CN104669129A - 一种陶瓷镀钛cbn砂轮及其制备方法 - Google Patents
一种陶瓷镀钛cbn砂轮及其制备方法 Download PDFInfo
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- 229910052582 BN Inorganic materials 0.000 title abstract description 3
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 title abstract description 3
- 229920001353 Dextrin Polymers 0.000 claims abstract description 22
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 15
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- FYGDTMLNYKFZSV-MRCIVHHJSA-N dextrin Chemical compound O[C@@H]1[C@@H](O)[C@H](O)[C@@H](CO)OC1O[C@@H]1[C@@H](CO)OC(O[C@@H]2[C@H](O[C@H](O)[C@H](O)[C@H]2O)CO)[C@H](O)[C@H]1O FYGDTMLNYKFZSV-MRCIVHHJSA-N 0.000 claims description 10
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Abstract
本发明属于超硬材料生产技术领域，涉及CBN砂轮生产技术领域，具体涉及一种陶瓷镀钛CBN砂轮及其制备方法。该砂轮工作层制备原料以重量百分比计，镀钛CBN磨料60～75%，陶瓷结合剂18～25%，石墨粉3~10%，糊精粉2～4%，湿润剂糊精液2~4%。其制备方法包括混料、成型、干燥、烧结等步骤。本发明主要改进点在于：采用了镀钛CBN磨料，提高了结合剂与磨粒的结合强度；石墨粉的加入，使得CBN砂轮使用过程中，石墨能与砂轮中气孔中的冷却液相结合，有助于从砂轮表面和被加工工件上除去磨削碎屑，所加工工件粗糙好，修整周期大幅提高。
Description
技术领域
本发明属于超硬材料生产技术领域，涉及CBN砂轮生产技术领域，具体涉及一种陶瓷镀钛CBN砂轮及其制备方法。
背景技术
CBN磨具是指以CBN（立方氮化硼）磨料为原料，以金属粉、树脂粉、陶瓷或电镀金属作结合剂，所制成的各种形状的加工制品。CBN砂轮作为CBN磨具中的一种，是工件产品的磨削、抛光、研磨等加工环节的常用工具。
CBN磨具结构一般由工作层、基体、过渡层三部分组成，其中基体是由铝、钢或电木加工而成，起支承工作层和装卡磨具的作用；过渡层又称非CBN层，由结合剂、金属粉和填料组成，是将CBN层牢固地连接在基体上的部分；工作层又称CBN层，由磨料、结合剂和填料组成，是磨具的工作部分，也是最为关键的核心部分。
根据加工工艺和所用结合剂的差异，一般将CBN砂轮分为四类：电镀CBN砂轮、烧结CBN砂轮、树脂CBN砂轮和陶瓷结合剂CBN砂轮，其中陶瓷结合剂的CBN砂轮因其磨削力强、高速加工不烧伤工件、可修正和耐用等优点，是目前最为理想的高速、高效和高精度的磨削工具。
现有技术中，针对CBN砂轮性能改进多是从结合剂改进入手，虽然能部分提高CBN砂轮性能，但是提升幅度有限，因而仍需探索新的CBN砂轮改进方向。
发明内容
本发明目的在于提供一种陶瓷结合剂镀钛CBN砂轮及其制备方法，本发明从改进磨料和增加特殊填料（即用石墨粉做固体润滑剂）入手，较好地改进了CBN砂轮的各项性能，尤其是砂轮寿命有了大幅度提高。
