An irregular resin diamond peripheral grinding wheel and a preparation method and application thereof

Abstract

The present application belongs to the field of superhard abrasive grinding wheel, and particularly relates to a special-shaped resin diamond peripheral grinding wheel and a preparation method and application thereof. The special-shaped resin diamond peripheral grinding wheel can simultaneously process gear cutter grains into a shape through one grinding wheel in one device, thereby reducing the processing time of the gear cutter grains, improving the manufacturing efficiency and precision of the gear cutter grains. Two superhard grinding wheels used by two devices are integrated on one grinding wheel, and one device and one special-shaped resin peripheral grinding wheel are used to complete the processing of the gear cutter grains, thereby improving the processing efficiency of the product, reducing the investment of the device and the waste of resources, making the product have a higher cost performance, and thus making the product have more market competitiveness.

Description

Technical Field

[0001] This invention belongs to the field of superhard abrasive grinding wheels, specifically relating to a high-efficiency resin-diamond peripheral grinding wheel for machining gear cutting inserts and its manufacturing method. It allows gear cutting inserts to be continuously machined into shape using a single grinding wheel and a single piece of equipment. This reduces the machining time for gear cutting inserts and improves the manufacturing efficiency and precision of the inserts. Background Technology

[0002] When machining cutting tools using peripheral grinding equipment, only the edges of the cutting tools are typically processed; grooving the surface of the cutting tools usually requires specialized grooving machines. Existing technology provides a universal turret-type grinding wheel head system and grinding machine for precision composite grinding, relating to the field of machine tool technology. The grinding wheel head system includes: a rotating device, a turret, a spindle device mounted on the turret, an internal grinding device, and a grinding fluid supply system. The spindle device includes external grinding wheels and end-face grinding wheels mounted at both ends, and the internal grinding device is equipped with internal grinding wheels. Existing technology provides a multi-functional integrated grinding center for bushing workpieces, which can simultaneously perform rough grinding, fine grinding, external grinding, and end-face grinding in a single setup. Existing technology discloses an integrated machining mechanism for crystal parts, with external grinding parts and end-face grinding parts respectively located on the front end face. The processing time for a single cutting tool is relatively long, and more equipment is required to complete the process. The low efficiency and high capital investment of cutting tools result in a low cost-performance ratio for the product, making it uncompetitive. Therefore, it is necessary to develop a special peripheral grinding wheel to solve the problems of low processing efficiency, high equipment investment, and low product cost performance. Summary of the Invention

[0003] The purpose of this invention is to provide a high-efficiency custom-shaped resin diamond peripheral grinding wheel for processing gear cutting inserts and its manufacturing method. This method enables the processing of gear cutting inserts using a single machine and a custom-shaped resin peripheral grinding wheel without altering product quality. This improves processing efficiency, reduces equipment investment and resource waste, and enhances the product's cost-effectiveness, thereby making the product more competitive in the market.

[0004] To achieve the above objectives, the specific technical solution of the present invention is as follows:

[0005] A special-shaped resin diamond peripheral grinding wheel includes a cast iron substrate and two abrasive layers. One abrasive layer is distributed on the upper part of the cast iron substrate, and the other abrasive layer is distributed on the outer circle of the cast iron substrate. Preferably, the grinding wheel is composed of a cast iron substrate and two abrasive layers.

[0006] In this invention, the cast iron matrix is ​​selected as ductile cast iron, and its hardness is modulated to HRC 30°±2.

[0007] In the high-efficiency gear cutting tool grinding wheel disclosed in this invention, the formulations of the two abrasive layers are different, and the sharpness, wear resistance, life, self-lubrication, and strength of the entire grinding wheel are balanced. In particular, the simultaneous processing of gear cutting tool edges and grooving results in a processing quality that is comparable to or even better than processing them separately.

[0008] This invention discloses a method for preparing the above-mentioned irregular resin diamond peripheral grinding wheel. The raw material of the abrasive layer distributed on the outer circle of the cast iron substrate is cold-pressed with the cast iron substrate, and then the raw material of the abrasive layer distributed on the upper part of the cast iron substrate is added, followed by cold pressing, and then hot pressing sintering and hardening to obtain the irregular resin diamond peripheral grinding wheel.

