CN103492126B - 磨削方法和磨料制品 - Google Patents
磨削方法和磨料制品 Download PDFInfo
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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
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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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B5/00—Machines or devices designed for grinding surfaces of revolution on work, including those which also grind adjacent plane surfaces; Accessories therefor
- B24B5/18—Machines or devices designed for grinding surfaces of revolution on work, including those which also grind adjacent plane surfaces; Accessories therefor involving centreless means for supporting, guiding, floating or rotating work
- B24B5/22—Machines or devices designed for grinding surfaces of revolution on work, including those which also grind adjacent plane surfaces; Accessories therefor involving centreless means for supporting, guiding, floating or rotating work for grinding cylindrical surfaces, e.g. on bolts
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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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- B24D3/04—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 inorganic
- B24D3/06—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 inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
- B24D3/10—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 inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements for porous or cellular structure, e.g. for use with diamonds as abrasives
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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
- B24D3/344—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 the bonding agent being organic
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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
本发明涉及一种适于磨削聚晶金刚石复合片的树脂结合剂磨轮。所述树脂结合剂磨轮使用以体积百分比计高浓度的金刚石,以及硬填料粒子和软填料粒子的混合物,以有效磨削聚晶金刚石复合片,并同时消除或减少连续修整树脂结合剂磨轮的外表面的需要。
Description
背景技术
聚晶金刚石复合片(PDC)包括结合至碳化钨基材的聚晶金刚石层。聚晶金刚石层提供高硬度和耐磨性,而碳化钨层改进复合材料的韧性。PDC通常用作用于钻孔至地表以获得天然资源的勘探钻头的切削刀头。
具有金刚石磨粒的树脂结合剂磨轮可用于将PDC研磨和精整至其最终指定尺寸。由于两个相异硬度的材料的界面,PDC极难以研磨。由于聚晶金刚石层的极高硬度,在树脂结合剂磨轮中的金刚石磨料极快钝化。另外,碳化钨基材承载磨轮,从而降低了研磨轮进一步磨削聚晶金刚石层的能力。因此,树脂结合剂磨轮必须用碳化硅石不时地修整,以降低或消除磨轮的碳化钨负载,并暴露新的金刚石切削点。
发明内容
为了改进使用树脂结合剂磨轮所进行的PCD的磨削,希望减少或消除用碳化硅石不时修整树脂结合剂磨轮的需要。减少或消除修整树脂结合剂磨轮的需要而同时仍然获得在PDC的聚晶金刚石层上的可接受的切削速率会改进磨削操作的安全性和效率。如果树脂结合剂磨轮在精整磨削PDC时不需要不时的修整,则磨***作者可运行不止一个磨床。
因此,在一方面,本发明在于一种磨削方法,其包括:使聚晶金刚石复合片与磨轮接触;所述磨轮包括金刚石、树脂粘结剂,以及硬填料粒子和软填料粒子的混合物;且其中基于体积计所述金刚石为175至225的金刚石浓度,基于体积计所述树脂粘结剂为30%至40%,混合物中硬填料粒子与软填料粒子的比例为85:15至15:85,且基于体积计硬填料粒子和软填料粒子的混合物为5%至30%。
在另一方面,本发明在于一种磨料制品,其包括:磨轮,所述磨轮包括金刚石、树脂粘结剂,以及硬填料粒子和软填料粒子的混合物;且其中基于体积计所述金刚石为175至225的金刚石浓度,基于体积计所述树脂粘结剂包含30%至40%,混合物中硬填料粒子与软填料粒子的比例为85:15至15:85,且基于体积计硬填料粒子和软填料粒子的混合物包含5%至30%。
附图说明
在说明书和附图中重复使用的参考标号旨在表示本发明相同或类似的特征或元件。
图1显示了使用操作用以将PDC磨削至其最终直径的树脂结合剂磨轮的无心磨削过程。
图2显示了本发明的树脂结合剂磨轮相对于具有不同修整频率的对比树脂结合剂磨轮的磨削结果。
定义
如本文所用,词语“包含”、“具有”和“包括”的变型在法律上是等同的且开放式的。因此,除了列举的元件、功能、步骤或限制之外,还可以有其他未列举的元件、功能、步骤或限制。
具体实施方式
参见图1,示出了无心磨机10。无心磨机包括树脂结合剂磨轮12、调节轮14和用于保持两个轮之间的PDC 18的支承件16。PDC包括结合至碳化钨基材22的聚晶金刚石层20。PDC行进通过两个轮之间的磨削界面的速度受控于树脂结合剂磨轮12的轴线与调节轮14的轴线之间的螺旋角α以及调节轮的旋转速度。现有技术的树脂结合剂磨轮需要使用碳化硅石不时地修整外表面26,以保持树脂结合剂磨轮磨削聚晶金刚石层的能力。
为了减少或消除研磨PDC时外表面的修整,希望使树脂结合剂磨轮表现类似于陶瓷结合的磨轮。这种效果可通过如下方式实现:使用极高的金刚石浓度,并同时包括硬填料粒子和软填料粒子两者以控制树脂结合剂研磨轮的破损速率。这种树脂结合剂磨轮将确保暴露轮中的新的金刚石粒子,并同时减少或消除使用过程中外表面的钝化(glazing)。高浓度金刚石部分可为磨轮的外环面、磨轮的分段部分或整个磨轮。
用于研磨轮的合适的金刚石包括例如天然金刚石、合成金刚石、树脂结合剂金刚石、金属结合剂金刚石、金属磨料粉末、前述的树脂结合剂或陶瓷结合剂金刚石附聚物,以及前述所有的组合。为了获得树脂结合剂研磨轮的所需硬度,金刚石浓度极高。特别地,作为磨轮的高浓度金刚石部分的总体积的体积百分比的金刚石浓度为175至225或180至200。小于175的金刚石浓度不会减少修整的需要,大于225的浓度变得难以以足够的完整性结合。可使用或不使用金属(如镍或铜)涂布金刚石。如果使用金属涂布的金刚石,则涂层重量百分比应小于40%,或小于或等于30%。过量的涂布量会将金刚石浓度降低至过低的水平,不会在使用过程中产生减少的树脂结合剂磨轮的修整。如果不凝聚,则金刚石的尺寸应在60/80目尺寸至200/230目尺寸之间。在这些极限以上和以下的范围不会提供所需的堆积密度以获得所需的金刚石浓度。
