A grinding wheel and a grinding disc synthesis and manufacturing process

Abstract

The present invention discloses a grinding wheel and a grinding disc. The grinding wheel and a grinding disc are made from the following raw materials: 20-35 parts of a binder, 8-15 parts of a wetting agent, 40-55 parts of a filler, 0.1-2 parts of a coupling agent, and 25-30 parts of an abrasive. The grinding wheel and abrasive disc of the present invention use hollow phenolic resin spheres as fillers to improve the smoothness of the workpiece and contribute to improved grinding efficiency. The wetting agent is a combination of furfural and liquid nitrile rubber, which synergistically improves the wear resistance of the grinding wheel and abrasive disc, reduces wear, and prolongs its life. The present invention also discloses a synthesis and manufacturing process for the grinding wheel and abrasive disc. The process uses four temperature stages to cure the blank in an oven to ensure the strength of the grinding wheel and abrasive disc.

Description

Technical Field

[0001] The invention belongs to the technical field of grinding wheels and relates to a synthesis and manufacturing process of a grinding wheel and a grinding disc. Background Art

[0002] Grinding wheels are tools used to grind and trim workpieces. They are commonly used in industries such as metal processing, glass processing, and stone processing. They have the characteristics of high strength, wear resistance, and long service life. The combined action of the grinding wheel and the grinding disc can remove excess metal protruding from the workpiece. During the process of extrusion, contact, movement, and friction, the grinding process is completed to improve the smoothness and precision of the surface to be ground. Different types of abrasive particle materials can be combined with different types of binder materials. For example, the use of superabrasive particles (such as diamond or cubic boron nitride) or aluminum oxide abrasive particles is common in grinding tools. The binder material can be an organic material, such as a resin. Certain other binder materials include inorganic materials, such as a composite that forms a glassy material, or an alternative metal material. The preparation process of the grinding wheel includes raw material ratio, mixing, molding, and sintering. By controlling these process parameters, a grinding wheel with ideal performance can be prepared.

[0003] The structure of existing grinding wheels for grinding metal materials is mostly composed of a skeleton and a grinding layer. The grinding layer is made of abrasives and a binder. Due to the high hardness and rigidity of the grinding layer, in order for the grinding wheel to achieve the purpose of grinding the workpiece to be bright, the workpiece must be metal-processed and achieve a high precision and smoothness before grinding, and then grinding to achieve a high-smoothness grinding effect. It is even more difficult to process metal planes to a certain smoothness on very thin workpieces. Therefore, there is still a lot of room for further optimization and improvement of the grinding effect of grinding wheels and grinding discs. Continuous research and improvement on the materials, structures, shapes and processes of grinding wheels have enabled grinding wheels to provide more efficient and precise grinding and dressing effects in processing in various industries. Summary of the Invention

[0004] The present invention aims to provide a process for synthesizing and manufacturing a grinding wheel and abrasive disc. The grinding wheel and abrasive disc are made of a binder, a wetting agent, a filler, a coupling agent, and an abrasive. Phenolic resin hollow spheres are used as fillers to improve the smoothness of the workpiece being ground, thereby enhancing grinding efficiency. The wetting agent is a combination of furfural and liquid nitrile rubber, which synergistically improves the wear resistance of the grinding wheel and abrasive disc, reduces wear, and prolongs their lifespan. The process employs four temperature stages to cure the blank in an oven, ensuring the strength of the grinding wheel and abrasive disc.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] A process for synthesizing and manufacturing a grinding wheel and a grinding disc, comprising the following steps:

[0007] S1: 0.1-2 parts by weight of coupling agent and 25-30 parts by weight of abrasive are first wetted in a high-speed blender, and then 10-15 parts by weight of binder and 40-55 parts by weight of filler are added and stirred to obtain material A1;

[0008] S2: Place material A1 in an oven at 100-120°C for 1-3 hours to remove moisture and dry the surface, then cool it to room temperature to obtain material A2;

[0009] S3: 8 to 15 parts by weight of a wetting agent is added to material A2 to wet material A2, and then 10 to 20 parts by weight of a binder is added and stirred for 10 to 20 minutes to obtain material A3;

[0010] S4: Take material A3 and put it into the die of the pressing die, and use the hydraulic press to press it to obtain a blank;

[0011] S5: Place the blank in an oven and solidify it in four temperature stages: 1) heat to 100°C and keep warm for 3 hours; 2) heat to 130°C and keep warm for 3 hours; 3) heat to 150°C and keep warm for 3 hours; 4) heat to 190°C and keep warm for 3 hours; finally, the desired product is obtained.

