WO2021169417A1 - Brazed diamond abrasive tool suitable for casting trim polishing - Google Patents
Brazed diamond abrasive tool suitable for casting trim polishing Download PDFInfo
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- WO2021169417A1 WO2021169417A1 PCT/CN2020/128535 CN2020128535W WO2021169417A1 WO 2021169417 A1 WO2021169417 A1 WO 2021169417A1 CN 2020128535 W CN2020128535 W CN 2020128535W WO 2021169417 A1 WO2021169417 A1 WO 2021169417A1
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- grinding
- grinding disc
- diamond
- abrasives
- disc
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D7/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor
- B24D7/02—Wheels in one piece
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
Definitions
- the invention belongs to the technical field of casting flash grinding application, and in particular relates to a brazed diamond abrasive tool suitable for casting flash grinding.
- the conventional grinding method for casting flash is that the grinder uses a manual grinder equipped with a resin grinding wheel to perform manual grinding. Because the resin grinding wheel is made by consolidating silicon carbide abrasives and corundum abrasives into a disc shape using the principle of resin curing, the bonding strength is low. Therefore, during the grinding process, the grinding disc is easy to consume, sparks, and smells. Disadvantages such as large dust. This is because the resin grinding wheel encounters excessive impact on the cast iron flash during the grinding process, which causes the abrasive to fall off while grinding, and because the exposed height of the abrasive is low, the grinding surface temperature is high, which causes the resin to soften and melt. Volatile, emitting a toxic and irritating odor. In addition, due to low abrasive exposure, the sharpness of the grinding disc is not ideal and the grinding efficiency is slow, making the grinding workload of the casting account for about a quarter of the overall manufacturing workload of the casting.
- the consolidation technology of diamond polycrystalline currently has three main bonding methods: electroplating, sintering, and brazing.
- electroplating electroplating
- sintering electroplating
- electroplating electroplating
- brazing uses solder melting to weld the diamond polycrystalline and the matrix together.
- the chemical metallurgical bonding between the solder and the abrasive occurs.
- the abrasive welding strength is high, so the abrasive is exposed to high and the grinding is sharp, which is an ideal production.
- brazed diamond tools basically have no abrasive shedding during use, and no resin melts and volatilizes. Because they are safe in use, no irritating odors are generated, and they are more environmentally friendly. This is consistent with the current development concept of low carbon and environmental protection.
- brazing technology to prepare brazed diamond tools by welding diamond on a steel substrate has been partially used in actual production, such as high-speed rail Borg plate grinding wheels and brazed diamond drill bits.
- high-speed rail Borg plate grinding wheels and brazed diamond drill bits there are no relevant reports and patents for diamond tools for professional grinding of casting flash.
- the existing brazed diamond grinding tools are of few types and are mostly used for grinding stone. The tool manufacturing process, the shape of the base body, and the grinding equipment are quite different, and cannot be applied to the grinding of castings.
- the hole template method uses a hole template made of a special material to orderly distribute the abrasive.
- the principle is to open a series of small holes on the substrate, and each hole contains a diamond, and then use related processes to adhere the diamonds arranged in sequence. On the surface of the substrate.
- This method is mostly used in the preparation of sintered diamond tools, such as saw blade bits. Currently, it can only be used for flat surfaces and a few simple geometric shapes.
- the vacuum adsorption method uses the principle of vacuuming to make a template with small holes have the adsorption force to adsorb diamonds, and then place it on the surface of the substrate.
- This method is similar to the hole template method. It can only prepare some relatively simple geometric surfaces. This method has not yet achieved the orderly distribution of abrasives according to the performance of the workpiece.
- the third cluster arrangement method refers to the use of a template with a certain geometric shape to distribute the diamond abrasive in the voids of the template, and the template can be sprinkled after it is arranged. This method is more common in electroplated diamond products. Because the template is relatively simple to make, it is widely used in electroplated products. However, this method can only achieve orderly macroscopic shapes, and the arrangement of diamond abrasives in each gap is still disordered It is impossible to achieve orderly arrangement, and it is difficult to effectively utilize the advantages of diamond abrasives.
- the present invention provides a brazed diamond abrasive tool suitable for grinding the flash of castings.
- the purpose of the present invention is to provide a brazed diamond abrasive tool suitable for the grinding of cast iron flashes.
- a manual grinder for grinding is used as a supporting machine, and according to the size, shape and grinding of cast iron flashes
- the size of the disc is optimized to calculate the arrangement of the diamond polycrystalline abrasive on the surface of the grinding disc, which has the characteristics of high grinding efficiency, light hand feeling, low vibration, odorless, long life, and beautiful appearance.
- the present invention provides a brazed diamond abrasive tool suitable for the grinding of casting flash, including the outer end of the grinding disc, the inclined surface of the grinding disc, the top of the grinding disc plane, the grinding disc, and the positioning hole arranged in the grinding disc, and The diamond poly-gold abrasives brazed uniformly on the outer end of the grinding disc, the inclined surface of the grinding disc, and the top surface of the grinding disc plane respectively, wherein the diamond poly-gold abrasives on the outer edge of the grinding disc are in an orderly close arrangement, and the inclined surface of the grinding disc
- the diamond poly-gold abrasive is a single particle and is distributed in an orderly and equal interval along the radial direction of the grinding disc.
- the diamond poly-gold abrasive on the top surface of the grinding disc is arranged in a cluster-like abrasive turbine shape, and the bottom of the grinding disc has a concave structure for chip removal.
- the positioning grinder is installed; the outer end of the grinding disc, the inclined surface of the grinding disc, the top of the plane of the grinding disc and the grinding disc are in a disc-shaped structure as a whole.
- the width of the flat top end of the grinding disc occupies 1/3-1/2 of the radius of the grinding disc, and the width of the inclined surface of the grinding disc is 3-5 mm.
- the outer diameter of the brazed diamond polycrystalline casting grinding disc with the disc-shaped structure is 100mm-180mm, and the thickness of the base body is 1.4mm-4.5mm.
- the included angle ⁇ between the inclined surface of the grinding disc and the horizontal direction is 5°-15°.
- the diamond poly-gold abrasive is brazed on the outer end of the grinding disc, the inclined surface of the grinding disc, and the top surface of the plane of the grinding disc, the solder is a nickel-copper-chromium-borosilicate alloy, and the brazing method is vacuum brazing.
- the diamond poly-gold abrasive on the outer edge of the grinding disc is an orderly and densely packed high-grade diamond-cutting abrasive with a grain size of 10-50 mesh.
- the lateral distance between two adjacent diamond poly-gold abrasives is 2d-4d
- the longitudinal distance between two adjacent diamond polygold abrasives is 2d-5d
- d is the maximum particle size of the diamond polygold abrasives.
- the number of diamond poly-gold abrasives on the inclined surface of the grinding disc is the same in the radial direction of the grinding disc.
- the diamond polygold abrasive on the top surface of the grinding disc is a medium-grade turbine-shaped arrangement of cluster grinding abrasives, with a particle size of 10-50 mesh, and each cluster has 3-8 diamond polygold abrasives. .
- a brazed diamond abrasive tool suitable for flash grinding of castings of the present invention is as follows: 1. It has high grinding efficiency, light hand feeling, low vibration, odorless, long life and beautiful appearance. According to the actual situation, different grades of abrasives are selected, which optimizes the cost and is more economical. It perfectly replaces the traditional resin grinding wheel. It is the development direction of casting grinding discs in the casting manufacturing industry and has a large market. Potential; 2. The preparation method has simple process and convenient operation, and can simply realize the orderly and clustered arrangement of diamond abrasives.
- Figure 1 is a schematic cross-sectional view of a brazed diamond abrasive tool suitable for flash grinding of castings according to the present invention
- FIG. 2 is a schematic diagram of the arrangement of abrasives on the outer edge of the grinding disc of a brazed diamond grinding tool suitable for the flash grinding of castings according to the present invention
- Fig. 3 is a schematic diagram of the arrangement of surface abrasives on the top of the grinding disc of a brazed diamond grinding tool suitable for the flash grinding of castings according to the present invention.
- a brazed diamond abrasive tool suitable for burr grinding of castings includes the outer end of the grinding disc 1, the inclined surface of the grinding disc 2, the flat top end of the grinding disc 3 and the grinding disc 4, and The positioning holes 5 are arranged in the grinding disc 4, and the diamond poly-gold abrasives 6 brazed uniformly on the outer end of the grinding disc 1, the inclined surface of the grinding disc 2, the top 3 of the flat surface of the grinding disc, wherein the outer end of the grinding disc 1
- the diamond poly-gold abrasive 6 on the edge is orderly and densely arranged, and the diamond poly-gold abrasive 6 on the inclined surface of the grinding disc 2 is a single particle and is distributed in an orderly and equal interval along the radial direction of the grinding disc.
- the bottom of the grinding disc 4 is a concave structure, used for chip removal and positioning the grinder; the outer end of the grinding disc 1. 4
- the whole is a disc-shaped structure.
