High-speed and high-efficiency rough grinding wheel and preparation method thereof

Abstract

The application belongs to abrasive tool technical field, and relates to a high-speed and high-efficiency rough grinding wheel and a preparation method thereof.The preparation method comprises the following steps: S1, weighing and mixing preparation raw materials of a grinding layer, and reserving; S2, preheating a mold to 40-50 DEG C, and putting part of the mixed preparation raw materials of the grinding layer into the mold and spreading; S3, putting a layer of non-alkali glass fiber reinforced mesh on the spread raw materials, baking the non-alkali glass fiber reinforced mesh by a heating device, and pressing the mesh; S4, putting the remaining part of the mixed preparation raw materials of the grinding layer on the non-alkali glass fiber reinforced mesh, and spreading; S5, putting a hole ring, and pressing to form a cutting piece semi-finished product; S6, according to product requirements, stacking 2-5 cutting piece semi-finished products, positioning a center hole by a prepared mandrel, ensuring concentricity of the several semi-finished products, and then sending into an oven for hardening, and cooling to room temperature to obtain a finished product.The prepared rough grinding wheel is stable in physical property, high-speed and high-efficiency.

Description

Technical Field

[0001] This invention belongs to the field of abrasive technology and relates to a high-speed and high-efficiency grinding wheel and its preparation method. Background Technology

[0002] Most abrasives are man-made abrasives made from abrasives and binders, while some are natural abrasives made directly from natural minerals. Besides their widespread use in machinery manufacturing and other metal processing industries, abrasives are also used in food processing, papermaking, and the processing of non-metallic materials such as ceramics, glass, stone, plastics, rubber, and wood. High-speed, high-efficiency grinding wheels are resin abrasives made with special fiber fabrics as reinforcement and using a special beading process. They possess high tensile, impact, and bending strength and are widely used for grinding, rust removal, and deburring of various metal materials, offering both high efficiency and economy.

[0003] Ordinary grinding wheels, lacking special fiber reinforcement, have low inherent strength and cannot be used with high-speed motors. Because the motor speeds of the equipment used are relatively low, ordinary grinding wheels cannot be designed with high-bonded, high-toughness abrasives. However, many users require highly efficient and durable grinding wheels, forcing them to use a method of stacking several large cutting discs. But this method requires the discs to wear synchronously, which is practically impossible to achieve, resulting in low wheel strength and significant waste. Summary of the Invention

[0004] This invention addresses the shortcomings of existing technologies by providing a physically stable, high-speed, and efficient grinding wheel and its preparation method.

[0005] The present invention provides a high-speed and high-efficiency grinding wheel, which includes alternating grinding layers and mesh layers. The mesh layers are located in even-numbered layers, and the grinding layers are located in odd-numbered layers, with some of them falling into the mesh layers. That is, the grinding wheel includes grinding layers, mesh layers, grinding layers, mesh layers, grinding layers, etc., in sequence, with the number of layers determined according to product requirements.

[0006] Preferably, the mesh layer is an alkali-free glass fiber reinforced mesh; the alkali-free glass fiber reinforced mesh has good bonding performance with the grinding layer, and the alternating superposition with the grinding layer is beneficial to improving the strength of the grinding wheel.

[0007] Preferably, the raw materials for preparing the grinding layer include the following components by mass percentage: cryolite 3-8%, barite 5-10%, phenolic resin liquid 3-7%, phenolic resin powder 9-11%, and the balance being abrasive.

[0008] Preferably, the particle size of the raw material used to prepare the grinding layer is 22-50 mesh.

[0009] This invention improves the strength of the grinding wheel by controlling the type of raw material, particle size, and content of binder (phenolic resin) in the grinding layer, thereby increasing the efficiency and durability of the grinding wheel's working surface.

[0010] Preferably, the abrasive comprises the following components by weight percentage: 38-45% primary brown fused alumina, 15-20% zirconium fused alumina, 9-13% white fused alumina, and 10-13% grinding aid. Zirconium fused alumina significantly improves the wear resistance of the rough grinding wheel, white fused alumina improves the sharpness of the grinding wheel, and the grinding aid further improves the sharpness of the grinding wheel. At the same time, the grinding aid is an inexpensive product, which can greatly reduce the cost of the grinding wheel.

[0011] Preferably, the grinding aid abrasive is pyrite particles. Pyrite particles are essentially iron sulfide particles. During grinding, they have very low hardness and quickly turn into powder, increasing the porosity of the grinding wheel and improving its chip removal and heat dissipation capabilities. The iron sulfide decomposes upon heating to produce sulfur vapor, which softens the steel and further enhances the grinding wheel's grinding ability.

