KR100439898B1 - method for manufacture of settle stool brick for electrical discharge machining - Google Patents
method for manufacture of settle stool brick for electrical discharge machining Download PDFInfo
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Abstract
본 발명은 방전가공용(放電加工)용 정반연와(定盤煙瓦) 등과 같은 대형 세라믹스 제조시 겔캐스팅법과 수화반응을 복합적으로 적용함으로써, 성형체의 기계적 강도 향상으로 건조시 크랙 발생을 억제하고, 소결 중에도 수화반응에 의한 강도 발현이 일정온도까지 유지됨으로 인하여 소결중에 발생되는 크랙의 생성을 억제하는데 적합한 대형 세라믹스 성형체 제조에 관한 것이다.The present invention by applying the gel casting method and the hydration reaction in the production of large-scale ceramics, such as a semi-static edge for electric discharge machining, to suppress the occurrence of cracks during drying by improving the mechanical strength of the molded body, sintering The present invention relates to the production of a large ceramic molded body suitable for suppressing the generation of cracks generated during sintering due to the fact that the strength development by the hydration reaction is maintained to a certain temperature.
이에 따른 구성은 증류수에 모노머(monomer)인 메타아크릴아미드(또는 아크릴아미드)와 메틸렌비스아크릴아미드를 첨가하여 용해한 후 여기에 세라믹스분말을 혼합하여 1차 슬러리를 얻고, 상기 슬러리에 수화반응을 일으키는 시멘트, 중합개시제, 촉매를 첨가하여 몰드에 주입한 후 모노머의 중합반응 및 수화반응을 통하여 성형한 후 건조, 소결, 가공하여서 됨을 특징으로 하는 겔캐스팅법을 이용한 방전가공(放電加工)용 정반연와(定盤煙瓦)의 제조방법에 관한 기술이다.According to the constitution, a monomer (methacrylamide) or methylenebisacrylamide, which is a monomer, is dissolved in distilled water, and then mixed with ceramic powder to obtain a primary slurry. After the injection into the mold by the addition of a polymerization initiator, a catalyst, and then formed by the polymerization and hydration reaction of the monomer, followed by drying, sintering, and processing, using the gel casting method It is a technique regarding the manufacturing method of the determination.
Description
본 발명은 방전가공(electrical discharge machining)용 정반연와(settle stool brick)의 제조에 관한 것으로, 보다 상세하세는 방전가공(放電加工)용 정반연와(定盤煙瓦) 등에 사용되는 대형 세라믹스 제조시 겔캐스팅법과 수화반응을 복합적으로 이용하여 성형과정 및 소결과정 중의 강도를 향상시켜 대형 세라믹스의 제조를 가능하게 하는데 적합한 제조방법에 관한 것이다.BACKGROUND OF THE INVENTION Field of the Invention [0001] The present invention relates to the manufacture of a static stool brick for electrical discharge machining, and more particularly, to the manufacture of large ceramics used for static grinding and the like for electrical discharge machining. The present invention relates to a manufacturing method suitable for enabling the production of large ceramics by improving the strength during molding and sintering by using a gel casting method and a hydration reaction in combination.
방전가공(electrical discharge machining)(放電加工)은 가공물과 전극을 등유 또는 물속에서 근접시키고 통전하면 표면의 뾰족한 부분에서 방전이 일어나 그 주변이 용해, 증발한다. 상기 방전을 계속하면 공작물의 전극과 맞닿는 곳은 점점 침식되어 공구와 같은 모양이 오목하게 파인다.In electrical discharge machining, when the workpiece and the electrode are brought close to each other in kerosene or water, electricity is discharged at the sharp part of the surface, and the surroundings are dissolved and evaporated. If the discharge is continued, the contact with the electrode of the workpiece is gradually eroded, and the tool-like shape is recessed.
상기와 같은 방전가공은 금형과 같이 복잡한 형태를 가공하거나 절단할 때 매우 효과적인 방법이다. 침적하는 액체로는 등유, 변압기유, 머신유, 물 , 물유리 등에서 조건에 따라 선정하여 사용한다. 상기 방전가공에는 전극형 방전가공, 와이어커트 방전가공, NC 방전가공 등이 있다.Such electric discharge machining is a very effective method when processing or cutting complex shapes such as molds. The liquid to be deposited is selected according to the conditions from kerosene, transformer oil, machine oil, water and water glass. The electric discharge machining includes electrode type electric discharge machining, wire cut electric discharge machining and NC electric discharge machining.
