CN115339121B - 一种柔性溶胶凝胶抛光块体的制备方法 - Google Patents
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Abstract
本发明公开了一种柔性溶胶凝胶抛光块体的制备方法包括,如下步骤:(1)将凝胶剂和W20金刚石磨料放入去离子水中搅拌均匀;(2)在步骤(1)所得的物料中加入400目的碳纤维混合均匀;(3)所述步骤(2)所得的物料缓慢注入模具内进行固化,获得固化凝胶;(4)将上述固化凝胶进行干燥,得到所述柔性溶胶凝胶抛光块体。本发明在制备溶胶凝胶基体时,加入了特定比例的碳纤维,使制备好的柔性溶胶凝胶抛光块体具有多孔结构,提高了抛光效果;本发明制备的柔性溶胶凝胶抛光块体不再只是表面一层涂覆,而是整个基体都可用于抛光,提高了抛光工具的使用寿命。
Description
技术领域
本发明属于硬质材料精密加工技术领域,具体涉及一种柔性溶胶凝胶抛光块体的制备方法。
背景技术
在传统的高精密加工领域,游离磨料加工与固结磨料加工是主要的两种方式。游离磨料加工很难同时获得高的加工效率和很好的加工质量,且这种加工方式废弃的抛光液会严重污染环境;而采用固结磨料加工方式,虽然可以提高加工效率,但是磨料在结合剂中很难均匀分布,磨具加工寿命短,且工件容易产生硬损伤。
针对游离磨料抛光和固结磨料抛光所出现的问题,同时为了解决超细磨料的团聚难题,现有技术提出了半固结磨料抛光方法,也就是利用溶胶凝胶原理制备磨抛工具进行加工。不同于化学机械抛光,这种半固结磨料抛光是将生物高分子材料与纤维基体复合进行抛光,此种抛光方式不仅具有绿色环保的特点,还能够提高加工精度,所以半固结磨料抛光在未来半导体与石材抛光领域具有巨大优势与前景。
以往,在半固结磨料抛光中所使用的溶胶凝胶抛光工具的研究中,一般是将凝胶涂覆在纤维垫或者无纺布表面,经固化干燥后用于抛光,这样获得的溶胶凝胶抛光工具虽然抛光效果显著,但使用过程中,由于只是表面涂覆了一层凝胶,所以工具的使用寿命较短,不能满足连续长时间加工的需求。此外在绿色环保理念的推动下,无水加工的需求越来越高,现有的溶胶凝胶抛光工具在无水加工中容易损坏。进一步的,为了进一步提高抛光精度并满足抛光工具产业化的需求,迫切的需要一种新型的溶胶凝胶抛光工具的制备方法。
发明内容
本发明的目的在于克服现有技术缺陷,提供一种柔性溶胶凝胶抛光块体的制备方法。
本发明的技术方案如下:
一种柔性溶胶凝胶抛光块体的制备方法,其特征在于:包括如下步骤:
(1)将凝胶剂和硬质磨料放入去离子水中搅拌均匀,该凝胶剂为λ型卡拉胶、结冷胶、羧甲基纤维素钠或魔芋胶;
(2)在步骤(1)所得的物料中加入400目的碳纤维混合均匀;
(3)所述步骤(2)所得的物料缓慢注入模具内进行固化,获得固化凝胶;
(4)将上述固化凝胶进行干燥,得到所述柔性溶胶凝胶抛光块体;
所述柔性溶胶凝胶抛光块体中,W20金刚石磨料的含量为9-11wt%,凝胶剂的含量为2.9-3.1wt%,碳纤维的含量为30-40wt%。
在本发明的一个优选实施方案中,所述凝胶剂为λ型卡拉胶。
进一步优选的,所述固化为浸泡于KCl溶液中。
在本发明的一个优选实施方案中,所述凝胶剂为魔芋胶。
进一步优选的,所述固化为浸泡于CaCl2溶液中。
在本发明的一个优选实施方案中,所述凝胶剂为羧甲基纤维素钠。
进一步优选的,所述固化为浸泡于Al2(SO4)3溶液中。
在本发明的一个优选实施方案中,所述凝胶剂为结冷胶。
进一步优选的,所述固化为浸泡于KCl溶液中。
在本发明的一个优选实施方案中,所述柔性溶胶凝胶抛光块体中,凝胶剂的含量为3wt%,凝胶骨架的含量为30wt%。
本发明的有益效果是:
1、本发明在制备柔性溶胶凝胶抛光块体时,加入了特定比例的碳纤维,使制备好的柔性溶胶凝胶抛光块体具有多孔结构,提高了抛光工具的加工效果
2、本发明制备的柔性溶胶凝胶抛光块体不再只是表面一层涂覆,而是整个基体都可用于抛光,提高了抛光工具的使用寿命。
附图说明
图1为本发明实施例1中不同凝胶剂含量的凝胶结块的照片。
