abrasive material is arranged on the surface of the cutter head;
(4)利用上述孔模板法按照粒度大小的次序从大到小分别布洒金刚石磨粒、立方氮化硼磨料、碳化硅磨料，排布结束后揭去孔模板；(4) Use the above hole template method to spread diamond abrasive grains, cubic boron nitride abrasives, and silicon carbide abrasives respectively according to the order of particle size from large to small, and remove the hole template after the arrangement is completed;
(5)布洒钎料合金粉末，合金粉末选用Ag-Cu-Ti，元素成分质量分数比为：78：16：6；(5) Sprinkle solder alloy powder, the alloy powder is Ag-Cu-Ti, the mass fraction ratio of element components is: 78:16:6;
(6)采用真空钎焊炉钎焊加热，最高温度905度，保温8分钟，真空度保持在0.01帕以内。(6) Use a vacuum brazing furnace for brazing heating, the maximum temperature is 905 degrees, and the heat preservation is 8 minutes, and the vacuum degree is kept within 0.01 Pa.
实施例二：Embodiment two:
制备用于磨削高强度钢结构表面的磨盘。磨盘外径125mm。基体采用盘状外形，在上端平面布料，用于对钢结构表面的磨削，抛光加工。磨盘基体采用65锰钢。Preparation of abrasive discs for grinding high-strength steel structural surfaces. The outer diameter of the grinding disc is 125mm. The base adopts a disc-shaped shape, and the upper end is covered with a flat surface, which is used for grinding and polishing the surface of the steel structure. The disc substrate is made of 65 manganese steel.
制备步骤如下：The preparation steps are as follows:
(1)确定3种磨料类型：金刚石磨料、立方氮化硼磨料、三氧化二铝磨料；3种磨料粒度：30/35、30/35、50/60；体积比例按：4：4：2；(1) Determine three abrasive types: diamond abrasive, cubic boron nitride abrasive, and aluminum oxide abrasive; three abrasive grain sizes: 30/35, 30/35, 50/60; volume ratio: 4:4:2 ;
(2)磨盘基体进行喷砂，然后进行超声波清洗，晾干待用；(2) The base of the grinding disc is sandblasted, then ultrasonically cleaned, and dried for later use;
(3)在磨盘表面布磨料区域刷涂粘结剂；(3) Brush the adhesive on the cloth abrasive area on the surface of the grinding disc;
(4)利用上述孔模板法，先根据磨料总数量制备复合孔模板，底层孔模板孔数量与总磨料数量一致，表层孔模板孔数量与先布料的金刚石数量一致，在重合孔内进行金刚石排布后，揭去表层孔模板，再排布立方氮化硼磨料，由于粒度大于三氧化二铝粒度，所排布的立方氮化硼不会填塞三氧化二铝所在位置孔，排布结束后再排布三氧化二铝磨料。布料结束后揭去孔模板，即可得到所需要磨料排布地貌。(4) Using the above-mentioned hole template method, first prepare a composite hole template according to the total amount of abrasives. The number of holes in the bottom hole template is consistent with the total number of abrasives. After distributing, remove the surface hole template, and then arrange cubic boron nitride abrasives. Since the particle size is larger than that of aluminum oxide, the arranged cubic boron nitride will not fill the hole where aluminum oxide is located. After the arrangement is completed, Al2O3 abrasives are arranged again. After the cloth is finished, the hole template is removed to obtain the required abrasive arrangement landform.
(5)布洒钎料合金粉末，合金粉末选用Cu-Sn-Ti，元素成分质量分数比为：75：18：7；(5) Sprinkle solder alloy powder, the alloy powder is Cu-Sn-Ti, the mass fraction ratio of element components is: 75:18:7;
(6)采用真空钎焊炉钎焊加热，最高温度930度，保温15分钟，真空度保持在0.01帕以内。(6) Use a vacuum brazing furnace for brazing heating, the maximum temperature is 930 degrees, the heat preservation is 15 minutes, and the vacuum degree is kept within 0.01 Pa.
本发明基于孔模板技术的多种磨料协同排布工艺不仅可以应用于如锯片、钻头、磨轮等钎焊超硬磨料工具制备，亦可以制备电镀超硬磨料工具，所制备工具可以应用于黑色金属、有色金属、复合材料、硬脆材料等的切割、磨削、抛光、钻削等加工工艺。The multi-abrasive collaborative arrangement process based on the hole template technology of the present invention can not only be applied to the preparation of brazed superabrasive tools such as saw blades, drill bits, grinding wheels, etc., but also can be used to prepare electroplated superabrasive tools. The prepared tools can be applied to black Cutting, grinding, polishing, drilling and other processing techniques of metals, non-ferrous metals, composite materials, hard and brittle materials, etc.
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下还可以作出若干改进，这些改进也应视为本发明的保护范围。The above is only a preferred embodiment of the present invention, it should be pointed out that for those of ordinary skill in the art, some improvements can also be made without departing from the principle of the present invention, and these improvements should also be regarded as the invention. protected range.
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| CN201410277323.5ACN104070469B (en) | 2014-06-19 | 2014-06-19 | Multi-abrasive collaborative arrangement process based on hole template technology |
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| CN201410277323.5ACN104070469B (en) | 2014-06-19 | 2014-06-19 | Multi-abrasive collaborative arrangement process based on hole template technology |
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