A grinding wheel cutting piece for cutting an amorphous magnetic core or core and a manufacturing method
By using a specific formula and process to prepare abrasive wheel cutting discs, the problems of insufficient sharpness and large precision errors of traditional cutting discs have been solved, achieving efficient and environmentally friendly cutting results and improving product quality and production efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- ZHONGSHAN AOTUOFU PRECISION INTELLIGENT SYST CO LTD
- Filing Date
- 2023-04-24
- Publication Date
- 2026-07-07
AI Technical Summary
In the existing technology, traditional ordinary abrasive wheel cutting discs have problems such as insufficient sharpness, large thickness accuracy error, poor flatness, low cutting efficiency, generation of harmful fumes, high cutting point temperature and poor electromagnetic performance when cutting amorphous magnetic cores or iron cores, resulting in high production costs, low efficiency and unstable product quality.
Abrasive wheel cutting discs with a specific formula, including green silicon carbide, black silicon carbide, phenolic resin liquid and powder, PVC liquid and other components, are produced by hydraulic dual-station automatic molding and high-temperature firing process to produce cutting discs with high sharpness, high thickness accuracy, good flatness and environmental protection, reducing the temperature at the cutting point and improving electromagnetic performance.
It achieves a cutting blade sharpness increase of over 40%, thickness accuracy error of less than 0.05mm, flatness of 0.05-0.1mm, a yield rate of 98%, improved cutting efficiency, reduced labor, equipment and environmental costs, lower cutting point temperature, environmentally friendly and harmless smoke, and excellent electromagnetic performance.
Smart Images
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Abstract
Description
Technical Field
[0001] This invention relates to the field of cutting tools, and more particularly to an abrasive wheel cutting disc for cutting amorphous magnetic cores or iron cores and a method for preparing it. Background Technology
[0002] Amorphous iron cores are machine parts made of iron-based amorphous ribbon. With a crystallization temperature of 550 degrees Celsius, they possess high saturation magnetic induction and low loss, significantly reducing equipment weight, size, and improving efficiency. They are widely used in various transformer cores, such as those for aviation transformers, railway control systems, mechanical parts quenching equipment, and laser power supplies. Cutting discs are abrasive wheels made of abrasive materials and bonding resins, used for cutting amorphous magnetic cores or iron cores.
[0003] Currently, the market uses traditional ordinary abrasive wheel cutting discs. Due to their outdated formula and primarily coarse abrasive grit size of #54, these discs produce workpieces with a surface finish of only 10 or coarse. This necessitates secondary manual and equipment grinding after cutting, increasing labor, equipment, space, utility, and environmental costs. Furthermore, the outdated formula results in significant thickness accuracy errors (around 0.3mm) and flatness errors (above 0.2mm), leading to large dimensional inconsistencies and poor product quality in batches. Additionally, the insufficient sharpness of traditional ordinary abrasive wheels causes scrambled cuts and skewed ends, resulting in a yield rate of only around 80%. Rapid wear during cutting necessitates frequent disc replacements, leading to low production efficiency and increased costs for customers. Traditional ordinary abrasive cutting discs reach cutting temperatures exceeding 300 degrees Celsius, generating large sparks and exhibiting poor heat dissipation. This results in blackening of the product's ends, unevenness and deformation at the thermal stress release points, roughness, and burns. Consequently, the gaps between the product's ends are large, directly leading to low inductance and electromagnetic properties and a yield rate of approximately 80%. Furthermore, traditional ordinary abrasive cutting discs contain internal glass fiber reinforcement mesh, which produces significant amounts of fumes during cutting, posing a health hazard to operators if inhaled. Summary of the Invention
[0004] This invention provides an abrasive wheel cutting disc for cutting amorphous magnetic cores or iron cores and a method for its preparation, so as to provide a cutting disc with superior sharpness, cutting endurance, thickness accuracy control and flatness, thereby improving work efficiency and reducing labor, equipment and other costs.
[0005] To address the aforementioned technical problems, one objective of this invention is to provide an abrasive wheel cutting disc for cutting amorphous magnetic cores or iron cores, comprising the following components by weight:
[0006] Green silicon carbide: 32-38 parts;
[0007] Black silicon carbide: 4-8 parts;
[0008] Phenolic resin solution: 14-20 parts;
[0009] Phenolic resin powder: 12-17 parts;
[0010] PVC liquid H-1622: 2-4 parts;
[0011] Additional ingredients: 11-25 parts;
[0012] Ferric oxide: 2-3 parts;
[0013] The phenolic resin liquid includes PR-55729 and PR-940, the phenolic resin powder includes PR-217 and PR-5195, and the excipients include white corundum, calcium carbonate, garnet, and single-crystal corundum.