[0012] This invention does not limit the thickness, outer diameter, or bore diameter of the grinding wheel, and can produce grinding wheels with any outer diameter and thickness. Currently, commonly used grinding wheels have a thickness of 10-18mm, an outer diameter of 300-500mm, and a bore diameter of 30-35mm.

[0013] Another aspect of the present invention provides a method for preparing a high-speed and high-efficiency grinding wheel, comprising the following steps:

[0014] S1. Weigh and mix the raw materials for preparing the grinding layer, and set aside.

[0015] S2. Preheat the mold to 40-50℃, put some of the mixed raw materials for preparing the grinding layer into the mold, and spread them out.

[0016] S3. Place a layer of alkali-free glass fiber reinforced mesh on the flattened raw material, use a heating device to soften the alkali-free glass fiber reinforced mesh, and press the mesh.

[0017] S4. Add the remaining mixed raw materials for preparing the grinding layer onto the alkali-free glass fiber reinforced mesh and spread them out.

[0018] S5. Insert the hole ring and press to form a semi-finished cutting disc.

[0019] S6. Depending on the product requirements, stack 2-5 semi-finished cutting discs, use a pre-made mandrel to position the center hole to ensure that the semi-finished discs are concentric, and then send them into an oven to harden and cool to room temperature to obtain the finished product.

[0020] When stacking 2-5 semi-finished cutting discs, the center hole is positioned using a pre-made mandrel of the corresponding height. This ensures that the semi-finished discs are concentric, which is beneficial for the synchronous wear of the grinding wheel and reduces waste.

[0021] The present invention employs a special process of first preparing semi-finished products, and then stacking 2-5 semi-finished products according to customer requirements, which can effectively improve the strength of the grinding wheel and improve the synchronization of wear.

[0022] Preferably, in step S3, the heating temperature is 90-110℃, and the dough is baked until soft for 2-4 seconds.

[0023] Preferably, in step S5, the mold is preheated to 45-60°C and the pressure is 15-25 MPa during the pressing process.

[0024] Preferably, in step S6, before stacking the semi-finished cutting discs, a layer of mixed phenolic resin liquid is brushed onto the surface of the semi-finished cutting discs that need to be stacked.

[0025] Preferably, the mixed phenolic resin solution is a phenolic resin solution containing 2-10 wt% silane coupling agent;

[0026] Preferably, the mixed phenolic resin solution is a phenolic resin solution containing 4-11 wt% thermoplastic epoxy resin;

[0027] Further preferably, the mixed phenolic resin solution is a phenolic resin solution containing 2-5 wt% silane coupling agent and 4-6 wt% thermoplastic epoxy resin.

[0028] Preferably, in step S6, after brushing the mixed phenolic resin liquid onto the surface of the semi-finished cutting disc, the static imbalance weight is first measured, marked, and classified. Then, the semi-finished cutting discs are stacked using a special method to make the static imbalance weight of the stacked finished product as close to zero as possible.

[0029] As a preferred method, the special stacking method is as follows: A stainless steel disc with its center marked and angles marked on its outermost circumference is pre-made. 1. Two discs stacked: A mandrel with a corresponding aperture is installed at the center of the disc. A semi-finished product is placed on the mandrel, and the marked static imbalance position on the semi-finished product is aligned with the zero-degree position of the disc by rotation. Then, another semi-finished product with the same static imbalance weight is placed on the mandrel, but its static imbalance position is aligned with the 180-degree position of the disc by rotation. 2. Three discs stacked: The previous two stacks are equivalent to the included angle of the static imbalance positions of the two semi-finished products being 180 degrees. The included angle of the three pieces is calculated to be 120 degrees (when the static unbalance weight is the same). If the static unbalance weights of the three semi-finished products are not the same, namely a grams, b grams, and c grams, the included angles of the static unbalance positions (P1, P2, P3) are: α between P2 and P3, β between P1 and P3, and γ between P1 and P2. This can be calculated using the formula cosα = (a... 2 -b 2 -c 2 ) / 2bc, cosβ=(b 2 -a2 -c 2 ) / 2ac, cosγ=(c 2 -a 2 -b 2 1) / 2ab, calculate the values ​​of α, β, and γ. 2. For four-piece stacking, first stack two pieces, then place the two stacked pieces together. 3. For five-piece stacking, first stack one two-piece piece, then one three-piece piece, then place them together. Continue in this manner; even with numerous semi-finished products stacked, the overall static imbalance weight can be close to zero after stacking.

