CN102896590B - Process for distributing grinding materials of grinding disc of ship body made of brass solder super-hard grinding material - Google Patents

Abstract

The invention discloses a process for arranging abrasives of brazed superhard abrasive ship hull grinding discs, which comprises the distribution of the outer end edge of the grinding disc, the inclined surface of the grinding disc and the flat top surface of the grinding disc, and the abrasive particle size of the outer end edge of the grinding disc. 16 to 80 mesh, the lateral distance between two adjacent abrasive grains is 1.6d to 4.5d, and the longitudinal distance between two adjacent abrasive grains is 1.5d to 5.5d, where d is the maximum particle size of the abrasive; the grinding The abrasive particle size of the cloth on the inclined surface of the disc is 25-100 mesh, the distance between adjacent abrasive grains in the radial direction of the grinding disc is 1.5d-4d, and the distance between two rows of abrasive grains distributed in the radial direction is 1.5d-6d; the grinding The abrasives of the flat cloth on the top of the disk are clustered abrasives, and a single clustered abrasive is densely packed with 1-115 abrasive grains, the grain size of the abrasive grains is 35-140 mesh, and the cluster area ranges from 3mm ² to 15mm ² . The grinding disc of the present invention has the characteristics of high grinding efficiency, light hand feeling, small vibration, no odor, long service life, beautiful appearance, etc. It perfectly replaces the traditional resin grinding wheel, and is the development direction of the hull grinding disc in the shipbuilding industry.

Description

Abrasive Arrangement Technology of Brazed Superabrasive Hull Grinding Disc

technical field

The invention belongs to the field of hull welding, welding scars and surface oxide skin grinding, and relates to a new process for arranging abrasives of brazed superhard abrasive hull grinding discs, which is suitable for removing rust, scars and splashes on the surface of large hulls. In addition, the present invention can also be applied to polishing non-metallic materials such as polysilicon and glass, and stone materials such as marble and granite.

Background technique

The shipbuilding industry is a modern comprehensive industry that provides technical equipment for water transportation, marine development, and national defense construction. It is also a labor-, capital-, and technology-intensive industry. my country has abundant labor resources and has a long coastline suitable for shipbuilding. The development of the shipbuilding industry has a comparative advantage. strong comparative advantage. At the same time, the rapid growth of my country's foreign trade has also provided better development opportunities for the shipbuilding industry. my country's shipbuilding industry is expected to become one of the most internationally competitive industries.

In 2008, unpredictable risks came one after another, and the US financial crisis quickly spread to the whole world. Affected by the US financial crisis, my country's shipping industry is facing a severe winter of financial turmoil. In addition, the continued high oil price and the rise in the price of raw materials such as steel constitute the main pressure on the operation of the industry. The trend of international industrial transfer has shown the huge opportunities of the shipbuilding industry in front of Chinese enterprises, but in the fierce market competition environment, how to avoid various risks and seize opportunities is a matter of fate for the development of enterprises.

In the shipbuilding process, one of the most critical tasks is to clean up the welding surface of the entire hull. Since the entire hull is mainly made of high-strength structural steel through special welding, the welding process reacts violently, resulting in various shapes of welds, individual weld spots, weld scars, and flux and melting point metal splashed out during the welding process. A large number of spatter points are formed, so many welding seams, long welding seams, dense welding spots, complex shapes and difficult grinding have become a difficulty in hull manufacturing. The conventional method at present is that the grinder manually grinds with a manual grinder equipped with a resin grinding wheel sheet. However, since the resin grinding wheel is made by using the principle of resin curing to consolidate superabrasives such as silicon carbide into a disc shape, its bonding strength is low, so during the grinding process, there will be problems such as easy consumption of the grinding disc, large sparks, and odor Large, dusty and other shortcomings. This is because the high-strength weld of the resin grinding wheel is subjected to excessive impact during the grinding process, causing the abrasive to fall off while grinding, and because the exposed height of the abrasive is low and the temperature of the grinding surface is high, the resin becomes soft and burns. Melt and volatilize, emit poisonous and irritating odor. In addition, due to the low abrasive exposure, the sharpness of the grinding disc is not ideal, and the grinding efficiency is slow, so that the grinding workload of the hull accounts for about one-third of the overall manufacturing workload of the ship.

Due to the above shortcomings and the cost control requirements of the shipbuilding industry, it is necessary to develop a new type of grinding disc to replace the traditional grinding disc in order to achieve high grinding efficiency, long life, and no pollution.