- the width of the flat top 3 of the grinding disc occupies 1/3-1/2 of the radius of the grinding disc, and the width of the inclined surface 2 of the grinding disc is 3-5 mm; and the brazed diamond polycrystalline casting of the disc-shaped structure
- the outer diameter of the grinding disc substrate is 100mm -180mm, and the thickness of the substrate is 1.4mm -4.5mm; and the angle ⁇ between the inclined surface of the grinding disc 2 and the horizontal direction is 5o-15o; and the diamond polygold abrasive 6 is brazed and polished
- the preparation method of the brazed diamond abrasive tool suitable for casting flash grinding of this structure includes the following steps: (1) punching of the outer diameter of the base body of the grinding disc; (2) chamfering the outer edge of the outer end of the grinding disc base; (3) grinding The surface of the disc substrate is sandblasted and ultrasonically cleaned; (4) A bonding agent is applied to the surface of the cleaned and dried substrate, and the bonding agent is used to bond diamond abrasive grains and solder; (5) Arrange the abrasives on the flat top of the grinding disc, the inclined surface of the grinding disc and the outer edge of the grinding disc; (6) After the abrasive arrangement is completed, add brazing filler and perform vacuum brazing to prepare a diamond grinding disc for grinding castings.
- the abrasive arrangement of the flat top of the grinding disc, the inclined surface of the grinding disc, and the outer edge of the grinding disc are all completed by the following steps: (1) Place a prefabricated orderly arrangement template designed according to the topography optimization on the substrate Surface; (2) Arrange diamond abrasives, which are distributed in the cavity area of the template, so as to obtain a topography optimized design according to the topography; the top of the polishing disk plane obtains a vortex-like arrangement of clusters and orderly landforms; The outer edge of the grinding disc obtains an orderly and densely arranged landform; the inclined surface of the grinding disc obtains a landform with single abrasive grains in an orderly arrangement and the same radial number; (3) remove the orderly arrangement template to obtain a diamond press The topography optimizes the arrangement of the surface topography.
- the present invention is a brazed diamond abrasive tool suitable for casting flash grinding, and abrasive material (diamond poly-gold abrasive 6) cloth for grinding discs (outer end of grinding disc 1, inclined surface of grinding disc 2, flat top end of grinding disc 3 and grinding disc 4) Determined according to the working condition of the grinding disc and the shape of the grinding disc.
- abrasive material diamond poly-gold abrasive 6
- the abrasive distribution on the disc is optimized for geomorphology.
- the topography of the abrasive arrangement on the outer edge of the grinding disc is optimized.
- the outer end of the grinding disc rotates at high speed while advancing, so the maximum force is applied to the outer end of the grinding disc, which requires a higher diamond brazing strength ,
- the load is greater, and the movement of the outer end of the grinding disc can be regarded as the movement of cutting while grinding. Therefore, in order to reduce the load of the outer end, the density of the outer end of the grinding disc should be as far as possible while ensuring the chip removal space. Therefore, the cloth at the outer end of the grinding disc should be closely packed and orderly, as shown in Figure 2.
- the abrasive used here is a large-size, high-grade abrasive for drilling and cutting.
- the abrasive particle size ranges from 10 mesh to 50 mesh, and the particle size of 35 mesh to 40 mesh is preferably used through the test.
- the lateral distance between two adjacent abrasive grains is 2d ⁇ 4d
- the longitudinal distance between two adjacent abrasive grains is 2d ⁇ 5d
- d is the maximum particle size of the abrasive.
- the topography of the abrasive arrangement on the inclined surface of the grinding disc is optimized. Because the operator often maintains a certain angle between the grinding disc and the grinding plane when using the grinder, the grinding disc can obtain a forward thrust to cut and grind the protruding casting flash. , And can ensure that the edge of the grinding disc can discharge the grinding debris through the inclined surface when the grinding disc is grinding the casting flash, and make the grinding disc have a certain adaptability to the grinding surface. Therefore, the upper end of the grinding disc is composed of a flat surface and a bevel with a certain inclination angle.
- the bevel angle ⁇ (as shown in Figure 1) can be determined according to the principle of ergonomics and the shape of the casting flash.
- the outer edge of the grinding disc is small due to the load on the inclined surface of the grinding disc, it still needs to play the role of grinding and chip removal.
- the requirements for this inclined surface are high grinding efficiency, long grinding life, good heat dissipation effect, and chip removal. The effect is good.
- the method of orderly arranging the abrasives is used to arrange the abrasives along the radial direction of the grinding disc.
- the specific arrangement is to separate the single abrasives at equal intervals in the radial direction of the grinding disc.
- the number of abrasive particles in the radial direction is the same. This is due to the high-speed rotation of the grinding disc.
- the abrasives are medium-sized and high-grade grinding abrasives.
- the angle ⁇ of the inclined plane is 5o ⁇ 15o.
- the distance between adjacent phase particles along the radial direction of the grinding disc is 1.5d ⁇ 4d, distributed along the radial direction.
- the distance between the two rows of abrasive grains ranges from 1.5d to 6d.
- the abrasive particle size ranges from 10 mesh to 50 mesh, and the particle size of 40 mesh to 50 mesh is optimized through experiments.
- the function of the plane is to remove chips, Further grinding, polishing and polishing the surface, so in order to improve the grinding accuracy and chip removal effect, the abrasive arrangement on the top of the grinding disc is shown in Figure 3.
- the principle of optimizing the topography of the top surface of the grinding disc is the best result of creatively optimizing the topography according to the requirements of the casting flash grinding, the shape of the polished casting flash, the speed of the grinder and other working conditions.
- each clustered abrasive can be a straight line, arc, involute, parabola, etc.
- the distance between two adjacent track lines ranges from 3mm to 25mm.
- the medium-grade and fine-grained grinding abrasives are selected as the abrasives here.
- the top surface of the grinding disc is arranged in clusters of abrasives in a turbine shape, and no abrasives are arranged in other parts.
- the grit size of the abrasive is 10-50 meshes, and the grit size of 40-50 meshes is optimized through experiments, with 3-8 abrasives per cluster, and the cluster area ranges from 4mm 2 to 12mm 2 .
- the cluster arrangement at the top plane increases the chip removal space of the plane grinding, ensures the heat dissipation space, and also improves the grinding efficiency.
- the clustered diamonds on the top plane are arranged in a turbine shape to ensure the smoothness of the grinding disc during high-speed rotation. This is because the cutting angle of each clustered diamond belt is the same, and the dynamic effective abrasive grains at the same time The numbers are the same.
- grade classification of abrasives involved in the present invention is the same as JB/GQ ⁇ F6010-86 Same (quality grading standards for synthetic diamond and cubic boron nitride products).
- the brazed diamond abrasive tool suitable for the grinding of casting flashes of the present invention polishes the rounded corners of the outer end of the disc base body, and the size of the rounded corners matches the thickness of the base body.
- the arrangement of the abrasives of the brazed diamond abrasive tool is as follows:
- the outer edge of the grinding disc is made of medium-level flat diamond abrasive with a grain size of 35-40 mesh.
- the horizontal distance between two adjacent abrasive grains is 2d and the longitudinal distance is 2d.
- the inclined surface of the grinding disc is made of high-grade diamond abrasives, with a grain size of 40-50 mesh, the distance between two abrasive grains in the radial direction is 1.5d, and the distance between two rows of abrasive grains distributed in the radial direction is 1.5d.
- the surface abrasives on the top of the grinding disc are arranged in circular clusters with a diameter of 3mm. Each cluster area is arranged with 10-15 medium-grade diamonds of 40-50 mesh.
- the trajectory line is an arc with a radius of 80, and 17 are all arranged. strip.
- the preparation method of the brazed diamond polycrystalline casting grinding disc is as follows:
- the base material of the grinding disc is 65Mn steel to ensure the strength of the tool, and the base thickness is 1.4mm.
- the role of the adhesive is to bond the diamond abrasive grains and the solder. Among them, first brush the adhesive on the top surface of the sanding disc.
- the template material is flexible and can be bent, so it can be closely attached to the surface of the grinding disc.
- Arrange diamond abrasives Use medium grade 40-50 mesh diamonds for grinding. Due to the orderly arrangement of the template, the diamond abrasives are only distributed in the cavity area of the template, which can be obtained according to the topography. Optimize the designed shape.
- the top surface of the grinding disc can be arranged in a cluster of orderly landforms arranged in a spiral shape.
- brazing fillers are added and vacuum brazing is carried out to prepare a diamond grinding disc for grinding castings.
- the brazed diamond abrasive tool suitable for the grinding of casting flashes of the present invention polishes the rounded corners of the outer end of the disc base body, and the size of the rounded corners matches the thickness of the base body.
- the arrangement of the abrasives of the brazed diamond abrasive tool is as follows:
- the outer edge of the grinding disc is made of medium flat diamond abrasive with a grain size of 35-40 mesh.
- the horizontal distance between two adjacent abrasive grains is 4d and the longitudinal distance is 5d.
- the inclined surface of the grinding disc is made of high-grade diamond abrasives with a grain size of 40-50 mesh.
- the distance between two abrasive grains in the radial direction is 3.5d, and the distance between two rows of abrasive grains distributed in the radial direction is 5d.
