High-efficiency polishing disk and preparation method thereof

Abstract

The invention belongs to an advanced material technology, and discloses a high-efficiency polishing disk and a preparation method thereof. The weaving cloth is adhered to the substrate, then the working layer raw material is coated, slotting is conducted after curing, and the high-efficiency polishing disc is obtained; the raw materials of the working layer comprise resin liquid, a curing agent, pore-forming powder and a multi-cutting-edge phenolic resin polymer particle grinding material. The high-efficiency polishing disk and the preparation method thereof disclosed by the invention are suitable for substrates with different thicknesses, and are independent of a base body; and the woven fabric is bonded on the substrate, then the working layer raw material is coated, grooving is conducted after curing, the high-efficiency polishing disc is obtained, and bonding of the working layer and the substrate is very good. The multi-cutting-edge phenolic resin polymer particle grinding material and the self-manufacturing pore forming agent are mixed into the resin binding agent, a porous structure can be naturally formed in the curing process, the service life of the polishing disc is prolonged, the sharpness of the polishing disc is improved, and the quality of the machined surface is improved.

Description

Technical Field

[0001] The invention belongs to advanced material technology and relates to an abrasive tool, in particular to a high-efficiency polishing disc and a preparation method thereof. Background Art

[0002] For workpieces with high requirements for surface roughness, they are processed multiple times using tools with different mesh sizes, where the equipment used for polishing is single-sided or double-sided polishing equipment, and the polishing disc is installed in the polishing machine to process the workpiece. The polishing discs currently used in the market have problems such as clogging after processing metal workpieces, short grinding wheel life, and long processing cycle.

[0003] The bonding of abrasive layers currently used in the market has high requirements on the properties of the substrate. For thin substrates (which can be deformed by hand), such as metallographic polishing discs and diamond grinding pads, ultraviolet curing resin is used to bond the substrate, and the cost of irradiation equipment and consumables is relatively high. For thicker substrates, such as ordinary polishing discs, the bonding method is to bond the lumps one by one, and the product preparation efficiency is low and the cost is higher.

[0004] Resin polishing discs are less sharp than ceramic polishing discs and are more prone to clogging, but they have a longer lifespan and better processing surface. To ensure effective bonding between the substrate and the abrasive layer, ceramic polishing discs can currently only be used on thicker, non-deformed substrates. Polishing discs with thinner substrates generally use resins with lower hardness as a binder. The hardness of the resin binder should not be too high, but in order to ensure cutting force and self-sharpening, the hardness of the resin needs to be increased as much as possible. After the two are balanced, the sharpness of the polishing disc cannot be further improved.

[0005] At present, the pore-forming method for polishing disks using ceramic or resin binders is pore-forming balls or heated volatilization pore-forming agents. The pores formed by pore-forming balls will remain in the binder, affecting the processing quality. The heated volatilization pore-forming agents require a high temperature of about 700°C to volatilize, and the pore-forming conditions are high.

[0006] Therefore, it is necessary to develop new polishing discs to solve the problems existing in existing polishing discs and process workpieces with high efficiency. Summary of the invention

[0007] The invention provides a polishing disc which takes into account tool life, sharpness and self-dressing as well as surface quality of a metal workpiece and a manufacturing method thereof.

[0008] The present invention adopts the following technical solution: A high-efficiency polishing disc comprises a substrate, a woven fabric and a working layer; the working layer comprises a resin binder, a pore-forming powder and a multi-blade phenolic resin polymer particle abrasive; the pore-forming powder comprises an alloy and inorganic fibers on its surface; the multi-blade phenolic resin polymer particle abrasive is prepared from raw materials including abrasive, metal powder, resin powder and protein liquid.

[0009] The invention discloses a method for preparing the above-mentioned high-efficiency polishing disc, comprising the following steps: sticking a woven cloth on a substrate, then coating a working layer raw material, and grooving after curing to obtain a high-efficiency polishing disc; the working layer raw material comprises resin liquid, curing agent, pore-forming powder, and multi-blade phenolic resin polymer particle abrasive.