[0030] The semi-finished cutting discs were statically balanced before being stacked, and then stacked using a special method, which greatly improved the overall balance of the finished product. The surface of the semi-finished products underwent special treatment; the combined use of silane coupling agent and thermoplastic epoxy resin increased the adhesion between the grinding layers. After stacking, the semi-finished products were tightly bonded together, and after hardening, this helped to improve the strength of the grinding wheel.

[0031] Preferably, the silane coupling agent is γ-(2,3-epoxypropoxy)propyltrimethoxysilane (KH-560) and / or γ-aminopropyltriethoxysilane (KH-550).

[0032] Preferably, the hardening step S6 is as follows: holding at 45-65℃ for 8-12 hours, then raising the temperature to 100-108℃ for 3-5 hours and holding for 2-3 hours; raising the temperature to 110-120℃ for 0.5-1.5 hours and holding for 1-3 hours; then holding at 110-130℃ for 0.5-1.5 hours; subsequently holding at 120-140℃ for 0.5-1.5 hours; then holding at 140-150℃ for 1-2 hours; finally, holding at 180-195℃ for 4-6 hours. After hardening, cooling to room temperature at a rate of 6-8℃ / hour yields the high-speed, high-efficiency grinding wheel.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] (1) This invention improves the strength of the grinding wheel by controlling the type of raw material, particle size and content of binder (phenolic resin) in the grinding layer, thereby increasing the efficiency and durability of the grinding wheel working surface.

[0035] (2) The present invention adopts a special process of first preparing the cutting disc semi-finished product, and then stacking 2-5 cutting disc semi-finished products according to the customer's requirements, which can effectively improve the strength of the grinding wheel and improve the synchronization of wear.

[0036] (3) Before stacking the cutting disc semi-finished products of the present invention, a mixed phenolic resin liquid is brushed onto the surface of the cutting disc semi-finished products to be stacked, which is beneficial to improve the adhesion between the grinding layers.

[0037] (4) The mixed phenolic resin liquid brushed on the surface of the cutting disc semi-finished product that needs to be stacked is a phenolic resin liquid containing 2-5wt% silane coupling agent and 4-6wt% thermoplastic epoxy resin. The combined use of silane coupling agent and thermoplastic epoxy resin can increase the adhesion between grinding layers. After stacking, the semi-finished products are closely connected together. After hardening, it is beneficial to improve the strength of the grinding wheel.

[0038] (5) Compared with directly producing grinding wheels to the thickness required by the user, the preparation method of the present invention reduces the complexity of production equipment and processes, and greatly improves the uniformity of grinding wheel density, thereby effectively improving the strength of the grinding wheel and the synchronicity of wear. Compared with the user's previous method of use (using several cutting discs stacked together), because the grinding wheel prepared by the present invention is already a whole, the synchronicity of wear and the impact resistance of the grinding wheel are greatly improved, and waste is greatly reduced. Detailed Implementation

[0039] The technical solution of the present invention will be further described and illustrated below through specific embodiments. It should be understood that the specific embodiments described herein are only for the purpose of helping to understand the present invention and are not intended to limit the present invention. Unless otherwise specified, the raw materials used in the embodiments of the present invention are all commonly used raw materials in the art, and the methods used in the embodiments are all conventional methods in the art.

[0040] Example 1

[0041] The raw materials for preparing the grinding layer include: 4% cryolite, 6% barite, 4% phenolic resin liquid (solid content 75%), 10% phenolic resin powder, and the remainder being abrasive. The abrasive consists of: 40% grade I brown fused alumina, 16% zirconium fused alumina, 10% white fused alumina, and 10% pyrite particles. The particle size of the raw materials is 22-50 mesh.

[0042] High-speed, high-efficiency grinding wheels are prepared by the following steps:

[0043] S1. Weigh and mix the raw materials for preparing the grinding layer, and set aside.

[0044] S2. Preheat the mold to 45°C, put some of the mixed raw materials for preparing the grinding layer into the mold, and spread them out.

[0045] S3. Place a layer of alkali-free glass fiber reinforced mesh on the flattened raw material, soften the alkali-free glass fiber reinforced mesh with a heating device (100℃, 2s), and press the mesh.

[0046] S4. Add the remaining mixed raw materials for preparing the grinding layer onto the alkali-free glass fiber reinforced mesh and spread them out.