尽管树脂结合剂金刚石可为合适的(特别是如果附聚的),但金刚石优选为金属结合剂金刚石。树脂结合剂金刚石通常过弱和易碎而无法用于树脂结合剂磨轮中以磨削PDC。可获得强度为易碎(更弱)至较不易碎(更强)的金属结合剂金刚石。这种强度评级由各个供应商使用不同的名称描述。为了更有效地暴露新的金刚石,优选更弱的金属结合剂金刚石。例如,如果使用来自ABC超硬磨料公司(ABC Superabrasives)的金刚石,则强度在ABS 2(弱)至ABS 9(强)的范围内评级。当使用ABC超硬磨料金刚石时,金刚石有利地为ABS 2或ABS 3。可获得WSG 200至WSG 900的世界范围的超硬磨料强度等级。合适强度的金刚石可包括WSG200、WSG300、WSG400和WSG500。LANDS超硬磨料具有名称为LS200、LS230、LS250、LS260、LS270和LS290的强度。合适强度的金刚石可包括LS200、LS230和LS240。通常,在50%之下的金属粘结剂金刚石的强度范围对于给定供应商是合适的。
与金刚石磨粒一起使用的合适的树脂粘结剂包括含甲醛的树脂,如苯酚甲醛、线性酚醛树脂且特别是具有添加的交联剂(例如六亚甲基四胺)的那些、酚醛塑料和氨基塑料;不饱和聚酯树脂;乙烯基酯树脂;烷基树脂,烯丙基树脂;呋喃树脂;环氧树脂;聚氨酯;氰酸盐酯;以及聚酰亚胺。在树脂结合剂磨轮中所用的粘结剂树脂的量为高浓度金刚石部分的约 30体积%至约40体积%,如大约35体积%。通常,树脂的量应该在制造过程中足以完全润湿所有单独粒子的表面,从而形成基本上无孔隙率的连续树脂结构,无机组分在整个所述连续树脂结构中离散结合,所述连续树脂结构包括磨轮的机械结构。
合适的填料添加剂可包括增强粒子、助磨剂、干燥剂、着色剂和润滑剂。如所述,除了金刚石之外,使用硬填料粒子和软填料粒子两者以增强并控制磨轮的破损速率。硬填料粒子(不包括金刚石)为Mohs硬度为7或更大的那些。合适的硬填料粒子包括氧化铝、碳化硅、氧化锆、通常衍生自水软铝石溶胶凝胶的陶瓷α氧化铝粒子,或具有所需Mohs硬度的其他磨粒。软填料粒子具有5或更小的Mohs硬度。合适的软填料包括石油焦炭、叶蜡石、冰晶石、石灰、石墨、耐火陶渣、球土、铜或滑石。硬填料粒子与软填料粒子的体积比为(可为)15:85至85:15,或30:70至70:30,或40:60至60:40。合适的硬填料粒子尺寸包括等于或小于约30微米的尺寸,如600、800或1000 ANSI目当量。合适的软填料粒子尺寸包括100目或更细。如果需要,软粒子可具有细部分和粗部分。所述细部分可比280目更细,所述粗部分可为100至180目。如果使用两种尺寸的软填料粒子,则粗粒子相对于细粒子的体积分数可为50:50至70:30。硬填料粒子的过大的体积分数阻止破损,从而导致磨轮的热量积聚和钝化,且软填料粒子的过大的体积分数会不利地增加磨轮的磨损速率。在树脂结合剂磨轮中使用的硬填料粒子和软填料粒子的混合物的体积百分比为高浓度金刚石部分的5%至30%,或8%至20%。
其他填料可包括纤维状和板状材料,如碳或玻璃晶须和云母。助磨剂例如冰晶石、四氟硼酸钾(KBF4)、聚氯乙烯、木质素磺酸盐和它们的共混物。可将诸如有机或无机颜料或染料的着色剂掺入磨轮中。
实例
本发明的目的和优点通过下面的非限制性实例进一步说明。这些实例中所提到的具体材料及其量以及其他条件和细节,均不应被解释为对本发明的不当限制。除非另外指出,在实例中的所有份数、百分比、比例等均以重量计。
使用如下材料制备本发明和对比磨轮。
表1:组分
制备实例1、7、9至14和对比例1A至6A的磨轮,并测试所述磨轮以评价它们对PDC的磨削性能。实例1和对比例1A在不同的磨轮修整工序下进行评价。各个磨轮的重量百分比组成示于表2。
用于形成磨轮部分的一般工序
表2中所列的每个组合物在1000ml聚乙烯混合广口瓶中完全混合4小时,辊压机(2杆滚筒底(2-Bar Tumbler Base),加利福尼亚州戈勒塔的C&M Topline公司(C&M ToplineInc.,Goleta CA))设定为大约180rpm。将研磨轮直接压在预成型的酚醛树脂芯部上,以产生1A1型研磨轮部分8″OD×1.25″TK×1.25″ID,且金刚石深度x=0.375。通过在环形台上旋转模具组件,并同时将磨料粉末混合物倾注至围绕芯部的环形腔体,从而用混合磨料组合物填充五片环形冲模双压塑钢模具中的模腔。然后用塑料直尺工具使粉末平滑和平坦,并用上部环形冲模封闭经填充的模具。