[0010] In the present invention, the specific method of adhering the woven fabric to the substrate is conventional technology, and the woven fabric with adhesive backing can be compounded with the substrate, or the woven fabric can be adhered to the substrate using conventional adhesives.

[0011] In the present invention, the raw materials for preparing the resin binder include resin and curing agent; preferably, the resin includes bicyclic resin.

[0012] The invention discloses a method for preparing the pore-forming powder for the high-efficiency polishing disc, comprising the following steps: mixing alloy powder, glass fiber powder and a bonding system, solidifying the mixture into blocks, and then crushing the mixture to obtain the pore-forming powder.

[0013] The invention discloses a method for preparing the multi-blade phenolic resin polymer particle abrasive for the high-efficiency polishing disc, comprising the following steps: mixing abrasive, metal powder, resin powder and protein solution, granulating, and then curing to obtain the multi-blade phenolic resin polymer particle abrasive.

[0014] In the present invention, the pore-forming powder includes an alloy and inorganic fibers on its surface, wherein the alloy includes nickel-iron powder, white copper powder, etc., preferably, the particle size is 2000#~10000#; the inorganic fiber includes glass fiber, and the particle size is 1000#~5000#.

[0015] Preferably, the alloy powder, glass fiber powder and bonding system are mixed and solidified into blocks, and then crushed to obtain pore-forming powder.

[0016] Preferably, the adhesive system comprises an epoxy resin adhesive, such as E-44 / 6101 epoxy resin adhesive.

[0017] In the present invention, in terms of mass percentage, the alloy powder accounts for 40-60%, the glass fiber powder accounts for 30-50%, and the bonding system accounts for the balance.

[0018] Preferably, in terms of mass percentage, the alloy powder is 45-55%, the glass fiber powder is 35-45%, and the bonding system is the balance.

[0019] In the present invention, the preparation method of multi-blade phenolic resin polymer particle abrasive comprises the following steps: abrasive, metal powder, resin powder and protein solution are mixed and granulated, and then solidified to obtain multi-blade phenolic resin polymer particle abrasive.

[0020] Preferably, the abrasive, metal powder, resin powder and protein solution are mixed and granulated in water; more preferably, the abrasive, metal powder, resin powder and protein solution are mixed and sprayed into water for granulation; more preferably, the water temperature is 50° C. to boiling water.

[0021] Preferably, the granulation is followed by filtration, and the filter cake is solidified; more preferably, the granulation is followed by filtration, and the filter cake is mixed with inorganic powder, solidified, and sieved to obtain multi-blade phenolic resin polymerized particle abrasive, wherein the inorganic powder includes silica powder.

[0022] Preferably, the particle size of the multi-blade phenolic resin polymerized particle abrasive is 30 to 100 microns, and preferably, the particle size of the multi-blade phenolic resin polymerized particle abrasive is 50 to 80 microns.

[0023] In the present invention, the abrasive includes diamond powder; the metal powder includes iron powder; the resin powder includes phenolic resin powder; and the protein liquid includes egg protein liquid.

[0024] Preferably, in terms of mass percentage, the resin powder is 30-50%, the diamond powder is 10-30%, the metal powder is 5-15%, and the remainder is egg white liquid.

[0025] Preferably, in terms of mass percentage, the resin powder is 35-45%, the diamond powder is 15-25%, the metal powder is 8-12%, and the remainder is egg white liquid.

[0026] In the present invention, the mass ratio of the resin liquid, the curing agent, the pore-forming powder, and the multi-blade phenolic resin polymer particle abrasive is (35-65): (0.2-1.5): (1-3): (35-50).