[0047] S5. Insert the hole ring and press to form (preheat the mold to 50℃ and the pressure is 20MPa) to obtain a semi-finished cutting disc with a thickness of 3mm.

[0048] S6. According to customer needs, five semi-finished cutting discs are first tested for static imbalance and marked, and then stacked using a special method. The center hole is positioned using a pre-made mandrel to ensure that the semi-finished discs are concentric. Then, they are sent to an oven for hardening. First, they are kept at 50℃ for 10 hours, then heated to 103℃ for 4 hours and kept at that temperature for 2.5 hours; then heated to 115℃ for 1 hour and kept at that temperature for 2 hours; then kept at 120℃ for 1 hour; then kept at 130℃ for 1 hour; then kept at 145℃ for 1.5 hours; and finally kept at 185℃ for 5 hours. After hardening, the temperature is lowered to room temperature at a rate of 6℃ / hour to obtain a high-speed and high-efficiency grinding wheel with a thickness of 15mm, an outer diameter of 400mm, and a hole diameter of 32mm.

[0049] Example 2

[0050] The raw materials for preparing the grinding layer in Example 2 are the same as those in Example 1.

[0051] High-speed, high-efficiency grinding wheels are prepared by the following steps:

[0052] S1. Weigh and mix the raw materials for preparing the grinding layer, and set aside.

[0053] S2. Preheat the mold to 45°C, put some of the mixed raw materials for preparing the grinding layer into the mold, and spread them out.

[0054] S3. Place a layer of alkali-free glass fiber reinforced mesh on the flattened raw material, soften the alkali-free glass fiber reinforced mesh with a heating device (100℃, 2s), and press the mesh.

[0055] S4. Add the remaining mixed raw materials for preparing the grinding layer onto the alkali-free glass fiber reinforced mesh and spread them out.

[0056] S5. Insert the hole ring and press to form (preheat the mold to 50℃ and the pressure is 20MPa) to obtain a semi-finished cutting disc with a thickness of 3mm.

[0057] S6. According to customer needs, stack 5 semi-finished cutting discs. Before stacking, apply a layer of phenolic resin liquid to the surfaces of the semi-finished cutting discs to be stacked, check the static imbalance and mark it, and then stack them according to a special method. The center hole is positioned using a pre-made mandrel to ensure that the semi-finished discs are concentric. Then, put them into an oven for hardening. First, keep them at 50℃ for 10 hours, then raise the temperature to 103℃ after 4 hours and keep them at 103℃ for 2.5 hours; then raise the temperature to 115℃ after 1 hour and keep them at 115℃ for 2 hours; then keep them at 120℃ for 1 hour; then keep them at 130℃ for 1 hour; then keep them at 145℃ for 1.5 hours; finally, keep them at 185℃ for 5 hours. After hardening, cool them to room temperature at a rate of 6℃ / h to obtain a high-speed and high-efficiency grinding wheel with a thickness of 15mm, an outer diameter of 400mm, and a hole diameter of 32mm.

[0058] Example 3

[0059] The raw materials for preparing the grinding layer in Example 3 are the same as those in Example 1.

[0060] High-speed, high-efficiency grinding wheels are prepared by the following steps:

[0061] S1. Weigh and mix the raw materials for preparing the grinding layer, and set aside.

[0062] S2. Preheat the mold to 45°C, put some of the mixed raw materials for preparing the grinding layer into the mold, and spread them out.

[0063] S3. Place a layer of alkali-free glass fiber reinforced mesh on the flattened raw material, soften the alkali-free glass fiber reinforced mesh with a heating device (100℃, 2s), and press the mesh.

[0064] S4. Add the remaining mixed raw materials for preparing the grinding layer onto the alkali-free glass fiber reinforced mesh and spread them out.

[0065] S5. Insert the hole ring and press to form (preheat the mold to 50℃ and the pressure is 20MPa) to obtain a semi-finished cutting disc with a thickness of 3mm.

[0066] S6. According to customer needs, stack 5 semi-finished cutting discs. Before stacking, apply a layer of mixed phenolic resin liquid to the surface of the semi-finished cutting discs to be stacked. The mixed phenolic resin liquid is a phenolic resin liquid containing 8wt% KH-560. First, check the static imbalance and mark it. Then stack them according to a special method. The center hole is positioned using a pre-made mandrel to ensure that the semi-finished discs are concentric. Then send them to the oven for hardening. First, keep them at 50℃ for 10 hours. After 4 hours, raise the temperature to 103℃ and keep it for 2.5 hours. After 1 hour, raise the temperature to 115℃ and keep it for 2 hours. Then keep them at 120℃ for 1 hour. Then keep them at 130℃ for 1 hour. Then keep them at 145℃ for 1.5 hours. Finally, keep them at 185℃ for 5 hours. After hardening, cool to room temperature at 6℃ / h to obtain a high-speed and high-efficiency grinding wheel with a thickness of 15mm, an outer diameter of 400mm, and a hole diameter of 32mm.

