A kind of super hard abrasive ordered arrangement methodTechnical field
The invention belongs to superhard material process field, be specifically related to a kind of super hard abrasive ordered arrangement method.
Background technology
Super hard abrasive instrument is used for shaping cutting, the polishing of the material such as hard brittle material, sheet metal, and its machining accuracy is high, efficiency is high, and application prospect is wide, is the huge instrument of a kind of market potential.But its cutting main body of consolidation super hard abrasive instrument is the super hard abrasive being arranged in tool surfaces, the kind of super hard abrasive, granularity, crystal formation and the arrangement mode on tool base surface thereof determine the processing characteristics of instrument.
Mostly super hard abrasive and metallic bond are mixed in existing abrasive material sort method, load in mould and carry out base and sintering.But this technique exists following problem: (1) mechanical batch mixing cannot ensure that abrasive material mixes in metallic bond, cause subregion abrasive concentration high, subregion abrasive concentration is low, and even some region does not have abrasive material to distribute; (2) because of abrasive material skewness, saw blade cutting usefulness declines, and the region Cutting Drag that abrasive concentration is high is large, and chip easily blocks, and cutting efficiency is low; In abrasive material thinning area, abrasive material can not effectively cut, and suffered impulsive force is large, and abrasive material is easy to broken and comes off; In the region without abrasive material, bonding agent quick abrasion, Cutting Drag is large; (3) because Cutting Drag is large, cutting temperature is high, and bonding agent and abrasive material are easily burnt.
First diamond order arrangement is applied to saw blade tip by Chinese emery wheel company doctor Song Jianmin in China Taiwan, and its patented technology (U.S.Patent6039641) proposed implements the ordered arrangement of diamond abrasive.The first step of this method, mixes carcass powder, adds suitable organic binder bond and the mixture of solvent, makes " dough ", then do straticulation by the method for roll extrusion; Second step, make the template with through hole by the particle diameter of diamond abrasive and arrangement mode, aperture is greater than single diamond particle diameter, be less than two diamond abrasive particle diameters and, guarantee that single diamond enters in pattern hole, template thickness is the 1/3-2/3 of diamond average grain diameter; 3rd step, is distributed in template through hole by diamond; 4th step, removes template, and the diamond in hole drops on the surface of thin layer, forms ordered arrangement array, and unnecessary diamond is removed together in company with template; 5th step, is pressed into diamond in carcass thin layer with plain plate.This technique can accurate ordered arrangement diamond abrasive, but there is following shortcoming: (1) every procedure manual operation, and waste time and energy, efficiency is low; (2) emery wheel company allows single diamond particles enter template, and the diamond like this for variable grain need do different templates, compares effort; (3) diamond upsetting ordered arrangement in the process of template is removed.
Because the grinding material sequential arraying technical research time is not long, the obvious Shortcomings of existing diamond grinding material sequential arraying technique, is mainly manifested in the aspects such as production efficiency is low, arrangement precision is low, apparatus expensive.
Summary of the invention
The object of the present invention is to provide efficient, accurate, cost-effective super hard abrasive ordered arrangement method.
Based on above-mentioned purpose, the present invention by the following technical solutions: a kind of super hard abrasive ordered arrangement method, comprises the following steps:
(1) pressure sensitive adhesive is laid at metal base surface;
(2) the uniform sequential water-soluble film being distributed with through hole of the layer of surface that bonds on pressure sensitive adhesive;
(3) after the through hole that pressure sensitive adhesive enters water-soluble film, dispense superabrasive particles at film surface, then baking and curing, make the abundant consolidation of abrasive grain;
(4) semi-finished product good for the consolidation obtained in step (3) are placed in water, water-soluble film are fully dissolved and dries.
Preferably, described water-soluble film is polyvinyl alcohol film, polyethylene oxide thin film, water-soluble cellulose film or water soluble starch class film.
Further, the aperture of through hole is 10-300 order, and pitch of holes is 0.02-10mm.