상기 방전가공 중에서 전극형 방전가공은 (-)전극을 공구로 사용하고, (+)극에 가공물을 고정구인 정반연와(定盤煙瓦) 위에 고정하여 방전가공하는 장치로 램 (ram)형과 퀼(quill)형이 있다. (-)전극인 공구의 이송은 정반연와에 고정된 가공물과 좁은 간극(0.025∼0.1mm)의 갭을 유지하면서 서보기구로 이송되며 이 사이를 유전액(誘電掖)이 흘러나가 금속가공 입자를 운반, 가공부분을 냉각을 시키며 유전액은 펌프로 선회, 계속 유동하면서 가공된다.Electrode-type discharge machining is a device for discharging machining by using a (-) electrode as a tool and fixing the workpiece to a positive electrode, which is a fixture, on a positive electrode. There is a quill type. The tool, which is a negative electrode, is conveyed to the servomechanism while maintaining a gap between the workpiece fixed to the surface and the narrow gap (0.025 ~ 0.1mm), and the dielectric fluid flows out between the metal particles. The conveying and processing parts are cooled and the oil is rotated by a pump and processed while continuing to flow.
상기 장치에서 정반연와와 같은 대형 세라믹스의 제조에 있어서는 소형 세라믹스의 제조에서와는 달리 형상적인 크기가 제조공정에 크게 영향을 미치므로 보다 치밀한 제조공정의 제어가 요구되는 등 성형체의 강도부족, 건조수축, 소결크랙 등에 대한 대책이 마련되어야 한다.In the manufacture of large ceramics such as semi-reversed in the above device, unlike in the manufacture of small ceramics, the shape size greatly affects the manufacturing process, which requires more precise control of the manufacturing process. Measures should be taken for cracks, etc.
종래의 세라믹스 성형법으로 대형 세라믹스를 제조할 수 있는 방법으로는 대표적으로 슬립캐스팅법과 냉간정수압 성형법(CIP)이 있다.Representative methods for producing large-scale ceramics using conventional ceramic molding methods include a slip casting method and a cold hydrostatic molding method (CIP).
슬립캐스팅법은 석고로 만든 몰드 속에 세라믹스 분말을 물 등의 분산매에 현탁한 슬러리를 주입하여 석고 표면에서 수분이 흡수되는 것을 이용하여 세라믹스 성형체를 얻는 방법이다. 석고에서 수분을 흡수시킨 후 몰드를 제거하고 건조시키면 세라믹스 성형체가 얻어지고 이를 소결시키면 제품이 완성된다.The slip casting method is a method of obtaining a ceramic formed body by injecting a slurry suspended in ceramic powder into a dispersion medium such as water in a mold made of gypsum and absorbing moisture from the surface of the gypsum. After absorbing the moisture from the gypsum, the mold is removed and dried to obtain a ceramic molding, which is then sintered to complete the product.
이 방법을 이용하여 두꺼운 제품을 성형할 경우에는 내부와 외부의 성형밀도 차이가 발생하여 최종제품의 형상 및 물성에 나쁜 영향이 미친다.In the case of forming a thick product using this method, a difference in molding density between the inside and the outside occurs, which adversely affects the shape and physical properties of the final product.
냉간정수압 성형법은 고무나 우레탄 등의 재질로 만든 몰드속에 스프레이 드라잉 등의 처리를 통하여 구형화된 세라믹스 원료를 주입하고 이를 밀봉한 후 물의수압을 이용하여 고압으로 처리하여 성형하는 방법이다. 이 방법은 대형의 세라믹스의 성형에 아주 유용하며 균일한 성형체를 얻을 수 있는 장점이 있으나, 대형 설비를 갖추어야 하므로 초기 투자비가 많이 드는 단점이 있다.Cold hydrostatic molding method is a method of injecting a spherical ceramic raw material through a process such as spray drying into a mold made of a material such as rubber or urethane, sealing it, and then molding it by treating it under high pressure using water pressure. This method is very useful for forming large ceramics and has the advantage of obtaining a uniform molded body, but has a disadvantage that the initial investment costs are high because a large facility must be provided.
