Preparation method of grinding wheel with regular abrasive shape and orderly arrangement and microstructure array

Abstract

The present invention relates to a method for preparing a grinding wheel and a microstructure array with regular abrasive grains and orderly arrangement. The method for preparing the grinding wheel includes the following steps: according to the preset abrasive grain arrangement rule and the shape and size of the abrasive grains, through holes corresponding to the regular abrasive grains are processed on the arrangement template; the arrangement template is fixed to the circumferential surface of the grinding wheel base, and then a substrate for the growth of diamond abrasive grains is formed at the through holes on the arrangement template, and the arrangement template on the surface of the grinding wheel base is removed after the electroplating is completed; diamond seed crystals are arranged on the substrate, and then chemical vapor deposition is performed on the grinding wheel base to make the diamond seed crystals grow into the required diamond regular abrasive grains. When manufacturing the orderly arranged grinding wheel, a template is used to grow an orderly and regular substrate on the grinding wheel base, allowing the abrasive grains to grow directly on the grinding wheel base, and the abrasive grains are arranged in an orderly manner while achieving regular size and shape, which can more conveniently use the grinding wheel grinding method to prepare a microstructure with higher precision on the surface to be processed.

Description

Technical Field

[0001] The present invention relates to the technical field of superhard abrasive tool processing, and in particular to a method for preparing a grinding wheel with regularly shaped and orderly arranged abrasive grains and a microstructure array. Background Art

[0002] Surface microstructure processing is widely used in emerging disciplines or fields such as mechanical electronics, aerospace, and life sciences. Manufacturing functional microstructures on the surface of a workpiece can improve the surface's specific performance according to specific needs, such as better hydrophobicity, friction performance, or heat dissipation performance. Optical glass can obtain higher light transmittance and specific refractive and diffraction properties by processing specific surface microstructures on its surface. At present, common methods for surface microstructure processing include chemical etching, high-energy particle beam processing, special processing, and micro-cutting processing. Among them, since special processing methods such as chemical etching and laser processing use or produce environmentally harmful gases and processing raw materials during processing and have high costs, mechanical processing is still one of the main surface microstructure processing methods. However, mechanical processing still has problems such as poor processing quality and low processing efficiency in the processing of surface microstructures.

[0003] Patent publication number CN109834553A, "Precision Grinding Method for Microgroove Structured Surfaces," designs a grinding wheel with a surface structure and uses real-time dressing to control the dressing of the grinding wheel and the processing of the microstructure of the machined surface based on an established trajectory model. Patent publication number CN102501152A, "A Method for Integrated Fine, Precision, and Mirror-Finished Grinding of Microstructured Array Surfaces," secures a diamond grinding wheel to a machine tool's grinding wheel spindle, parallel to the machined surface. After grinding, the spindle is rotated horizontally and ground again, creating a corresponding groove array on the machined surface through the V-shaped sharp angle of the diamond tool. The patent with publication number CN108747822A, "A new method for preparing diamond grinding wheels and a high-efficiency ultra-precision processing method for microstructure arrays", designs a microstructure array on the surface of the grinding wheel, arranges the dressing wheel, grinding wheel and workpiece in space according to the design, uses a dressing wheel to pre-dress the diamond grinding wheel, and laser ablates the surface contour of the grinding wheel on the surface of the grinding wheel. The grinding wheel grinds the surface of the workpiece to achieve the processing of the workpiece surface microstructure.