Further, the thickness of pressure sensitive adhesive and water-soluble film is 0.1-1mm.
Further, the abrasive grain that the surface of semi-finished after baking and curing is not bonded sweeps backwardness, then sample is placed in water.
Further, before the pressure sensitive adhesive that metal base surface is laid, first metal base surface is put into alcohol ultrasonic cleaning.
Further, described metal base surface is plane or curved surface.
Further, described super hard abrasive is one or more in diamond, electroplated diamond, cubic boron nitride, electroplating cubic boron nitride, polycrystalline cubic boron nitride and carbide alloy crushed particles.
Further, the temperature 60 ~ 80 DEG C of baking and curing in step (3), the time is 0.5 ~ 1h.
Further, in step (4), water temperature is 20 ~ 80 DEG C, and bake out temperature is 100 ~ 150 DEG C.
Compared with prior art, super hard abrasive ordered arrangement method provided by the invention has the following advantages:
(1) this method efficient, accurately, save cost, be easy to industrialization promotion;
(2) allow the pressure sensitive adhesive on matrix be oozed out by the hole on water-soluble film in this method, form " the glue point " of ordered arrangement, each glue point can bond super hard abrasive, not by the impact of the impact of abrasive grain type and granular size, and highly versatile;
(3) this method utilizes water-soluble material to make template, allows template automatic hydrolysis, can not destroy putting in order of super hard abrasive;
(4) water-soluble material that this method utilizes makes template, and be fexible film, matrix can be plane or curved surface, does not all affect its ordered arrangement effect.
Accompanying drawing explanation
Fig. 1 is schematic flow sheet of the present invention;
Fig. 2 is the photo of the bowl-type grinding disc adopting the method for embodiment 1 to prepare.
Detailed description of the invention
Below in conjunction with embodiment, the present invention is described in detail.
embodiment 1
A kind of super hard abrasive ordered arrangement method, as shown in Figure 1, comprises the following steps:
(1) cut-off footpath is the bowl-type 65 manganese steel matrix of 10cm, matrix is put into the alcoholic solution of 5% ~ 15%, with Ultrasonic Cleaning 3 ~ 5 minutes, is placed in ventilation and dries for subsequent use; Choose 30-40 object diamond particles, be placed in acetone soln Ultrasonic Cleaning, the impurity such as the dust of removal diamond surface attachment and grease; On the surface of bowl abrasive disc bound abrasive grains, smear pressure sensitive adhesive, colloid thickness is 0.5 ~ 1mm;
(2) the foursquare polyvinyl alcohol film that a length of side is greater than 10cm is got, laser-beam drilling machine carries out punching process, making a call to a diameter every 1mm is 20 object holes (pitch of holes can be selected according to the size of superabrasive particles, is advisable to be independent of each other between particle); By the polyvinyl alcohol film of this porous paving matrix surface after treatment, and pressing makes pressure sensitive adhesive ooze out from through hole;
(3) by after the surface of semi-finished of naturally unrestrained for diamond particles step (2) gained, semi-finished product are placed in the baking oven 0.5h of 60 DEG C, pressure sensitive adhesive is solidified, diamond particles is cemented on pressure sensitive adhesive; Banister brush is used to be swept gently by not bonded abrasive grain;
(4) semi-finished product be cured are put into the water of 60 DEG C, polyvinyl alcohol film is hydrolyzed, after its complete hydrolysis (about 5min), take out from water, dry at 100-150 DEG C and get product 1.