将经填充的模具置于200吨受热台板液压机中,台板调节点温度设定在350℉。关闭压机台板以使环形冲模表面与模具外壳齐平。将磁力温度计附接至模具外壳的侧面,并监控模具温度。当模具外壳达到350℉时,模具在压力下保持关闭20分钟。
在350℉下20分钟之后,将模具组件从受热台板压机中取出,并置于水冷钢台上,使其冷却至室温。使用50吨液压机和钢垫片从成型的轮部分去除模具外壳。根据如下程序在空气中固化成型的轮部分。1小时升温至150℉,1小时在150℉下保温,4小时升温至350℉,7小时在350℉下保温,之后3小时冷却至室温。
将轮部分表面磨削至厚度,然后使用环氧树脂粘合剂将两个部分结合在一起。然后使用3M E228精修和修正机上的40/60粗粒度SiC磨轮精修和修整结合结构,以制得最终测试磨轮。
磨削测试
使用无心磨机(Acme 47型无心磨机,密歇根州奥本山阿珂姆制造公司(AcmeManufacturing Company,Auburn Hills,Michigan))磨削获自犹他州奥瑞姆美国合成公司(US Synthetic Corporation,Orem,Utah)的圆柱形金刚石切割机插件(PDC),所述无心磨机使用实例1和对比例A的8″直径×2.5″宽的树脂结合剂金刚石轮。在磨削过程中,将PDC安装于弹簧支承的夹具中以保持PCD。磨轮速度为约4000SFPM,调节轮速度为约55SFPM,调节轮的螺旋角设定为约3度。这提供了约5.5秒/PDC载荷的磨削接触时间。使用在水中的5%“Shell Metalina Y-850”(得克萨斯州休斯敦的壳牌润滑剂公司(Shell Lubricants,Houston,Texas))的冷却剂流。取决于PDC的尺寸,如下所述使用2 PDC/载荷或3 PDC/载荷进行测试:
测试方式 | PDC直径 | 金刚石深度/PDC | 碳化钨深度/PDC |
2 PDC | 标称0.63″ | 0.085″ | 0.4365″ |
3 PDC | 标称0.63″ | 0.062″ | 0.257″ |
使用对比例1A进行测试,并证实2 PDC模式提供与3 PDC模式类似的聚晶金刚石体积去除速率。经由调节轮的进料控制来将磨削过程中的马达载荷控制至空载以上约2.5-3.1安培。在每趟之后,修整测试磨轮以用于高频率修整测试。对于低频率修整测试,在每10趟之后修整每个磨轮。通过使220粗粒度,1″×1″×6″白色修整棒(“3M修整棒200TH”,明尼苏达州圣保罗的3M公司(3M Company,St.Paul,Minnesota))与轮接触,并使所述白色修整棒移动经过轮总共6趟,从而完成修整。
对比例1A为具有部件号码MMMRBDW26435-R的由3M公司销售的现有技术的树脂结合剂磨轮。对比例2A和3A使用非附聚的树脂结合剂金刚石,当磨削PDC时,所述非附聚的树脂结合剂金刚石过于易碎,并在磨轮的外表面上脱离,从而导致过度钝化和较差的切割。对比例4A使用大约125的与对比例1A相同的金刚石浓度,并使用易碎的软填料粒子而不是可延展的软填料粒子。修整的需要减少,但并不显著。对比例6A使用相同的125的金刚石浓度,但用更粗级别的金刚石代替细级别的金刚石。未注意到显著的性能差异。实例1(185)、实例7(225)、实例9(200)和实例10(200) 使用显著更高的金刚石浓度以及硬填料粒子和软填料粒子的混合物,如上所述。在PDC上测试磨削的过程中,修整的需要显著减少。
现在参见图2,当每趟使用修整时,本发明的磨轮的切割速率显著大于对比磨轮的切割速率(0.0027立方英寸相对于0.0023立方英寸),当仅仅每10趟使用修整时,本发明的轮具有良好的切割速率水平(0.0013立方英寸相对于0.0008立方英寸)。使用仅每10趟的修整的本发明的轮的切割速率为单趟切割速率的大约48%,与对比轮1A的大约35%相对。