[0004] Although the above-mentioned prior art can manufacture corresponding surface microstructures or microstructure arrays on the surface of the workpiece, it has the defects of complicated process, complex equipment and low production efficiency. The microstructure processed by V-type grinding wheel by controlling the grinding wheel spindle requires high precision of the grinding wheel spindle, and only one groove can be processed at a time during processing, which has low processing efficiency. The patents with publication numbers CN109834553A and CN108747822A pre-process the required structure on the grinding wheel surface and complete the microstructure processing on the surface to be processed by real-time dressing, which can achieve high-precision surface microstructure processing, but the equipment used is relatively complex, and because it is a real-time dressing-processing method, it is impossible to complete the processing of microstructure arrays with more complex shapes or arrangements. Summary of the Invention

[0005] In response to the problems existing in the prior art, the purpose of the present invention is to provide a method for preparing a grinding wheel and a microstructure array with regularly shaped and orderly arranged abrasive particles, which can more conveniently use a grinding wheel to prepare a microstructure with higher precision on the surface to be processed.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] The method for preparing a grinding wheel with regular abrasive grains and orderly arrangement comprises the following steps:

[0008] According to the preset abrasive arrangement rules and the shape and size of the abrasive particles, through holes that are adapted to the regular abrasive particles are processed on the arrangement template;

[0009] The arrangement template is fixed to the circumferential surface of the grinding wheel base, and then the grinding wheel base is placed in an electroplating tank for electroplating, so that the through holes on the arrangement template form a substrate for the growth of diamond abrasive grains. After the electroplating is completed, the arrangement template on the surface of the grinding wheel base is removed;

[0010] Diamond seed crystals are placed on a substrate, and then chemical vapor deposition is performed on a grinding wheel base to grow the diamond seed crystals into required regular diamond abrasive grains, thereby obtaining a grinding wheel with regular abrasive grain shapes and orderly arrangements.

[0011] Furthermore, the grinding wheel base is electroplated to form a substrate for growing diamond abrasive grains. The electroplating solution used is a molybdenum salt solution, and the substrate is a metal molybdenum boss with a height of 0.5-1.0 mm.

[0012] Furthermore, the grinding wheel substrate formed with the metal molybdenum boss is immersed in a KOH solution for ultrasonic oscillation to remove residual electroplating solution and impurities on the surface of the grinding wheel substrate, and then the surface solution is taken out and cleaned with deionized water.

[0013] Furthermore, the cleaned grinding wheel substrate is placed in a H2O2 solution and allowed to stand to corrode the oxides formed on the surface of the molybdenum boss.

[0014] Furthermore, the grinding wheel matrix was taken out and placed in a newly configured KOH solution for ultrasonic oscillation to remove the oxides generated in the H2O2 solution and enhance the surface activity of the molybdenum bosses on the surface of the grinding wheel matrix.

[0015] Furthermore, a diamond seed crystal is arranged on the substrate by washing the surface oxide of the molybdenum boss with KOH solution with deionized water and then placing the grinding wheel substrate in a diamond powder acetone suspension for shaking. After the surface activity is enhanced, fine diamond particles are left on the molybdenum boss, thereby increasing the nucleation rate of diamond on the molybdenum boss.

[0016] Furthermore, the chemical vapor deposition method is to air-dry the surface-treated grinding wheel substrate and place it in an HFCVD device, control the temperature of the grinding wheel substrate to be in the appropriate temperature range for diamond growth, introduce a mixed gas of CH4 and H2, and decompose it into various groups at high temperature, which react with the grinding wheel to form diamond.

[0017] Furthermore, after the diamond abrasive grains are prepared, the grinding wheel substrate is placed in a nickel salt solution for electroplating, so that 50% to 60% of the height of the newly grown diamond abrasive grain protrusions is covered by the electroplated nickel layer.

[0018] The invention discloses a grinding wheel with regular abrasive grains and orderly arrangement, and is prepared by adopting a method for preparing a grinding wheel with regular abrasive grains and orderly arrangement.

[0019] The preparation method of the microstructure array is to install a grinding wheel with regular abrasive shape and orderly arrangement on the grinding wheel shaft of a grinding machine, control relevant parameters, and process the microstructure array of the surface to be processed.