Finished product 1 surface uniform to be arranged one deck powdered filler metal; then vacuum or controlled atmosphere furnace is put into; be heated to solder melt; after cooling, diamond abrasive fixedly secures at 65 manganese steel matrix surfaces by soldering bonding agent; form bowl-type grinding disc; as shown in Figure 2, the abrasive material on grinding disc surface is evenly distributed, and occurs without the situation that abrasive material is assembled and abrasive material is sparse.
embodiment 2
A kind of super hard abrasive ordered arrangement method, comprises the following steps:
(1) cut-off footpath is the circle 65 manganese steel matrix of 8cm, matrix is put into the alcoholic solution of 5% ~ 15%, with Ultrasonic Cleaning 3 ~ 5 minutes, is placed in ventilation and dries for subsequent use; Choose 50-60 object CBN(cubic boron nitride) diamond particles of particle, be placed in acetone soln Ultrasonic Cleaning, remove the impurity such as the dust of CBN particle surface attachment and grease; On the surface of circular abrasive disc bound abrasive grains, smear pressure sensitive adhesive, colloid thickness is 0.4 ~ 0.8mm;
(2) the foursquare polyvinyl alcohol film that a length of side is greater than 8cm is got, the thickness of polyvinyl alcohol film and the consistency of thickness of pressure sensitive adhesive, laser-beam drilling machine carries out punching process, making a call to a diameter every 0.8mm is 40 object holes (pitch of holes can be selected according to the size of superabrasive particles, is advisable to be independent of each other between particle); By the matrix surface after the process of the polyvinyl alcohol film of this porous paving, and pressing makes pressure sensitive adhesive ooze out from through hole;
(3) by after the surface of semi-finished of naturally unrestrained for CBN particle step (2) gained, semi-finished product are placed in the baking oven 0.5h of 70 DEG C, pressure sensitive adhesive is solidified, by CBN Particle consolidation on pressure sensitive adhesive; Banister brush is used to be swept gently by not bonded CBN particle;
(4) semi-finished product be cured are put into the water of 50 DEG C, polyvinyl alcohol film is hydrolyzed, after its complete hydrolysis (about 7min), semi-finished product are taken out, dry at 100-150 DEG C and get product 2.
To be arranged by finished product 2 surface uniform one deck powdered filler metal, then put into vacuum or controlled atmosphere furnace, be heated to solder and melt, after cooling, CBN abrasive grain is fixedly secured at 65 manganese steel matrix surfaces by soldering bonding agent, forms round grinding disc.
embodiment 3
A kind of super hard abrasive ordered arrangement method, comprises the following steps:
(1) getting external diameter is 18cm, and internal diameter is 3.2cm, and width is the grinding wheel base body of 2cm, and basic material is 45 steel, matrix is put into the alcoholic solution of 5% ~ 15%, with Ultrasonic Cleaning 3 ~ 5 minutes, is placed in ventilation and dries for subsequent use; Choose 20-30 object CBN(cubic boron nitride) grains, be placed in acetone soln Ultrasonic Cleaning, the impurity such as the dust of removal CBN particle surface attachment and grease; At grinding wheel base body revolution cylindrical bound abrasive grains, smear pressure sensitive adhesive, colloid thickness is 0.6 ~ 1mm;
(2) the square polyethylene oxide thin film that 4 length of sides are greater than 5cm is got, the thickness of polyethylene oxide thin film and the consistency of thickness of pressure sensitive adhesive, laser-beam drilling machine carries out punching process, making a call to a diameter every 2mm is 10 object holes (pitch of holes can be selected according to the size of superabrasive particles, is advisable to be independent of each other between particle); This porous polyethylene alcohol film is layered on the matrix surface after process, and pressing makes pressure sensitive adhesive ooze out from through hole, because matrix is circular turned part, using 4 films, all being covered by base circumferential when sprawling;
(3) by after the surface of semi-finished of naturally unrestrained for CBN particle step (2) gained, semi-finished product are placed in the baking oven 0.5h of 80 DEG C, pressure sensitive adhesive is solidified, by CBN Particle consolidation on pressure sensitive adhesive; Banister brush is used to be swept gently by not bonded CBN particle;
(4) semi-finished product be cured are put into the water of 70 DEG C, polyethylene oxide thin film is hydrolyzed, after its complete hydrolysis (about 5min), semi-finished product are taken out, dry at 100-150 DEG C and get product 3.
