CN104759993A - 磨曲轴用陶瓷微晶刚玉砂轮及其制造方法 - Google Patents
磨曲轴用陶瓷微晶刚玉砂轮及其制造方法 Download PDFInfo
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Abstract
本发明具体涉及一种磨曲轴用陶瓷微晶刚玉砂轮及其制造方法,砂轮的特征在于磨削部分为:粒度为46-80#的陶瓷微晶刚玉磨料10-50份;粒度为60-100#单晶刚玉磨料20-40份;粒度为60-100#白刚玉磨料10-60份;低温陶瓷结合剂10-20份;成孔剂5-10份;晶须材料2-4份;湿润剂3-6份;着色剂0.6-1.2份;夹持部分为:粒度为60-100#白刚玉磨料100份;低温陶瓷结合剂10-20份;晶须材料2-4份;湿润剂4-6份;本发明的有益效果为:磨削能力强,加工精度高,加工效率高,使用寿命长,散热好,不烧伤工件,修整频次少,自锐性好,加工表面粗糙度好,使用寿命长,价格远远低于超硬材料砂轮,节约成本。
Description
技术领域
本发明属于砂轮及其制造方法领域,具体涉及一种磨曲轴用陶瓷微晶刚玉砂轮及其制造方法。
背景技术
曲轴作为汽车发动机的关键零部件之一,它的加工质量直接影响汽车发动机的动力性能,曲轴轴颈的几何精度如圆度、圆柱度、平行度、光洁度等参数要求也逐渐提高。影响曲轴加工精度的因素除机床本身外,加工工具的选择是另外一个重要因素。正确使用砂轮不但可以充分发挥磨床效能,提高生产率,降低成本,并可保证产品零件的加工质量。通常人们认为,普通磨料砂轮难以获得理想的磨削效果,加工效率低,形状保持性差,修整频繁,使用寿命低,难以获得理想的加工效果,而采用超硬磨料砂轮磨削才能获得理想的磨削效果,但超硬磨料砂轮的价格较贵,并且它对磨床有较高的要求,所以使用受到一定的限制。
发明内容
本发明的目的在于解决现有技术普通磨料砂轮无法加工汽车曲轴,采用超硬磨料砂轮又存在价格昂贵的缺陷,提供一种磨曲轴用陶瓷微晶刚玉砂轮及其制造方法,其带微气孔结构,用于磨削发动机曲轴的油封面、法兰端面及轮毂,替代普通砂轮,提高生产效率,加工精度及耐用度,同时降低成本,满足机床的使用要求和磨削要求。
本发明是通过如下技术方案来实现的:
即一种磨曲轴用陶瓷微晶刚玉砂轮,其特征在于包括磨削部分和夹持部分,磨削部分的原料组分及重量百分比含量为:
所述成孔剂为Al2O3空心球,晶须材料为硫酸钙,着色剂为氧化钴;
夹持部分的原料组分及重量百分比含量为:
所述晶须材料为硫酸钙。
砂轮的外缘,其截面为Z形。
低温陶瓷结合剂的原料组成及重量百分比为:
陶瓷结合剂耐火度为700-800℃。
陶瓷微晶刚玉磨料是80年代出现的一种新磨料,是以独特的陶瓷技术(Sol-gel)合成的具有微细晶体结构的高纯度刚玉磨料。普通电熔刚玉磨料每颗磨料中仅含少量单晶体,晶体尺寸大,而陶瓷微晶刚玉磨料每颗磨粒是由成千上万个亚微米级或微米级细小晶体组成,晶体尺寸为普通刚玉磨料的1/15-1/200,这种磨料本身就含有成千上万个磨削刃。因此其制作的砂轮与普通刚玉砂轮相比就有着独特的优势:
(1)磨粒锋利,磨削效率高,切削能力强;
(2)自锐性好,不堵塞,修整频次少;
(3)耐用度高,使用寿命长;
