Multilayer heterogeneous composite grinding wheel

Abstract

The utility model discloses a multilayer different particle size composite grinding wheel relates to abrasive tool technical field, aims at solving the problem of traditional multilayer grinding wheel abrasive waste, easy separation between layers. It includes annular inner aluminum core and at least two layers annular outer sand ring, and the outer circle surface of inner aluminum core is equipped with multiple evenly distributed tenons in the axial direction, and the inner circle surface of outer sand ring is equipped with matched mortises, and after the mortise and tenon of both are nested, they are fixed as an organic whole with high-temperature resistant ceramic base adhesive, the mesh number of outer sand ring abrasive increases gradually from bottom to top, and the axial thickness decreases synchronously to form gradient, and the surface of inner aluminum core is treated by anodic oxidation. The design reduces the consumption of abrasive with aluminum core, improves the stability between layers with double fixing, adapts to the requirement of rough grinding to fine grinding with gradient, improves processing efficiency with one clamping, prolongs the life with aluminum core heat dissipation and oxide film protection, and is suitable for precision parts multi-roughness grinding.

Description

Technical Field

[0001] This utility model relates to the field of abrasive technology, specifically a composite grinding wheel structure that achieves the processing of multiple roughness regions of a part in a single operation by coaxially combining multiple layers of heterogeneous grit grinding wheels. Background Technology

[0002] In the field of precision grinding in machining, multi-layer composite grinding wheels have gained attention for their advantage of "completing multiple processes in one clamping" to meet the needs of machining multiple roughnesses on the same part.

[0003] While existing multi-layer composite grinding wheels use different abrasives in each layer, they are typically still an integrated structure. Even if the inner layer near the mounting hole only serves a supporting function, it still needs to be filled with the same abrasive as the working layer, such as CBN or diamond. The abrasive content in the non-grinding area can reach 30% to 40%, especially in large-diameter grinding wheels, resulting in significant abrasive waste and increased material costs. Furthermore, a fully abrasive layer has a lower heat capacity, making it prone to abrasive grain shedding due to localized overheating during grinding, thus shortening the grinding wheel's lifespan. Utility Model Content

[0004] To overcome any technical defects or shortcomings in the existing technology, this utility model provides a multi-layer heterogeneous particle size composite grinding wheel. The technical solution adopted is as follows: A multi-layer heterogeneous abrasive wheel includes an annular inner aluminum core and at least two annular outer abrasive rings. The outer surface of the annular inner aluminum core is machined with multiple tenons along the axial direction. The inner surface of the annular outer abrasive rings is provided with multiple mortises that match the tenons. Each annular outer abrasive ring is nested and fitted with the annular inner aluminum core through a tenon-mortise structure. Each annular outer abrasive ring is fixed to the annular inner aluminum core, and adjacent annular outer abrasive rings are fixed together using a high-temperature resistant ceramic-based adhesive. The abrasive mesh size of each annular outer abrasive ring increases progressively from bottom to top along the axial direction.

[0005] Furthermore, the axial thickness of each of the annular outer sand rings decreases gradually from bottom to top along the axial direction, forming a thickness gradient.

[0006] Furthermore, the axial thickness of the bottommost annular outer sand ring is 6~10mm, and the axial thickness of the topmost annular outer sand ring is 3~5mm.

[0007] Furthermore, the axial thickness difference between two adjacent annular outer sand rings is 1~2mm, and the direction of thickness decrease is consistent with the direction of abrasive mesh number increase.

[0008] Furthermore, the number of tenons is 12-36 sets, evenly distributed along the circumference of the annular inner aluminum core.

[0009] Furthermore, the cross-sectional shape of the tenon is trapezoidal or rectangular, wherein the included angle of the tooth groove of the trapezoidal tenon is 60°~90°.

[0010] Furthermore, the axial length of the tenon is the same as the axial length of the annular inner aluminum core, the tooth width of the tenon is 3~6mm, and the tooth height is 2~5mm.

[0011] Furthermore, the number of annular outer sand rings is 2 to 4 layers, and the axial thickness difference between adjacent annular outer sand rings is 1 to 3 mm.

[0012] Furthermore, the abrasive mesh size of the bottommost annular outer sand ring is 40#~60#, and the abrasive mesh size of the topmost annular outer sand ring is 150#~320#.

[0013] Furthermore, the surface of the annular inner aluminum core is anodized, and the oxide film thickness is 10~15μm.