한편, 상기한 방전가공용 정반연와 같은 대형 세라믹스를 직법 제조한바는 없으나, 세라믹스의 새로운 성형법으로 형상이 복잡하거나 종래의 성형법으로는 제조가 어려운 제품의 성형에 사용되는 겔캐스팅 방법이 있다(Galcasting : US Pat. No. 4,894,194. Jan. 16. 1990).On the other hand, there is no direct manufacturing of large-scale ceramics, such as the above-mentioned semi-reverse for electric discharge machining, there is a gel casting method used for the molding of products that are complicated in the new molding method of ceramics or difficult to manufacture by conventional molding method (Galcasting: US Pat. No. 4,894,194. Jan. 16. 1990).
갤캐스팅법은 전통적인 세라믹스 공정과 중합체 제작 기술이 합쳐진 기술로서 보다 상세하게는 세라믹스분말에 모노머(monomer)인 메타아크릴아미드(또는 아크릴아미드)와 메틸렌비스아크릴아미드, 분산제, 분산매(수계 또는 비수계), 습윤제, 탈포제 등을 첨가하여 슬러리를 제조한 후 여기에 중합개시제인 암모늄퍼설페이트, 촉매인 테트라메틸에틸렌디아민을 첨가한 후 중합반응을 일으켜 세라믹스 성형체를 얻는 기술이다.Galcasting is a combination of traditional ceramic processes and polymer fabrication techniques. More specifically, methacrylamide (or acrylamide), methylenebisacrylamide, dispersant, and dispersion medium (aqueous or non-aqueous), which are monomers, are used in ceramic powder. After preparing a slurry by adding a wetting agent, a defoamer, etc., it adds ammonium persulfate which is a polymerization initiator, and tetramethylethylenediamine which is a catalyst, and performs a polymerization reaction and obtains a ceramic molded object.
이 방법은 슬러리의 유동과정과 고화과정의 완전한 분리가 가능하여 성형체의 균일성을 향상시킬 수 있으며, 결합제로 사용된 모노머의 양이 건조체 전체 중량의 5% 미만으로 작아 탈지 과정이 용이하며 건조체의 강도가 높고 가공이 가능하다는 장점이 있다.This method can improve the uniformity of the molded body by allowing complete separation of the slurry flow and solidification process, and the amount of monomer used as a binder is less than 5% of the total weight of the dry body, so that the degreasing process is easy. It has the advantage of high strength and processing.
1m 이상의 크기를 가지는 대형 세라믹스의 제조에 있어서 가장 중요한 요소는 세라믹스를 성형, 건조, 소결하는 단계에서 크랙의 발생을 억제하고 균일성을 유지하는 것이다.The most important factor in the production of large ceramics having a size of 1 m or more is to suppress the occurrence of cracks and to maintain uniformity during the molding, drying and sintering of the ceramics.
그러나 겔캐스팅법으로 대형 세라믹스를 제조할 경우 모노머의 중합반응으로 형성된 겔의 건조가 충분하게 이루어지기 전까지는 성형체의 강도가 높지 않다. 그리고 성형체의 건조는 성형체의 수축을 동반한다. 성형체의 수축정도는 슬러리에 포함된 세라믹스분말의 부피비율 및 용제의 양에 따라 결정되는데, 일반적으로 1∼5%의 수축이 발생한다.However, when the large-scale ceramics are manufactured by the gel casting method, the strength of the molded body is not high until the gel formed by the polymerization of the monomers is sufficiently dried. And drying of the molded body is accompanied by shrinkage of the molded body. The shrinkage of the molded article is determined by the volume ratio of the ceramic powder contained in the slurry and the amount of the solvent. Generally, shrinkage of 1 to 5% occurs.
이 때 성형체에 발생되는 응력이 재료의 강도를 초과할 경우에 크랙이 발생되는데, 불완전하게 건조된 겔의 강도만으로는 대형의 세라믹스의 건조 수축을 이겨낼 수가 없다.In this case, cracks are generated when the stress generated in the molded body exceeds the strength of the material, and only the strength of the incompletely dried gel cannot overcome the dry shrinkage of large ceramics.