- the surface abrasives on the top of the grinding disc are arranged in circular clusters with a diameter of 6mm.
- Each cluster area is arranged with 25 to 30 medium-grade diamonds of 40-50 mesh, 35 diamonds in each cluster.
- the preparation method of the brazed diamond polycrystalline casting grinding disc is as follows:
- the base material of the grinding disc is 65Mn steel to ensure the strength of the tool, and the base thickness is 4.5mm.
- the role of the adhesive is to bond the diamond abrasive grains and the solder. Among them, first brush the adhesive on the top surface of the sanding disc.
- the template material is flexible and can be bent, so it can be closely attached to the surface of the grinding disc.
- Arrange diamond abrasives Use medium grade 40-50 mesh diamonds for grinding. Due to the orderly arrangement of the template, the diamond abrasives are only distributed in the cavity area of the template, which can be obtained according to the topography. Optimize the designed shape.
- the top surface of the grinding disc can be arranged in a cluster of orderly landforms arranged in a spiral shape.
- brazing fillers are added and vacuum brazing is carried out to prepare a diamond grinding disc for grinding castings.
- the brazed diamond casting grinding disc produced by this method has the characteristics of high grinding efficiency, light hand feeling, low vibration, odorless, long life, beautiful appearance, etc., and different grades of abrasives are selected according to the actual situation, which optimizes the cost and has more advantages. Economical, it perfectly replaces the traditional resin grinding wheel. It is the development direction of casting grinding discs in the casting manufacturing industry, and it has great market potential.
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- Polishing Bodies And Polishing Tools (AREA)
Abstract
A brazed diamond abrasive tool suitable for casting trim polishing, comprising a polishing disc outer end (1), a polishing disc inclined surface (2), a polishing disc plane top end (3), a polishing disc (4), a positioning hole (5), and diamond polymetallic abrasives (6). The diamond polymetallic abrasives (6) at the edge of the polishing disc outer end (1) are orderly and densely arranged. The diamond polymetallic abrasives (6) on the polishing disc inclined surface (2) are single and are orderly distributed at equal intervals along the radial direction of the polishing disc. The diamond polymetallic abrasives (6) on the surface of the polishing disc plane top end (3) are tufted abrasives and are arranged in the shape of vortex. The bottom of the polishing disc is of a concave surface structure. The abrasive tool has characteristics of high polishing efficiency, light touch, low vibration, being odorless, long service life, good appearance, etc., and abrasives of different grades are selected according to actual conditions to perfectly replace the conventional resin grinding wheel piece.
Description
本发明属于铸件飞边打磨应用技术领域,具体涉及一种适用于铸件飞边打磨的钎焊金刚石磨具。The invention belongs to the technical field of casting flash grinding application, and in particular relates to a brazed diamond abrasive tool suitable for casting flash grinding.
目前,铸件飞边常规的打磨方法是打磨工用安装了树脂砂轮片的手动砂轮机进行手动打磨。由于树脂砂轮片是利用树脂固化的原理将碳化硅磨料、刚玉磨料固结成盘状制作而成,其结合强度低,因此在打磨过程中,会出现打磨盘易消耗、火花大、气味大、粉尘大等缺点。这是由于树脂砂轮片在打磨过程中遇到铸铁件飞边受到过大冲击,导致磨料边磨削边脱落,并由于磨料出露高度低,磨削表面温度高,导致树脂***、烧熔挥发,散发出有毒、刺激气味。此外,由于磨料出露低导致打磨盘锋利度不理想,打磨效率较慢,使得铸件的打磨工作量占铸件整体制造工作量的四分之一左右。At present, the conventional grinding method for casting flash is that the grinder uses a manual grinder equipped with a resin grinding wheel to perform manual grinding. Because the resin grinding wheel is made by consolidating silicon carbide abrasives and corundum abrasives into a disc shape using the principle of resin curing, the bonding strength is low. Therefore, during the grinding process, the grinding disc is easy to consume, sparks, and smells. Disadvantages such as large dust. This is because the resin grinding wheel encounters excessive impact on the cast iron flash during the grinding process, which causes the abrasive to fall off while grinding, and because the exposed height of the abrasive is low, the grinding surface temperature is high, which causes the resin to soften and melt. Volatile, emitting a toxic and irritating odor. In addition, due to low abrasive exposure, the sharpness of the grinding disc is not ideal and the grinding efficiency is slow, making the grinding workload of the casting account for about a quarter of the overall manufacturing workload of the casting.
由于存在以上的缺点,再加上铸件制造业对成本控制的要求,需要开发一种新型打磨盘来取代传统打磨盘,以达到磨削效率高、寿命长、无污染等目的。Due to the above shortcomings, coupled with the cost control requirements of the casting manufacturing industry, it is necessary to develop a new type of grinding disc to replace the traditional grinding disc in order to achieve the goals of high grinding efficiency, long life, and pollution-free.
金刚石聚晶的固结技术目前有电镀、烧结、钎焊等三种主要结合方式。通过对以上三种结合方式进行对比发现,烧结技术与电镀技术磨料出露高度底,胎体对磨料把持强度低,锋利度不理想,排屑效果差,已证明难以胜任打磨铸件飞边的要求。而钎焊技术是利用焊料熔化将金刚石聚晶与基体焊接在一起,焊料与磨料之前发生了化学冶金结合,磨料焊接强度高,因此磨料出露高,磨削锋利,是较为理想的一种制作打磨铸件飞边的技术。相比其它磨料,金刚石为目前最硬的物质;研磨性好;比热小而导热率大,因此易升温也容易散热,而且金刚石是打磨金属较为理想的材料。相比于传统树脂砂轮片,钎焊金刚石工具由于在使用过程中基本不会出现磨料脱落现象,而且无树脂熔化挥发,因在使用过程安全,无刺激性气味产生,更具有绿色环保的特点。这与目前低碳、环保的发展理念是一致的。The consolidation technology of diamond polycrystalline currently has three main bonding methods: electroplating, sintering, and brazing. Through the comparison of the above three combination methods, it is found that the sintering technology and the electroplating technology have a low level of abrasive exposure, the carcass has low abrasive holding strength, unsatisfactory sharpness, and poor chip removal. It has proved difficult to meet the requirements of grinding casting flash . The brazing technology uses solder melting to weld the diamond polycrystalline and the matrix together. The chemical metallurgical bonding between the solder and the abrasive occurs. The abrasive welding strength is high, so the abrasive is exposed to high and the grinding is sharp, which is an ideal production. The technology to polish the flash of castings. Compared with other abrasives, diamond is currently the hardest material; it has good abrasiveness; it has low specific heat and high thermal conductivity, so it is easy to heat up and dissipate heat, and diamond is an ideal material for grinding metals. Compared with traditional resin grinding wheels, brazed diamond tools basically have no abrasive shedding during use, and no resin melts and volatilizes. Because they are safe in use, no irritating odors are generated, and they are more environmentally friendly. This is consistent with the current development concept of low carbon and environmental protection.
目前,利用钎焊技术,将金刚石焊接在钢基体上制备钎焊金刚石工具已有部分应用于实际生产中,比如高铁博格板磨轮,钎焊金刚石钻头等。但对于专业打磨铸件飞边的金刚石工具目前尚未有相关报道与专利出现。现有的钎焊金刚石打磨工具种类少,且多用于打磨石材,工具的制作工艺,基体外形、以及打磨设备均有较大不同,无法应用于铸件打磨上。At present, the use of brazing technology to prepare brazed diamond tools by welding diamond on a steel substrate has been partially used in actual production, such as high-speed rail Borg plate grinding wheels and brazed diamond drill bits. However, there are no relevant reports and patents for diamond tools for professional grinding of casting flash. The existing brazed diamond grinding tools are of few types and are mostly used for grinding stone. The tool manufacturing process, the shape of the base body, and the grinding equipment are quite different, and cannot be applied to the grinding of castings.
而且目前常规的钎焊磨盘多为在磨盘基体表面无序排布一定数量的金刚石,然后经过高温钎焊制作而成。其磨盘表面磨料排布由于工艺限制,难以做到均匀排布,而且未有根据磨盘的实际形貌进行地貌优化,即浪费了金刚石用量,又制约了磨盘的磨削效率与寿命。At present, most of the conventional brazed grinding discs are made by randomly arranging a certain amount of diamonds on the surface of the grinding disc substrate and then brazing them at a high temperature. Due to process limitations, the abrasive arrangement on the surface of the grinding disc is difficult to achieve uniform arrangement, and the topography is not optimized according to the actual topography of the grinding disc, which wastes the amount of diamond and restricts the grinding efficiency and life of the grinding disc.