[0020] In general, the present invention has the following advantages:

[0021] The present invention uses a template to grow an orderly and regular substrate on the grinding wheel base when manufacturing the orderly arranged grinding wheel, allowing the abrasive grains to grow directly on the grinding wheel matrix. While the abrasive grains are arranged in an orderly manner, the size and shape are regularized, and it is more convenient to use the grinding wheel grinding method to prepare a microstructure with higher precision on the surface to be processed. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 The figure is a flow chart of a method for preparing a grinding wheel with regular abrasive shapes and orderly arrangement;

[0023] Figure 2 This is the arrangement template form 1 of this embodiment;

[0024] Figure 3 This is the second arrangement template form of this embodiment;

[0025] Figure 4 This is the third arrangement template form of this embodiment;

[0026] Figure 5 The abrasive grains of this embodiment are in regular shape and arranged in an orderly manner.

[0027] Figure 6 Schematic diagram of the HFCVD device of this embodiment;

[0028] Figure 7 This is a schematic diagram of a heating wire placed in a ring shape around the circumference of a grinding wheel;

[0029] Figure 8 Schematic diagram of the microstructure array of this embodiment Figure 1 ;

[0030] Figure 9 Schematic diagram of the microstructure array of this embodiment Figure 2 ;

[0031] In the picture:

[0032] 1- Grinding wheel base;

[0033] 2-arrangement template, 21-through hole;

[0034] 3-Regular abrasive grains;

[0035] 41- bell jar, 411- vacuum chamber, 42- heating power supply, 43- heating wire, 44- molybdenum boss, 45- barometer, 46- cooling gauge, 47- sensor, 48- heating fixture, 49- vacuum pump, 410- reaction gas;

[0036] 5-Microstructure array. DETAILED DESCRIPTION

[0037] The present invention will be described in further detail below.

[0038] like Figure 1 、 Figure 5 As shown, the method for preparing a grinding wheel with regular abrasive shapes and orderly arrangement includes the following steps:

[0039] According to the preset abrasive arrangement rule on the grinding wheel and the shape and size of the regular abrasive 3, through holes 21 adapted to the regular abrasive 3 are processed on the arrangement template 2, wherein the arrangement rule and the shape and size of the regular abrasive 3 can be changed as needed; specifically, the required arrangement template 2 is obtained by ablating through holes 21 adapted to the regular abrasive 3 on the insulating tape according to the arrangement rule. Figure 2-Figure 4 These are three examples, and the arrangement template 2 can be in any form as needed;

[0040] The arrangement template 2 is fixed on the circumferential surface of the grinding wheel base 1, and the fixed grinding wheel base 1 is placed in an alcohol solution for shaking and cleaning for 3 minutes to remove surface oil and other impurities.

[0041] The grinding wheel substrate 1 is then placed in a plating bath using a molybdenum salt solution for electroplating. The plating time is controlled to ensure that a metal molybdenum boss 44 with a height of approximately 0.5-1.0 mm is plated at the insulating tape ablation hole 21 on the grinding wheel substrate 1. This molybdenum boss 44 serves as the substrate for the growth of the regular diamond abrasive grains 3. After plating is complete, the insulating tape is removed from the substrate surface.

[0042] The electroplated grinding wheel substrate 1 is immersed in a 1 mol / L KOH solution and ultrasonically vibrated for 2 minutes to remove residual plating solution and other impurities on the substrate surface. The surface solution is then removed and cleaned with deionized water. The cleaned substrate is placed in a 30% H2O2 solution by mass for 3 minutes. The H2O2 solution can corrode the oxides formed on the molybdenum bosses 44 on the substrate surface. After the grinding wheel substrate 1 is removed, it is placed in a fresh 1 mol / L KOH solution and ultrasonically vibrated for 5 minutes to remove the oxides formed in the H2O2 solution and enhance the surface activity of the molybdenum bosses 44 on the grinding wheel substrate surface.