본 발명은 상기한 종래의 문제점을 해결하기 위한 것으로, 정반연와 등과 같은 대형 세라믹스 제조시 겔캐스팅법과 수화반응을 복합적으로 적용함으로써, 성형체의 기계적 강도 향상으로 건조 수축율이 감소하여 건조시 크랙 발생을 억제하고,소결 중에도 수화반응에 의한 강도 발현이 일정온도까지 유지됨으로 인하여 소결중에 발생되는 크랙의 생성을 억제하는데 적합한 정반연와 등의 대형 세라믹스 성형체를 얻는데 그 목적이 있다.The present invention is to solve the above-mentioned problems, by applying a combination of the gel casting method and the hydration reaction in the production of large ceramics, such as semi-reversed, by reducing the mechanical shrinkage of the molded product to reduce the dry shrinkage to suppress cracking during drying In addition, during the sintering, the strength development by the hydration reaction is maintained to a certain temperature to obtain a large ceramic molded body, such as semi-shiny and suitable for suppressing the generation of cracks generated during sintering.
상기한 목적을 달성하기 위한 본 발명은 증류수에 모노머를 첨가하여 용액을 만든 후 세라믹스분말을 혼합하여 1차 슬러리를 얻고, 상기 슬러리에 수화반응을 일으키는 시멘트, 중합개시제, 촉매를 첨가하여 몰드에 주입한 후 모노머의 중합반응 및 수화반응을 통하여 성형한 후 건조, 소결, 가공하여서 됨을 특징으로 하는겔캐스팅법을 이용한 방전가공용 정반연와의 제조방법으로 구성된다.The present invention for achieving the above object is to make a solution by adding a monomer to distilled water and then mixing the ceramic powder to obtain a first slurry, the cement, a polymerization initiator, a catalyst that causes a hydration reaction to the slurry is added to the mold After the molding through the polymerization and hydration reaction of the monomer, and then dried, sintered, and processed by the gel casting method characterized in that the manufacturing method of the semi-finished with the semi-finished lead.
상기 세라믹스의 겔캐스팅 방법은 모노머인 메타아크릴아미드(또는 아크릴아미드)와 메틸렌비스아크릴아미드를 증류수에 완전히 녹여 용액을 만든다. 상기 용액은 증류수 100에 메타아크릴아미드(또는 아크릴아미드) 10∼20중량%, 메틸렌비스아크릴아미드 0.5∼2중량% 혼합되어 있음이 바람직하다.In the gel casting method of the ceramics, the monomer methacrylamide (or acrylamide) and methylenebisacrylamide are completely dissolved in distilled water to make a solution. It is preferable that 10-20 weight% of methacrylamide (or acrylamide) and 0.5-2 weight% of methylenebisacrylamides are mixed with the said solution in distilled water 100.
그리고 상기 용액에 알루미나와 같은 세라믹스분말을 첨가하여 50 vol% 이상의 알루미나 함량을 가지는 1차 슬러리를 만든다. 모노머의 첨가는 세라믹스 원료의 해교에 영향을 주지 않는 것으로 알려져 있으므로 기존에 사용하는 세라믹스 해교제를 이용할 수 있다.And a ceramic slurry such as alumina is added to the solution to make a primary slurry having an alumina content of 50 vol% or more. Since addition of monomer does not affect the peptizing of a ceramic raw material, the ceramic peptizing agent used conventionally can be used.
상기 1차 슬러리에 수화반응을 일으키는 원료로서 시멘트를 혼합하는데, 시멘트는 알루미나 시멘트 또는 포틀랜드 시멘트를 사용할 수 있으며, 바람직한 시멘트의 양은 1∼50중량% 이다.Cement is mixed as a raw material causing the hydration reaction to the primary slurry, cement may be used alumina cement or portland cement, the preferred amount of cement is 1 to 50% by weight.
상기 시멘트를 사용함에 있어, 첨가량이 1% 이하이면 경화 및 건조중에 있어서 강도보강 특성의 발현이 어려우며, 첨가량이 50% 이상이면 2차 혼합시 경화시간이 빨라져서 공정조절이 어려워지고 슬립의 해교성이 저하되는 등 슬립의 특성이 나빠진다.In using the cement, when the addition amount is 1% or less, it is difficult to express the strength reinforcing characteristics during curing and drying, and when the addition amount is 50% or more, the curing time becomes faster during the second mixing, making process control difficult and the peptizing resistance of slip. The properties of the slip deteriorate, such as deterioration.