磨料排布技术在钎焊、电镀产品中已有部分应用,实际应用于生产的技术有孔模板法、真空吸附法以及簇状排布法。其中孔模板法是利用特殊材料制成的孔模板来有序分布磨料,其原理是在基板上开有序列小孔,每孔容纳一颗金刚石,然后利用相关工艺将序列排布的金刚石粘附于基体表面。此方法多用于制备烧结金刚石工具中,如锯片刀头,目前只能用于平面以及少量简单几何外形。真空吸附法是利用抽真空的原理让一带有小孔的模板具有吸附力吸附金刚石,然后置于基体表面,此种方式与孔模板法类似,只能制备一些较为简单的几何面,而且上述两种方法目前尚未做到按照工件使用性能来有序分布磨料。第三种簇状排布法指利用一定几何外形的模板,使金刚石磨料分布于此模板的空隙内,布好后撒去模板即可。此种方式多见于电镀金刚石产品中,由于模板制作较为简单,在电镀产品中应用广泛,但此种方法仅能做到宏观形状有序,而每个空隙中的金刚石磨料排布仍然是无序的,无法做到有序排布,难以有效发挥金刚石磨料的优势。Abrasive arrangement technology has been partially applied in brazing and electroplating products, and the actual production technologies include hole template method, vacuum adsorption method and cluster arrangement method. The hole template method uses a hole template made of a special material to orderly distribute the abrasive. The principle is to open a series of small holes on the substrate, and each hole contains a diamond, and then use related processes to adhere the diamonds arranged in sequence. On the surface of the substrate. This method is mostly used in the preparation of sintered diamond tools, such as saw blade bits. Currently, it can only be used for flat surfaces and a few simple geometric shapes. The vacuum adsorption method uses the principle of vacuuming to make a template with small holes have the adsorption force to adsorb diamonds, and then place it on the surface of the substrate. This method is similar to the hole template method. It can only prepare some relatively simple geometric surfaces. This method has not yet achieved the orderly distribution of abrasives according to the performance of the workpiece. The third cluster arrangement method refers to the use of a template with a certain geometric shape to distribute the diamond abrasive in the voids of the template, and the template can be sprinkled after it is arranged. This method is more common in electroplated diamond products. Because the template is relatively simple to make, it is widely used in electroplated products. However, this method can only achieve orderly macroscopic shapes, and the arrangement of diamond abrasives in each gap is still disordered It is impossible to achieve orderly arrangement, and it is difficult to effectively utilize the advantages of diamond abrasives.
因此,基于上述问题,本发明提供一种适用于铸件飞边打磨的钎焊金刚石磨具。Therefore, based on the above-mentioned problems, the present invention provides a brazed diamond abrasive tool suitable for grinding the flash of castings.
本发明的目的是提供一种适用于铸件飞边打磨的钎焊金刚石磨具,根据铸铁件打磨的具体要求,以打磨用手动砂轮机为配套机器,并根据铸铁件飞边大小、外形以及打磨盘的大小优化计算金刚石聚晶磨料在打磨盘表面的排布,具有打磨效率高、手感轻、震动小、无气味、寿命长、外形美观的特点。The purpose of the present invention is to provide a brazed diamond abrasive tool suitable for the grinding of cast iron flashes. According to the specific requirements of cast iron grinding, a manual grinder for grinding is used as a supporting machine, and according to the size, shape and grinding of cast iron flashes The size of the disc is optimized to calculate the arrangement of the diamond polycrystalline abrasive on the surface of the grinding disc, which has the characteristics of high grinding efficiency, light hand feeling, low vibration, odorless, long life, and beautiful appearance.
技术方案:本发明提供一种适用于铸件飞边打磨的钎焊金刚石磨具,包括打磨盘外端、打磨盘斜面、打磨盘平面顶端和打磨盘,及设置在打磨盘内的定位孔,及分别均布钎焊在打磨盘外端、打磨盘斜面、打磨盘平面顶端表面的金刚石聚金磨料,其中,所述打磨盘外端边缘的金刚石聚金磨料为有序密排,打磨盘斜面的金刚石聚金磨料为单颗并沿磨盘径向有序等间距分布,打磨盘平面顶端表面的金刚石聚金磨料为簇状磨料涡轮状排布,且打磨盘的底部为凹面结构,用于排屑和安装定位砂轮机;所述打磨盘外端、打磨盘斜面、打磨盘平面顶端和打磨盘整体为圆盘形结构。Technical Solution: The present invention provides a brazed diamond abrasive tool suitable for the grinding of casting flash, including the outer end of the grinding disc, the inclined surface of the grinding disc, the top of the grinding disc plane, the grinding disc, and the positioning hole arranged in the grinding disc, and The diamond poly-gold abrasives brazed uniformly on the outer end of the grinding disc, the inclined surface of the grinding disc, and the top surface of the grinding disc plane respectively, wherein the diamond poly-gold abrasives on the outer edge of the grinding disc are in an orderly close arrangement, and the inclined surface of the grinding disc The diamond poly-gold abrasive is a single particle and is distributed in an orderly and equal interval along the radial direction of the grinding disc. The diamond poly-gold abrasive on the top surface of the grinding disc is arranged in a cluster-like abrasive turbine shape, and the bottom of the grinding disc has a concave structure for chip removal. And the positioning grinder is installed; the outer end of the grinding disc, the inclined surface of the grinding disc, the top of the plane of the grinding disc and the grinding disc are in a disc-shaped structure as a whole.
本技术方案的,所述打磨盘平面顶端的宽度占磨盘半径的1/3-1/2,打磨盘斜面的宽度为3-5mm。According to the technical solution, the width of the flat top end of the grinding disc occupies 1/3-1/2 of the radius of the grinding disc, and the width of the inclined surface of the grinding disc is 3-5 mm.
本技术方案的,所述圆盘形结构的钎焊金刚石聚晶铸件打磨盘基体外径为100mm -180mm,基体厚度为1.4mm -4.5mm。According to the technical scheme, the outer diameter of the brazed diamond polycrystalline casting grinding disc with the disc-shaped structure is 100mm-180mm, and the thickness of the base body is 1.4mm-4.5mm.
本技术方案的,所述打磨盘斜面与水平方向的夹角θ为5º-15º。In this technical solution, the included angle θ between the inclined surface of the grinding disc and the horizontal direction is 5°-15°.
本技术方案的,所述金刚石聚金磨料钎焊在打磨盘外端、打磨盘斜面、打磨盘平面顶端表面,焊料为镍铜铬硼硅合金,钎焊方式为真空钎焊。According to the technical scheme, the diamond poly-gold abrasive is brazed on the outer end of the grinding disc, the inclined surface of the grinding disc, and the top surface of the plane of the grinding disc, the solder is a nickel-copper-chromium-borosilicate alloy, and the brazing method is vacuum brazing.
本技术方案的,所述打磨盘外端边缘的金刚石聚金磨料是有序密排的高品级的钻切用磨料,粒度为10-50目,相邻两颗金刚石聚金磨料的横向间距为2d-4d,相邻两颗金刚石聚金磨料的纵向间距为2d-5d,其中d为金刚石聚金磨料的最大粒径。In this technical solution, the diamond poly-gold abrasive on the outer edge of the grinding disc is an orderly and densely packed high-grade diamond-cutting abrasive with a grain size of 10-50 mesh. The lateral distance between two adjacent diamond poly-gold abrasives is 2d-4d, the longitudinal distance between two adjacent diamond polygold abrasives is 2d-5d, where d is the maximum particle size of the diamond polygold abrasives.
本技术方案的,所述打磨盘斜面的金刚石聚金磨料在沿磨盘径向方向上数量相同。According to the technical solution, the number of diamond poly-gold abrasives on the inclined surface of the grinding disc is the same in the radial direction of the grinding disc.
本技术方案的,所述打磨盘平面顶端平面的金刚石聚金磨料是中等品级的涡轮状排布的簇状磨削用磨料,粒度为10-50目,每簇3-8颗金刚石聚金磨料。According to the technical scheme, the diamond polygold abrasive on the top surface of the grinding disc is a medium-grade turbine-shaped arrangement of cluster grinding abrasives, with a particle size of 10-50 mesh, and each cluster has 3-8 diamond polygold abrasives. .
与现有技术相比,本发明的一种适用于铸件飞边打磨的钎焊金刚石磨具的有益效果在于:1、具有打磨效率高、手感轻、震动小、无气味、寿命长、外形美观等特点,并且根据实际情况选择不同品级的磨料,优化了成本,更具有经济性,较为完美地替代了传统的树脂砂轮片,是铸件制造业中铸件打磨盘发展的方向,具有很大的市场潜力;2、制备方法工艺简单,操作方便,能够简单的实现金刚石磨料的有序、簇状排布。Compared with the prior art, the beneficial effects of a brazed diamond abrasive tool suitable for flash grinding of castings of the present invention are as follows: 1. It has high grinding efficiency, light hand feeling, low vibration, odorless, long life and beautiful appearance. According to the actual situation, different grades of abrasives are selected, which optimizes the cost and is more economical. It perfectly replaces the traditional resin grinding wheel. It is the development direction of casting grinding discs in the casting manufacturing industry and has a large market. Potential; 2. The preparation method has simple process and convenient operation, and can simply realize the orderly and clustered arrangement of diamond abrasives.