[0014] By adopting the above-mentioned scheme, this application uses special phenolic resin liquid and phenolic resin powder, combined with special PVC liquid, which can improve the bonding strength of the cutting disc, enhance the production forming capability of the abrasive wheel cutting disc, facilitate thickness accuracy control and improve flatness, resulting in smaller thickness accuracy errors, higher product quality consistency, and a dimensional error rate more than 90% higher than traditional discs. The combination of ferric oxide and resin improves the wear resistance and cut resistance of the cutting disc. With the increased bonding strength of the resin, the adhesion between the auxiliary materials and the bonding system is good, resulting in high product formability and excellent thickness accuracy control. This allows for one-time forming of the cutting end, eliminating the need for secondary manual and equipment grinding. The sharpness of the cutting disc is significantly improved, reducing the frequency of disc replacement. No harmful fumes or dust are generated during cutting, and it has passed SGS environmental certification, ensuring safety for human health. Using a special formula, the cutting point temperature is much lower than traditional discs, with no sparks and excellent heat dissipation at the end. The end is flat, bright, does not blacken, deform, burn, or fall apart, and the two ends close seamlessly. It exhibits excellent inductive and electromagnetic properties, with a yield rate of over 98%.
[0015] As a preferred embodiment, the phenolic resin liquid comprises PR-55729 and PR-940 in a mass ratio of 1:1.
[0016] As a preferred embodiment, the phenolic resin powder comprises PR-217 and PR-5195 in a mass ratio of 3:2.
[0017] As a preferred embodiment, the auxiliary materials include 4-8 parts by weight of white corundum, 4-6 parts by weight of calcium carbonate, 4-6 parts by weight of garnet, and 3-5 parts by weight of monocrystalline corundum.
[0018] As a preferred embodiment, the green silicon carbide has a mesh size of 350-450, and the black silicon carbide has a mesh size of 100-150.
[0019] As a preferred embodiment, the white corundum has a mesh size of 100-150; the calcium carbonate has a mesh size of 200-250; the garnet has a mesh size of 220-260; and the single-crystal corundum has a mesh size of 300-350.
[0020] As a preferred embodiment, the ferric oxide has a mesh size of 300-350.
[0021] To solve the above-mentioned technical problems, the second objective of this invention is to provide a method for preparing a grinding wheel cutting disc for cutting amorphous magnetic cores or iron cores, comprising the following steps: using a hydraulic dual-station automatic molding equipment, the formula materials are mixed and fermented, then the equipment automatically feeds the materials, automatically flattens them, automatically puts them into the mold, automatically applies 7-9 MPa pressure, and simultaneously heats and shapes them, then demolds them, removes the materials, and then fires them at a high temperature curve in a hardening furnace to obtain the finished product.
[0022] As a preferred option, the firing temperature profile is as follows: 80℃ at room temperature for 4 hours; 120℃ for 8 hours; 160℃ for 4 hours; 185℃ for 4 hours; and 215℃ for 3 hours.
[0023] As a preferred option, the fermentation time is 60-75 hours, the heating and molding temperature is 75-85℃, and the heating time is 20-50 seconds.
[0024] Compared with the prior art, the embodiments of the present invention have the following beneficial effects:
[0025] 1. The special abrasive wheel cutting disc for "amorphous magnetic core iron core" in this application mainly uses fine abrasive, and the surface finish of the processed workpiece is 13 or finer, so that the cutting end is formed in one step, without the need for secondary manual and equipment grinding, saving customers a lot of labor costs, equipment costs, site costs, water and electricity fees, and environmental costs.
[0026] 2. The cutting disc of this application can ensure that after high-temperature curing, the thickness accuracy of the cutting disc is controlled within ±(0.05)mm, and the flatness can be achieved at 0.05-0.1mm. This results in small thickness accuracy error of the cut products, high product quality consistency, and a dimensional error rate that is more than 90% higher than that of traditional discs. The cutting sharpness is also more than 40% higher than that of traditional discs. The products will not be cut in pieces or the ends will not be cut at an angle, and the yield rate will reach more than 98%.