[0043] The grinding wheel substrate 1 with the oxide removed from the surface of the molybdenum boss 44 is washed with deionized water to remove the surface KOH solution and then placed in a diamond powder acetone suspension and shaken for 30 minutes. After the surface activity is enhanced, fine diamond particles are left on the molybdenum boss 44 substrate, achieving the purpose of "planting seed crystals", thereby increasing the nucleation rate of diamond on the molybdenum substrate.

[0044] The grinding wheel substrate 1 is taken out and placed in an alcohol solution for ultrasonic cleaning for 1 minute to remove the residual solution on the substrate surface and the larger diamond particles on the surface of the molybdenum boss 44.

[0045] like Figure 6As shown, the surface-treated grinding wheel base 1 is air-dried and then placed in a HFCVD device. The HFCVD method for growing diamonds is simple to operate and the device is easy to prepare. The conventional HFCVD device places the substrate base on a flat workbench and clamps it with a heating fixture 48. The flat workbench is connected to a heating power supply 42 and a cooling water pipeline. The substrate temperature is controlled within a specific range by controlling the working power of the heating power supply 42 and the cooling water circulation. The reaction gas 410 enters the vacuum chamber 411 through the control valve via the bell jar 41, and is heated by the heating wire 43 above the substrate base to react with the substrate. The air pressure in the vacuum chamber 411 is monitored by a barometer 45 and adjusted by a vacuum pump 49. Since the present invention needs to grow diamonds on a substrate on the circumference of the grinding wheel, the heating wire 43 is designed to be annular and arranged outside the circumference of the grinding wheel. The grinding wheel base 1 is fixed upside down on the grinding wheel fixture, and the thermocouple and cooling water device are placed in the heating fixture 48. The temperature of the base and the substrate is monitored by the thermal sensor 47 placed above the grinding wheel base 1. By adjusting the power of the thermocouple and the heating power supply 42 in the heating fixture 48, and controlling the cooling water circulation through the cooling table 46, the temperature is controlled to be in the suitable temperature range for diamond growth (600-850℃). The three-dimensional model of the grinding wheel clamping method and the placement of the heating wire 43 is shown as follows Figure 7 shown.

[0046] CH4 is used as the reaction gas source, introducing a mixture of CH4 and H2 at a ratio of 1:3. Upon entering the chamber, the gas is pyrolyzed at high temperatures into various radicals, which react with the grinding wheel to form diamond. Reaction times are controlled to 4, 8, or 12 hours, depending on the desired abrasive height.

[0047] After the reaction is completed, the device is allowed to cool and the grinding wheel substrate 1 after CVD deposition is completed is taken out after the device is cooled to room temperature.

[0048] The grinding wheel base 1 is shaken and cleaned in an alcohol solution for 2 minutes to remove impurities and oil stains on the surface, thereby obtaining a grinding wheel with regular abrasive shapes and orderly arrangement.

[0049] The grinding wheel substrate 1 is then placed in an electroplating apparatus using a nickel salt solution. The electroplating parameters and time are controlled so that 50% to 60% of the height of the newly grown diamond regular abrasive grains 3 are covered by the electroplated nickel layer, reinforcing the regular abrasive grains 3 and effectively preventing them from falling off.

[0050] After electroplating is completed, remove the grinding wheel substrate 1 and clean it in an alcohol solution by shaking to remove the residual solution on the surface.

[0051] The preparation method of the microstructure array 5 is to install a grinding wheel with regular abrasive shapes and orderly arrangement on the grinding wheel shaft of a grinding machine, control relevant parameters, and process the microstructure array 5 of the surface to be processed.

[0052] The present invention uses a template to grow an orderly and regular substrate on the grinding wheel base when manufacturing the orderly arranged grinding wheel, allowing the abrasive grains to grow directly on the grinding wheel base 1, and realizes regularization of size and shape while the abrasive grains are arranged in an orderly manner, thereby realizing the surface microstructure array 5 of grooves of different shapes and sizes on the surface to be processed. Compared with special processing solutions such as chemical etching and laser processing, the mechanical processing solution of this design is more efficient and simpler to implement. Compared with existing mechanical processing solutions, the microstructure of the diamond surface is realized by using abrasive grains of regular shape and size arranged in an orderly manner on the grinding wheel surface, which not only makes the grinding wheel have higher strength and wear resistance, but also realizes the processing of surface microstructure arrays 5 of different groove shapes and sizes.