图2为本发明实施例1中不同凝胶剂含量的凝胶结块的特性对比图。
图3为本发明实施例2中不同碳纤维含量的凝胶结块照片。
图4为本发明实施例3中以魔芋胶为凝胶剂的凝胶结块照片。
图5为本发明实施例3中以魔芋胶为凝胶剂的凝胶结块微观形貌图。
图6为本发明实施例3中使用以魔芋胶为凝胶剂的凝胶结块抛光大理石效果图。
图7为本发明实施例4中以羧甲基纤维素钠为凝胶剂的凝胶结块的照片。
图8为本发明实施例4中以羧甲基纤维素钠为凝胶剂的凝胶结块的微观形貌图。
图9为本发明实施例4中使用以羧甲基纤维素钠为凝胶剂的凝胶块体抛光大理石效果图。
图10为本发明实施例5中以结冷胶为凝胶剂的凝胶结块的照片。
图11为本发明实施例5中以结冷胶为凝胶剂的凝胶结块的微观形貌图。
图12为本发明实施例5中使用以结冷胶为凝胶剂的凝胶结块抛光大理石效果图。
图13为本发明实施例6中以λ型卡拉胶为凝胶剂的凝胶结块的照片。
图14为本发明实施例6中以λ型卡拉胶为凝胶剂的凝胶结块的微观形貌图。
图15为本发明实施例6中使用以λ型卡拉胶为凝胶剂的凝胶结块抛光大理石效果图。
具体实施方式
以下通过具体实施方式结合附图对本发明的技术方案进行进一步的说明和描述。
下述实施例中的凝胶结块的制备方法均采用如下步骤:
(1)将凝胶剂和W20金刚石磨料(除实施例1至2以外)放入去离子水中搅拌均匀,该凝胶剂为卡拉胶、结冷胶、羧甲基纤维素钠或魔芋胶;
(2)在步骤(1)所得的物料中加入400目的碳纤维混合均匀;
(3)所述步骤(2)所得的物料缓慢注入模具内进行固化,获得固化凝胶;
(4)将上述固化凝胶进行干燥,得到凝胶抛光。
实施例1
选取λ型卡拉胶作为研究对象,控制碳纤维含量为30wt%制备凝胶结块(具体制备方法参考实施例6),研究不同凝胶含量对制备凝胶结块的影响。如图1所示,添加凝胶含量分别为2wt%、3wt%以及4wt%时所制备的凝胶结块,由图可知,当凝胶含量为2wt%与4wt%时,凝胶结块变形收缩严重,在凝胶含量为3wt%时形状完整。如图2所示为不同凝胶含量的体积收缩率以及邵氏硬度值,可以发现在凝胶含量为2wt%时,体积收缩率较大,在3wt%以及4wt%时体积收缩率变化较小,硬度随着凝胶含量的变化较小。因此综上可得,在凝胶含量为3wt%时制备的凝胶结块的性能最好。
实施例2
选取λ型卡拉胶为凝胶剂,碳纤维为凝胶骨架,凝胶剂含量为3wt%,研究添加不同含量的碳纤维对制备凝胶结块(具体制备方法参考实施例6)的影响,根据已有经验,分别选取碳纤维含量为10wt%、20wt%、30wt%、40wt%,如图3所示为不同含量碳纤维制备的凝胶结块图,由图可知,碳纤维含量在10wt%以及20wt%时结块变形程度较大,在30wt%以及40wt%时变形程度较小。如表1所示为不同碳纤维含量的凝胶结块的性能,其中随着碳纤维含量的增加,性能逐渐增强,在30wt%与40wt%时基本保持稳定,因此从经济的角度来讲,选取碳纤维含量为30wt%时较为合适。
表1添加不同碳纤维含量的凝胶块体的性能
碳纤维含量(wt%) | 邵氏硬度(Ha) | 体积收缩率(wt%) | 抗压强度(MPa) |
0 | 50 | 89.9 | 11.5 |
10wt% | 65 | 76.1 | 20.3 |
20wt% | 70 | 68.4 | 31.2 |
30wt% | 85 | 50.2 | 40.1 |
40wt% | 85 | 49.8 | 40.4 |
实施例3
室温下选取魔芋胶3g、碳纤维30g和W20金刚石磨料10g加入到100mL去离子水中搅拌,搅拌时间为8h;配制0.5mol/L的CaCl2溶液,将搅拌均匀的混合溶液缓慢加入到圆形的模具中并放入到配制好的CaCl2溶液中,常温下静置3h;最后将固化好的凝胶结块在常温常压下干燥72h,所得的凝胶结块如图4所示,其微观形貌如图5所示,抛光后大理石的表面形貌如图6所示,其中抛光压力为15N,抛光转速为100r/min,抛光时间为14min,以下实施例加工参数相同,大理石表面粗糙度在35nm左右,表面光泽度值为88左右。
实施例4