The consolidation technology of superabrasives currently has three main bonding methods: electroplating, sintering, and brazing. Through the comparison of the above three combination methods, it is found that the sintering technology and the electroplating technology have a low exposure height of the abrasive, the matrix has low holding strength on the abrasive, the sharpness is not ideal, and the chip removal effect is poor. It has been proved that it is difficult to grind high-strength welds. Require. The brazing technology is to use the melting of solder to weld the superhard abrasive and the substrate together. The chemical metallurgical combination of the solder and the abrasive has occurred before, and the abrasive welding strength is high, so the abrasive is exposed high and the grinding is sharp. It is an ideal production. Technique for grinding weld seams. Compared with other superabrasives, diamond is currently the hardest substance; it has good abrasiveness; its specific heat is small and its thermal conductivity is high, so it is easy to heat up and dissipate heat, and diamond is an ideal material for grinding metals. Compared with traditional resin grinding wheels, brazed diamond tools basically do not shed abrasives during use, and there is no melting and volatilization of resin, so they are safe in use and have no irritating odor, and are more environmentally friendly. This is consistent with the current development concept of low carbon and environmental protection.

At present, using brazing technology to weld superabrasives on steel substrates to prepare brazed superabrasive tools has been partially used in actual production, such as high-speed rail Borg plate grinding wheels, brazed diamond drills, etc. However, there are no relevant reports and patents for diamond tools for professional grinding of hull welds. There are few types of existing brazed diamond grinding tools, and they are mostly used for grinding stone materials. The manufacturing process of the tools, the shape of the substrate, and the grinding equipment are quite different, so they cannot be applied to the grinding of the hull.

Moreover, most conventional brazed grinding discs are made by arranging a certain amount of diamonds randomly on the surface of the disc substrate, and then brazing at a high temperature. Due to the limitations of the process, it is difficult to achieve a uniform arrangement of abrasives on the surface of the grinding disc, and the landform has not been optimized according to the actual shape of the grinding disc, which wastes the amount of abrasives and restricts the grinding efficiency and life of the grinding disc, resulting in brazing Welding discs have not yet been revolutionized in the field of steel grinding.

Abrasive arrangement technology has been partially applied in sintering, brazing, and electroplating products, and the technologies actually used in production include hole template method, vacuum adsorption method and cluster arrangement method. Among them, Dr. Song Jianmin (U.S. Patent 6039641), a Chinese grinding wheel company in Taiwan, my country, invented the hole template method, which uses a hole template made of special materials to distribute abrasives in an orderly manner. The principle is to open a sequence of small holes on the substrate, each hole A diamond is accommodated, and then the abrasives arranged in sequence are adhered to the surface of the base body by a related process. This method is mostly used in the preparation of sintered diamond tools, such as saw blades, but currently it can only be used for flat surfaces and a small number of simple geometric shapes. The vacuum adsorption method invented by Chengdu Zhonghao Superhard Material Co., Ltd. (200820061656.4) is to use the principle of vacuum to make a template with small holes have adsorption force to absorb diamond, and then place it on the surface of the substrate. This method is similar to the hole template. Similar to the above method, only some relatively simple geometric surfaces can be prepared, and the above two methods have not yet achieved orderly distribution of abrasives according to the performance of the workpiece. The third cluster arrangement method refers to using a template with a certain geometric shape, so that the diamond abrasive is distributed in the gaps of the template, and the template can be sprinkled after the layout is completed. This method is more common in electroplated diamond products. Because the template is relatively simple, it is widely used in electroplating products. However, this method can only achieve orderly macroscopic shapes, and the arrangement of diamond abrasives in each gap is still disordered. It cannot be arranged in an orderly manner, and it is difficult to effectively take advantage of the advantages of diamond abrasives.

Contents of the invention

In view of the above problems, the present invention provides an abrasive arrangement process for brazed superabrasive hull grinding discs. Its main principle is to optimize and calculate the arrangement of abrasives on the surface of the grinding disc according to the specific requirements of hull grinding, using a manual grinder for grinding as a complete set, combined with the brazing process of brazing superabrasive tools. Through the optimization design of the above parameters, the most suitable brazed superabrasive grinding disc abrasive arrangement and matching abrasive selection are obtained.