[0053] The above embodiments are preferred implementation modes of the present invention, but the implementation modes of the present invention are not limited to the above embodiments. Any other changes, modifications, substitutions, combinations, and simplifications that do not deviate from the spirit and principles of the present invention should be considered as equivalent replacement methods and are included in the scope of protection of the present invention.

Claims

1. A method for preparing a grinding wheel with regularly shaped and orderly arranged abrasive grains, characterized in that: The following steps are included: According to the preset abrasive arrangement rules and the shape and size of the abrasive particles, through holes that are adapted to the regular abrasive particles are processed on the arrangement template; The arrangement template is fixed to the circumferential surface of the grinding wheel base, and then the grinding wheel base is placed in an electroplating tank for electroplating, so that the through holes on the arrangement template form a substrate for the growth of diamond abrasive grains. After the electroplating is completed, the arrangement template on the surface of the grinding wheel base is removed; A diamond seed crystal is placed on a substrate, and then chemical vapor deposition is performed on a grinding wheel substrate to grow the diamond seed crystal into the required regular diamond abrasive grains, thereby obtaining a grinding wheel with regular abrasive grain shapes and orderly arrangements; The grinding wheel substrate is electroplated to form a substrate for the growth of diamond abrasive grains. The electroplating solution used is a molybdenum salt solution, and the substrate is a metal molybdenum boss with a height of 0.5-1.0 mm. The grinding wheel substrate with the metal molybdenum boss formed thereon is immersed in a KOH solution for ultrasonic oscillation to remove the residual electroplating solution and impurities on the surface of the grinding wheel substrate, and then the surface solution is washed with deionized water; The cleaned grinding wheel substrate is placed in a H2O2 solution to corrode the oxides formed on the surface of the molybdenum boss; After taking out the grinding wheel matrix, put it into the newly prepared KOH solution for ultrasonic vibration again to remove the oxides generated in the H2O2 solution and enhance the surface activity of the molybdenum boss on the surface of the grinding wheel matrix; The method of setting diamond seed crystals on the substrate is to remove the oxide on the surface of the molybdenum boss by washing the surface KOH solution with deionized water, and then place it in a diamond powder acetone suspension and shake it. After the surface activity is enhanced, fine diamond particles are left on the molybdenum boss, increasing the nucleation rate of diamond on the molybdenum boss.

2. The method for preparing a grinding wheel with regularly shaped and orderly arranged abrasive grains according to claim 1, characterized in that: The chemical vapor deposition method is to air-dry the surface-treated grinding wheel substrate and place it in the HFCVD device. The temperature of the grinding wheel substrate is controlled in the appropriate temperature range for diamond growth. A mixed gas of CH4 and H2 is introduced, and it is cracked into various groups at high temperature. The groups react with the grinding wheel to form diamond.

3. The method for preparing a grinding wheel with regularly shaped and orderly arranged abrasive grains according to claim 1, characterized in that: After the diamond abrasive grains are prepared, the grinding wheel substrate is placed in a nickel salt solution for electroplating, so that 50%-60% of the height of the newly grown diamond abrasive grain protrusions is covered by the electroplated nickel layer.

4. The grinding wheel has regular abrasive shapes and orderly arrangement, characterized by: The grinding wheel is prepared by the method for preparing a grinding wheel with regular abrasive shapes and orderly arrangement according to any one of claims 1 to 3.

5. A method for preparing a microstructure array, characterized in that: The grinding wheel with regular abrasive shapes and orderly arrangement as claimed in claim 4 is mounted on the grinding wheel shaft of a grinding machine, and relevant parameters are controlled to process the microstructure array of the surface to be processed.

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