상기 시멘트 첨가에 이어서 중합개시제로서 암모늄퍼설페이트와 촉매인 테트라메틸에틸렌디아민을 첨가하여 약 5분∼30분간 혼합하여 2차 혼련한 후 진공탈포하여 슬러리중의 기포 제거 후 몰드에 주입하여 중합반응 및 수화반응을 이용하여 성형체를 완성한다.Following the addition of cement, ammonium persulfate and tetramethylethylenediamine as a catalyst were added as a polymerization initiator, mixed for about 5 minutes to 30 minutes, followed by secondary kneading, vacuum degassing, foaming in the slurry, and then injection into a mold for polymerization. Complete the molded body by using the hydration reaction.
상기 2차 혼련하는 시간은 5분∼30분 정도가 적당하나, 이 시간은 중합개시제 및 촉매의 양에 따라서 변할 수 있다. 중합개시제 및 촉매의 양이 많아지면 경화가 빨리 시작되므로 혼합시간은 이들의 양에 의해서 결정되며, 혼합시간이 너무 짧으면 원료의 혼합이 잘 이루어지지 않아 경화 특성이 저하되거나 균일한 제품의 제조가 어려우며, 혼합시간이 너무 길어지면 혼합과정에서 경화가 시작될 수 있다.The second kneading time is suitably about 5 to 30 minutes, but this time may vary depending on the amount of polymerization initiator and catalyst. When the amount of polymerization initiator and catalyst increases, the curing starts quickly, and the mixing time is determined by these amounts. If the mixing time is too short, the mixing of the raw materials is difficult to perform, so that the curing properties are reduced or it is difficult to produce a uniform product. However, if the mixing time is too long, curing may begin during the mixing process.
본 발명은 상기 1차 슬러리 제조시 분산제로서 폴리아크릴레이트계를 세라믹스분말 대비 0.5∼1중량%첨가할 수 있으며, 습윤제와 탈포제를 소량 첨가할 수 있다.The present invention can be added to the polyacrylate-based 0.5 to 1% by weight compared to the ceramic powder as a dispersant in the production of the primary slurry, a small amount of a wetting agent and a defoaming agent can be added.
이상에서와 같이 제조된 본 발명의 성형체는 중합된 겔의 강도에 수화반응에 의한 강도가 보강되어 취급중에 파손이나 크랙발생의 염려가 적으며 건조과정에서도 강도가 유지되어 안정된 건조가 가능하다.The molded article of the present invention prepared as described above is reinforced by the hydration reaction to the strength of the polymerized gel is less fear of breakage or cracking during handling and the strength is maintained even during the drying process, it is possible to stable drying.
상기와 같은 방법으로 성형체를 제조하여 통상적인 방법으로 건조, 소결하면 본발명이 완성된다.The present invention is completed when the molded product is manufactured in the same manner as described above, dried and sintered by a conventional method.
다음은 실시예에 따라 설명한다.The following is described according to the embodiment.
증류수100에 메타아크릴아미드 10∼20중량%, 메틸렌비스아크릴아미드 0.5∼2중랭% 첨가하여 모노머 용액을 만든 후 알루미나분말을 첨가하여 (표 1)과 같이 50부피%와 55부피% 첨가하였으며, 습윤제와 탈포제를 소량 첨가하여 1차 슬러리를 만들었다.10 to 20% by weight of methacrylamide and 0.5 to 2% by weight of methylenebisacrylamide were added to distilled water 100 to make a monomer solution, and 50% by volume and 55% by volume of alumina powder were added as shown in Table 1 A small amount of and defoamer was added to make a primary slurry.
상기 완료된 1차 슬러리에 수화반응을 일으키는 원료인 시멘트를 5중량% 첨가하고 또한 중합재시제인 암모늄퍼설페이트와 촉매인 테트라메틸렌디아민을 첨가하여 알루미나 겔캐스팅용 슬러리를 제조하였다.A slurry for alumina gel casting was prepared by adding 5% by weight of cement which is a raw material for causing a hydration reaction to the finished primary slurry, and adding tetramethylenediamine as a catalyst and ammonium persulfate as a polymerization reagent.