[0027] Preferably, the mass ratio of the resin liquid, the curing agent, the pore-forming powder, and the multi-blade phenolic resin polymer particle abrasive is (45-55): (0.5-1.2): (1-3): (40-50).

[0028] In the present invention, the solid content of the resin liquid is 60-75%, preferably, the solid content of the resin liquid is 65-70%.

[0029] In the present invention, the substrate and the woven fabric are existing products. For example, the substrate is a metal substrate, and its thickness can be any existing substrate, as long as it meets the requirements of the polishing equipment, such as greater than 0.1 mm, further greater than 0.2 mm, such as 0.3 mm to 30 mm; the woven fabric is a conventional non-woven fabric, and its thickness is 0.05 mm to 1 mm, preferably 0.1 to 0.5 mm, and further preferably 0.2 to 0.4 mm, and its porosity is 50 to 200 / cm², preferably 80 to 150 / cm².

[0030] In the present invention, the mesh size range of diamond is 400#~10000#; the mesh size range of iron powder is 2000#~8000#.

[0031] In the prior art, the bonding of the abrasive layer has high requirements on the properties of the substrate. For thinner substrates (0.1mm to 2mm), ultraviolet curing resin is required to bond with the substrate, and the cost of the irradiation equipment and consumables is relatively high; for thicker substrates (more than 2mm), the lumps need to be bonded piece by piece, and the product preparation efficiency is low and the cost is higher. The high-efficiency polishing disc and its preparation method disclosed in the present invention are suitable for substrates of different thicknesses and are not dependent on the substrate; the woven cloth is bonded to the substrate, and then the working layer raw material is coated, and the groove is cut after curing to obtain a high-efficiency polishing disc. The working layer and the substrate are bonded very well, which not only solves the problem that the existing thin substrate needs to be photocured, but also overcomes the problem that the existing thick substrate needs to bond the grinding disc piece by piece.

[0032] The invention discloses the application of the high-efficiency polishing disc as a polishing tool or the application in preparing the polishing tool.

[0033] The invention discloses the application of the high-efficiency polishing disc in processing workpieces.

[0034] Preferably, the workpiece comprises a metal product.

[0035] The invention discloses a workpiece polishing method, comprising the following steps: utilizing the high-efficiency polishing disc to process the workpiece to achieve polishing.

[0036] In the present invention, the woven cloth is adhered to the substrate, and then the working layer raw material is coated, and the resin liquid (containing a curing agent) therein penetrates the woven cloth to complete the bonding of the binder to different substrates, and after curing, the working layer and the substrate are stably bonded. In the present invention, multi-blade phenolic resin polymerized particle abrasive and self-made pore agent are mixed into the resin binder, and a porous structure can be naturally formed during the curing process, thereby improving the life, sharpness and processing surface quality of the polishing disc. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a micrograph of the self-made porogen of the present invention, wherein a single particle thereof appears as a sun under a microscope.

[0038] Figure 2 The following are the actual photos and processing parameters of the high-efficiency polishing disc of Example 3.

[0039] Figure 3 The figures are the real objects of the steel annular sheet after the polishing disc of the present invention is processed and the surface photos of the steel annular sheet before and after the processing.

[0040] Figure 4 The figures are the real object of the alloy turning tool after being processed by the high-efficiency polishing disc of the present invention and the surface photos of the alloy turning tool before and after processing. DETAILED DESCRIPTION

[0041] In the prior art, the bonding of the abrasive layer has high requirements on the properties of the substrate. The high-efficiency polishing disc and its preparation method disclosed in the present invention are suitable for substrates of different thicknesses and are independent of the substrate. The woven cloth is bonded to the substrate, and then the working layer raw material is coated. After curing, the grooving is performed to obtain a high-efficiency polishing disc. The working layer is bonded to the substrate very well, which not only solves the problem that the existing thin substrate needs to be photocured, but also overcomes the problem that the existing thick substrate needs to bond the grinding sheets one by one. In the present invention, the penetration between the double-ring resin liquid and the adhesive-backed woven cloth material completes the bonding of the binder to different substrates. Compared with the existing resin or ceramic polishing discs, the present invention mixes a self-made pore-forming agent. The single particle of the pore-forming agent is sun-shaped under a microscope. After the resin is fully stirred with the pore-forming agent, a porous structure can be naturally formed during the curing process. Multi-blade phenolic resin polymer particle abrasive is also mixed into the resin binder; the life, sharpness and surface quality of the polishing disc can be improved.