Technical scheme of the present invention is as follows:

A process for arranging abrasives of brazed superabrasive hull grinding discs, including cloth for the outer edge of the grinding disc, cloth for the inclined surface of the grinding disc, and plane cloth for the top of the grinding disc, characterized in that:

The abrasive particle size of the cloth at the outer edge of the grinding disc is 16-80 mesh, the lateral distance between two adjacent abrasive grains is 1.6d-4.5d, and the longitudinal distance between two adjacent abrasive grains is 1.5d-5.5d, wherein d is the maximum particle size of the abrasive;

The abrasive particle size of the cloth on the inclined surface of the grinding disc is 25-100 meshes, the distance between adjacent abrasive grains in the radial direction of the grinding disc is 1.5d-4d, and the distance between two rows of abrasive grains distributed in the radial direction is 1.5d-6d;

The abrasive material of the plane cloth on the top of the grinding disc is a cluster abrasive material, and a single cluster abrasive material is densely arranged with 1-115 abrasive grains, the grain size of the abrasive grains is 35-140 mesh, and the cluster area ranges from 3 mm ² to 15 mm ² .

The outer diameter of the grinding disc ranges from 60 mm to 250 mm, and the thickness of the substrate is 0.1 mm to 5 mm.

The abrasive grains on the outer edge of the grinding disc are high-grade abrasives for drilling and cutting, the lateral distance between two adjacent abrasive grains is 2.5d, the longitudinal distance between two adjacent abrasive grains is 3d, and the grain size of the abrasive grains is 30 mesh to 40 mesh. head.

The abrasive used for grinding the cloth on the inclined surface of the disc is a high-grade grinding abrasive, and the particle size of the abrasive is 35 mesh to 50 mesh.

The geometrical shape of the plane tufted abrasives at the top of the grinding disc is circular, triangular, rectangular or regular polygonal.

The trajectory formed by each of the clustered abrasives arranged on the upper end of the grinding disc is a straight line, an arc, an involute or a parabolic trajectory, and the distance between two adjacent trajectory lines is 3 mm to 25 mm.

The grinding disc: the abrasives arranged on the top plane are medium-grade abrasives for grinding, and the particle size of the abrasives is 50 mesh to 80 mesh.

Through the above creative invention design, the best abrasive landform optimization effect can be obtained, and the brazing superhard tool technology can be used to weld the abrasive to the designed new type of grinding disc substrate through the abrasive abrasive arrangement method, and then it can be prepared. New grinding disc for hull grinding. The landform optimization designed in the present invention creatively combines the orderly arrangement of plane single abrasives with the arrangement of clustered abrasives, which solves the problem that the traditional grinding head arrangement method is difficult to optimize the landform according to the working conditions and use parameters, and The orderly distribution of regional abrasives is realized. In addition, the abrasives used in the present invention can be distributed according to the requirements of use, so that the use of abrasives is more reasonable and economical.

The grinding disc of the present invention has the characteristics of high grinding efficiency, light hand feeling, small vibration, no odor, long life, beautiful appearance, etc., and it perfectly replaces the traditional resin grinding wheel, and is the development direction of the hull grinding disc in the shipbuilding industry, and It can also be better applied to other non-metal fields such as ceramics, stone materials, polysilicon, etc., and has great market potential.

Description of drawings

Figure 1 The base structure of the brazed hull grinding disc;

Fig. 2 Optimization of the abrasive topography on the outer edge of the brazed hull grinding disc;

Figure 3 The spacing of the smallest unit of abrasive grains;

Fig. 4 Optimizing the abrasive landform on the surface of the brazed hull grinding disc;

Figure 5 The layout scheme of brazed diamond grinding disc with an outer diameter of 100;

Figure 6. Distributing scheme of brazed diamond multifunctional grinding disc with an outer diameter of 125.

Detailed ways

Below in conjunction with accompanying drawing, the present invention is described in detail:

The hull grinding disc is installed on the manual grinder, and its shape is disc-shaped, with a hole in the center, through which it is positioned on the grinding wheel and fixed. A certain arrangement of abrasive materials is arranged on the top surface of the disc, which is fixed by solder brazing. The bottom is concave for chip removal and positioning on the grinder. The shape of the base of the grinding disc is shown in Figure 1. The base body of the grinding disc is disc-shaped, and the top of the disc is not a plane, but has a bevel on its edge with a width of about 5mm. The width of the top plane of the disc substrate is determined according to the overall outer diameter of the disc, and the plane width should account for 1/3~1/2 of the radius of the disc. The outer end of the disc substrate is rounded. The fillet size matches the substrate thickness. The size range of the grinding disc applicable to the present invention is: the outer diameter is 60 mm to 250 mm, and the thickness of the substrate is 0.1 mm to 5.0 mm.