对本发明所采取的详细技术方案介绍如下。
一种陶瓷镀钛CBN砂轮，其工作层制备原料以重量百分比计，镀钛CBN磨料60～75%，陶瓷结合剂18～25%，石墨粉3~10%，糊精粉2～4%，湿润剂糊精液2~4%；
所述陶瓷结合剂配方为：按重量百分比计，50.61%的 SiO2； 9.65%的Al2O3； 2.50%的ZrO2； 1.52%的TiO2； 20.55%的B2O3； 9.63%的Na2O；1.78%的Li2O； 1.58%的CaO； 2.18%的MnO2。
所述陶瓷镀钛CBN砂轮，其工作层制备原料较佳配方为：镀钛CBN磨料71%，陶瓷结合剂18.3%，石墨粉4.2%，糊精粉2.5%，湿润剂糊精液4%。
所述陶瓷镀钛CBN砂轮的制备方法，包括以下步骤：
（1）混料，按比例称取各物料后，首先将镀钛CBN磨料与湿润剂糊精液搅拌混合研磨均匀，使镀钛CBN磨料得到充分润湿；然后加入陶瓷结合剂、石墨粉和糊精粉充分搅拌、混合均匀；
（2）成型，将步骤（1）中混料后物料在模具中压制成型，成型后CBN砂轮规格优选为：外径×高度×内径=45×33×35（规格单位，cm），密度为2.5～2.2g/cm3；
（3）干燥，将步骤（2）成型的CBN砂轮在140℃条件下保温1~3h，自由冷却至室温；保温时优选在烘箱中进行干燥，升温速率控制在20℃/h，从室温升至140℃，保温2h；
（4）烧结，将步骤（3）中干燥后的CBN砂轮进行烧结，烧结温度为810~890℃，保温1~3h，保温结束后自由冷却至室温即可按常规方法增加过渡层、基体等部分制备本发明所述陶瓷镀钛CBN砂轮；烧结时，优选在高温炉中进行烧结，升温速率控制在60℃/h，从室温升至850℃，保温2h。
本发明所提供的陶瓷镀钛CBN砂轮，相比现有砂轮，本发明的主要改进点在于：第一，采用了镀钛CBN磨料，从而改善了烧结过程中CBN磨粒与陶瓷结合剂的润湿性，提高了结合剂与磨粒的结合强度，并减少了磨削过程中由于粘结剂的破坏而使磨粒过早脱落的缺陷；第二，陶瓷镀钛CBN砂轮结构中，固体润滑剂——石墨粉的加入，使得CBN砂轮使用过程中，尤其是湿磨过程中，石墨能与砂轮中气孔中的冷却液相结合，有助于从砂轮表面和被加工工件上除去磨削碎屑，所加工工件粗糙好，修整周期大幅提高。因而总体而言，本发明所提供的陶瓷镀钛CBN砂轮的磨削性、耐磨性等性能都得到了较好的改善和提高。
具体实施方式
下面结合实施例对本发明做进一步的解释说明。
实施例1
本实施例所提供的陶瓷镀钛CBN砂轮，其工作层制备原料以重量百分比计，镀钛CBN磨料71%，陶瓷结合剂18.3 %，石墨粉4.2%，糊精粉2.5%，湿润剂糊精液4%。
所述陶瓷结合剂配方为：按重量百分比计，50.61%的 SiO2； 9.65%的Al2O3；2.50%的ZrO2； 1.52%的TiO2； 20.55%的B2O3； 9.63%的Na2O；1.78%的Li2O； 1.58%的CaO； 2.18%的MnO2。
所述陶瓷镀钛CBN砂轮的制备方法，包括以下步骤：
（1）混料，按比例称取各物料后，首先将镀钛CBN磨料与湿润剂糊精液搅拌混合研磨均匀，根据物料多少来具体确定具体研磨搅拌时间，一般在10~30min，但需确保镀钛CBN磨料得到充分润湿；然后加入陶瓷结合剂、石墨粉和糊精粉充分搅拌、混合均匀。
（2）成型，将步骤（1）中混料后物料在模具中压制成型，成型后CBN砂轮密度在2.5～2.2g/cm3，砂轮规格为，外径×高度×内径=45×33×35（规格单位，cm）
（3）干燥，将步骤（2）成型的CBN砂轮在烘箱中进行干燥，升温速率控制在20℃/h，从室温升至140℃，保温2h，然后自由冷却至室温；
（4）烧结，将步骤（3）中干燥后的CBN砂轮在高温炉中进行烧结，升温速率控制在60℃/h，从室温升至850℃，保温2h，保温结束后自由冷却至室温即可。
