CN104889894B - 磨瓦楞辊砂轮及其制造方法 - Google Patents

磨瓦楞辊砂轮及其制造方法 Download PDF

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CN104889894B
CN104889894B CN201510206472.7A CN201510206472A CN104889894B CN 104889894 B CN104889894 B CN 104889894B CN 201510206472 A CN201510206472 A CN 201510206472A CN 104889894 B CN104889894 B CN 104889894B
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余卫东
马强
单冬冬
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Sisha taililai (Qingdao) grinding Co.,Ltd.
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Abstract

本发明属于砂轮及其制造方法领域，具体涉及一种磨瓦楞辊砂轮及其制造方法。其砂轮的特征在于磨削部分的原料组分及重量百分比含量为：粒度为36目～120目的磨料68‑80％；陶瓷结合剂8‑15％；成孔材料10‑15％；其制造方法的特征在于步骤如下：1)混料；2)成型；3)干燥；4)装窑；5)烧成；6)毛坯干燥及尺寸加工。本发明具有回转强度大、硬度高、组织均匀性好、静平衡性能好、散热性能好、磨削性能好、磨削效率高、磨削精度高的优点。

Description

磨瓦楞辊砂轮及其制造方法
技术领域
本发明属于砂轮及其制造方法领域，具体涉及一种磨瓦楞辊砂轮及其制造方法。
背景技术
瓦楞辊是瓦楞纸板生产设备中最重要的组成部分，它的直径大(可达280至600mm)、长度长(1.6米至2.5米)，磨削加工难度特别大。近年以来，国内包装机械行业的部分企业为了提高瓦楞辊的磨削精度和磨削效率，陆续从德国、日本等发达国家引进了部分磨削效率及磨削精度高的瓦楞辊数控磨床，为了提高瓦楞辊的耐磨性，避免在使用过程中因磨损不均匀而出现凹陷或凹坑影响加工精度和使用寿命，将瓦楞辊所用材料由普通42CrMo、45钢等合金钢改为硬度高、耐磨性好的材料，如硬度高于HRC60的48CrMoA钢及碳化钨等，某些厂家还选用延展性好的50CrVA等难磨材料，可大幅提高瓦楞辊的使用寿命。该磨床所用砂轮粒度较传统砂轮细1至2个粒度号，组织疏松(大气孔)，静平衡性能要求高，硬度均匀性好。目前，国内磨轧辊砂轮离上述要求还有较大差距，满足不了使用要求，该磨床所用砂轮要求静平衡值比国标规定值加严25％至50％。目前该磨床主要使用泰利莱、日本的吴诺顿、德国的温特等国外著名砂轮制造企业的磨瓦楞辊砂轮,价格昂贵。
瓦楞辊属于硬度高延展性好的难磨材料，为避免产品烧伤和变形，现有国产的磨瓦楞辊砂轮由于组织疏松(组织号为12#至14#)，砂轮的内部及表面分布着许多气孔，砂轮的强度很低，工作线速度难以达到35m/s，并且因为成孔材料分布存在不均匀性及砂轮烧成过程中成孔剂烧失后，会影响砂轮的组织均匀性，对砂轮的静平衡性能造成了较大影响。
发明内容
本发明的目的在于解决现有技术国产磨瓦楞辊砂轮无法满足加工要求，只能选用进口产品，存在价格昂贵，生产成本高的缺陷，提供一种磨瓦楞辊砂轮及其制造方法，既能降低成本，又能满足瓦楞辊的加工要求。
本发明是通过如下技术方案来实现的：
即一种磨瓦楞辊砂轮，其特征在于磨削部分的原料组分及重量百分比含量为：
粒度为36目～120目的磨料 68-80％；
陶瓷结合剂 8-15％；
成孔材料 10-15％。
本发明的陶瓷结合剂的原料组分及重量百分比含量为：
本发明的磨料为白刚玉或单晶刚玉或铬刚玉。
本发明的磨料为白刚玉、单晶刚玉、铬刚玉中任意两种的组合，两种磨料的混合比例为1:1或1：1.5。
本发明的成孔材料为核桃壳或杏壳或刚玉空心球。
本发明陶瓷结合剂中的着色剂为氧化铬或氧化铁或氧化钴。
一种磨瓦楞辊砂轮的制作方案，其特征在于步骤如下：
1)混料
1.1)采用水玻璃、糊精混合液对成孔材料进行浸泡，浸泡时间20-30分钟；
1.2)配制陶瓷结合剂；
1.3)将称量好的磨料放入混料锅内，按照磨料量的1-3％加入水玻璃混合5-6分钟，再将混匀的陶瓷结合剂与糊精倒入混料锅内混合10-20分钟，再加入成孔材料混合5分钟，过筛；
2)成型
使用多工位成型机进行成型，刮料时先进行粗刮然后再精刮；
3)干燥
本产品所采用烘干曲线
升温速度(℃/h) 2.5 2 0 2 0
达到温度(℃) 室温 35 60 60 80
段时间(h) 12.5 6 10 15
由于该产品组织松、膨胀系数大，易发生干燥裂纹，因此要求该产品烘干速率低，烘