[0009] In this invention, the raw material formula of the abrasive layer distributed above the cast iron substrate by weight is as follows:

[0010] 20-40 parts of phenolic resin powder

[0011] 15-20 parts of silicon carbide

[0012] 5-15 parts copper powder

[0013] 5-8 parts graphite powder

[0014] 15-25 parts of uncoated abrasive.

[0015] The raw material formulation for the abrasive layer distributed on the outer circumference of the cast iron substrate, by weight, is as follows:

[0016] 20-40 parts of phenolic resin powder

[0017] 15-30 parts copper powder

[0018] 3-10 parts zinc oxide

[0019] 3-8 parts calcium oxide

[0020] 1-6 parts graphite powder

[0021] 25-40 parts of nickel-plated weight-increasing abrasive.

[0022] Preferred,

[0023] The raw material formulation for the abrasive layer distributed above the cast iron matrix, by weight, is as follows:

[0024] 30-40 parts of phenolic resin powder

[0025] 15-20 parts of silicon carbide

[0026] 5-10 parts copper powder

[0027] 5-8 parts graphite powder

[0028] 20-25 parts of uncoated abrasive.

[0029] The raw material formulation for the abrasive layer distributed on the outer circumference of the cast iron substrate, by weight, is as follows:

[0030] 20-30 parts of phenolic resin powder

[0031] 25-30 parts copper powder

[0032] 6-10 parts zinc oxide

[0033] 3-7 parts calcium oxide

[0034] 1-5 parts graphite powder

[0035] 25-35 parts of nickel-plated weight-increasing abrasive.

[0036] In this invention, the abrasive in the abrasive layer distributed above the cast iron substrate is unplated abrasive, i.e., abrasive that has not undergone surface treatment or weight-adding treatment; the abrasive in the abrasive layer distributed on the outer circumference of the cast iron substrate is nickel-plated and weight-adding abrasive, preferably nickel-plated abrasive with a 56% weight increase. This invention preferably uses abrasive in both abrasive layers, which is advantageous for simultaneously performing high-quality gear cutting edge machining and grooving; the effect of this technique is unpredictable.

[0037] The present invention discloses a high-efficiency gear cutting tool-shaped resin diamond peripheral grinding wheel with two abrasive layers: one abrasive layer is distributed on the upper part of the substrate and the other abrasive layer is distributed on the outer circle of the substrate. Conventional peripheral grinding wheels do not have this abrasive layer.

[0038] This invention discloses the application of the aforementioned irregularly shaped resin diamond peripheral abrasive wheel in the machining of gear cutting inserts, specifically its application in simultaneously machining the edges and grooves of the gear cutting inserts. The edges of the gear cutting inserts are machined by an abrasive layer distributed on the upper surface of the substrate, while the grooves of the gear cutting inserts are machined by an abrasive layer distributed on the outer circumference of the substrate.

[0039] Due to the application of the above-described solution, the present invention has the following advantages compared with the prior art:

[0040] 1. This invention discloses for the first time a high-efficiency profiled resin diamond peripheral grinder for machining gear cutting inserts and its manufacturing method, which combines the functions of two grinding wheels on one grinding wheel, thereby shortening the machining time of the cutting inserts and significantly improving the efficiency of machining gear cutting inserts;

[0041] 2. The resin peripheral mill of the present invention completes the processing of gear cutting inserts on one machine, reducing mechanical errors caused by changing equipment and improving the precision of gear cutting inserts;

[0042] 3. The resin peripheral mill of this invention reduces the number of machines from two to one, reducing the customer's equipment asset investment, while also significantly reducing the purchase cost of grinding wheels;

[0043] 4. This invention can reduce the number of grinding wheels of the same type that need to be manufactured;

[0044] 5. The resin grinding wheel disclosed in this invention has a simple preparation process, no special requirements for raw materials, and is suitable for industrial production. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of the overall structure of the grinding wheel.