图1是本发明的一种适用于铸件飞边打磨的钎焊金刚石磨具的剖视结构示意图;Figure 1 is a schematic cross-sectional view of a brazed diamond abrasive tool suitable for flash grinding of castings according to the present invention;
图2是本发明的一种适用于铸件飞边打磨的钎焊金刚石磨具的打磨盘外端边缘磨料排布结构示意图;2 is a schematic diagram of the arrangement of abrasives on the outer edge of the grinding disc of a brazed diamond grinding tool suitable for the flash grinding of castings according to the present invention;
图3是本发明的一种适用于铸件飞边打磨的钎焊金刚石磨具的打磨盘顶端平面磨料排布结构示意图。Fig. 3 is a schematic diagram of the arrangement of surface abrasives on the top of the grinding disc of a brazed diamond grinding tool suitable for the flash grinding of castings according to the present invention.
下面结合附图和具体实施例,进一步阐明本发明。The present invention will be further clarified below in conjunction with the drawings and specific embodiments.
如图1、图2和图3所示的一种适用于铸件飞边打磨的钎焊金刚石磨具,包括打磨盘外端1、打磨盘斜面2、打磨盘平面顶端3和打磨盘4,及设置在打磨盘4内的定位孔5,及分别均布钎焊在打磨盘外端1、打磨盘斜面2、打磨盘平面顶端3表面的金刚石聚金磨料6,其中,所述打磨盘外端1边缘的金刚石聚金磨料6为有序密排,打磨盘斜面2的金刚石聚金磨料6为单颗并沿磨盘径向有序等间距分布,打磨盘平面顶端3表面的金刚石聚金磨料6为簇状磨料涡轮状排布,且打磨盘4的底部为凹面结构,用于排屑和安装定位砂轮机;所述打磨盘外端1、打磨盘斜面2、打磨盘平面顶端3和打磨盘4整体为圆盘形结构。As shown in Figure 1, Figure 2 and Figure 3, a brazed diamond abrasive tool suitable for burr grinding of castings includes the outer end of the grinding disc 1, the inclined surface of the grinding disc 2, the flat top end of the grinding disc 3 and the grinding disc 4, and The positioning holes 5 are arranged in the grinding disc 4, and the diamond poly-gold abrasives 6 brazed uniformly on the outer end of the grinding disc 1, the inclined surface of the grinding disc 2, the top 3 of the flat surface of the grinding disc, wherein the outer end of the grinding disc 1 The diamond poly-gold abrasive 6 on the edge is orderly and densely arranged, and the diamond poly-gold abrasive 6 on the inclined surface of the grinding disc 2 is a single particle and is distributed in an orderly and equal interval along the radial direction of the grinding disc. It is arranged in a cluster of abrasives in a turbine shape, and the bottom of the grinding disc 4 is a concave structure, used for chip removal and positioning the grinder; the outer end of the grinding disc 1. 4 The whole is a disc-shaped structure.
进一步优选的,所述打磨盘平面顶端3的宽度占磨盘半径的1/3-1/2,打磨盘斜面2的宽度为3-5mm;及所述圆盘形结构的钎焊金刚石聚晶铸件打磨盘基体外径为100mm -180mm,基体厚度为1.4mm -4.5mm;及所述打磨盘斜面2与水平方向的夹角θ为5º-15º;及所述金刚石聚金磨料6钎焊在打磨盘外端1、打磨盘斜面2、打磨盘平面顶端3表面,焊料为镍铜铬硼硅合金,钎焊方式为真空钎焊;及所述打磨盘外端1边缘的金刚石聚金磨料6是有序密排的高品级的钻切用磨料,粒度为10-50目,相邻两颗金刚石聚金磨料6的横向间距为2d-4d,相邻两颗金刚石聚金磨料6的纵向间距为2d-5d,其中d为金刚石聚金磨料6的最大粒径;及所述打磨盘斜面2的金刚石聚金磨料6在沿磨盘径向方向上数量相同;及所述打磨盘平面顶端3平面的金刚石聚金磨料6是中等品级的涡轮状排布的簇状磨削用磨料,粒度为10-50目,每簇3-8颗金刚石聚金磨料6。Further preferably, the width of the flat top 3 of the grinding disc occupies 1/3-1/2 of the radius of the grinding disc, and the width of the inclined surface 2 of the grinding disc is 3-5 mm; and the brazed diamond polycrystalline casting of the disc-shaped structure The outer diameter of the grinding disc substrate is 100mm -180mm, and the thickness of the substrate is 1.4mm -4.5mm; and the angle θ between the inclined surface of the grinding disc 2 and the horizontal direction is 5º-15º; and the diamond polygold abrasive 6 is brazed and polished The outer end of the disc 1, the inclined surface of the grinding disc 2, the top 3 surface of the plane of the grinding disc, the solder is nickel-copper-chromium-borosilicate alloy, and the brazing method is vacuum brazing; and the diamond polygold abrasive 6 on the edge of the outer end 1 of the grinding disc is Orderly close-packed high-grade abrasives for drilling and cutting, with a grain size of 10-50 mesh, the horizontal distance between two adjacent diamond poly-gold abrasives 6 is 2d-4d, and the longitudinal distance between two adjacent diamond poly-gold abrasives 6 is 2d-5d, where d is the maximum particle size of the diamond poly-gold abrasive 6; and the diamond poly-gold abrasive 6 of the bevel surface 2 of the grinding disc 2 has the same quantity in the radial direction of the grinding disc; and the flat top 3 of the grinding disc Diamond poly-gold abrasive 6 is a medium-grade turbine-shaped arrangement of cluster-like grinding abrasives, with a particle size of 10-50 mesh, and 3-8 diamond poly-gold abrasives 6 in each cluster.
本结构的适用于铸件飞边打磨的钎焊金刚石磨具的制备方法,包括以下步骤:(1)打磨盘基体外径冲压;(2)打磨盘基体外端边缘进行倒角;(3)打磨盘基体表面进行喷砂处理,并进行超声清洗;(4)在清洗晾干的基体表面进行涂覆粘结剂,所述粘结剂用于粘结金刚石磨粒与焊料;(5)依次对打磨盘平面顶端、打磨盘斜面和打磨盘外端边缘进行磨料排布;(6)磨料排布完成后,添加钎焊焊料并进行真空钎焊,制备出铸件打磨用金刚石磨盘。The preparation method of the brazed diamond abrasive tool suitable for casting flash grinding of this structure includes the following steps: (1) punching of the outer diameter of the base body of the grinding disc; (2) chamfering the outer edge of the outer end of the grinding disc base; (3) grinding The surface of the disc substrate is sandblasted and ultrasonically cleaned; (4) A bonding agent is applied to the surface of the cleaned and dried substrate, and the bonding agent is used to bond diamond abrasive grains and solder; (5) Arrange the abrasives on the flat top of the grinding disc, the inclined surface of the grinding disc and the outer edge of the grinding disc; (6) After the abrasive arrangement is completed, add brazing filler and perform vacuum brazing to prepare a diamond grinding disc for grinding castings.
进一步优选的,所述打磨盘平面顶端、打磨盘斜面和打磨盘外端边缘进行磨料排布均通过以下步骤完成:(1)将预制的按地貌优化所设计的有序排布模板置于基体表面;(2)排布金刚石磨料,金刚石磨料分布于模板的空洞区域内,从而得到按照地貌优化所设计的形貌;所述打磨盘平面顶端得到旋涡状排布的簇状有序的地貌;所述打磨盘外端边缘得到有序密排的地貌;所述打磨盘斜面得到单颗磨粒有序排布且径向数目相同的地貌;(3)撤除有序排布模板,得到金刚石按地貌优化排布表面形貌。Further preferably, the abrasive arrangement of the flat top of the grinding disc, the inclined surface of the grinding disc, and the outer edge of the grinding disc are all completed by the following steps: (1) Place a prefabricated orderly arrangement template designed according to the topography optimization on the substrate Surface; (2) Arrange diamond abrasives, which are distributed in the cavity area of the template, so as to obtain a topography optimized design according to the topography; the top of the polishing disk plane obtains a vortex-like arrangement of clusters and orderly landforms; The outer edge of the grinding disc obtains an orderly and densely arranged landform; the inclined surface of the grinding disc obtains a landform with single abrasive grains in an orderly arrangement and the same radial number; (3) remove the orderly arrangement template to obtain a diamond press The topography optimizes the arrangement of the surface topography.
本发明的适用于铸件飞边打磨的钎焊金刚石磨具,打磨盘(打磨盘外端1、打磨盘斜面2、打磨盘平面顶端3和打磨盘4)的磨料(金刚石聚金磨料6)布料根据磨盘工作情况以及磨盘外形确定。打磨盘工作时沿打磨盘中心轴高速旋转,并可按照任意方向、特定角度运动,因此,打磨盘磨削的运动极为复杂,根据其实际应用的状态逆向分析,确定钎焊金刚石聚晶铸件打磨盘上的磨料分布并进行地貌优化。The present invention is a brazed diamond abrasive tool suitable for casting flash grinding, and abrasive material (diamond poly-gold abrasive 6) cloth for grinding discs (outer end of grinding disc 1, inclined surface of grinding disc 2, flat top end of grinding disc 3 and grinding disc 4) Determined according to the working condition of the grinding disc and the shape of the grinding disc. When the grinding disc is working, it rotates at high speed along the central axis of the grinding disc and can move in any direction and at a specific angle. Therefore, the grinding movement of the grinding disc is extremely complicated. According to the reverse analysis of the actual application state, it is determined that the brazed diamond polycrystalline casting is polished The abrasive distribution on the disc is optimized for geomorphology.