干温度低，烘干时间长。
4)装窑
5)烧成
烧成曲线如下
为了加快燃烧后的成孔材料挥发，保证砂轮外观质量，在升温第一段加大负压(是其它产品的2倍左右)。
6)毛坯干燥及尺寸加工。
本发明工艺步骤1.1)中，水玻璃：水＝1:10，糊精取总量的15％加入混合液中。
本发明工艺步骤1.2)中，陶瓷结合剂里的着色剂用来对砂轮进行着色，提高砂轮的外观商品化。
本发明工艺步骤1.3)中，糊精为总量的剩余85％。
本发明工艺步骤2)中，采用两次刮料，确保刮料的均匀性。
本发明工艺步骤4)中，装窑时摞装高度不得超过100mm；
本发明工艺步骤5)中，为了便于成孔材料在烧成过程中挥发，烧成时，在400℃以前采取负压，是普通产品的2倍负压力。
本发明针对目前现状，研发满足数控磨瓦楞辊磨床使用的砂轮来取代进口砂轮。本发明所述的砂轮硬度、组织均匀一致，工作线速度要求不低于35m/s，静平衡值比国标规定值加严25％至50％，采用本发明所述的砂轮后，被磨工件的表面粗糙度由0.8um提高到了0.4um,磨削效率可提高30％以上，解决了磨损不均匀、磨削堵塞等现象，延长了使用寿命。
本发明具有如下优点：
1、该砂轮属于大气孔砂轮，具有良好的散热性；
2、选用核桃壳、杏壳、刚玉空心球等环保成孔材料，改进磨削过程的散热性，解决该砂轮在磨削过程中因磨削面积大等原因导致的磨削烧伤、裂纹、磨削效率低等问题，提高磨削精度；
3、砂轮的回转强度大、硬度高、组织均匀性及磨削性能好；
4、针对核桃壳、杏壳等成孔剂在砂轮成型过程中容易膨胀导致砂轮毛坯反弹，而导致砂轮裂纹、厚度不易控制等问题，采用水玻璃、糊***对其进行技术处理，保证产品质量；
5、使用等静压成型工艺，确保砂轮的组织均匀性及静平衡性能；
6、使用氧化铬、氧化铁、氧化钴等着色剂对砂轮进行着色，提高砂轮的外观商品化；
7、加入氧化锌晶须可提高该砂轮的强度及韧性，使砂轮在修整后具有良好的形状、脱落均匀，以保证被磨瓦楞辊的齿形及加工精度。
具体实施方式
实施例1
砂轮配方
磨料(铬刚玉) 成孔剂(杏壳) 结合剂
陶瓷结合剂配方
高岭土粉 长石粉 硼玻璃粉 氧化锌晶须 氧化铬
31％ 42％ 16％ 5％ 6％
上述陶瓷结合剂中，着色剂为氧化铬，产品烧成后呈现绿色。
本实施例的步骤如下：
1.混料
1.1采用水玻璃、糊***对成孔剂进行浸泡，水玻璃：水＝1:10，将糊精总量的15％加入到混合液中使用；
1.2配制陶瓷结合剂；
1.3将称量好的磨料放入混料锅内，按照磨料量的1-3％加入水玻璃混合5-6分钟，再加入混匀的结合剂与糊精(剩余的85％糊精)倒入混料锅内混合10-20分钟，加入成孔材料混合5分钟，过筛；
2.成型
2.1开动多工位成型压机，将称量准确的成型料倒入模具内，开动自动搅刮料装置进行搅刮料。首先开动自动搅料叉将成型料搅匀后再进行刮料，为确保刮料的均匀性，我们将行业普遍采用的一级刮料改为粗刮和精刮两级刮料的方法进行，先进行粗刮然后再精刮；
2.2在成型过程中，使用电子编码器、磁栅尺等技术控制砂轮毛坯厚度公差，确保同一组砂轮的硬度均匀一致；
3.干燥
干燥曲线如下
其它产品同规格烘干曲线
升温速度(℃/h) 3 3 4 0 6 0
达到温度(℃) 室温 35 50 78 78 102
段时间(h) 5 7 2 4 20
本产品所采用烘干曲线
升温速度(℃/h) 2.5 2 0 2 0
达到温度(℃) 室温 35 60 60 80
段时间(h) 12.5 6 10 15
由于该产品组织松、膨胀系数大，易发生干燥裂纹，因此要求该产品烘干速率低，烘干温度低，烘干时间长。
4.装窑
4.1装在同规格砂轮之上，且摞装高度不得超过100mm；
4.2其它：同正常产品装窑工艺。
5.烧成
烧成曲线如下：
为了加快燃烧后的成孔材料挥发，保证砂轮外观质量，在升温第一段加大负压(是其它产品的2倍左右)。
6.毛坯干燥及尺寸加工
尺寸加工时使用带有金刚石刀头的数控全加工机床，在同一台机床上对砂轮平面、孔径和外径进行加工，可确保砂轮孔径与平面的垂直度及尺寸加工精度；
6.1先加工砂轮的一个端面，再加工砂轮孔径，随后在加工砂轮的另一个端面；
6.2最后再加工砂轮外径。
实施例2
砂轮配方
磨料(白刚玉) 成孔材料(刚玉空心球) 陶瓷结合剂
75％ 11％ 14％
陶瓷结合剂配方
高岭土粉 长石粉 硼玻璃粉 氧化锌晶须 氧化铁
32％ 40％ 18％ 4％ 6％
上述陶瓷结合剂中，着色剂为氧化铁，产品烧成后呈现淡黄色或橘黄色。
本实施例的工艺步骤同实施例1。
实施例3
砂轮配方
磨料(单晶刚玉与白刚玉1:1混合) 成孔剂(核桃壳) 陶瓷结合剂
78％ 13％ 9％
陶瓷结合剂配方
高岭土粉 长石粉 硼玻璃粉 氧化锌晶须 氧化钴
34％ 40％ 17％ 4％ 5％
上述陶瓷结合剂中，着色剂为氧化钴，产品烧成后呈现蓝色。
使用本发明制得的砂轮研发指标与国标允许值对比如下
本发明制得的砂轮与传统砂轮的使用效果对比如下
单位：mm
本发明制得的砂轮与传统砂轮的研发指标对比如下：
单位：mm