[0012] As a preferred technical solution of the present invention, the filler is a homemade coating material phenolic resin hollow ball, and the preparation method of the phenolic resin hollow ball is as follows: sucrose powder is moistened with liquid phenolic resin to obtain a moistening powder, and the moistening powder is heated at 70-100°C for 1-4 hours to obtain hollow large-particle thin-walled hollow balls, namely phenolic resin hollow balls.

[0013] Phenolic resin hollow balls have a low density, which can effectively reduce the overall weight of the grinding wheel. This helps reduce the centrifugal force on the wheel disc and alleviates pressure on the grinding surface, thereby reducing heat and friction, and improving the stability and working efficiency of the grinding wheel. Due to their hollow structure, phenolic resin hollow balls have a certain degree of thermal insulation. During the grinding process, they can play a certain role in heat preservation and reduce the degree of heat transfer to the wheel surface. This is beneficial for applications with materials sensitive to grinding temperature or sensitive to thermal effects on the workpiece surface. The hollow structure of phenolic resin hollow balls has vibration absorption and damping properties. During the grinding process, they can absorb and reduce the transmission of vibration and impact force, reduce vibration between the grinding wheel and the workpiece, improve grinding stability, and reduce noise and vibration during grinding. The hollow structure of phenolic resin hollow balls helps to evenly distribute the abrasive throughout the grinding wheel, helping to achieve uniform grinding and polishing results. They can provide a more stable and consistent cutting behavior, reducing surface scratches and wear.

[0014] As a preferred technical solution of the present invention, the weight ratio of the liquid phenolic resin to sucrose powder is 1:2 to 1:5.

[0015] As a preferred technical solution of the present invention, the binder is polyimide.

[0016] As a preferred technical solution of the present invention, the wetting agent is composed of furfural and liquid nitrile rubber, with the weight ratio of furfural to liquid nitrile rubber being 1:1 to 1:2. The use of a wetting agent helps improve process performance and product quality in grinding wheel production. By improving wettability and adhesion, the wetting agent can promote mixing and dispersion of the various components, helping to achieve a more uniform distribution of ingredients and better grinding wheel performance.

[0017] As a preferred technical solution of the present invention, the coupling agent is KH550, whose Chinese name is γ-aminopropyltriethoxysilane.

[0018] As a preferred technical solution of the present invention, the abrasive is selected according to the material of the workpiece to be ground, and the abrasive is any one of white corundum, brown corundum, and silicon carbide.

[0019] As a preferred technical solution of the present invention, the mold for the pressing in step S4 is a mold for a grinding wheel and a mold for a grinding disc.

[0020] A grinding wheel and a grinding disc are prepared by the above-mentioned synthesis and manufacturing process.

[0021] Beneficial effects of the present invention:

[0022] (1) The present invention provides a grinding wheel and a grinding disc, wherein the filler is a phenolic resin hollow ball. Compared with the alumina hollow balls and potassium sulfate in the prior art, the phenolic resin hollow balls as a filler make the workpiece ground by the grinding wheel have excellent smoothness, which helps to improve the grinding efficiency.

[0023] (2) The present invention provides a grinding wheel and a grinding disc, wherein the wetting agent is a combination of furfural and liquid nitrile rubber, which synergistically improves the wear resistance of the grinding wheel and the grinding disc, reduces wear, and prolongs the service life.

[0024] (3) The present invention provides a process for synthesizing and manufacturing a grinding wheel and a grinding disc, wherein the process uses four temperature stages to solidify the blank in an oven, thereby ensuring the strength of the grinding wheel and the grinding disc. DETAILED DESCRIPTION

[0025] In order to further illustrate the technical means and effects adopted by the present invention to achieve the predetermined purpose of the invention, the specific implementation methods, structures, features and effects of the present invention are described in detail below in combination with the embodiments.

[0026] Example 1

[0027] A process for synthesizing and manufacturing a grinding wheel and a grinding disc, comprising the following steps:

[0028] S1: 1 part by weight of coupling agent and 25 parts by weight of abrasive are mixed in a high-speed mixer to wet the abrasive. Then, 12 parts by weight of binder and 45 parts by weight of filler are added and stirred to obtain material A1.