(4)韧性好,磨损小,砂轮形状保持型好,加工精度高;
(5)价格上远远低于超硬磨料砂轮。
因此此类砂轮能够填补普通刚玉磨具和超硬磨具之间的空白。
本发明的成孔材料为Al2O3空心球,用于排屑和散热。
本发明的晶须材料为硫酸钙,用于结构补强。
本发明的着色剂为氧化钴。
本发明砂轮的夹持部分无陶瓷刚玉与单晶刚玉磨料,节省成本。
本发明的砂轮的外缘,其截面为Z形。可以同时磨削曲轴油封面、法兰端面及轮毂。
本发明所述砂轮使用线速度为63m/s。
一种带有微气孔结构的新型陶瓷微晶刚玉(CA)砂轮的制造方法,其特征在于步骤如下:
1)陶瓷低温结合剂的制备过程如下:将各种原料称量,放入球磨机中混合18-20小时,后经熔融,淬冷,粉碎,过筛制成陶瓷低温结合剂;
2)配料:按砂轮配方进行称量;
3)混料:将称量好的普通刚玉磨料和陶瓷刚玉磨料及湿润剂倒入混料锅内混合5分钟,加入结合剂、晶须材料及成孔剂混合20分钟,过16#筛;
4)根据砂轮规格选择模具、垫铁、付压垫;
5)安装模具,用脱模剂均匀擦拭模具、模板,模具、模板的使用面不得存在块状脱模剂;
6)开动转模机,将事先称量好的成型料倒入模具中,搅匀后刮平;
7)停止转模机,盖上模盖、付压垫,在付压垫上部放上水压垫;
8)将小车开至压机中心,进行压制,砂轮在压制时必须缓慢压制,砂轮压平后,注意保压;
9)保压结束后,将小车开回原处,将砂轮顶出,取下模盖板和付压垫,搬起砂轮快速、平稳的放在准备好的专用托板上,按顺序编上号码,放置在干燥车上;
10)自然干燥,时间30小时;
11)置于干燥室内干燥,时间为72小时,最高温度为90℃;
12)烧成,温度为800-850℃;
13)硬度测试;
14)加工;
15)检查;
16)磨削试验。
本发明的有益效果为:提供了一种带有微气孔结构的新型陶瓷微晶刚玉(CA)砂轮,可以同时磨削发动机曲轴的油封面、法兰端面及轮毂,替代普通砂轮,磨削能力强,加工精度高,加工效率高,使用寿命长,散热好,不烧伤工件,修整频次少,自锐性好,加工表面粗糙度好,使用寿命长,价格远远低于超硬材料砂轮,节约成本。
附图说明
图1为本发明的结构示意图;
图2为图1的A-A剖视图。
如图中所示:1.磨削部分;2.夹持部分;3.砂轮孔。
具体实施方式
本发明低温陶瓷结合剂经配料混合,而后放入高温炉中在1300℃下熔炼,冷却后研磨,过240#筛。陶瓷结合剂耐火度为700-800℃,结合剂强度满足微气孔砂轮于63m/s的转速下使用。具体方案详见表1。
表1:低温陶瓷结合剂方案
实施例1:
如图1,2所示,本发明的砂轮包括磨削部分1、夹持部分2和砂轮孔3,磨削部分1的外缘其界面为Z形。
本实施例1的制作步骤如下:
1)低温陶瓷结合剂选择表1中序号3方案:将各种原料称量,放入球磨机中混合18-20小时,后经熔融,淬冷,粉碎,过筛制成陶瓷低温结合剂。
2)配料:
a)磨削部分:按砂轮配方进行称量,CA磨料选择80#,普通刚玉磨料选择100#,10份陶瓷微晶刚玉(CA)磨料,30份单晶刚玉磨料,60份白刚玉磨料,18份低温陶瓷结合剂,8份成孔剂,3份晶须材料,4份湿润剂,着色剂1份。
b)夹持部分:按砂轮配方进行称量,刚玉磨料选择100#,100份白刚玉磨料,20份低温陶瓷结合剂,2份晶须材料,5份湿润剂。
3)混料:
a)工作层:将称量好的普通刚玉磨料和陶瓷刚玉磨料及湿润剂倒入混料锅内混合5分钟,加入与着色剂混匀的结合剂,晶须材料及成孔剂混合20分钟,过16#筛;
b)非工作层:将称量好的白刚玉磨料及湿润剂倒入混料锅内混合5分钟,加入结合剂,晶须材料混合20分钟,过16#筛;
4)根据砂轮规格选择模具、垫铁、付压垫;
5)安装模具,用脱模剂均匀擦拭模具、模板,模具、模板的使用面不得存在块状脱模剂;
6)开动转模机,将事先称量好的成型料倒入模具中,搅匀后刮平;
7)停止转模机,盖上模盖、付压垫,在付压垫上部放上水压垫;
8)将小车开至压机中心,进行压制,砂轮在压制时必须缓慢压制,砂轮压平后,注意保压;
9)保压结束后,将小车开回原处,将砂轮顶出,取下模盖板和付压垫,搬起砂轮快速、平稳的放在准备好的专用托板上,按顺序编上号码,放置在干燥车上;
10)自然干燥,时间30小时;
11)置于干燥室内干燥,时间为72小时,最高温度为90℃;
12)烧成,温度为800℃;
13)硬度测试;
14)加工;
15)检查。
16)磨削试验。
实施例2
本实施例中砂轮结构与实施例1中相同,
本实施例的制作步骤如下:
1)低温陶瓷结合剂选择表1中序号4方案:将各种原料称量,放入球磨机中混合18-20小时,后经熔融,淬冷,粉碎,过筛制成陶瓷低温结合剂。
2)配料:
a)工作层:按砂轮配方进行称量,CA磨料选择60#,普通刚玉磨料选择80#,30份陶瓷微晶刚玉(CA)磨料,20份单晶刚玉磨料,50份白刚玉磨料,15份低温陶瓷结合剂,5份成孔剂,4份晶须材料,3份湿润剂,0.9份着色剂。
b)非工作层:按砂轮配方进行称量,刚玉磨料选择80#,100份白刚玉磨料,17份低温陶瓷结合剂,4份晶须材料,4份湿润剂。
3)混料:
a)工作层:将称量好的普通刚玉磨料和陶瓷刚玉磨料及湿润剂倒入混料锅内混合5分钟,加入与着色剂混匀的结合剂,晶须材料及成孔剂混合20分钟,过16#筛;
b)非工作层:将称量好的白刚玉磨料及湿润剂倒入混料锅内混合5分钟,加入结合剂,晶须材料混合20分钟,过16#筛;
4)根据砂轮规格选择模具、垫铁、付压垫;
5)安装模具,用脱模剂均匀擦拭模具、模板,模具、模板的使用面不得存在块状脱模剂;
6)开动转模机,将事先称量好的成型料倒入模具中,搅匀后刮平;
7)停止转模机,盖上模盖、付压垫,在付压垫上部放上水压垫;
8)将小车开至压机中心,进行压制,砂轮在压制时必须缓慢压制,砂轮压平后,注意保压;
9)保压结束后,将小车开回原处,将砂轮顶出,取下模盖板和付压垫,搬起砂轮快速、平稳的放在准备好的专用托板上,按顺序编上号码,放置在干燥车上;
10)自然干燥,时间30小时;
11)置于干燥室内干燥,时间为72小时,最高温度为90℃;
12)烧成,温度为820℃;
13)硬度测试;
14)加工;
15)检查。
16)磨削试验。
实施例3
本实施例中砂轮结构与实施例1中相同,
本实施例的制作步骤如下:
1)低温陶瓷结合剂选择表1中序号5方案:将各种原料称量,放入球磨机中混合18-20小时,后经熔融,淬冷,粉碎,过筛制成陶瓷低温结合剂。
2)配料:
a)工作层:按砂轮配方进行称量,CA磨料选择70#,普通刚玉磨料选择80#,50份陶瓷微晶刚玉(CA)磨料,40份单晶刚玉磨料,10份白刚玉磨料,20份低温陶瓷结合剂,10份成孔剂,2份晶须材料,6份湿润剂,1.2份着色剂。