To be arranged by finished product 3 surface uniform one deck powdered filler metal, then put into vacuum or controlled atmosphere furnace, be heated to solder and melt, after cooling, CBN abrasive grain is fixedly secured on 45 steel matrix surfaces by soldering bonding agent, forms CBN emery wheel.
embodiment 4
A kind of super hard abrasive ordered arrangement method, comprises the following steps:
(1) cut-off footpath is the circle 65 manganese steel matrix of 8cm, matrix is put into the alcoholic solution of 5% ~ 15%, with Ultrasonic Cleaning 3 ~ 5 minutes, is placed in ventilation and dries for subsequent use; Choose the diamond particles of 50-60 object electroplated diamond and diamond particles, be placed in acetone soln Ultrasonic Cleaning, the impurity such as the dust that removal electroplated diamond and diamond particle surfaces adhere to and grease; On the surface of circular abrasive disc bound abrasive grains, smear pressure sensitive adhesive, colloid thickness is 0.1 ~ 0.5mm;
(2) the foursquare water-soluble cellulose film that a length of side is greater than 8cm is got, the thickness of water-soluble cellulose film and the consistency of thickness of pressure sensitive adhesive, laser-beam drilling machine carries out punching process, making a call to a diameter every 10mm is 10 object holes (pitch of holes can be selected according to the size of superabrasive particles, is advisable to be independent of each other between particle); By the matrix surface after the process of the water-soluble cellulose film of this porous paving, and pressing makes pressure sensitive adhesive flow out from hole;
(3), after electroplated diamond and diamond particles being trickled down the surface of semi-finished of step (2) gained naturally, semi-finished product are placed in the baking oven 0.5h of 70 DEG C, pressure sensitive adhesive is solidified, electroplated diamond and diamond particles are cemented on pressure sensitive adhesive; Banister brush is used to be swept gently by not bonded abrasive grain;
(4) semi-finished product be cured are put into the water of 50 DEG C, water-soluble cellulose film is hydrolyzed, after its complete hydrolysis (about 7min), semi-finished product are taken out, dry at 100-150 DEG C and get product 4.
To be arranged by finished product 4 surface uniform one deck powdered filler metal, then put into vacuum or controlled atmosphere furnace, be heated to solder and melt, after cooling, abrasive grain is fixedly secured at 65 manganese steel matrix surfaces by soldering bonding agent, forms round grinding disc.
embodiment 5
A kind of super hard abrasive ordered arrangement method, comprises the following steps:
(1) cut-off footpath is the bowl-type 65 manganese steel matrix of 10cm, matrix is put into the alcoholic solution of 5% ~ 15%, with Ultrasonic Cleaning 3 ~ 5 minutes, is placed in ventilation and dries for subsequent use; Choose 280-300 object electroplating cubic boron nitride and polycrystalline cubic boron nitride particle, be placed in acetone soln Ultrasonic Cleaning, the impurity such as the dust of removal electroplating cubic boron nitride and polycrystalline cubic boron nitride surface attachment and grease; On the surface of bowl abrasive disc bound abrasive grains, smear pressure sensitive adhesive, colloid thickness is 0.2-0.41mm;
(2) the foursquare water soluble starch class film that a length of side is greater than 10cm is got, laser-beam drilling machine carries out punching process, making a call to a diameter every 0.2mm is 300 object holes (pitch of holes can be selected according to the size of superabrasive particles, is advisable to be independent of each other between particle); By the water soluble starch class film of this porous paving matrix surface after treatment, and pressing makes pressure sensitive adhesive ooze out from through hole;
(3) after electroplating cubic boron nitride and polycrystalline cubic boron nitride particle being trickled down the surface of semi-finished of step (2) gained naturally, semi-finished product are placed in the baking oven 0.5h of 80 DEG C, pressure sensitive adhesive is solidified, by electroplating cubic boron nitride and polycrystalline cubic boron nitride Particle consolidation on pressure sensitive adhesive; Banister brush is used to be swept gently by not bonded abrasive grain;
(4) semi-finished product be cured are put into the water of 80 DEG C, water soluble starch class film is hydrolyzed, after its complete hydrolysis (about 7min), takes out from water, dry at 100-150 DEG C and get product 5.