本实施例所制备的陶瓷镀钛CBN砂轮可作为空调压缩机气缸内圆磨砂轮使用。
为验证本发明所提供的陶瓷镀钛CBN砂轮的具体性能改善情况，发明人按现有配方采用与本发明相同的制备方法制备了CBN砂轮，具体配方对照如下表所示。
备注：现有配方中的陶瓷结合剂组成同本实施例。
需要说明的是，上述CBN磨料原料均由郑州沈发金刚石有限公司新郑分公司提供。
以上述配方为基础，分别制备了陶瓷镀钛CBN砂轮（即本实施例）和现有的常用CBN砂轮样品，然后分别作为某空调生产厂家的空调压缩机气缸内圆磨砂轮使用，具体性能测试结果如下表所示。
从上述实际使用性能结果可以看出，本发明所提供的陶瓷镀钛CBN砂轮不仅能满足相应的技术要求，而且相较于现有技术所制备的砂轮，其粗糙度有较好降低，而平均寿命有大幅度提高，体现出较好的技术效果，能够一定程度降低企业的生产成本，因而具有较好的推广应用价值。
实施例2
本实施例所提供的陶瓷镀钛CBN砂轮，其工作层制备原料以重量百分比计，镀钛CBN磨料60%，陶瓷结合剂25 %，石墨粉10%，糊精粉2.5%，湿润剂糊精液2.5%，成型密度2.32g/cm3 。陶瓷结合剂同实施例1。
制备方法及所制备的陶瓷镀钛CBN砂轮规格同实施例1，烧结温度为810℃，保温3h。
实施例3
本实施例所提供的陶瓷镀钛CBN砂轮，其工作层制备原料以重量百分比计，镀钛CBN磨料75%，陶瓷结合剂18%，石墨粉3%，糊精粉2%，湿润剂糊精液2%，成型密度2.26g/cm3 。陶瓷结合剂同实施例1。
制备方法及所制备的陶瓷镀钛CBN砂轮规格同实施例1，烧结温度为890℃，保温1h。
需要说明的是，实施例1是本发明的较佳实施例，在实施例1基础上，对相关的物料配比进行适当修改即可得到本发明的完整的权利要求，为简略期间，不再过于重复描述相关实施例，但在本发明构思基础之上所作修改均应在本发明所请求权利要求保护范围之内。
Claims (5)
1.一种陶瓷镀钛CBN砂轮，其特征在于，该砂轮工作层制备原料以重量百分比计为：镀钛CBN磨料60～75%，陶瓷结合剂18～25%，石墨粉3~10%，糊精粉2～4%，湿润剂糊精液2~4%；
所述陶瓷结合剂按重量百分比计，配方为：50.61%的SiO2； 9.65%的Al2O3； 2.50%的ZrO2； 1.52%的TiO2； 20.55%的B2O3； 9.63%的Na2O；1.78%的Li2O； 1.58%的CaO； 2.18%的MnO2。
2.如权利要求1所述陶瓷镀钛CBN砂轮，其特征在于，该砂轮工作层制备原料以重量百分比计为：镀钛CBN磨料71%，陶瓷结合剂18.3%，石墨粉4.2%，糊精粉2.5%，湿润剂糊精液4%。
3.权利要求1或2所述陶瓷镀钛CBN砂轮的制备方法，其特征在于，该方法包括以下步骤：
（1）混料：按比例称取各物料后，首先将镀钛CBN磨料与湿润剂糊精液搅拌混合研磨均匀，使镀钛CBN磨料得到充分润湿；然后加入陶瓷结合剂、石墨粉和糊精粉充分搅拌、混合均匀；
（2）成型：将步骤（1）中混料后物料在模具中压制成型；
（3）干燥：将步骤（2）成型的CBN砂轮在140℃条件下保温1~3h，自由冷却至室温；
（4）烧结：将步骤（3）中干燥后的CBN砂轮进行烧结，烧结温度为810~890℃，保温1~3h，保温结束后自由冷却至室温即可按常规方法制备本发明所述的陶瓷镀钛CBN砂轮。
4.如权利要求3所述陶瓷镀钛CBN砂轮的制备方法，其特征在于，步骤（4）所述烧结，烧结温度为850℃，保温2h。
5.如权利要求3所述陶瓷镀钛CBN砂轮的制备方法，其特征在于，步骤（2）中，成型后CBN砂轮规格为：外径×高度×内径=45×33×35，规格单位为cm，密度为2.5～2.2g/cm3。
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