(1) Topography optimization of the abrasive material arrangement at the outer end of the grinding disc

During the use of the grinding disc, the outer end of the grinding disc is pushed forward while rotating at a high speed. Therefore, the force on the outermost end of the grinding disc is the largest, which requires a higher brazing strength of the abrasive material, a greater load, and the movement of the outer end of the grinding disc. It can be regarded as a movement of grinding while cutting. Therefore, in order to reduce the load on the outer end, the density of the abrasive at the outer end of the grinding disc should be as much as possible while ensuring the space for chip removal, so the cloth at the outer end of the grinding disc can be densely packed. in order, as shown in Figure 2.

According to the analysis of the load and the movement track of the grinding disc, the abrasives here are large-grained and high-grade abrasives for drilling and cutting. The abrasive particle size ranges from 16 mesh to 80 mesh, and the particle size of 30 mesh to 40 mesh is optimized through experiments.

The parameters of the dense packing of abrasive grains are designed as follows: when the abrasive grains are arranged, four similar abrasive grains can be regarded as a unit, as shown in Figure 3, the diagonal lines L1 and L2 can be seen from the horizontal and vertical spacing of the abrasive grains . Assuming that the maximum particle size of the abrasive is d, the lateral distance between two adjacent abrasive grains is 1.6d to 4.5d, the optimal choice is 2.5d, and the longitudinal distance is 1.5d to 5.5d, and the optimal choice is 3d.

(2) Landform optimization of the abrasive material arrangement on the beveled surface of the grinding disc

Since the load on the inclined surface of the grinding disc is smaller than that of the outer edge, it still needs to be used for grinding and chip removal. The requirements for this inclined surface are high grinding efficiency, long grinding life, good heat dissipation effect, and good chip removal effect. Due to the high-speed rotation of the grinding disc, in order to ensure the minimum vibration and the highest grinding efficiency, the number of abrasive grains participating in grinding at the same time in the direction of rotation is consistent to ensure the stability of grinding. In order to achieve the above requirements, the method of orderly arranging abrasives is adopted. The abrasive grains are generally arranged radially along the grinding disc. The spacing range is 1.5d～6d.

According to the analysis of the load and the movement track of the grinding disc, the abrasives here are medium-sized and high-grade grinding abrasives. The abrasive particle size ranges from 25 mesh to 100 mesh, and the particle size of 35 mesh to 50 mesh is optimized through experiments.

(3) Landform optimization of the plane abrasive arrangement on the top of the grinding disc

The principle of top plane landform optimization is the best result obtained by creative landform optimization according to the hull grinding requirements, the shape of the weld seam to be ground, the speed of the grinder and other working conditions. Since the movement of the grinding disc on the hull is actually a combination of cutting and grinding, the surface to be ground still has a certain accuracy requirement. Therefore, in order to improve the grinding accuracy and chip removal effect, the arrangement of abrasive materials on the top of the grinding disc is shown in Figure 3.

Clusters of abrasives are arranged in the shape of turbines on the top plane, and no abrasives are arranged on other parts. The geometric shapes of a single cluster can be circles, triangles, rectangles, regular polygons and other complex geometric shapes. A single cluster of abrasives is densely arranged, the number of abrasive grains ranges from 1 to 115, and the cluster area ranges from 3mm ² to 15mm ² .

The locus L3 formed by each tufted abrasive can be a straight line, an arc, an involute, a parabola, and the like. The distance between two adjacent trajectory lines ranges from 3mm to 25mm.

According to the analysis of the load and the movement track of the grinding disc, the abrasives here are medium-grade and finer-grained grinding abrasives. The abrasive grain size ranges from 35 mesh to 140 mesh, and the particle size of 50 mesh to 80 mesh is optimized through experiments.

The grade classification of abrasives involved in the present invention is the same as JB/GQ·F6010-86 (synthetic diamond, cubic boron nitride product quality grading standard)

Embodiment one

The orderly arrangement of abrasives for a new hull weld grinding disc is designed as follows:

Taking the brazed diamond hull grinding disc with an outer diameter of 100 mm as an example, as shown in Figure 5, its orderly arrangement scheme is:

① The outer edge of the grinding disc is made of diamond abrasive with a particle size of 30-35 mesh. The horizontal distance between two adjacent abrasive grains is 1.2mm, and the vertical distance is 1.5mm.

② The upper inclined surface of the grinding disc is made of diamond abrasive, with a particle size of 35-40 meshes, the lateral distance between two abrasive grains along the radial direction is 1.0mm, and the distance between two rows of abrasive grains distributed along the radial direction is 1.8mm.

③ The flat abrasives on the upper end of the grinding disc are arranged in circular clusters with a cluster diameter of 3 mm, and 10 to 15 diamonds of 50 to 60 mesh are arranged in each cluster area, and the trajectory line is an arc with a radius of 115.