[0042] The following is a detailed description of the technical progress of the present invention. The raw materials used are existing commercial products, and the specific preparation operations and performance tests are all conventional technologies. Phenolic resin powder is a product for combining existing grinding wheels and abrasives, and it only needs to meet the conventional requirements of grinding wheels and abrasives; double-ring resin, Wanglin New Materials WL1901, diluent and curing agent are supporting products of the manufacturer. The fabric is Pengxu self-adhesive A-grade environmentally friendly non-woven fabric, with a gram weight specification of 50g. The mesh range of diamond is 4000#~5000#; the mesh range of iron powder is 3000#~5000#. Embodiment 1

[0043] A pore-forming agent is in powder form, with a layer of glass fiber attached to the surface of alloy powder particles.

[0044] In terms of mass percentage, the formula is: alloy powder - 50%, adhesive - 10%, glass fiber powder - 40%; the alloy is white copper powder with a particle size of 4000#~5000#, the adhesive is Xingchen E-44 / 6101 epoxy resin system, the curing ratio is 4:1, and the particle size of the glass fiber powder is 1000#-2000#.

[0045] The preparation method is as follows: alloy powder, adhesive, glass fiber powder, and adhesive curing agent are uniformly stirred, poured into a colloid through a silicone mold, and solidified, and then demolded to form a granular agglomerate, which is crushed by a crusher and then screened for use. The particle size distribution is 10 μm to 40 μm, and is used in the following embodiments.

[0046] Figure 1This is a microscopic photograph of the self-made pore-forming agent, and its single particle is sun-shaped under a microscope. The self-made pore-forming agent of the present invention is a new type of physical place-occupying pore-forming method. After the self-made pore-forming agent is mixed with the double-ring resin as a binder, due to its surface properties, a large number of tiny pores can be naturally formed in the resin binder after the binder resin is stirred and attached to the pore-forming powder. The pores are retained after solidification. The chip removal and heat dissipation capabilities of the grinding wheel can be improved, and the service life is increased; and it has low adhesion to the binder resin and is easy to detach, the self-sharpening of the grinding tool is improved, and the cutting force of the polishing disc is increased; in particular, because the surface properties of its pore-forming agent are flexible, the particles have no effect on the surface quality of the processed workpiece after peeling. Embodiment 2

[0047] A self-made resin-bonded aggregate multi-blade abrasive is prepared as follows: phenolic resin powder, iron powder, diamond powder, and egg protein liquid are mixed into a colloid, and then spray granulated by spraying, sprayed into 100°C water, condensed into a preliminary aggregate abrasive, filtered, and the filter cake is mixed with silicon dioxide particles (10-20μm), and finally baked at 200°C to form, sieved, and particles with a diameter of 55-65 microns are taken as resin-bonded aggregate multi-blade abrasives for the following embodiments.

[0048] In terms of mass percentage, resin powder accounts for 40%, diamond powder accounts for 20%, iron powder accounts for 10%, and egg protein liquid accounts for 30%; in terms of volume percentage, silica particles account for 50% of the filter cake.