[0046] Figure 2 This is a schematic diagram of the overall structure of the grinding wheel, with dimensions marked. Detailed Implementation

[0047] Unlike existing multi-part grinding, machining the edges and grooves of gear cutting inserts requires good matching, which is why existing technologies process them separately. Currently, there is no grinding wheel that can simultaneously and effectively machine the edges and grooves of gear cutting inserts. This invention adopts a different technical approach than existing processes, integrating two superhard grinding wheels used by two machines onto a single grinding wheel. Through the preparation of abrasive layers, the two abrasive layers of one grinding wheel can complete the edge grinding and grooving of gear cutting inserts, thereby enhancing the competitiveness of the product.

[0048] The method for preparing a high-efficiency, custom-shaped resin-diamond peripheral grinding wheel for gear cutting inserts disclosed in this invention includes: mixing materials, hot pressing in a mold, and sintering and hardening; then, the hardened grinding wheel is machined to the shape and size required by the drawing, and after passing inspection according to the national standard for superhard grinding wheels, it is put into storage. This step is a conventional technique. This invention discloses the above-mentioned method for preparing a custom-shaped resin-diamond peripheral grinding wheel, in which the raw material of the abrasive layer distributed on the outer circumference of a cast iron substrate is cold-pressed with the cast iron substrate, then the raw material of the abrasive layer distributed on the upper part of the cast iron substrate is added, followed by cold pressing, then hot pressing, sintering, and hardening to obtain the custom-shaped resin-diamond peripheral grinding wheel. See the structure below. Figure 1 Specifically:

[0049] (1) Conventional, the substrate is embedded in the mold;

[0050] (2) First fill the outer abrasive layer, then cold press to form;

[0051] (3) Fill the end face with abrasive layer, cold press to form, and finally put it into a flat vulcanizer for high temperature and high pressure sintering and hardening.

[0052] The present invention relates to a method for preparing a high-efficiency gear cutting tool with a profiled resin diamond peripheral grinding wheel. The mold is made using conventional technology, and its specific dimensions are determined according to the specific dimensions of the grinding wheel required for the application.

[0053] The present invention will be further described below with reference to the accompanying drawings and embodiments; the raw materials involved are all existing grinding wheel products, and the specific preparation operations and performance tests are conventional techniques; Tables 1 and 2 are the dimensions of the grinding wheels in the embodiments and comparative examples, respectively, and the specific letters mean conventional techniques, see [reference]. Figure 2 .

[0054] Table 1 Dimensional data of the forming grinding wheel in the embodiment

[0055] project Example 1 Example 2 D1 376 372 W1 10 15 T1 6 6 D2 400 400 W2 8 10 T2 6 6

[0056] Table 2 Dimensional data of comparative forming grinding wheels

[0057] Example 1

[0058] The grinding wheel is made as follows:

[0059] (1) Mixing:

[0060] ① Weigh the following components of the end-face abrasive layer according to weight: 40 parts phenolic resin powder, 10 parts copper powder, 20 parts silicon carbide, 7 parts graphite powder, and 23 parts uncoated diamond abrasive (140 / 170), totaling 1 kg. Hand-mix the resin powder, copper powder, graphite powder, and abrasive powder through an 80# sieve, then mechanically mix them using a three-dimensional mixer for 60 minutes. Pass the mixture through an 80# sieve and hand-mix three times to obtain the mixed end-face abrasive layer raw material, then bag it for later use.

[0061] ② Weigh the following components of the outer cylindrical abrasive layer according to weight: 25 parts phenolic resin powder, 28 parts copper powder, 9 parts zinc oxide, 5 parts calcium oxide, 3 parts graphite powder, and 30 parts nickel-plated diamond abrasive (140 / 170), totaling 1 kg. Hand-mix the resin powder, copper powder, zinc oxide, calcium oxide, graphite powder, and abrasive powder, then mechanically mix them using a three-dimensional mixer for 60 minutes. Pass the mixture through an 80# sieve and hand-mix three times to obtain the mixed outer cylindrical abrasive layer raw material, then bag it for later use.

[0062] ③ All the above materials are commercially available products, and their quality meets the national standards for grinding wheels.