이어서 진공탈포 공정으로 슬러리내의 기포를 제거한 후 이를 금형내에 주입한 후 중합반응 및 수화반응을 이용하여 성형체를 완성하였다.Subsequently, the bubbles in the slurry were removed by a vacuum defoaming process and then injected into the mold to complete the molded body by using a polymerization reaction and a hydration reaction.
한편, 상기 공정과 동일하게 적용하되 수화반응을 일으키는 원료를 첨가하지 않은 겔캐스팅용 슬러리를 비교예로 하여 그 결과를 하기 (표 1)에 나타냈다.On the other hand, it was applied in the same manner as the above process, but the gel casting slurry without the addition of the raw material causing the hydration reaction as a comparative example and the results are shown in the following (Table 1).
상기 (표 1)에 나타난 바와 같이 수화반응을 일으키는 시멘트를 첨가한 본 발명의 실시예의 경우 겔캐스팅 성형체의 강도가 향상되며 건조수축율이 감소하여 건조시 크랙의 발생을 억제할 수 있다. 또한 소결중에도 수화반응에 의한 강조발현이 일전온도까지 유지됨으로 인하여 소결중에 발생되는 크랙의 발생을 억제하는 효과가 있다.As shown in Table 1, in the embodiment of the present invention to which the cement causing the hydration reaction is added, the strength of the gel-casting molded body is improved, and the drying shrinkage rate is reduced to suppress the occurrence of cracks during drying. In addition, during the sintering, since the stress expression by the hydration reaction is maintained up to the previous temperature, there is an effect of suppressing the occurrence of cracks generated during the sintering.
이상에서와 같이 본 발명은 세라믹스 성형체를 제조하는 겔캐스팅법을 적용함에 있어 수화반응을 일으키는 원료의 첨가로 겔캐스팅 성형체의 기계적 강도를 보강하여 건조, 소결중 크랙의 발생을 억제하는 효과가 있어 방전가공용 정반연와 등과 같은 대형 세라믹스 성형체를 용이하게 제조할 수 있다.As described above, the present invention has the effect of suppressing the occurrence of cracks during drying and sintering by reinforcing the mechanical strength of the gel-casting molded body by adding a raw material causing a hydration reaction in applying the gel-casting method of manufacturing a ceramic molded body. It is possible to easily manufacture a large ceramic molded body such as a square for processing.
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Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS59102909A (en) * | 1982-12-04 | 1984-06-14 | Esuren Kako Kk | Production of water-containing gel |
| JPH05319899A (en) * | 1992-05-16 | 1993-12-03 | Kawasaki Refract Co Ltd | Insulating fire-resisting material |
| KR960022369A (en) * | 1994-12-30 | 1996-07-18 | 성재갑 | Molding slurry composition containing coupling agent and molding method using the same |
| JPH11262907A (en) * | 1997-12-02 | 1999-09-28 | Toto Ltd | Manufacture of ceramic |
| US6152211A (en) * | 1998-12-31 | 2000-11-28 | General Electric Company | Core compositions and articles with improved performance for use in castings for gas turbine applications |
| KR20010077623A (en) * | 2000-02-03 | 2001-08-20 | 신동우 | Fabrication of the Green Body Consisting of Silicon Carbide Mixed with Carbon Powders Using Gel-casting Method |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS59102909A (en) * | 1982-12-04 | 1984-06-14 | Esuren Kako Kk | Production of water-containing gel |
| JPH05319899A (en) * | 1992-05-16 | 1993-12-03 | Kawasaki Refract Co Ltd | Insulating fire-resisting material |
| KR960022369A (en) * | 1994-12-30 | 1996-07-18 | 성재갑 | Molding slurry composition containing coupling agent and molding method using the same |
| JPH11262907A (en) * | 1997-12-02 | 1999-09-28 | Toto Ltd | Manufacture of ceramic |
| US6152211A (en) * | 1998-12-31 | 2000-11-28 | General Electric Company | Core compositions and articles with improved performance for use in castings for gas turbine applications |
| KR20010077623A (en) * | 2000-02-03 | 2001-08-20 | 신동우 | Fabrication of the Green Body Consisting of Silicon Carbide Mixed with Carbon Powders Using Gel-casting Method |
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