[0049] After screening and grading, it is used as a high cutting force aggregate abrasive. The secondary combination of the resin aggregate abrasive and the resin binder increases the cutting force of the polishing disc, reduces the damage to the workpiece surface, and increases the service life. Embodiment 3

[0050] The preparation method of high-efficiency polishing disc is as follows: (1) Preparation of working layer raw materials (resin abrasive layer): conventionally mix the resin liquid with the abrasive and pore-forming agent, and finally add the resin curing agent. Stir uniformly to obtain the working layer raw materials; The resin liquid is obtained by dissolving the double ring type resin powder into the resin liquid diluent; By mass percentage, resin powder-35%, resin liquid diluent-18%, resin curing agent-1%, multi-blade resin polymer abrasive ball-44%, pore-forming powder-2%, conventional mixing; (2) The woven fabric with adhesive backing (0.3 mm thick) is used as the intermediate layer between the processing layer and the substrate. The adhesive backing side is adhered to the substrate (stainless steel disc, 0.3 mm thick), and then the working layer raw material is coated and left to cure at room temperature. The resin and the adhesive layer are reliably bonded. The woven fabric material provides a certain tensile strength and heat resistance, and will not affect the bonding effect when the substrate is deformed. Then conventional grooving is performed to obtain a high-efficiency polishing disc.

[0051] The polishing disc of the present invention adopts a new bonding method. The preparation steps of the polishing disc include the preparation of pore-forming agent, the preparation of aggregate abrasive, and the bonding between the processing layer and the base disc. A flexible double-ring resin liquid is used as a binder, and a high-toughness woven material with a backing adhesive is used as an intermediate layer between the processing layer and the substrate. The side with the backing adhesive is adhered to the substrate. The woven material is porous and objectively has high permeability. The prepared mixed liquid is evenly spread on the woven fabric. Through the penetration between the resin liquid and the flexible woven material, the reliable bonding of the binder and the substrates with different properties is completed. After waiting for solidification, conventional trimming and grooving are performed to obtain a polishing disc with little scratches on the workpiece and high processing roughness of the polishing disc. Embodiment 4

[0052] On the basis of Example 3, a stainless steel disc with a thickness of 20 mm was used as a substrate to obtain a polishing disc.

[0053] Comparative Example 1 On the basis of Example 3, existing hollow glass microspheres are used to replace the product of Example 1 as the pore-forming agent, and the rest is the same to obtain a polishing disc.

[0054] Comparative Example 2 A self-made abrasive is prepared as follows: phenolic resin powder, iron powder and diamond powder are heated and mixed into a colloid, then baked into a shape, crushed and sieved, and particles with a diameter of 55 to 65 microns are taken as abrasives to replace the abrasives in Example 3. The rest is the same to obtain a polishing disc.

[0055] By mass percentage, resin powder - 45%, diamond powder - 35%, iron powder - 20%.

[0056] Comparison Example The polishing discs with good application in similar applications are currently produced and imported products. Application Examples

[0057] See also Figure 2 , which are the actual photos and processing parameters of the high-efficiency polishing disc of Example 3. For the polishing of the 45 steel ring sheet with an initial surface RA of -0.35μm, the removal rate of the present invention reaches 5μm / min, and the RA after processing can reach 0.005μm. For comparison, under the same processing, the RA after processing of Comparative Example 1 is 0.17μm, and the RA after processing of Comparative Example 2 is 0.11μm. It can be seen that the polishing disc prepared by the pore-forming agent, aggregate abrasive, and bonding between the processing layer and the base disc of the present invention has very good processing performance, see Figure 3 , which are the real object of the steel ring sheet after the polishing disk of the present invention is processed and the surface photos of the steel ring sheet before and after processing. It can be seen that the surface after processing is very smooth.

[0058] See also Figure 4In the fourth embodiment, the grinding machine parameters are set to 60 / 120 Rpm and the pressure is 5.5 KN for the surface processing of alloy turning tools. After processing, the surface has only processing textures and no scratches. The surface RA is -0.01μm and the removal rate is 10μm / min. As a control, the existing polishing disc is processed in the same way, the surface RA is -0.016μm and the removal rate is 8.3μm / min.