b)非工作层:按砂轮配方进行称量,刚玉磨料选择80#,100份白刚玉磨料,20份低温陶瓷结合剂,2份晶须材料,5份湿润剂。
3)混料:
a)工作层:将称量好的普通刚玉磨料和陶瓷刚玉磨料及湿润剂倒入混料锅内混合5分钟,加入与着色剂混匀的结合剂,晶须材料及成孔剂混合20分钟,过16#筛;
b)非工作层:将称量好的白刚玉磨料及湿润剂倒入混料锅内混合5分钟,加入结合剂,晶须材料混合20分钟,过16#筛;
4)根据砂轮规格选择模具、垫铁、付压垫;
5)安装模具,用脱模剂均匀擦拭模具、模板,模具、模板的使用面不得存在块状脱模剂;
6)开动转模机,将事先称量好的成型料倒入模具中,搅匀后刮平;
7)停止转模机,盖上模盖、付压垫,在付压垫上部放上水压垫;
8)将小车开至压机中心,进行压制,砂轮在压制时必须缓慢压制,砂轮压平后,注意保压;
9)保压结束后,将小车开回原处,将砂轮顶出,取下模盖板和付压垫,搬起砂轮快速、平稳的放在准备好的专用托板上,按顺序编上号码,放置在干燥车上;
10)自然干燥,时间30小时;
11)置于干燥室内干燥,时间为72小时,最高温度为90℃;
12)烧成,温度为850℃;
13)硬度测试;
14)加工;
15)检查。
16)磨削试验。
原有普通刚玉砂轮与新型陶瓷微晶刚玉砂轮性能指标对比见下表2。
表2 普通刚玉砂轮与新型陶瓷微晶刚玉砂轮性能指标
Claims (4)
1.一种磨曲轴用陶瓷微晶刚玉砂轮,其特征在于包括磨削部分和夹持部分,磨削部分的原料组分及重量份数比为:
所述成孔剂为Al2O3空心球,晶须材料为硫酸钙,着色剂为氧化钴;
夹持部分的原料组分及重量百分比含量为:
所述晶须材料为硫酸钙。
2.根据权利要求1所述的磨曲轴用陶瓷微晶刚玉砂轮,其特征在于砂轮的外缘,其截面为Z形。
3.根据权利要求1所述的磨曲轴用陶瓷微晶刚玉砂轮,其特征在于低温陶瓷结合剂的原料组成及重量百分比为:
4.一种磨曲轴用陶瓷微晶刚玉砂轮的制法,其特征在于步骤如下:
1)陶瓷低温结合剂的制备过程如下:将各种原料称量,放入球磨机中混合18-20小时,后经熔融,淬冷,粉碎,过筛制成陶瓷低温结合剂;
2)配料:按砂轮配方进行称量;
3)混料:将称量好的普通刚玉磨料和陶瓷刚玉磨料及湿润剂倒入混料锅内混合5分钟,加入结合剂、晶须材料及成孔剂混合20分钟,过16#筛;
4)根据砂轮规格选择模具、垫铁、付压垫;
5)安装模具,用脱模剂均匀擦拭模具、模板,模具、模板的使用面不得存在块状脱模剂;
6)开动转模机,将事先称量好的成型料倒入模具中,搅匀后刮平;
7)停止转模机,盖上模盖、付压垫,在付压垫上部放上水压垫;
8)将小车开至压机中心,进行压制,砂轮在压制时必须缓慢压制,砂轮压平后,注意保压;
9)保压结束后,将小车开回原处,将砂轮顶出,取下模盖板和付压垫,搬起砂轮快速、平稳的放在准备好的专用托板上,按顺序编上号码,放置在干燥车上;
10)自然干燥,时间30小时;
11)置于干燥室内干燥,时间为72小时,最高温度为90℃;
12)烧成,温度为800-850℃;
13)硬度测试;
14)加工;
15)检查;
16)磨削试验。
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