Claims (3)

1.一种磨瓦楞辊砂轮，其特征在于磨削部分的原料组分及重量百分比含量为：
粒度为36目～120目的磨料 68-80％；
陶瓷结合剂 8-15％；
成孔材料 10-15％；
磨料为白刚玉或单晶刚玉或铬刚玉中任意一种或任意两种的组合，两种磨料的混合比例为1:1或1：1.5；
成孔材料为核桃壳或杏壳或刚玉空心球；
陶瓷结合剂的原料组分及重量百分比含量为：
2.根据权利要求1所述的磨瓦楞辊砂轮，其特征在于着色剂为氧化铬或氧化铁或氧化钴。
3.一种根据权利要求1所述的磨瓦楞辊砂轮的制作方法，其特征在于步骤如下：
1)混料
1.1)采用水玻璃、糊精混合液对成孔材料进行浸泡，浸泡时间20-30分钟；
1.2)配制陶瓷结合剂；
1.3)将称量好的磨料放入混料锅内，按照磨料量的1-3％加入水玻璃混合5-6分钟，再将混匀的陶瓷结合剂与糊精倒入混料锅内混合10-20分钟，再加入成孔材料混合5分钟，过筛；
2)成型
使用多工位成型机进行成型，刮料时先进行粗刮然后再精刮；
3)干燥
烘干曲线如下:
升温速度(℃/h) 2.5 2 0 2 0 达到温度(℃) 室温 35 60 60 80 段时间(h) 12.5 6 10 15
4)装窑
5)烧成
烧成曲线如下：
6)毛坯干燥及尺寸加工。
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