由使用无心磨削生产PDC的顾客评价实例1。无心磨削应用将PDC的外径降低至最终所需的直径/公差,并且在冷却剂流下进行。之前由顾客使用的现有的磨轮需要频繁的或基本上连续的研磨介质修整,以使用现有的金刚石研磨磨轮保持原料去除。当将实例1磨轮安装于无心磨机上时,使用与之前现有的金刚石研磨磨轮相同的之前的磨削条件加工PDC。在PDC的无心磨削过程中,不在实例1磨轮上使用外部研磨修整介质。使用现有的过程参数,无心磨削操作能够连续将PDC制备成所需的最终尺寸并同时获得相同的生产率,而无需在制备PDC的过程中在实例1的磨轮的表面上使用研磨轮修整或整修介质。在所用的任何之前的磨轮的现有加工条件下,在磨削PDC时完全不存在修整介质在之前是不可能的。此外,在磨削PDC时实例1的磨轮完全消耗至芯部,并且在磨削过程中的任何时刻都不会变得钝化或不工作。
在不脱离本发明的精神和范围的前提下,更具体地讲,在不脱离所附权利要求书中所示出的精神和范围的前提下,本领域的普通技术人员可以实践本发明的其他修改形式和变型形式。应当理解,多种实施例的方面可以整体地或部分地与多种实施例的其他方面互换或结合。以上获得专利证书的专利申请中所有引用的参考文献、专利或专利申请的全文通过一致的方式以引用方式并入本文中。在并入的参考文献部分与本专利申请之间存在不一致或矛盾的情况下,应以前述说明中的信息为准。为了使本领域的普通技术人员能够实践受权利要求书保护的本发明而给定的前述说明不应理解为是对本发明的范围的限制,本发明的范围由权利要求书及其所有等同形式所限定。
Claims (8)
1.一种磨削方法,其包括:
使聚晶金刚石复合片与磨轮接触;
所述磨轮包括金刚石、树脂粘结剂,以及硬填料粒子和软填料粒子的混合物;和
其中基于体积计所述金刚石包含175至225的金刚石浓度,基于体积计所述树脂粘结剂为30%至40%,所述混合物中硬填料粒子与软填料粒子的比例为85:15至15:85,且基于体积计硬填料粒子和软填料粒子的混合物为5%至30%。
2.根据权利要求1所述的方法,其中所述混合物中硬填料粒子与软填料粒子的比例为70:30至30:70。
3.根据权利要求1所述的方法,其中所述金刚石包括金属结合剂金刚石。
4.根据权利要求2所述的方法,其中所述硬填料粒子包括陶瓷α氧化铝,且所述软填料粒子包括石油焦炭。
5.一种磨料制品,其包括:
磨轮,所述磨轮包括金刚石、树脂粘结剂,以及硬填料粒子和软填料粒子的混合物;和
其中基于体积计所述金刚石包含175至225的金刚石浓度,基于体积计所述树脂粘结剂为30%至40%,所述混合物中硬填料粒子与软填料粒子的比例为85:15至15:85,且基于体积计硬填料粒子和软填料粒子的混合物为5%至30%。
6.根据权利要求5所述的磨料制品,其中所述混合物中硬填料粒子与软填料粒子的比例为70:30至30:70。
7.根据权利要求5所述的磨料制品,其中所述金刚石包括金属结合剂金刚石。
8.根据权利要求5所述的磨料制品,其中所述硬填料粒子包括陶瓷α氧化铝,且所述软填料粒子包括石油焦炭。
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PCT/US2012/033880 WO2012145284A2 (en) | 2011-04-18 | 2012-04-17 | Resin bonded grinding wheel |
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EP2699387B1 (en) | 2022-06-29 |
EP2699387A4 (en) | 2014-08-27 |
CA2833342A1 (en) | 2012-10-26 |
WO2012145284A2 (en) | 2012-10-26 |
WO2012145284A3 (en) | 2012-12-27 |
CA2833342C (en) | 2020-05-12 |
US20140057534A1 (en) | 2014-02-27 |
BR112013026817A2 (pt) | 2017-01-10 |
CN103492126A (zh) | 2014-01-01 |
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RU2013146357A (ru) | 2015-05-27 |
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