室温下选取碳纤维含量为30wt%,将6g的羧甲基纤维素钠与20g W20金刚石磨料加入到200mL去离子水中搅拌均匀,再将60g碳纤维加入到此混合物中充分混合搅拌,搅拌时间为8h;配制0.5mol/L的Al2(SO4)3溶液,将搅拌均匀的混合溶液缓慢加入到圆形的模具中并放入到配制好的Al2(SO4)3溶液中,常温下静置3h;最后将羧甲基纤维素钠凝胶取出放入冷冻干燥机中,冷冻温度低于-40℃,冷冻时间为8h,设置干燥时间为10h,真空压力小于15Pa,环境温度为15℃,即可得到凝胶结块,如图7所示,其微观形貌图如图8所示,制备得到的凝胶块体具有弹性,疏水性好且具有多孔结构,能承受一定的压强,在抛光实验中效果显著,抛光大理石效果如图9所示,抛光后大理石表面粗糙度在27.552nm,光泽度值为90,此种大理石工厂出厂标准光泽度值为80左右。
实施例5
室温下,将6g的结冷胶与20gW20金刚石磨料加入到200mL去离子水中搅拌均匀,再将60g碳纤维加入其中充分混合搅拌,搅拌时间为7h;配制0.5mol/L的KCl溶液,将搅拌均匀的混合溶液缓慢加入到圆形的模具中并放入到配制好的KCl溶液中,常温下静置5h;最后将结冷胶凝胶取出微波干燥,干燥时间为2h,即可得到结冷胶凝胶结块,所得结块如图10所示,微观形貌如图11所示,制备得到的凝胶块体具有弹性,疏水性好且具有多孔结构,能承受一定的压强,在抛光实验中效果显著抛光大理石效果如图12所示,抛光后大理石粗糙度在30.378nm,测得的平均光泽度值为92,此种大理石工厂出厂标准光泽度值为80左右。
实施例6
常温常压下选取6gλ型卡拉胶与20g W20金刚石磨料加入到200mL去离子水中搅拌均匀,再将60g碳纤维加入其中充分混合搅拌,搅拌时间为7h,配制0.5mol/L的KCl溶液,将搅拌均匀的混合溶液缓慢加入到圆形的模具中并放入到配制好的KCl溶液中,常温下静置3h;最后将卡拉胶凝胶取出在50℃烘箱里热风干燥,干燥时间为2h,即可得到卡拉胶凝胶结块,所得结块如图13所示,微观形貌如图14所示,制备得到的凝胶块体抛光实验中效果显著,抛光大理石效果如图15所示,抛光后大理石粗糙度在30.378nm,测得的平均光泽度值为92,此种大理石工厂出厂标准光泽度值为80左右。
以上所述,仅为本发明的较佳实施例而已,故不能依此限定本发明实施的范围,即依本发明专利范围及说明书内容所作的等效变化与修饰,皆应仍属本发明涵盖的范围内。
Claims (10)
1.一种柔性溶胶凝胶抛光块体的制备方法,其特征在于:包括如下步骤:
(1)将凝胶剂和W20金刚石磨料放入去离子水中搅拌均匀,该凝胶剂为λ型卡拉胶、结冷胶、羧甲基纤维素钠或魔芋胶;
(2)在步骤(1)所得的物料中加入400目的碳纤维混合均匀;
(3)所述步骤(2)所得的物料缓慢注入模具内进行固化,获得固化凝胶;
(4)将上述固化凝胶进行干燥,得到所述柔性溶胶凝胶抛光块体;
所述柔性溶胶凝胶抛光块体中,W20金刚石磨料的含量为9-11wt%,凝胶剂的含量为2.9-3.1wt%,碳纤维的含量为30-40wt%。
2.如权利要求1所述的制备方法,其特征在于:所述凝胶剂为λ型卡拉胶。
3.如权利要求2所述的制备方法,其特征在于:所述固化为浸泡于KCl溶液中。
4.如权利要求1所述的制备方法,其特征在于:所述凝胶剂为魔芋胶。
5.如权利要求4所述的制备方法,其特征在于:所述固化为浸泡于CaCl2溶液中。
6.如权利要求1所述的制备方法,其特征在于:所述凝胶剂为羧甲基纤维素钠。
7.如权利要求6所述的制备方法,其特征在于:所述固化为浸泡于Al2(SO4)3溶液中。
8.如权利要求1所述的制备方法,其特征在于:所述凝胶剂为结冷胶。
9.如权利要求8所述的制备方法,其特征在于:所述固化为浸泡于KCl溶液中。
10.如权利要求1至9中任一权利要求所述的制备方法,其特征在于:所述柔性溶胶凝胶抛光块体中,凝胶剂的含量为3wt%,碳纤维的含量为30wt%。
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