[0063] (2) Sintering: Assemble the mold and embed it into the cast iron matrix; first fill the outer abrasive layer material, cold press at 50MPa, then fill the end face abrasive layer material, cold press at 50MPa; then place the molded grinding wheel in a hot press, hot press at 150MPa pressure and 170℃ temperature for 90min to obtain the grinding wheel blank. The cast iron matrix is ​​ductile iron with a hardness of HRC 30°±2.

[0064] (3) Hardening: The sintered grinding wheel blank is placed in an oven for subsequent hardening. Hardening process: 0.5h from room temperature to 130℃, hold for 1h; then 0.5h to 150℃, hold for 2h; then 1h to 170℃, hold for 10h; cool to room temperature and take out to obtain the grinding wheel molded body.

[0065] Grinding wheels are precision machined using conventional methods: The grinding wheel is shaped according to the drawings and machined to the specified dimensions and shape on a lathe and grinding machine. After passing the inspection according to the superhard grinding wheel standard JB / T 7425-94, it is packaged and put into storage. Example 2

[0066] The preparation process of the grinding wheel is the same as in Example 1, but the size is different.

[0067] Comparative Example 1

[0068] Based on Example 1, the end face abrasive layer or the outer circle abrasive layer is omitted to obtain comparison grinding wheel 1-1 and comparison grinding wheel 1-2.

[0069] Comparative Example 2

[0070] Based on Example 2, the end face abrasive layer or the outer circle abrasive layer is omitted to obtain comparison grinding wheel 2-1 and comparison grinding wheel 2-2.

[0071] As is common sense, the matrix of the comparative grinding wheel changes accordingly, and is similar to the matrix used in the machining of the two existing grinding wheels.

[0072] The same gear cutting inserts (made of cemented carbide and powder metallurgy) were machined using the grinding wheels in the examples and comparative examples, and the results are shown in Table 3. Compared to grinding wheels which require two separate machines, the present invention completes two steps on the same machine. With the same removal speed and removal amount, the significant advantage of the grinding wheel of the present invention is evident.

[0073] Table 3 Processing data for the examples and comparative examples

[0074]

[0075] Processing test analysis:

[0076] 1. The grinding wheel in the embodiment completes the machining of a single gear insert in more than 20% faster than the comparative example. If the turnaround time between different devices before and after the insert is taken into account, the machining time in the embodiment is significantly shorter than that in the comparative example. Therefore, the peripheral grinder of the present invention is far more efficient than the prior art method using two devices.

[0077] 2. As can be seen from the product size fluctuations, the gear cutting bits produced by the grinding wheel in this embodiment have better dimensional stability than those produced by conventional grinding wheel structures, which is something that those skilled in the art could not have predicted.

[0078] 3. In terms of equipment investment, the resin peripheral mill of the present invention uses fewer pieces of equipment than traditional equipment.

[0079] Comparison Example

[0080] Currently, there are two grinding wheels used in production for machining gear cutting inserts. The customer feedback indicates that the machining effect is the best, with dimensional fluctuations of ±3 (edge) and ±3.5 (grooving). The parallelism between the groove center and the edge is 2-4 μm. The machining time is 215 seconds (excluding tool change time), and the rotation speed is 1500 rpm and 2000 rpm.

[0081] Comparative Example 3

[0082] Based on Example 1, the abrasive in the end face abrasive layer material was replaced with nickel-plated 56 diamond abrasive (140 / 170), while the rest remained the same, resulting in Comparative Grinding Wheel 3-1.

[0083] Based on Example 1, the abrasive in the outer abrasive layer material was replaced with unplated diamond abrasive (140 / 170), while the rest remained the same, resulting in Comparative Grinding Wheel 3-2.

[0084] The two comparative examples showed inferior dimensional fluctuations and parallelism in the gear cutting inserts processed with sand compared to the control example.

[0085] Based on Example 1, replacing the outer cylindrical abrasive layer material with the end face abrasive layer material, or replacing the end face abrasive layer material with the outer cylindrical abrasive layer material, resulted in grinding wheels that could not be used, and the processing effect was significantly worse than that of the control example.