(1)打磨盘外端边缘磨料排布地貌优化,打磨盘在使用过程中,打磨盘外端边高速转动边向前推进,因此在打磨盘外端受力最大,要求金刚石钎焊强度更高,所承担负载更大,而且打磨盘外端的运动可以看作一边切割一边磨削的运动,因此,为了减小外端负载,磨盘外端磨料的密度应在保证排屑空间的情况下尽可能的多,因此磨盘外端布料要做到密排有序,如图2所示。(1) The topography of the abrasive arrangement on the outer edge of the grinding disc is optimized. During the use of the grinding disc, the outer end of the grinding disc rotates at high speed while advancing, so the maximum force is applied to the outer end of the grinding disc, which requires a higher diamond brazing strength , The load is greater, and the movement of the outer end of the grinding disc can be regarded as the movement of cutting while grinding. Therefore, in order to reduce the load of the outer end, the density of the outer end of the grinding disc should be as far as possible while ensuring the chip removal space. Therefore, the cloth at the outer end of the grinding disc should be closely packed and orderly, as shown in Figure 2.
根据负载与磨盘运动轨迹分析,此处磨料选用大粒度、高品级的钻切用磨料。磨料粒度范围为10目~50目,通过试验优选用35目~40目粒度。相邻两颗磨粒的横向间距为2d ~
4d,相邻两颗磨粒的纵向间距为2d~ 5d,其中d为磨料的最大粒径。According to the analysis of the load and the movement trajectory of the grinding disc, the abrasive used here is a large-size, high-grade abrasive for drilling and cutting. The abrasive particle size ranges from 10 mesh to 50 mesh, and the particle size of 35 mesh to 40 mesh is preferably used through the test. The lateral distance between two adjacent abrasive grains is 2d ~
4d, the longitudinal distance between two adjacent abrasive grains is 2d~5d, where d is the maximum particle size of the abrasive.
(2)打磨盘斜面磨料排布地貌优化,由于操作人员在使用打磨机时打磨盘与打磨平面常会保持一定夹角,使得打磨盘能获得一个向前的推力对突起的铸件飞边进行切磨,而且可以保证打磨盘在打磨铸件飞边时磨片边缘能够通过斜面将磨屑排出,并使得打磨盘对打磨面有一定的适应性。因此打磨盘上端是一个由平面与一定倾角的斜面组成的,斜面角度θ(如图1所示)可根据人体工程学的原理以及结合铸件飞边的外形来确定。(2) The topography of the abrasive arrangement on the inclined surface of the grinding disc is optimized. Because the operator often maintains a certain angle between the grinding disc and the grinding plane when using the grinder, the grinding disc can obtain a forward thrust to cut and grind the protruding casting flash. , And can ensure that the edge of the grinding disc can discharge the grinding debris through the inclined surface when the grinding disc is grinding the casting flash, and make the grinding disc have a certain adaptability to the grinding surface. Therefore, the upper end of the grinding disc is composed of a flat surface and a bevel with a certain inclination angle. The bevel angle θ (as shown in Figure 1) can be determined according to the principle of ergonomics and the shape of the casting flash.
打磨盘斜面上由于承受负载打磨盘外端边缘较小,但仍需要起到磨削、排屑的作用,对此斜面的要求是磨削效率高、磨削寿命长、散热效果佳、排屑效果好,为了实现上述要求,采用有序排布磨料的方法,将磨料在沿磨盘上沿径向排列,具体排布方式为在打磨盘径向方向上,将单颗磨料按照等间距分开,并且径向方向上磨料颗粒数量相同。这是由于磨盘高速回转,为保证振动最小且磨削效率最高,则在回转方向上同一时刻参与磨削的磨粒数量一致从而保证磨削的平稳性。此外磨粒的有序性排列也提高了打磨盘的美观性。根据负载与磨盘运动轨迹分析,此处磨料选用中等粒度、高品级的磨削用磨料。Because the outer edge of the grinding disc is small due to the load on the inclined surface of the grinding disc, it still needs to play the role of grinding and chip removal. The requirements for this inclined surface are high grinding efficiency, long grinding life, good heat dissipation effect, and chip removal. The effect is good. In order to achieve the above requirements, the method of orderly arranging the abrasives is used to arrange the abrasives along the radial direction of the grinding disc. The specific arrangement is to separate the single abrasives at equal intervals in the radial direction of the grinding disc. And the number of abrasive particles in the radial direction is the same. This is due to the high-speed rotation of the grinding disc. In order to ensure the smallest vibration and the highest grinding efficiency, the number of abrasive particles involved in the grinding at the same time in the rotation direction is the same to ensure the smoothness of the grinding. In addition, the orderly arrangement of abrasive grains also improves the aesthetics of the grinding disc. According to the analysis of the load and the movement trajectory of the grinding disc, the abrasives here are medium-sized and high-grade grinding abrasives.
为了实现上述要求,斜面角度θ为5º~15º,磨料在打磨盘上沿径向分布时,沿磨盘径向沿磨盘径向相邻相颗磨粒间距范围1.5d~4d,沿径向分布的两列磨粒的间距范围1.5d~ 6d。磨料粒度范围10目~50目,通过试验优化选用40目~50目粒度。In order to achieve the above requirements, the angle θ of the inclined plane is 5º~15º. When the abrasive is distributed on the grinding disc in the radial direction, the distance between adjacent phase particles along the radial direction of the grinding disc is 1.5d~4d, distributed along the radial direction. The distance between the two rows of abrasive grains ranges from 1.5d to 6d. The abrasive particle size ranges from 10 mesh to 50 mesh, and the particle size of 40 mesh to 50 mesh is optimized through experiments.
(3)打磨盘顶端平面磨料排布地貌优化(3) Optimization of the topography of the surface abrasive arrangement on the top of the grinding disc
由于铸件打磨盘的运动实际上是切削、磨削合二为一的运动,且所打磨的表面有一定精度的要求,因此在磨盘外端与斜面进行切磨后,平面的作用是排屑、进一步磨削、抛光打磨表面,因此为了提高打磨精度以及排屑效果,打磨盘顶端磨料排布情况如图3所示。Since the movement of the casting grinding disc is actually a combination of cutting and grinding, and the polished surface has certain accuracy requirements, after cutting and grinding the outer end of the grinding disc and the inclined surface, the function of the plane is to remove chips, Further grinding, polishing and polishing the surface, so in order to improve the grinding accuracy and chip removal effect, the abrasive arrangement on the top of the grinding disc is shown in Figure 3.
打磨盘平面顶端平面地貌优化原理是根据铸件飞边打磨要求以及打磨的铸件飞边外形、砂轮机转速等工作条件进行创造性地地貌优化所得出的最佳结果。The principle of optimizing the topography of the top surface of the grinding disc is the best result of creatively optimizing the topography according to the requirements of the casting flash grinding, the shape of the polished casting flash, the speed of the grinder and other working conditions.
每一条簇状磨料形成的轨迹可以是直线,圆弧,渐开线,抛物线等轨迹。两邻两条轨迹线之间的间距范围 3mm~25mm。根据负载与磨盘运动轨迹分析,此处磨料选用中等品级、粒度较细的磨削用磨料。打磨盘平面顶端平面处按照涡轮状排布簇状磨料,其它部位不排布磨料。磨料粒度为 10 ~
50目,通过试验优化选用40目~50目粒度,每簇3~ 8颗磨料,簇状面积范围为4mm
2~
12mm
2。
The trajectory formed by each clustered abrasive can be a straight line, arc, involute, parabola, etc. The distance between two adjacent track lines ranges from 3mm to 25mm. According to the analysis of the load and the movement trajectory of the grinding disc, the medium-grade and fine-grained grinding abrasives are selected as the abrasives here. The top surface of the grinding disc is arranged in clusters of abrasives in a turbine shape, and no abrasives are arranged in other parts. The grit size of the abrasive is 10-50 meshes, and the grit size of 40-50 meshes is optimized through experiments, with 3-8 abrasives per cluster, and the cluster area ranges from 4mm 2 to 12mm 2 .
顶端平面处进行簇状排布提高了平面打磨的排屑空间,保证散热空间,亦提高了打磨效率。顶端平面的簇状金刚石按照涡轮状排布,保证了打磨盘在高速转动中的平稳性,这是由于每条簇状金刚石带的切入角都是一致的,而且在同一时刻的动态有效磨粒数一致。The cluster arrangement at the top plane increases the chip removal space of the plane grinding, ensures the heat dissipation space, and also improves the grinding efficiency. The clustered diamonds on the top plane are arranged in a turbine shape to ensure the smoothness of the grinding disc during high-speed rotation. This is because the cutting angle of each clustered diamond belt is the same, and the dynamic effective abrasive grains at the same time The numbers are the same.