The brazed diamond hull grinding disc produced by this method has the characteristics of high grinding efficiency, light hand feeling, small vibration, no smell, long life, beautiful appearance, etc., and different grades of abrasives are selected according to the actual situation, which optimizes the cost and is more economical. It perfectly replaces the traditional resin grinding wheel. It is the development direction of the hull grinding disc in the shipbuilding industry. It is also suitable for ceramics, stone, polysilicon and other non-metallic fields. It has great market potential. .

Embodiment two

A kind of grinding disc and abrasive material arrangement scheme that can be applied to steel grinding and non-metallic grinding such as stone and polysilicon is designed as follows:

Take a brazed diamond grinding disc with an outer diameter of 125mm as an example, as shown in Figure 6, its orderly arrangement scheme is:

① The outer edge of the grinding disc is made of diamond abrasive, with a particle size of 35-40 mesh. The horizontal distance between two adjacent abrasive grains is 1.5mm, and the vertical distance is 1.5mm.

② The upper inclined surface of the grinding disc is made of diamond abrasive, with a particle size of 45 to 50 meshes. The lateral distance between two abrasive grains along the radial direction is 1.5 mm, and the distance between two rows of abrasive grains distributed along the radial direction is 2.0 mm.

③ The surface abrasives on the upper end of the grinding disc are arranged in regular triangle clusters, the cluster area is 4.5mm ² , and each cluster area is arranged with 20-25 diamonds of 60-70 mesh. .

The multifunctional brazed diamond hull grinding disc produced by this method can not only be used for grinding metals such as steel, but also be suitable for other non-metal fields such as ceramics, stone materials, polysilicon, etc., and has great market potential.

Claims (7)

1. A brazing superabrasive hull grinding disc abrasive material arrangement process, comprising the outer end edge cloth of the grinding disc, the inclined surface cloth of the grinding disc and the plane cloth at the top of the grinding disc, characterized in that: the outer end edge cloth of the grinding disc The abrasive particle size is 16 ~ 80 mesh, the lateral distance between two adjacent abrasive grains is 1. 6d ~ 4. 5d, and the longitudinal distance between two adjacent abrasive grains is 1. 5d ~ 5. 5d, where d is the maximum Particle size; The abrasive particle size of the inclined surface of the grinding disc is 25-100 mesh, the distance between two adjacent abrasive grains along the radial direction of the grinding disc is 1.5d-4d, and the distance between two rows of abrasive grains distributed radially is 1.5d. 5d ~ 6d; The abrasive material of the plane cloth on the top of the grinding disc is a cluster abrasive material, and a single cluster abrasive material is densely packed with 1-115 abrasive grains, the grain size of the abrasive grains is 35-140 mesh, and the cluster area ranges from 3 mm ² to 15 mm ² . 2. The brazing superabrasive hull grinding disc abrasive arrangement process according to claim 1, characterized in that: the outer diameter of the grinding disc ranges from 60mm to 250mm, and the substrate thickness is 0.1mm to 5mm. 3. The brazed superabrasive hull grinding disc abrasive material arrangement process according to claim 1 is characterized in that: the abrasive grains on the outer edge of the grinding disc are high-grade abrasives for drilling and cutting, and two adjacent abrasive grains The horizontal distance between the grains is 2.5d, the vertical distance between two adjacent abrasive grains is 3d, and the grain size of the abrasive grains is 30 mesh to 40 mesh. 4. The brazing superabrasive hull grinding disc abrasive material arrangement process according to claim 1 is characterized in that: the abrasive material of the inclined surface cloth of the grinding disc is a high-grade grinding abrasive, and the particle size of the abrasive material is 35 orders ~ 50 orders . 5 . The process of arranging abrasive materials for brazed superabrasive hull grinding discs according to claim 1 , characterized in that: the geometric shape of the clustered abrasives on the top of the grinding disc is circular, triangular, rectangular or regular polygonal. 6. The brazing superabrasive hull grinding disc abrasive arrangement process according to claim 5, characterized in that: the track formed by each cluster of abrasives arranged on the top of the grinding disc is: a straight line, an arc, Involute or parabolic trajectory, the distance between two adjacent trajectory lines ranges from 3mm to 25mm. 7. The brazed superabrasive ship hull grinding disc abrasive material arrangement process according to claim 1, characterized in that: the abrasive material arranged on the top plane of the grinding disc is a medium-grade grinding abrasive, and the particle size of the abrasive material is 50 Mesh ~ 80 mesh.