[0014] The beneficial technical effects of this utility model are as follows: 1. Significantly reduce material costs and abrasive waste: By replacing the inner support part in the traditional all-abrasive structure with an annular inner aluminum core, redundant filling of expensive abrasives (such as CBN and diamond) in the non-grinding area (near the mounting hole side) is avoided, reducing abrasive usage by 30% to 40% and significantly reducing material costs; at the same time, the cost of aluminum core material is lower than that of abrasive, further optimizing the overall cost. 2. Enhanced structural stability and connection reliability: The annular inner aluminum core and the annular outer grinding ring are nested together by a tenon and mortise structure to form a mechanical interlock. Combined with the double fixation of high-temperature ceramic-based adhesive, this effectively prevents interlayer slippage or axial movement during high-speed grinding (≥3000r / min). The coaxiality error is controlled within 0.01mm, ensuring machining accuracy. The high strength of the aluminum core also enhances the overall rigidity of the grinding wheel, reducing the impact of vibration on machining quality. 3. Adaptable to various surface roughness requirements, improving efficiency: The annular outer abrasive ring adopts a collaborative design of "gradually increasing abrasive grit from bottom to top + gradually decreasing thickness"—the lower layer of low-grit (40#~60#) abrasive rings is thick (6~10mm), suitable for large-mass rough grinding; the upper layer of high-grit (150#~320#) abrasive rings is thin (3~5mm), meeting the requirements of precision grinding. Machining of different surface roughness areas of the part can be completed in a single setup, eliminating downtime for changing grinding wheels and improving machining efficiency by more than 35%. 4. Optimized heat dissipation and service life: The aluminum core has a higher heat capacity than the abrasive layer, which can quickly conduct the local heat generated by grinding and reduce the risk of abrasive grains falling off due to overheating; at the same time, the anodizing treatment on the surface of the aluminum core (10~15μm oxide film) improves corrosion resistance and wear resistance, is compatible with grinding fluid environment, and extends the overall service life of the grinding wheel by more than 30%. In summary, this utility model, through structural innovation of "aluminum core replacement + tenon and mortise nesting + gradient design", forms a synergistic advantage in reducing costs, improving stability, and optimizing processing efficiency and lifespan, effectively solving the problems of abrasive waste, easy separation between layers, and poor adaptability of existing multi-layer composite grinding wheels. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of this utility model.

[0016] Figure 2 for Figure 1 Partial diagram. Detailed Implementation

[0017] In the description of this utility model, it should be noted that the terms "upper," "lower," "left," and "right" indicate the orientation or positional relationship based on the paper. This orientation or positional relationship is only for the convenience of describing this utility model and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0018] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "communication" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0019] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0020] A multi-layer heterogeneous particle size composite grinding wheel, such as Figure 1-2As shown, it includes an annular inner aluminum core 1 and at least two annular outer abrasive rings 2; the outer circular surface of the annular inner aluminum core 1 is machined with multiple tenons 11 along the axial direction; the inner circular surface of the annular outer abrasive rings 2 is provided with multiple mortises 21 that match the multiple tenons 11, and each annular outer abrasive ring 2 is nested and fitted with the annular inner aluminum core 1 through the tenon and mortise structure; each annular outer abrasive ring 2 and the annular inner aluminum core 1, as well as adjacent annular outer abrasive rings 2, are fixed together by a high-temperature resistant ceramic-based adhesive; the abrasive mesh count of each annular outer abrasive ring 2 increases gradually from bottom to top along the axial direction.

[0021] The following section further explains this embodiment from the perspective of the synergistic mechanism of structural design, material properties, and functional adaptation.

[0022] The annular inner aluminum core uses aluminum to replace the inner support layer in the traditional all-abrasive structure. The principle is to use the low cost and high strength of aluminum to reduce the redundant consumption of expensive abrasive in the non-grinding area (near the mounting hole side). At the same time, the high thermal conductivity of aluminum can quickly dissipate the local heat generated by grinding and prevent the abrasive grains from falling off due to overheating. The oxide film formed by anodizing the surface enhances the surface hardness and corrosion resistance, adapts to the grinding fluid environment, and extends the service life of the core.