[0086] Comparative Example 4

[0087] Based on Example 1, the graphite in the abrasive layer material on the end face was replaced with graphene oxide, while the rest remained the same, resulting in the comparative grinding wheel 4-1. The dimensional fluctuation of the gear cutting bit was ±4 (edge) and ±3.5 (groove).

[0088] Based on Example 1, the copper powder in the abrasive layer material was replaced with tin powder, while the rest remained the same, resulting in the comparative grinding wheel 4-2. The parallelism between the groove center and the edge of the gear cutting tool was 2.5 to 5.5 μm.

[0089] Based on Example 1, zinc oxide and calcium oxide in the abrasive layer material were replaced with silicon oxide and magnesium oxide, while the rest remained the same, resulting in the comparative grinding wheel 4-3. The dimensional fluctuation of the gear cutting bits was ±3.5 (edge) and ±4.5 (grooving).

[0090] Cubic boron nitride abrasives are used for machining ferrous materials and are not suitable for machining cemented carbide. The grinding wheel of this invention is designed to use ductile iron, which has the advantages of good thermal stability and low grinding noise during the machining process compared to the commonly used aluminum alloy and 45# steel.

[0091] As a technological improvement aimed at saving processing time and costs, it is necessary to ensure that the processing effect is comparable to existing processing methods (mainly dimensional fluctuations). Sacrificing processing effect to reduce costs is unacceptable and cannot be used in customer production. The irregularly shaped resin diamond peripheral grinding wheel prepared by the specific formula of this invention can not only efficiently process gear cutting tools, but also improve the processing quality compared with existing production methods. Moreover, the grinding wheel has uniform size and less fluctuation, making it more suitable for automated production. It effectively solves the problem of mutual interference when processing edges and grooves at the same time. Through the design of the abrasive layer formula, the processing of edges and grooves is balanced. On this basis, the processing time is significantly reduced. This significant technological advancement is unexpected.

Claims

1. A profiled resin diamond peripheral grinding wheel, characterized by, The grinding wheel is used in the machining of gear cutting inserts. The shaped resin diamond peripheral grinding wheel includes a cast iron substrate and two abrasive layers. One abrasive layer is distributed on the upper part of the cast iron substrate, and the other abrasive layer is distributed on the outer circle of the cast iron substrate. The abrasive layer distributed on the upper part of the substrate is used to machine the edges of the gear cutting inserts, and the abrasive layer distributed on the outer circle of the substrate is used to machine the grooves of the gear cutting inserts. The edge machining and grooving of the gear cutting inserts are performed simultaneously. The raw material formulation of the abrasive layer distributed above the cast iron matrix, by weight, is as follows: 30-40 parts of phenolic resin powder 15-20 parts of silicon carbide 5-10 parts copper powder 5-8 parts graphite powder 20-25 parts of uncoated abrasive The raw material formulation for the abrasive layer distributed on the outer circumference of the cast iron substrate, by weight, is as follows: 20-30 parts of phenolic resin powder 25-30 parts copper powder 6-10 parts zinc oxide 3-7 parts calcium oxide 1-5 parts graphite powder 25-35 parts of nickel-plated weight-increasing abrasive.

2. The shaped resin bond peripheral grinding wheel of claim 1, wherein The cast iron matrix is ​​ductile cast iron.

3. The shaped resin bond peripheral grinding wheel of claim 1 wherein, The preparation method of the irregular resin diamond peripheral grinding wheel includes the following steps: cold pressing the raw material of the abrasive layer distributed on the outer circle of the cast iron substrate with the cast iron substrate, then adding the raw material of the abrasive layer distributed on the upper part of the cast iron substrate, cold pressing again, and then hot pressing sintering and hardening to obtain the irregular resin diamond peripheral grinding wheel.

4. A method for machining gear cutting inserts using the shaped resin diamond peripheral grinding wheel as described in claim 1, characterized in that, The edges of the gear cutting inserts are machined using an abrasive layer distributed on the upper part of the substrate, and the grooves of the gear cutting inserts are machined using an abrasive layer distributed on the outer circle of the substrate; the edges of the gear cutting inserts and the grooving are machined simultaneously.

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