[0029] S2: Place material A1 in an oven at 110°C for 2 hours to remove moisture and dry the surface, then cool it down to room temperature to obtain material A2.

[0030] S3: 10 parts by weight of a wetting agent was added to material A2 to wet material A2, and then 15 parts by weight of a binder was added and stirred for 10 minutes to obtain material A3;

[0031] S4: Take material A3 and put it into the die of the pressing die, and use the hydraulic press to press it to obtain a blank;

[0032] S5: Place the blank in an oven and solidify it in four temperature stages: 1) heat to 100°C and keep warm for 3 hours; 2) heat to 130°C and keep warm for 3 hours; 3) heat to 150°C and keep warm for 3 hours; 4) heat to 190°C and keep warm for 3 hours; finally, the desired product is obtained.

[0033] The filler is a homemade coating material phenolic resin hollow ball. The preparation method of the phenolic resin hollow ball is as follows: sucrose powder is moistened with liquid phenolic resin to obtain moistening powder, and the moistening powder is heated at 80° C. for 3 hours to obtain hollow large-particle thin-walled hollow balls, namely phenolic resin hollow balls.

[0034] The weight ratio of the liquid phenolic resin to sucrose powder is 1:3.

[0035] The binder is polyimide.

[0036] The wetting agent consists of furfural and liquid nitrile rubber, and the weight ratio of the furfural to the liquid nitrile rubber is 3:5.

[0037] The coupling agent is KH550, whose Chinese name is γ-aminopropyltriethoxysilane.

[0038] The abrasive is selected based on the material of the workpiece being ground. In Example 1, the abrasive selected was white corundum. White corundum (Al2O3), also a type of aluminum oxide, has a slightly higher crystal structure and hardness than brown corundum. White corundum is commonly used for high-precision machining such as grinding and polishing steel, such as mirror polishing and precision parts processing.

[0039] The molds for the pressing in step S4 are the molds of the grinding wheel and the molds of the grinding disc.

[0040] A grinding wheel and a grinding disc are prepared by the above-mentioned synthesis and manufacturing process.

[0041] Example 2

[0042] A process for synthesizing and manufacturing a grinding wheel and a grinding disc, comprising the following steps:

[0043] S1: 2 parts by weight of coupling agent and 30 parts by weight of abrasive are mixed in a high-speed mixer to wet the abrasive, and then 10 parts by weight of binder and 45 parts by weight of filler are added and stirred to obtain material A1;

[0044] S2: Place material A1 in an oven at 110°C for 2 hours to remove moisture and dry the surface, then cool it down to room temperature to obtain material A2.

[0045] S3: 15 parts by weight of a wetting agent was added to material A2 to wet material A2, and then 15 parts by weight of a binder was added and stirred for 12 minutes to obtain material A3;

[0046] S4: Take material A3 and put it into the die of the pressing die, and use the hydraulic press to press it to obtain a blank;

[0047] S5: Place the blank in an oven and solidify it in four temperature stages: 1) heat to 100°C and keep warm for 3 hours; 2) heat to 130°C and keep warm for 3 hours; 3) heat to 150°C and keep warm for 3 hours; 4) heat to 190°C and keep warm for 3 hours; finally, the desired product is obtained.

[0048] The filler is a homemade coating material phenolic resin hollow ball. The preparation method of the phenolic resin hollow ball is as follows: sucrose powder is moistened with liquid phenolic resin to obtain moistening powder, and the moistening powder is heated at 80° C. for 3 hours to obtain hollow large-particle thin-walled hollow balls, namely phenolic resin hollow balls.

[0049] The weight ratio of the liquid phenolic resin to sucrose powder is 1:2.

[0050] The binder is polyimide.

[0051] The wetting agent consists of furfural and liquid nitrile rubber, and the weight ratio of the furfural to the liquid nitrile rubber is 3:5.

[0052] The coupling agent is KH550.

[0053] The abrasive is selected based on the material of the workpiece being ground. In Example 2, the abrasive selected was white corundum. White corundum (Al2O3), also a type of aluminum oxide, has a slightly higher crystal structure and hardness than brown corundum. White corundum is commonly used for high-precision machining such as grinding and polishing steel, such as mirror polishing and precision parts processing.