本发明涉及的磨料的品级分类与 JB/GQ·F6010-86
相同(人造金刚石、立方氮化硼产品质量分等标准)。The grade classification of abrasives involved in the present invention is the same as JB/GQ·F6010-86
Same (quality grading standards for synthetic diamond and cubic boron nitride products).
实施例一Example one
本发明的适用于铸件飞边打磨的钎焊金刚石磨具,打磨盘基体外端倒圆角,圆角大小与基体厚度匹配。The brazed diamond abrasive tool suitable for the grinding of casting flashes of the present invention polishes the rounded corners of the outer end of the disc base body, and the size of the rounded corners matches the thickness of the base body.
该钎焊金刚石磨具的磨料的排布如下:The arrangement of the abrasives of the brazed diamond abrasive tool is as follows:
①打磨盘外端边缘选用中等平级金刚石磨料,粒度35~40目,相邻两颗磨粒横向间距为2d,纵向间距2d。①The outer edge of the grinding disc is made of medium-level flat diamond abrasive with a grain size of 35-40 mesh. The horizontal distance between two adjacent abrasive grains is 2d and the longitudinal distance is 2d.
②打磨盘斜面选用高等品级金刚石磨料,粒度40~50目,沿径向两颗磨粒横向间距为1.5d,沿径向分布的两列磨粒间距1.5d。②The inclined surface of the grinding disc is made of high-grade diamond abrasives, with a grain size of 40-50 mesh, the distance between two abrasive grains in the radial direction is 1.5d, and the distance between two rows of abrasive grains distributed in the radial direction is 1.5d.
③打磨盘顶端平面磨料按圆形簇状排布,簇状直径3mm, 每个簇状区排布 40~50目中等品级金刚石10~15 颗,轨迹线为半径80的圆弧,均排17条。③The surface abrasives on the top of the grinding disc are arranged in circular clusters with a diameter of 3mm. Each cluster area is arranged with 10-15 medium-grade diamonds of 40-50 mesh. The trajectory line is an arc with a radius of 80, and 17 are all arranged. strip.
该适用于铸件飞边打磨的钎焊金刚石磨具中,钎焊金刚石聚晶铸件打磨盘的制备方法如下:In the brazed diamond abrasive tool suitable for casting flash grinding, the preparation method of the brazed diamond polycrystalline casting grinding disc is as follows:
(1)打磨盘基体外径冲压。所用打磨盘基体材料为65Mn钢,保证工具强度,基体厚度为1.4mm。(1) Punching the outer diameter of the grinding disc substrate. The base material of the grinding disc is 65Mn steel to ensure the strength of the tool, and the base thickness is 1.4mm.
(2)打磨盘基体外端边缘进行倒角,倒角尺寸r=0.5。(2) Grind the outer edge of the disc base body to chamfer, and the chamfer size r=0.5.
(3)打磨盘基体表面进行喷砂处理,并进行超声清洗。(3) Grind the surface of the disc substrate with sandblasting and ultrasonic cleaning.
(4)在清洗晾干的基体表面进行涂覆粘结剂,此粘结剂的作用是粘结金刚石磨粒与焊料。其中首先在打磨盘顶端平面处刷粘结剂。(4) Coating the adhesive on the surface of the cleaned and dried substrate, the role of the adhesive is to bond the diamond abrasive grains and the solder. Among them, first brush the adhesive on the top surface of the sanding disc.
(5)将本实施例中打磨盘磨料的排布方式预制的按地貌优化所设计的有序排布模板置于基体表面。模板材料柔韧性好,可以进行弯曲,因此可以与磨盘表面紧密贴合。(5) Place the prefabricated orderly arrangement template designed according to the geomorphology optimization on the surface of the substrate. The template material is flexible and can be bent, so it can be closely attached to the surface of the grinding disc.
(6)进行排布金刚石磨料,金刚石选用中等品级的40~50目的磨削用金刚石,由于有序排布模板的作用,金刚石磨料只分布于模板的空洞区域内,由此便可以得到按照地貌优化所设计的形貌。打磨盘顶端平面处便可得到按旋涡状排布的簇状有序的地貌。(6) Arrange diamond abrasives. Use medium grade 40-50 mesh diamonds for grinding. Due to the orderly arrangement of the template, the diamond abrasives are only distributed in the cavity area of the template, which can be obtained according to the topography. Optimize the designed shape. The top surface of the grinding disc can be arranged in a cluster of orderly landforms arranged in a spiral shape.
(7)将有序排布模板撤除,便实现了打磨盘顶端平面磨料的排布。(7) The orderly arrangement template is removed, and the arrangement of the surface abrasives on the top of the grinding disc is realized.
(8)按步骤(4)~(7)的方法对打磨盘斜面进行布料,磨料选用高品级的40~50目的磨削用金刚石。所得到的地貌为单颗磨粒径向有序排布,且径向数目相同。(8) According to the method of steps (4) to (7), cloth the inclined surface of the grinding disc, and use high-grade 40-50 mesh grinding diamond as the abrasive. The obtained landform is that the single grains are arranged in an orderly manner, and the radial numbers are the same.
(9)按步骤(4)~(7)对打磨盘外端边缘进行布料,磨料选用高品级的35~40目的钻切用金刚石。所得到的为密排有序分布的磨料地貌。(9) Follow steps (4) to (7) to fabric the outer edge of the grinding disc, and use high-grade 35-40 mesh diamonds for the abrasive. The result is a close-packed and orderly distributed abrasive landform.
(10)磨料排布完成后,添加钎焊焊料并进行真空钎焊,制备出铸件打磨用金刚石磨盘。(10) After the abrasive arrangement is completed, brazing fillers are added and vacuum brazing is carried out to prepare a diamond grinding disc for grinding castings.
实施例二Example two
本发明的适用于铸件飞边打磨的钎焊金刚石磨具,打磨盘基体外端倒圆角,圆角大小与基体厚度匹配。The brazed diamond abrasive tool suitable for the grinding of casting flashes of the present invention polishes the rounded corners of the outer end of the disc base body, and the size of the rounded corners matches the thickness of the base body.
该钎焊金刚石磨具的磨料的排布如下:The arrangement of the abrasives of the brazed diamond abrasive tool is as follows:
①打磨盘外端边缘选用中等平级金刚石磨料,粒度35~40目,相邻两颗磨粒横向间距为4d,纵向间距5d。①The outer edge of the grinding disc is made of medium flat diamond abrasive with a grain size of 35-40 mesh. The horizontal distance between two adjacent abrasive grains is 4d and the longitudinal distance is 5d.
②打磨盘斜面选用高等品级金刚石磨料,粒度40~50目,沿径向两颗磨粒横向间距为3.5d,沿径向分布的两列磨粒间距5d。②The inclined surface of the grinding disc is made of high-grade diamond abrasives with a grain size of 40-50 mesh. The distance between two abrasive grains in the radial direction is 3.5d, and the distance between two rows of abrasive grains distributed in the radial direction is 5d.
③打磨盘顶端平面磨料按圆形簇状排布,簇状直径6mm, 每个簇状区排布 40~50目中等品级金刚石25~30 颗,均排35条。③The surface abrasives on the top of the grinding disc are arranged in circular clusters with a diameter of 6mm. Each cluster area is arranged with 25 to 30 medium-grade diamonds of 40-50 mesh, 35 diamonds in each cluster.
该适用于铸件飞边打磨的钎焊金刚石磨具中,钎焊金刚石聚晶铸件打磨盘的制备方法如下:In the brazed diamond abrasive tool suitable for casting flash grinding, the preparation method of the brazed diamond polycrystalline casting grinding disc is as follows:
(1)打磨盘基体外径冲压。所用打磨盘基体材料为65Mn钢,保证工具强度,基体厚度为4.5mm。(1) Punching the outer diameter of the grinding disc substrate. The base material of the grinding disc is 65Mn steel to ensure the strength of the tool, and the base thickness is 4.5mm.
(2)打磨盘基体外端边缘进行倒角,倒角尺寸r=0.5。(2) Grind the outer edge of the disc base body to chamfer, and the chamfer size r=0.5.
(3)打磨盘基体表面进行喷砂处理,并进行超声清洗。(3) Grind the surface of the disc substrate with sandblasting and ultrasonic cleaning.
(4)在清洗晾干的基体表面进行涂覆粘结剂,此粘结剂的作用是粘结金刚石磨粒与焊料。其中首先在打磨盘顶端平面处刷粘结剂。(4) Coating the adhesive on the surface of the cleaned and dried substrate, the role of the adhesive is to bond the diamond abrasive grains and the solder. Among them, first brush the adhesive on the top surface of the sanding disc.
(5)将本实施例中打磨盘磨料的排布方式预制的按地貌优化所设计的有序排布模板置于基体表面。模板材料柔韧性好,可以进行弯曲,因此可以与磨盘表面紧密贴合。(5) Place the prefabricated orderly arrangement template designed according to the geomorphology optimization on the surface of the substrate. The template material is flexible and can be bent, so it can be closely attached to the surface of the grinding disc.