[0059] In the present invention, the woven cloth is adhered to the substrate, and then the working layer raw material is coated, and the resin liquid (containing a curing agent) therein penetrates the woven cloth to complete the bonding of the binder to different substrates, and after curing, the working layer and the substrate are stably bonded. In the present invention, multi-blade phenolic resin polymerized particle abrasive and self-made pore agent are mixed into the resin binder, and a porous structure can be naturally formed during the curing process, thereby improving the life, sharpness and processing surface quality of the polishing disc.

Claims

1. A high-efficiency polishing disc, comprising a substrate, a fabric and a working layer, characterized in that: The working layer comprises resin binder, pore-forming powder and multi-blade phenolic resin polymer particle abrasive; the pore-forming powder comprises alloy and inorganic fibers on its surface; the multi-blade phenolic resin polymer particle abrasive is prepared from raw materials including abrasive, metal powder, resin powder and protein solution.

2. The high-efficiency polishing disc according to claim 1, characterized in that: The raw materials for preparing the resin binder include resin and curing agent; the alloy includes nickel iron powder and white copper powder; the inorganic fiber includes glass fiber; the abrasive includes diamond powder; the metal powder includes iron powder; the resin powder includes phenolic resin powder; and the protein liquid includes egg protein liquid.

3. The method for preparing the high-efficiency polishing disc according to claim 1, characterized in that: The method comprises the following steps: adhering the woven cloth to the substrate, coating the working layer raw material, and grooving after curing to obtain a high-efficiency polishing disc; the working layer raw material comprises resin liquid, curing agent, pore-forming powder, and multi-blade phenolic resin polymerized particle abrasive.

4. The method for preparing a high-efficiency polishing disc according to claim 3, characterized in that: The alloy powder, glass fiber powder and bonding system are mixed and solidified into blocks, and then broken to obtain pore-forming powder; the abrasive, metal powder, resin powder and protein solution are mixed and granulated, and then solidified to obtain multi-blade phenolic resin polymer particle abrasive.

5. The method for preparing a high-efficiency polishing disc according to claim 4, characterized in that: In terms of mass percentage, alloy powder accounts for 40-60%, glass fiber powder accounts for 30-50%, and bonding system accounts for the balance. In terms of mass percentage, resin powder accounts for 30-50%, diamond powder accounts for 10-30%, metal powder accounts for 5-15%, and egg protein liquid accounts for the balance.

6. The method for preparing a high-efficiency polishing disc according to claim 4, characterized in that: Abrasive, metal powder, resin powder and protein solution are mixed and granulated in water, filtered after granulation, and then the filter cake is solidified to obtain multi-blade phenolic resin polymer particle abrasive.

7. The method for preparing a high-efficiency polishing disc according to claim 3, characterized in that: The mass ratio of the resin liquid, the curing agent, the pore-forming powder and the multi-blade phenolic resin polymer particle abrasive is (35-65): (0.2-1.5): (1-3): (35-50).

8. The method for preparing the pore-forming powder for high-efficiency polishing discs according to claim 1, characterized in that: The method comprises the following steps: mixing alloy powder, glass fiber powder and a bonding system, solidifying the mixture into blocks, and then crushing the mixture to obtain pore-forming powder; or the method for preparing multi-blade phenolic resin polymer particle abrasive for high-efficiency polishing discs according to claim 1, characterized in that the method comprises the following steps: mixing abrasive, metal powder, resin powder and protein solution, granulating the mixture, and then solidifying the mixture to obtain multi-blade phenolic resin polymer particle abrasive.

9. Use of the high-efficiency polishing disc described in claim 1 as a polishing tool; or use in the preparation of a polishing tool; or use of the high-efficiency polishing disc described in claim 1 in processing a workpiece.

10. A method for polishing a workpiece, comprising the following steps: processing the workpiece using the high-efficiency polishing disc according to claim 1 to achieve polishing.

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