[0067] Example 4

[0068] The raw materials for preparing the grinding layer in Example 4 are the same as those in Example 1.

[0069] High-speed, high-efficiency grinding wheels are prepared by the following steps:

[0070] S1. Weigh and mix the raw materials for preparing the grinding layer, and set aside.

[0071] S2. Preheat the mold to 45°C, put some of the mixed raw materials for preparing the grinding layer into the mold, and spread them out.

[0072] S3. Place a layer of alkali-free glass fiber reinforced mesh on the flattened raw material, soften the alkali-free glass fiber reinforced mesh with a heating device (100℃, 2s), and press the mesh.

[0073] S4. Add the remaining mixed raw materials for preparing the grinding layer onto the alkali-free glass fiber reinforced mesh and spread them out.

[0074] S5. Insert the hole ring and press to form (preheat the mold to 50℃ and the pressure is 20MPa) to obtain a semi-finished cutting disc with a thickness of 3mm.

[0075] S6. According to customer needs, stack 5 semi-finished cutting discs. Before stacking, apply a layer of mixed phenolic resin liquid to the surface of the semi-finished cutting discs to be stacked. The mixed phenolic resin liquid is a phenolic resin liquid containing 8wt% bisphenol A type epoxy resin. First, check the static imbalance and mark it. Then stack them according to a special method. The center hole is positioned using a pre-made mandrel to ensure that the semi-finished discs are concentric. Then send them to the oven for hardening. First, keep them at 50℃ for 10 hours. After 4 hours, raise the temperature to 103℃ and keep it for 2.5 hours. After 1 hour, raise the temperature to 115℃ and keep it for 2 hours. Then keep them at 120℃ for 1 hour. Then keep them at 130℃ for 1 hour. Then keep them at 145℃ for 1.5 hours. Finally, keep them at 185℃ for 5 hours. After hardening, cool to room temperature at 6℃ / h to obtain a high-speed and high-efficiency grinding wheel with a thickness of 15mm, an outer diameter of 400mm, and a hole diameter of 32mm.

[0076] Example 5

[0077] The raw materials for preparing the grinding layer in Example 5 are the same as those in Example 1.

[0078] High-speed, high-efficiency grinding wheels are prepared by the following steps:

[0079] S1. Weigh and mix the raw materials for preparing the grinding layer, and set aside.

[0080] S2. Preheat the mold to 45°C, put some of the mixed raw materials for preparing the grinding layer into the mold, and spread them out.

[0081] S3. Place a layer of alkali-free glass fiber reinforced mesh on the flattened raw material, soften the alkali-free glass fiber reinforced mesh with a heating device (100℃, 2s), and press the mesh.

[0082] S4. Add the remaining mixed raw materials for preparing the grinding layer onto the alkali-free glass fiber reinforced mesh and spread them out.

[0083] S5. Insert the hole ring and press to form (preheat the mold to 50℃ and the pressure is 20MPa) to obtain a semi-finished cutting disc with a thickness of 3mm.

[0084] S6. According to customer needs, stack 5 semi-finished cutting discs. Before stacking, apply a layer of mixed phenolic resin liquid to the surfaces of the semi-finished cutting discs to be stacked. The mixed phenolic resin liquid is a phenolic resin liquid containing 3% wt KH-560 and 5 wt% bisphenol A type epoxy resin. First, check the static imbalance and mark it. Then stack them according to a special method. The center hole is positioned using a pre-made mandrel to ensure that the semi-finished discs are concentric. Then send them to the oven for hardening. First, keep them at 50℃ for 10 hours. After 4 hours, raise the temperature to 103℃ and keep it for 2.5 hours. After 1 hour, raise the temperature to 115℃ and keep it for 2 hours. Then keep them at 120℃ for 1 hour. Then keep them at 130℃ for 1 hour. Then keep them at 145℃ for 1.5 hours. Finally, keep them at 185℃ for 5 hours. After hardening, cool to room temperature at 6℃ / h to obtain a high-speed and high-efficiency grinding wheel with a thickness of 15mm, an outer diameter of 400mm, and a hole diameter of 32mm.