[0027] 3. The cutting point temperature of the cutting disc in this application is much lower than that of traditional discs, with no sparks, and the heat dissipation effect at the port is good. The port is flat, bright, does not turn black, does not deform, does not burn, and does not break apart. The two ends are seamless when closed. It has excellent inductive and electromagnetic properties, and the yield rate is over 98%. It does not produce harmful fumes and dust during cutting, and has passed SGS environmental certification, which is safe for human health. Detailed Implementation
[0028] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.
[0029] Table 1 - Sources and types of raw materials used in the embodiments or comparative examples of this application.
[0030] Raw material name model factory Performance parameters Green silicon carbide F400 Commercially available The mesh size is 400. black silicon carbide F120 Commercially available Mesh count: 120 White corundum F120 Commercially available Mesh count: 120 Calcium carbonate F240 Commercially available The mesh size is 240. Garnet F240 Commercially available The mesh size is 240. Single crystal corundum F320 Commercially available The mesh size is 320. Phenolic resin liquid PR-55729 Sumitomo Bakelite Co., Ltd. - Phenolic resin liquid PR-940 Sumitomo Bakelite Co., Ltd. - PVC liquid H-1622 Dongguan Jinghong Adhesives Co., Ltd. - PVC liquid JL-268 Dongguan Juli Adhesive Products Co., Ltd. - Phenolic resin powder PR-217 Sumitomo Bakelite Co., Ltd. - Phenolic resin powder PR-5195 Sumitomo Bakelite Co., Ltd. - Ferric oxide F320 Gongyi Fuquan Refractory Materials Co., Ltd. The mesh size is 320.
[0031] Examples 1-3
[0032] A grinding wheel cutting disc for cutting amorphous magnetic cores or iron cores, as shown in Table 2 below, includes green silicon carbide, black silicon carbide, white corundum, calcium carbonate, garnet, single-crystal corundum, phenolic resin liquid PR-55729, phenolic resin liquid PR-940, PVC liquid H-1622, phenolic resin powder PR-217, phenolic resin powder PR-5195, and iron oxide. Its preparation method includes the following steps: using a 400-ton hydraulic dual-station automatic molding machine, the formulated materials are mixed and fermented for 72 hours. Then, the equipment automatically feeds, rolls, and molds the material, applies 8MPA pressure, and simultaneously heats at 80℃ for 30 seconds to form the product. After demolding, the material is removed and then batch-fired in a hardening furnace at high temperatures (curve: 80℃ for 4 hours; 120℃ for 8 hours; 160℃ for 4 hours; 185℃ for 4 hours; 215℃ for 3 hours) to obtain the finished product.
[0033] Table 2 - Components and content of the cutting discs in the embodiments of this application
[0034]
[0035]
[0036] Performance testing
[0037] 1. Use a digital vernier caliper to measure the thickness accuracy of the cutting disc at any 10 different points. The thickness difference at different points in this application needs to be controlled within ±(0.05) mm. The results are shown in Table 3.
[0038] 2. Place the cutting disc flat on a marble surface with a flatness of less than 0.02mm after polishing. Use plug gauges of different thicknesses to insert between the cutting disc and the marble surface, and insert them around the outer circle of the cutting disc. If none of them can be inserted, then the flatness of the cutting disc is determined to be within the required thickness. The results are shown in Table 3.
[0039] 3. Surface roughness of workpiece: After cutting amorphous material workpieces on a cutting device, a diamond stylus with a tip curvature radius of about 2 micrometers is used to slowly slide along the surface of the workpiece to be measured using a handheld or benchtop roughness measuring instrument. The surface roughness value is obtained by measuring the vertical displacement of the diamond stylus. The results are shown in Table 3.
[0040] 4. Sharpness and Cutting Resistance: On the same cutting equipment, using the same fixture, cutting amorphous materials of the same specifications from the same supplier, with the same feed speed and cutting blade rotation speed, the higher the current, the blunter the cutting blade; conversely, the lower the current, the sharper the cutting blade. The cutting current displayed on the inverter connected to the main motor can be used to judge the sharpness of different cutting blades. Using the cutting blade to cut a 15×15mm strip-shaped amorphous material workpiece, cutting amorphous materials of the same specifications from the same supplier, with the same feed speed and cutting blade rotation speed, the number of cuts determines the cutting resistance. The more cuts, the more cut-resistant; the fewer cuts, the less cut-resistant. The results are shown in Table 3.
[0041] Table 3 - Performance test results of the cutting discs in the examples and comparative examples
[0042]
[0043] Based on the performance test results of Example 2 and Comparative Example 1 in Table 3, it can be seen that the addition of PVC liquid H-1622 to the cutting disc improves the production forming capability of the abrasive wheel cutting disc compared to other PVC liquids, making it easier to achieve thickness accuracy control and forming flatness. The thickness difference is controlled below 0.05mm, and the flatness is controlled between 0.05-0.1mm.