[0054] The molds for the pressing in step S4 are the molds of the grinding wheel and the molds of the grinding disc.

[0055] A grinding wheel and a grinding disc are prepared by the above-mentioned synthesis and manufacturing process.

[0056] Example 3

[0057] A process for synthesizing and manufacturing a grinding wheel and a grinding disc, comprising the following steps:

[0058] S1: 2 parts by weight of coupling agent and 30 parts by weight of abrasive were mixed in a high-speed mixer to wet the abrasive. 15 parts by weight of binder and 50 parts by weight of filler were then added and stirred to obtain material A1.

[0059] S2: Place material A1 in an oven at 110°C for 2 hours to remove moisture and dry the surface, then cool it down to room temperature to obtain material A2.

[0060] S3: 15 parts by weight of a wetting agent was added to material A2 to wet material A2, and then 15 parts by weight of a binder was added and stirred for 15 minutes to obtain material A3;

[0061] S4: Take material A3 and put it into the die of the pressing die, and use the hydraulic press to press it to obtain a blank;

[0062] S5: Place the blank in an oven and solidify it in four temperature stages: 1) heat to 100°C and keep warm for 3 hours; 2) heat to 130°C and keep warm for 3 hours; 3) heat to 150°C and keep warm for 3 hours; 4) heat to 190°C and keep warm for 3 hours; finally, the desired product is obtained.

[0063] The filler is a homemade coating material phenolic resin hollow ball. The preparation method of the phenolic resin hollow ball is as follows: sucrose powder is moistened with liquid phenolic resin to obtain moistening powder, and the moistening powder is heated at 80° C. for 3 hours to obtain hollow large-particle thin-walled hollow balls, namely phenolic resin hollow balls.

[0064] The weight ratio of the liquid phenolic resin to sucrose powder is 1:2.

[0065] The binder is polyimide.

[0066] The wetting agent consists of furfural and liquid nitrile rubber, and the weight ratio of the furfural to the liquid nitrile rubber is 1:1.5.

[0067] The coupling agent is KH550, whose Chinese name is γ-aminopropyltriethoxysilane.

[0068] The abrasive is selected based on the material of the workpiece being ground. In Example 3, the abrasive selected was white corundum. White corundum (Al2O3), also a type of aluminum oxide, has a slightly higher crystal structure and hardness than brown corundum. White corundum is commonly used for high-precision machining such as grinding and polishing steel, such as mirror polishing and precision parts processing.

[0069] The molds for the pressing in step S4 are the molds of the grinding wheel and the molds of the grinding disc.

[0070] A grinding wheel and a grinding disc are prepared by the above-mentioned synthesis and manufacturing process.

[0071] Comparative Example 1

[0072] On the basis of Example 3, the phenolic resin hollow spheres were replaced with alumina hollow spheres of equal weight.

[0073] Comparative Example 2

[0074] On the basis of Example 3, the phenolic resin hollow spheres were replaced with an equal weight of potassium sulfate.

[0075] Comparative Example 3

[0076] Based on Example 3, furfural was replaced by an equal weight of liquid nitrile rubber.

[0077] Comparative Example 4

[0078] On the basis of Example 3, the liquid nitrile rubber was replaced with an equal weight of furfural.

[0079] Performance testing:

[0080] 1. Roughness test

[0081] Test materials: Grinding wheels and grinding discs manufactured in accordance with the above-mentioned Examples 1 to 3 and Comparative Examples 1 to 2 of the present invention, and steel plates.

[0082] Test method: After grinding the steel plate at rotation speeds of 800 rpm and 1200 rpm, the roughness of the upper and lower surfaces of the steel plate was tested.

[0083] Test results: 5 batches of samples were tested according to the law. The specific test data are shown in Table 1.

[0084] Table 1 Steel plate roughness test results

[0085] Group Speed ​​800rpm Speed ​​1200rpm Example 1 0.035 0.041 Example 2 0.036 0.042 Example 3 0.032 0.039 Comparative Example 1 0.064 0.071 Comparative Example 2 0.059 0.068

[0086] It can be seen from the test results in Table 1 that compared with the workpiece ground by the grinding wheel using hollow alumina balls or potassium sulfate as fillers in the prior art, the workpiece steel plate ground by the grinding wheel and grinding disc provided by the present invention has excellent smoothness, which helps to improve the grinding efficiency.