[0085] Example 6

[0086] The raw materials for preparing the grinding layer in Example 6 are the same as those in Example 1.

[0087] High-speed, high-efficiency grinding wheels are prepared by the following steps:

[0088] S1. Weigh and mix the raw materials for preparing the grinding layer, and set aside.

[0089] S2. Preheat the mold to 45°C, put some of the mixed raw materials for preparing the grinding layer into the mold, and spread them out.

[0090] S3. Place a layer of alkali-free glass fiber reinforced mesh on the flattened raw material, soften the alkali-free glass fiber reinforced mesh with a heating device (100℃, 2s), and press the mesh.

[0091] S4. Add the remaining mixed raw materials for preparing the grinding layer onto the alkali-free glass fiber reinforced mesh and spread them out.

[0092] S5. Insert the hole ring and press to form (preheat the mold to 50℃ and the pressure is 20MPa) to obtain a semi-finished cutting disc with a thickness of 3mm.

[0093] S6. According to customer needs, stack 5 semi-finished cutting discs. Before stacking, apply a layer of mixed phenolic resin liquid to the surface of the semi-finished cutting discs to be stacked. The mixed phenolic resin liquid is a phenolic resin liquid containing 3% wt KH-560 and 5 wt% bisphenol A type epoxy resin. There is no special stacking method. The center hole is directly positioned by a pre-made mandrel to ensure that the semi-finished discs are concentric. Then, they are sent to the oven for hardening. First, they are kept at 50℃ for 10 hours. After 4 hours, the temperature is raised to 103℃ and kept for 2.5 hours. After 1 hour, the temperature is raised to 115℃ and kept for 2 hours. Then, they are kept at 120℃ for 1 hour. Then, they are kept at 130℃ for 1 hour. Then, they are kept at 145℃ for 1.5 hours. Finally, they are kept at 185℃ for 5 hours. After hardening, the temperature is lowered to room temperature at 6℃ / h to obtain a high-speed and high-efficiency grinding wheel with a thickness of 15mm, an outer diameter of 400mm, and a hole diameter of 32mm.

[0094] Comparative Example 1

[0095] The raw materials for preparing the grinding layer include: 4% cryolite, 6% barite, 3% phenolic resin liquid (solid content 75%), 7% phenolic resin powder, 20% grade I brown fused alumina, and 60% grade II brown fused alumina. The particle size of the raw materials is 22-50 mesh.

[0096] The grinding wheel of Comparative Example 1 was prepared by the following steps:

[0097] S1. Weigh and mix the raw materials for preparing the grinding layer, and set aside.

[0098] S2. Preheat the mold to 45°C, put the raw materials for preparing the grinding layer into the mold, and spread them out.

[0099] S3. Insert the perforated ring, press it into shape (pressure of 10MPa), and then send it to the oven for hardening. First, keep it at 50℃ for 10h, then raise the temperature to 103℃ after 4h and keep it at that temperature for 2.5h; then raise the temperature to 115℃ after 1h and keep it at that temperature for 2h; then keep it at 120℃ for 1h; then keep it at 130℃ for 1h; then keep it at 145℃ for 1.5h; finally keep it at 185℃ for 5h. After hardening, cool it to room temperature at 6℃ / h to obtain a finished grinding wheel with a thickness of 15mm, an outer diameter of 400mm, and a hole diameter of 32mm.

[0100] Comparative Example 2

[0101] The raw materials for preparing the grinding layer in Comparative Example 2 are the same as those in Example 1.

[0102] The cutting disc is prepared by the following steps:

[0103] S1. Weigh and mix the raw materials for preparing the grinding layer, and set aside.

[0104] S2. Preheat the mold to 45°C, put some of the mixed raw materials for preparing the grinding layer into the mold, and spread them out.

[0105] S3. Place a layer of alkali-free glass fiber reinforced mesh on the flattened raw material, soften the alkali-free glass fiber reinforced mesh with a heating device (100℃, 2s), and press the mesh.

[0106] S4. Add the remaining mixed raw materials for preparing the grinding layer onto the alkali-free glass fiber reinforced mesh and spread them out.