[0044] Based on the performance test results of Example 2 and Comparative Examples 2-3 in Table 3, it can be seen that the cutting disc of this application is configured with special resin liquid PR-55729 / PR-940 and resin powder PR-5195 / PR-217. The overall combination of these components can comprehensively improve the sharpness, cut resistance, and cutting efficiency of the cutting disc.
[0045] Based on the performance test results of Example 2 and Comparative Example 4 in Table 3, it can be seen that black silicon carbide can supplement and improve the grinding and cutting effect of green silicon carbide on amorphous alloy materials, and improve the sharpness and cutting resistance of the cutting disc.
[0046] Based on the performance test results of Example 2 and Comparative Example 5 in Table 3, it can be seen that the cutting disc contains four auxiliary materials: single crystal corundum, white corundum, calcium carbonate, and garnet. These materials synergistically enhance the sharpness of the cutting disc and reduce the surface roughness of the workpiece, which is conducive to cutting the workpiece more quickly, improving cutting resistance, increasing service life, reducing changeover time, and thus improving work efficiency.
[0047] Based on the performance test results of Example 2 and Comparative Example 6 in Table 3, it can be seen that the addition of ferric oxide to the cutting disc enhances its wear resistance and cutting ability, thus extending its service life.
[0048] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the scope of protection of the present invention. In particular, it should be noted that any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention for those skilled in the art.
Claims
1. A grinding wheel for cutting amorphous magnetic cores or iron cores, characterized in that, Includes the following components by weight: Green silicon carbide: 32-38 parts; Black silicon carbide: 4-8 parts; Phenolic resin solution: 14-20 parts; Phenolic resin powder: 12-17 parts; PVC liquid H-1622: 2-4 parts; Additional ingredients: 11-25 parts; Ferric oxide: 2-3 parts; The phenolic resin liquid includes PR-55729 and PR-940, the phenolic resin powder includes PR-217 and PR-5195, and the excipients include 4-8 parts by weight of white corundum, 4-6 parts by weight of calcium carbonate, 4-6 parts by weight of garnet, and 3-5 parts by weight of monocrystalline corundum.
2. The abrasive wheel cutting disc for cutting amorphous magnetic cores or iron cores as described in claim 1, characterized in that, The phenolic resin solution comprises PR-55729 and PR-940 in a mass ratio of 1:
1.
3. The abrasive wheel cutting disc for cutting amorphous magnetic cores or iron cores as described in claim 1, characterized in that, The phenolic resin powder comprises PR-217 and PR-5195 in a mass ratio of 3:
2.
4. The abrasive wheel cutting disc for cutting amorphous magnetic cores or iron cores as described in claim 1, characterized in that, The green silicon carbide has a mesh size of 350-450, and the black silicon carbide has a mesh size of 100-150.
5. The abrasive wheel cutting disc for cutting amorphous magnetic cores or iron cores as described in claim 1, characterized in that, The white corundum has a mesh size of 100-150; the calcium carbonate has a mesh size of 200-250; the garnet has a mesh size of 220-260; and the single-crystal corundum has a mesh size of 300-350.
6. The abrasive wheel cutting disc for cutting amorphous magnetic cores or iron cores as described in claim 1, characterized in that, The ferric oxide has a mesh size of 300-350.
7. A method for preparing an abrasive wheel cutting disc for cutting amorphous magnetic cores or iron cores as described in any one of claims 1-6, characterized in that, Includes the following steps: The hydraulic dual-station automatic molding equipment is used to mix the formula materials, ferment them, and then automatically feed, roll, and mold the materials. It applies 7-9 MPa pressure and heats the materials at the same time to form the product. After that, the material is demolded, removed, and then fired at a high temperature curve in a hardening furnace to obtain the finished product.
8. A method for preparing an abrasive wheel cutting disc for cutting amorphous magnetic cores or iron cores as described in claim 7, characterized in that, The firing temperature profile is as follows: 80℃ for 4 hours at room temperature; 120℃ for 8 hours; 160℃ for 4 hours; 185℃ for 4 hours; and 215℃ for 3 hours.
9. A method for preparing an abrasive wheel cutting disc for cutting amorphous magnetic cores or iron cores as described in claim 7, characterized in that, The fermentation time is 60-75 hours, and the heating and molding temperature is 75-85℃ for 20-50 seconds.