To be arranged by finished product 5 surface uniform one deck powdered filler metal, then put into vacuum or controlled atmosphere furnace, be heated to solder and melt, after cooling, abrasive material fixedly secures at 65 manganese steel matrix surfaces by soldering bonding agent, forms bowl-type grinding disc.
embodiment 6
A kind of super hard abrasive ordered arrangement method, comprises the following steps:
(1) cut-off footpath is the bowl-type 65 manganese steel matrix of 10cm, matrix is put into the alcoholic solution of 5% ~ 15%, with Ultrasonic Cleaning 3 ~ 5 minutes, is placed in ventilation and dries for subsequent use; Choose 80-90 object hard alloy particle, be placed in acetone soln Ultrasonic Cleaning, the impurity such as the dust of removal carbide surface attachment and grease; On the surface of bowl abrasive disc bound abrasive grains, smear pressure sensitive adhesive, colloid thickness is 0.5 ~ 1mm;
(2) the foursquare polyethylene oxide thin film that a length of side is greater than 10cm is got, laser-beam drilling machine carries out punching process, making a call to a diameter every 0.5mm is 80 object holes (pitch of holes can be selected according to the size of superabrasive particles, is advisable to be independent of each other between particle); By the polyethylene oxide thin film of this porous paving matrix surface after treatment, and pressing makes pressure sensitive adhesive ooze out from through hole;
(3) by after the surface of semi-finished of naturally unrestrained for hard alloy particle step (2) gained, semi-finished product are placed in the baking oven 0.5h of 60 DEG C, pressure sensitive adhesive is solidified, hard alloy particle is cemented on pressure sensitive adhesive; Banister brush is used to be swept gently by not bonded abrasive grain;
(4) semi-finished product be cured are put into the water of 20 DEG C, polyethylene oxide thin film is hydrolyzed, after its complete hydrolysis (about 14min), take out from water, dry at 100-150 DEG C and get product 6.
To be arranged by finished product 6 surface uniform one deck powdered filler metal, then put into vacuum or controlled atmosphere furnace, be heated to solder and melt, after cooling, hard alloy abradant fixedly secures at 65 manganese steel matrix surfaces by soldering bonding agent, forms bowl-type grinding disc.
comparative example
The difference of comparative example and embodiment 1 is: after matrix surface lays pressure sensitive adhesive, directly on pressure sensitive adhesive, dispenses abrasive grain and solder flux, then solidifies, dries and obtain sample 7, without the need to using polyvinyl alcohol film.
To be arranged by sample 7 surface uniform one deck powdered filler metal, then put into vacuum or controlled atmosphere furnace, be heated to solder and melt, after cooling, diamond abrasive fixedly secures at 65 manganese steel matrix surfaces by soldering bonding agent, forms bowl-type grinding disc.Through the abrasive grain skewness on the known grinding disc surface of observation, respective regions occurs that abrasive material is assembled, and the situation that abrasive material is sparse appears in some region.
performance test is tested
Respectively Performance Detection is carried out to the bowl-type grinding disc adopting the method for embodiment 1 and comparative example to prepare.
The bowl-type grinding disc of the 10cm using embodiment 1 and comparative example to prepare respectively is polished to 45 steel, and result is as follows
The grinding efficiency of the bowl-type grinding disc adopting the method for comparative example to prepare is 8 ~ 10g/min, and service life is the 6h that polishes continuously; The grinding efficiency of the bowl-type grinding disc adopting the method for embodiment 1 to prepare is 12 ~ 14g/min, and service life is the 8.5h that polishes continuously.Compared with comparative example, the grinding efficiency of the bowl-type grinding disc of embodiment 1 improves 40% ~ 50%, and service life improves 42%.