[0107] S5. Insert the perforated ring and press it into shape (preheat the mold to 50℃ and the pressure to 20MPa). Then send it to the oven for hardening. First, keep it at 50℃ for 10 hours, then raise the temperature to 103℃ after 4 hours and keep it at that temperature for 2.5 hours; then raise the temperature to 115℃ after 1 hour and keep it at that temperature for 2 hours; then keep it at 120℃ for 1 hour; then keep it at 130℃ for 1 hour; then keep it at 145℃ for 1.5 hours; finally keep it at 185℃ for 5 hours. After hardening, cool it to room temperature at a rate of 6℃ / h to obtain a cut disc with a thickness of 3mm, an outer diameter of 400mm, and a hole diameter of 32mm.

[0108] When using it, simply stack the five cutting discs from Comparative Example 2 together.

[0109] Comparative Example 3

[0110] The raw materials for preparing the grinding layer in Comparative Example 3 are the same as those in Example 1.

[0111] The grinding wheel of Comparative Example 3 was prepared by the following steps:

[0112] S1. Weigh and mix the raw materials for preparing the grinding layer, and set aside.

[0113] S2. Preheat the mold to 45°C, put some of the raw materials for preparing the grinding layer into the mold, and spread them out.

[0114] S3. Place a layer of alkali-free glass fiber reinforced mesh on the flattened raw material, soften the alkali-free glass fiber reinforced mesh with a heating device (100℃, 2s), and press the mesh.

[0115] S4. Then, put some of the raw materials for preparing the grinding layer onto the alkali-free glass fiber reinforced mesh and spread it out.

[0116] Then repeat steps S3-S4 4 times;

[0117] S5. Insert the perforated ring and press it into shape (preheat the mold to 50℃ and the pressure to 20MPa). Then send it to the oven for hardening. First, keep it at 50℃ for 10 hours, then raise the temperature to 103℃ after 4 hours and keep it at that temperature for 2.5 hours; then raise the temperature to 115℃ after 1 hour and keep it at that temperature for 2 hours; then keep it at 120℃ for 1 hour; then keep it at 130℃ for 1 hour; then keep it at 145℃ for 1.5 hours; finally keep it at 185℃ for 5 hours. After hardening, cool it to room temperature at a rate of 6℃ / h to obtain a finished grinding wheel with a thickness of 15mm, an outer diameter of 400mm, and a hole diameter of 32mm.

[0118] The grinding wheels prepared in Examples 1-6 and Comparative Examples 1-3 were subjected to performance tests. The steel material ground by the grinding wheels in Examples 1-6 and Comparative Examples 1-3 was the same 300mm×300mm×20mm 45# steel block, and the grinding time for each block was 10 minutes. The results are shown in Table 1. The burst tests were all conducted in a grinding wheel rotation strength testing machine.

[0119] Bursting velocity: The speed at which a grinding wheel breaks under continuous acceleration in a grinding wheel rotation strength testing machine. A higher velocity indicates a higher safety factor for the grinding wheel.

[0120] Grinding ratio: The ratio of workpiece weight loss to grinding wheel weight loss. The higher the value, the more durable the grinding wheel.

[0121] Grinding efficiency: workpiece loss per minute; the higher the efficiency, the sharper the grinding wheel.

[0122] Imbalance weight: The minimum mass required to align the center of mass and geometric center of the grinding wheel at the same point when the grinding wheel is stationary. A higher imbalance weight is detrimental to the use of the grinding wheel and increases safety. Due to unavoidable reasons during the manufacturing process, the center of mass and geometric center of the grinding wheel are often not at the same point, causing vibration when the grinding wheel rotates on the grinding machine (slight vibrations are imperceptible and produce little noise; heavier vibrations can cause numbness and loud noise; in the most serious cases, the grinding wheel can shatter and cause injury).

[0123] Table 1 Comparison of grinding wheel performance in Examples 1-6 and Comparative Examples 1-3

[0124]

[0125]

[0126] As shown in Table 1, the blasting speed, grinding ratio, and grinding efficiency of Examples 1-6 of the present invention are superior to those of Comparative Examples 1-3, and Examples 1-5 offer a better user experience. Example 6 demonstrates that by first detecting, marking, and classifying the static imbalance weight, and then employing a special stacking method, the static imbalance weight of the grinding wheel can be significantly reduced, resulting in a substantial increase in the blasting speed. Examples 1 and 2 show that when the surfaces of the semi-finished cutting discs to be stacked are only coated with phenolic resin liquid, it does not significantly improve grinding performance. Example 5 uses a phenolic resin liquid containing 3 wt% silane coupling agent and 5 wt% bisphenol A epoxy resin to be brushed onto the surfaces of the semi-finished cutting discs to be stacked, resulting in superior grinding performance and a higher safety factor compared to Examples 1-4.