[0023] The nested fit of the mortise and tenon structure is the core principle for improving stability: the tenon of the annular inner aluminum core and the mortise of the outer sand ring form a mechanical interlock, which greatly increases the interlayer contact area and friction. Combined with the chemical fixation of the high-temperature resistant ceramic-based adhesive, a dual connection of "mechanical interlocking + chemical bonding" is constructed. This physically prevents circumferential slippage and axial movement between layers during high-speed rotation, ensuring coaxiality accuracy. At the same time, the gap between the mortise and tenon provides filling space for the adhesive, further strengthening the overall rigidity.

[0024] The "increasing grit size + decreasing thickness" design of the annular outer grinding ring follows the grinding process logic: the lower layer of low-grit grinding rings (40#~60#) corresponds to the rough grinding process and requires a larger thickness (6~10mm) to withstand the impact force of large-mass cutting; the upper layer of high-grit grinding rings (150#~320#) corresponds to the fine grinding process, and a smaller thickness (3~5mm) can reduce rigidity redundancy and improve surface precision control. This gradient design allows for the matching of continuous processing requirements from "rough grinding" to "fine grinding" in a single clamping, eliminating downtime for changing grinding wheels. Essentially, it improves processing efficiency through precise matching of structure and function.

[0025] In summary, through the synergistic effect of "material substitution for cost reduction - mortise and tenon interlocking for structural stability - gradient design to adapt to the process", the various design elements systematically solve the problems of waste of abrasive, easy separation between layers and low efficiency in traditional multi-layer grinding wheels, and ultimately achieve comprehensive optimization of cost, accuracy and life.

[0026] In another preferred embodiment, the axial thickness of each of the annular outer grinding rings 2 gradually decreases from bottom to top along the axial direction, forming a thickness gradient. This design adapts to the stress requirements of different grinding stages through thickness differentiation: the lower rough grinding process needs to withstand greater cutting forces, and a larger thickness can improve structural strength; the upper fine grinding process focuses on precision control, and a smaller thickness can reduce rigidity redundancy, achieving a dynamic balance between "strength and precision".

[0027] In another preferred embodiment, the axial thickness of the bottommost annular outer sand ring 2 is 6-10 mm, and the axial thickness of the topmost annular outer sand ring 2 is 3-5 mm. This thickness range precisely matches the actual machining scenario: the lower layer thickness of 6-10 mm is sufficient to support the large cutting impact during rough grinding, while the upper layer thickness of 3-5 mm is suitable for the fine control of surface accuracy during fine grinding. This avoids both insufficient thickness leading to excessively rapid wear of the sand ring and redundant thickness increasing ineffective energy consumption.

[0028] In another preferred embodiment, the axial thickness difference between two adjacent annular outer abrasive rings 2 is 1~2mm, and the direction of thickness decrease is consistent with the direction of abrasive mesh count increase. The gradual thickness change and mesh count gradient work together to reduce the processing stress fluctuation caused by structural abrupt changes during grinding, making the transition from rough grinding to fine grinding smoother and reducing the risk of scratches or deformation on the workpiece surface due to stress concentration.

[0029] In another preferred embodiment, the number of tenons 11 is 12-36 sets, evenly distributed along the circumference of the annular inner aluminum core 1. A sufficient and evenly distributed tenon structure can disperse interlayer forces to more contact points, avoiding deformation or breakage of the tenon structure due to excessive local stress. Especially during high-speed rotation, it can evenly resist centrifugal force, further improving the stability of the interlayer connection.

[0030] In another preferred embodiment, the cross-sectional shape of the tenon 11 is trapezoidal or rectangular, wherein the included angle of the groove of the trapezoidal tenon is 60°~90°. The trapezoidal structure utilizes the self-locking property of the inclined surface to enhance the interlayer pull-out resistance, while the rectangular structure is easy to process and has a flat stress surface; the included angle range of 60°~90° ensures the mechanical interlocking strength of the trapezoidal tenon, while avoiding assembly difficulties caused by too small an angle or weakening of the self-locking effect by too large an angle.

[0031] In another preferred embodiment, the axial length of the tenon 11 is the same as the axial length of the annular inner aluminum core 1, and the tooth width of the tenon 11 is 3~6mm, and the tooth height is 2~5mm. The tenon with a full axial length allows for full-length contact between the sand ring and the inner aluminum core, improving the stability of the fit; the tooth width of 3~6mm and the tooth height of 2~5mm ensure structural strength while reserving a suitable gap for adhesive filling, ensuring the dual fixing effect of "mechanical interlocking + chemical bonding".