[0087] 2. Wear resistance test

[0088] Test materials: grinding wheels and grinding discs, and steel plates prepared in Examples 1 to 3 and Comparative Examples 2 to 4.

[0089] Test method: Use a digital caliper to measure the initial diameter of the grinding wheel. Install the grinding wheel to be measured on the grinding equipment and grind the steel plate material for 4 hours a day. Measure the diameter after one week of grinding. Select multiple positions for measurement and take the average value.

[0090] Wear amount = initial size - size after wear

[0091] Test results: 6 batches of samples were tested according to the law. The specific test data are shown in Table 2.

[0092] Table 2 Grinding wheel wear resistance test

[0093] Group Wear amount (mm) Example 1 0.86 Example 2 0.90 Example 3 0.79 Comparative Example 2 1.51 Comparative Example 3 1.46 Comparative Example 4 1.58

[0094] From the data in Table 2, it can be seen that the present invention provides a grinding wheel and a grinding disc, and the wetting agent is a combination of furfural and liquid nitrile rubber, which synergistically improves the wear resistance of the grinding wheel and the grinding disc and prolongs their service life.

[0095] The above description is merely a preferred embodiment of the present invention and does not constitute any form of limitation to the present invention. Although the present invention has been disclosed as above in terms of a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art can, without departing from the scope of the technical solution of the present invention, make some changes or modifications to equivalent embodiments using the technical contents disclosed above. However, any brief modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A process for synthesizing and manufacturing a grinding wheel and a grinding disc, characterized in that: The synthesis and manufacturing process comprises the following steps: S1: 0.1-2 parts by weight of coupling agent and 25-30 parts by weight of abrasive are first wetted in a high-speed blender, and then 10-15 parts by weight of binder and 40-55 parts by weight of filler are added and stirred to obtain material A1; S2: Place material A1 in an oven at 100-120°C for 1-3 hours to remove moisture and dry the surface, then cool it to room temperature to obtain material A2. S3: 8 to 15 parts by weight of a wetting agent is added to material A2 to wet material A2, and then 10 to 20 parts by weight of a binder is added and stirred for 10 to 20 minutes to obtain material A3; S4: Take material A3 and put it into the die of the pressing die, and use the hydraulic press to press it to obtain a blank; S5: The blank is placed in an oven and cured in four temperature stages: 1) heating to 100°C and holding for 3 hours; 2) heating to 130°C and holding for 3 hours; 3) heating to 150°C and holding for 3 hours; 4) heating to 190°C and holding for 3 hours; and finally the desired product is obtained. The filler is a homemade coating material, phenolic resin hollow balls. The preparation method of the phenolic resin hollow balls is as follows: sucrose powder is moistened with liquid phenolic resin to obtain a moistening powder, and the moistening powder is heated at 70-100° C. for 1-4 hours to obtain hollow large-particle thin-walled hollow balls, namely the phenolic resin hollow balls; The wetting agent consists of furfural and liquid nitrile rubber, and the weight ratio of the furfural to the liquid nitrile rubber is 1:1.

5.

2. A process for synthesizing and manufacturing a grinding wheel and a grinding disc according to claim 1, characterized in that: The weight ratio of the liquid phenolic resin to sucrose powder is 1:2 to 1:

5.

3. A process for synthesizing and manufacturing a grinding wheel and a grinding disc according to claim 1, characterized in that: The binder is polyimide.

4. A process for synthesizing and manufacturing a grinding wheel and a grinding disc according to claim 1, characterized in that: The coupling agent is KH550.

5. The process for synthesizing and manufacturing a grinding wheel and a grinding disc according to claim 1, wherein: The abrasive is selected according to the material of the workpiece to be ground. The abrasive is any one of white corundum, brown corundum, and silicon carbide.

6. A process for synthesizing and manufacturing a grinding wheel and a grinding disc according to claim 1, characterized in that: The mold of the pressing mold in S4 is a mold of a grinding wheel and a mold of a grinding disc.

7. A grinding wheel and a grinding disc, characterized in that: The grinding wheel and the grinding disc are prepared by the grinding wheel and the grinding disc synthesis and manufacturing process according to any one of claims 1 to 6.