[0127] Finally, it should be noted that the specific embodiments described herein are merely illustrative of the spirit of the invention and are not intended to limit the implementation of the invention. Those skilled in the art can make various modifications or additions to the described embodiments or use similar methods to replace them; it is neither necessary nor possible to exemplify all embodiments here. However, these obvious variations or modifications derived from the essential spirit of the invention still fall within the scope of protection of the invention, and interpreting them as any additional limitation would contradict the spirit of the invention.

Claims

1. A method for manufacturing a high speed and high efficiency rough grinding wheel, characterized by, The rough grinding wheel comprises alternately stacked grinding layers and mesh layers, the mesh layers are located at even layers, and the grinding layers are located at odd layers and partially fall into the mesh layers; The mesh layer is an alkali-free glass fiber reinforced mesh; The preparation method comprises the following steps: S1, weighing and mixing the preparation raw materials of the grinding layer, and standby; S2, preheating the mold to 40-50℃, and putting part of the mixed preparation raw materials of the grinding layer into the mold and flattening; S3, placing an alkali-free glass fiber reinforced mesh on the flattened raw materials, baking the alkali-free glass fiber reinforced mesh with a heating device, and pressing the mesh; S4, putting the remaining part of the mixed preparation raw materials of the grinding layer onto the alkali-free glass fiber reinforced mesh and flattening; S5, placing a hole ring and pressing to form a cutting piece semi-finished product; S6, brushing mixed phenolic resin liquid on the surface of the cutting piece semi-finished product that needs to be stacked, the mixed phenolic resin liquid is a phenolic resin liquid containing 2-5wt% silane coupling agent and 4-6wt% thermoplastic epoxy resin; after brushing the mixed phenolic resin liquid on the surface of the cutting piece semi-finished product, first detecting the static unbalance grams and marking and classifying, according to the product needs, stacking 2-5 cutting piece semi-finished products, positioning the center hole with a pre-prepared mandrel, ensuring that the several semi-finished products are concentric, making the static unbalance grams of the stacked product close to zero, and then sending into an oven for hardening and cooling to room temperature to obtain a finished product; The silane coupling agent is γ-(2,3-epoxypropoxy) propyl trimethoxysilane and / or γ-aminopropyl triethoxysilane; The method for making the static unbalance grams of the stacked product close to zero comprises: making a stainless steel disc in advance, marking the center of the circle, and marking the angle on the circumference of the outermost circle; when the cutting piece is stacked by two, installing a mandrel with a corresponding hole diameter at the center of the disc, sleeving one semi-finished product on the mandrel, and rotating the static unbalance position on the semi-finished product to correspond to zero on the disc, and then sleeving another semi-finished product with the same static unbalance grams on the mandrel, but the static unbalance position of this semi-finished product is rotated to correspond to 180 degrees on the disc; when the cutting piece is stacked by three, and the static unbalance grams are the same, the included angle of the static unbalance positions of the three semi-finished products is 120 degrees; when the cutting piece is stacked by four, first stacking two, and then stacking two two-stacked ones together; when the cutting piece is stacked by five, first stacking one two, then stacking one three, and then stacking them together; The hardening step of step S6 is: keeping at 45-65℃ for 8-12h, rising to 100-108℃ for 3-5h, keeping for 2-3h; rising to 110-120℃ for 0.5-1.5h, keeping for 1-3h; then keeping at 110-130℃ for 0.5-1.5h; subsequently keeping at 120-140℃ for 0.5-1.5h; again keeping at 140-150℃ for 1-2h; finally keeping at 180-195℃ for 4-6h.

2. The production method according to claim 1, characterized by, The preparation raw materials of the grinding layer comprise the following components in mass percentage: 3-8% ice crystal stone, 5-10% barite, 4-7% phenolic resin liquid, 10-11% phenolic resin powder, and the balance is abrasive.

3. The preparation method according to claim 1, characterized in that, The particle size of the preparation raw materials of the grinding layer is 22-50 meshes.

4. The production method according to claim 2, characterized by, The abrasive comprises the following mass percentage components: primary brown corundum 48-54%, zirconium corundum 22-26%, white corundum 12-14%, and grinding aid abrasive 12-18%.

5. The production method according to claim 4, characterized by, The grinding aid abrasive is pyrite particles.

6. The method of claim 1, wherein, In the press forming of step S5, the mold is preheated to 45-60 DEG C, and the pressure is 15-25 MPa.

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