[0032] In another preferred embodiment, the number of annular outer sand rings 2 is 2 to 4 layers, and the axial thickness difference between adjacent annular outer sand rings 2 is 1 to 3 mm. The design of 2 to 4 layers can adapt to the conventional processing flow of "rough grinding - semi-fine grinding - fine grinding" for most parts, avoiding structural complexity caused by too many layers; the thickness difference of 1 to 3 mm balances the functional emphasis of different sand rings, ensuring that each layer can effectively participate in the grinding process.

[0033] In another preferred embodiment, the abrasive mesh size of the bottommost annular outer abrasive ring 2 is 40#~60#, and the abrasive mesh size of the topmost annular outer abrasive ring 2 is 150#~320#. This mesh size range precisely covers the process requirements from coarse grinding (efficient removal of excess material) to fine grinding (obtaining a low-roughness surface): the coarse abrasive particles of 40#~60# are suitable for rapid cutting, while the fine abrasive particles of 150#~320# can achieve micron-level surface accuracy, allowing for multi-roughness machining to be completed in a single setup.

[0034] In another preferred embodiment, the surface of the annular inner aluminum core 1 is anodized, and the oxide film thickness is 10~15μm. The oxide film can significantly improve the surface hardness (HV≥150) and corrosion resistance of the aluminum core, effectively resisting the erosion of grinding fluid and friction damage during sand ring assembly; the 10~15μm film thickness ensures the protective effect without affecting the high thermal conductivity of the aluminum core, ensuring timely dissipation of grinding heat.

[0035] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A multi-layer heterogeneous particle size composite grinding wheel, characterized in that, It includes an annular inner aluminum core (1) and at least two annular outer abrasive rings (2); the outer circular surface of the annular inner aluminum core (1) is machined with multiple tenons (11) along the axial direction; the inner circular surface of the annular outer abrasive ring (2) is provided with multiple mortises (21) that match the multiple tenons (11), and each annular outer abrasive ring (2) is nested and fitted with the annular inner aluminum core (1) through the tenon and mortise structure; each annular outer abrasive ring (2) and the annular inner aluminum core (1), as well as adjacent annular outer abrasive rings (2), are fixed together by a high-temperature resistant ceramic-based adhesive; the abrasive mesh number of each annular outer abrasive ring (2) increases gradually from bottom to top along the axial direction.

2. The multi-layer heterogeneous particle size composite grinding wheel according to claim 1, characterized in that, The axial thickness of each of the annular outer sand rings (2) decreases gradually from bottom to top along the axial direction, forming a thickness gradient.

3. The multi-layer heterogeneous particle size composite grinding wheel according to claim 2, characterized in that, The axial thickness of the bottommost annular outer sand ring (2) is 6~10mm, and the axial thickness of the topmost annular outer sand ring (2) is 3~5mm.

4. The multi-layer heterogeneous particle size composite grinding wheel according to claim 2, characterized in that, The axial thickness difference between two adjacent annular outer sand rings (2) is 1~2mm, and the direction of thickness decrease is consistent with the direction of abrasive mesh number increase.

5. The multi-layer heterogeneous particle size composite grinding wheel according to claim 1, characterized in that, The number of tenons (11) is 12-36 sets, which are evenly distributed along the circumference of the annular inner aluminum core (1).

6. The multi-layer heterogeneous particle size composite grinding wheel according to claim 1, characterized in that, The cross-sectional shape of the tenon (11) is trapezoidal or rectangular, wherein the tooth groove angle of the trapezoidal tenon is 60°~90°.

7. The multi-layer heterogeneous particle size composite grinding wheel according to claim 1, characterized in that, The axial length of the tenon (11) is the same as the axial length of the annular inner aluminum core (1), and the tooth width of the tenon (11) is 3~6mm and the tooth height is 2~5mm.

8. The multi-layer heterogeneous particle size composite grinding wheel according to claim 1, characterized in that, The number of annular outer sand rings (2) is 2 to 4 layers, and the axial thickness difference between adjacent annular outer sand rings (2) is 1 to 3 mm.

9. The multi-layer heterogeneous particle size composite grinding wheel according to claim 1, characterized in that, The bottommost annular outer sand ring (2) has an abrasive mesh size of 40#~60#, and the topmost annular outer sand ring (2) has an abrasive mesh size of 150#~320#.

10. The multi-layer heterogeneous particle size composite grinding wheel according to claim 1, characterized in that, The surface of the annular inner aluminum core (1) is anodized, and the oxide film thickness is 10~15μm.

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