(6)进行排布金刚石磨料,金刚石选用中等品级的40~50目的磨削用金刚石,由于有序排布模板的作用,金刚石磨料只分布于模板的空洞区域内,由此便可以得到按照地貌优化所设计的形貌。打磨盘顶端平面处便可得到按旋涡状排布的簇状有序的地貌。(6) Arrange diamond abrasives. Use medium grade 40-50 mesh diamonds for grinding. Due to the orderly arrangement of the template, the diamond abrasives are only distributed in the cavity area of the template, which can be obtained according to the topography. Optimize the designed shape. The top surface of the grinding disc can be arranged in a cluster of orderly landforms arranged in a spiral shape.
(7)将有序排布模板撤除,便实现了打磨盘顶端平面磨料的排布。(7) The orderly arrangement template is removed, and the arrangement of the surface abrasives on the top of the grinding disc is realized.
(8)按步骤(4)~(7)的方法对打磨盘斜面进行布料,磨料选用高品级的40~50目的磨削用金刚石。所得到的地貌为单颗磨粒径向有序排布,且径向数目相同。(8) According to the method of steps (4) to (7), cloth the inclined surface of the grinding disc, and use high-grade 40-50 mesh grinding diamond as the abrasive. The obtained landform is that the single grains are arranged in an orderly manner, and the radial numbers are the same.
(9)按步骤(4)~(7)对打磨盘外端边缘进行布料,磨料选用高品级的35~40目的钻切用金刚石。所得到的为密排有序分布的磨料地貌。(9) Follow steps (4) to (7) to fabric the outer edge of the grinding disc, and use high-grade 35-40 mesh diamonds for the abrasive. The result is a close-packed and orderly distributed abrasive landform.
(10)磨料排布完成后,添加钎焊焊料并进行真空钎焊,制备出铸件打磨用金刚石磨盘。(10) After the abrasive arrangement is completed, brazing fillers are added and vacuum brazing is carried out to prepare a diamond grinding disc for grinding castings.
通过此方法生产的钎焊金刚石铸件打磨盘,具有打磨效率高、手感轻、震动小、无气味、寿命长、外形美观等特点,并且根据实际情况选择不同品级的磨料,优化了成本,更具有经济性,较为完美地替代了传统的树脂砂轮片,是铸件制造业中铸件打磨盘发展的方向,具有很大的市场潜力。The brazed diamond casting grinding disc produced by this method has the characteristics of high grinding efficiency, light hand feeling, low vibration, odorless, long life, beautiful appearance, etc., and different grades of abrasives are selected according to the actual situation, which optimizes the cost and has more advantages. Economical, it perfectly replaces the traditional resin grinding wheel. It is the development direction of casting grinding discs in the casting manufacturing industry, and it has great market potential.
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以作出若干改进,这些改进也应视为本发明的保护范围。The above are only the preferred embodiments of the present invention. It should be pointed out that for those of ordinary skill in the art, without departing from the principle of the present invention, several improvements can be made, and these improvements should also be regarded as the present invention. The scope of protection.
Claims (8)
- 一种适用于铸件飞边打磨的钎焊金刚石磨具,其特征在于:包括打磨盘外端 (1)、打磨盘斜面(2)、打磨盘平面顶端(3)和打磨盘(4),及设置在打磨盘(4)内的定位孔(5),及分别均布钎焊在打磨盘外端(1)、打磨盘斜面(2)、打磨盘平面顶端(3)表面的金刚石聚金磨料(6),其中,所述打磨盘外端(1)边缘的金刚石聚金磨料(6)为有序密排,打磨盘斜面(2)的金刚石聚金磨料(6)为单颗并沿磨盘径向有序等间距分布,打磨盘平面顶端(3)表面的金刚石聚金磨料(6)为簇状磨料涡轮状排布,且打磨盘(4)的底部为凹面结构,用于排屑和安装定位砂轮机;所述打磨盘外端(1)、打磨盘斜面(2)、打磨盘平面顶端(3)和打磨盘(4)整体为圆盘形结构。A brazed diamond abrasive tool suitable for burr grinding of castings, characterized in that it comprises an outer end of a grinding disc (1), a bevel of a grinding disc (2), a top end of the plane of the grinding disc (3) and a grinding disc (4), and The positioning holes (5) set in the grinding disc (4), and the diamond polygold abrasives brazed uniformly on the outer end of the grinding disc (1), the inclined surface of the grinding disc (2), and the top surface of the grinding disc (3) (6), wherein the diamond poly-gold abrasive (6) on the edge of the outer end (1) of the grinding disc is ordered and close-packed, and the diamond poly-gold abrasive (6) on the bevel (2) of the grinding disc is a single particle and is arranged along the grinding disc. The diamond poly-gold abrasives (6) on the surface of the flat top (3) of the grinding disc are arranged in a turbine-like arrangement of cluster abrasives, and the bottom of the grinding disc (4) is a concave surface structure, which is used for chip removal and A positioning grinder is installed; the outer end of the grinding disc (1), the inclined surface of the grinding disc (2), the top of the plane of the grinding disc (3) and the grinding disc (4) are in a disc-shaped structure as a whole.
- 根据权利要求1所述的一种适用于铸件飞边打磨的钎焊金刚石磨具,其特征在于:所述打磨盘平面顶端(3)的宽度占磨盘半径的1/3-1/2,打磨盘斜面(2)的宽度为3-5mm。The brazed diamond abrasive tool suitable for casting flash grinding according to claim 1, characterized in that: the width of the flat top (3) of the grinding disc occupies 1/3-1/2 of the radius of the grinding disc. The width of the disc inclined surface (2) is 3-5mm.
- 根据权利要求1所述的一种适用于铸件飞边打磨的钎焊金刚石磨具,其特征在于:所述圆盘形结构的钎焊金刚石聚晶铸件打磨盘基体外径为100mm -180mm,基体厚度为1.4mm -4.5mm。The brazed diamond grinding tool suitable for casting flash grinding according to claim 1, characterized in that: the outer diameter of the brazed diamond polycrystalline casting grinding disc of the disc-shaped structure is 100mm-180mm, and the base is The thickness is 1.4mm -4.5mm.
- 根据权利要求1所述的一种适用于铸件飞边打磨的钎焊金刚石磨具,其特征在于:所述打磨盘斜面(2)与水平方向的夹角θ为5º-15º。The brazed diamond grinding tool suitable for the grinding of casting flashes according to claim 1, characterized in that the included angle θ between the inclined surface of the grinding disc (2) and the horizontal direction is 5°-15°.
- 根据权利要求1所述的一种适用于铸件飞边打磨的钎焊金刚石磨具,其特征在于:所述金刚石聚金磨料(6)钎焊在打磨盘外端(1)、打磨盘斜面(2)、打磨盘平面顶端(3)表面,焊料为镍铜铬硼硅合金,钎焊方式为真空钎焊。The brazed diamond abrasive tool suitable for the flash grinding of castings according to claim 1, characterized in that: the diamond poly-gold abrasive (6) is brazed on the outer end (1) of the grinding disc and the inclined surface of the grinding disc ( 2) The surface of the top (3) of the flat surface of the grinding disc, the solder is nickel-copper-chromium-borosilicate alloy, and the brazing method is vacuum brazing.
- 根据权利要求5所述的一种适用于铸件飞边打磨的钎焊金刚石磨具,其特征在于:所述打磨盘外端(1)边缘的金刚石聚金磨料(6)是有序密排的高品级的钻切用磨料,粒度为10-50目,相邻两颗金刚石聚金磨料(6)的横向间距为2d-4d,相邻两颗金刚石聚金磨料(6)的纵向间距为2d-5d,其中d为金刚石聚金磨料(6)的最大粒径。According to claim 5, a brazed diamond abrasive tool suitable for casting flash grinding, characterized in that: the diamond poly-gold abrasive (6) on the edge of the outer end (1) of the grinding disc is ordered and close-packed High-grade abrasives for drilling and cutting, with a grain size of 10-50 mesh, the horizontal distance between two adjacent diamond poly-gold abrasives (6) is 2d-4d, and the longitudinal distance between two adjacent diamond poly-gold abrasives (6) is 2d -5d, where d is the maximum particle size of the diamond polygold abrasive (6).
- 根据权利要求1所述的一种适用于铸件飞边打磨的钎焊金刚石磨具,其特征在于:所述打磨盘斜面(2)的金刚石聚金磨料(6)在沿磨盘径向方向上数量相同。The brazed diamond abrasive tool suitable for casting flash grinding according to claim 1, characterized in that: the diamond poly-gold abrasive (6) on the inclined surface of the grinding disc (2) is in the radial direction along the grinding disc. same.
- 根据权利要求1所述的一种适用于铸件飞边打磨的钎焊金刚石磨具,其特征在于:所述打磨盘平面顶端(3)平面的金刚石聚金磨料(6)是中等品级的涡轮状排布的簇状磨削用磨料,粒度为10-50目,每簇3-8颗金刚石聚金磨料(6)。The brazed diamond abrasive tool suitable for casting flash grinding according to claim 1, characterized in that: the diamond poly-gold abrasive (6) on the top (3) of the flat surface of the polishing disc is a medium-grade turbine-shaped Arranged clusters of abrasives for grinding, with a particle size of 10-50 mesh, and 3-8 diamond polygold abrasives per cluster (6).
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