Ultra-long-life heavy-load abrasive belt special for grinding metal and manufacturing method thereof

Abstract

The invention discloses an ultra-long-life heavy-load abrasive belt special for grinding metal and a manufacturing method thereof.The abrasive belt comprises a base material, the front face of the base material is coated with primer to form a first primer layer, and abrasive materials are implanted into the first primer layer to form a gravity sand-planting abrasive material layer; primer is sprayed on the first primer layer and the gravity sand-planting grinding material layer to form a second primer layer, grinding materials are continuously planted on the second primer layer to form a primary electrostatic sand-planting grinding material layer and a secondary electrostatic sand-planting grinding material layer, and the primary electrostatic sand-planting grinding material layer and the secondary electrostatic sand-planting grinding material layer form a multi-layer full standing structure. The second bottom glue layer is coated with a composite glue layer, and the composite glue layer is coated with a super coating. The prepared product has good grinding life; the abrasive material of the working sand layer of the prepared product can keep a multi-layer full-standing structure, the conflict problem between the grinding service life and the grinding sharpness is solved, the grinding later-stage sharpness can be basically equal to the grinding early-stage sharpness, and the phenomena that grinding is strenuous and an abrasive belt slips are avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of multi-layer composite abrasive implanting technology, and particularly to a super-high-life heavy-duty abrasive belt for grinding metals and a manufacturing method thereof. Background Art

[0002] With the rapid development of the machinery industry, the requirements for coated abrasive products are getting higher and higher. In the field of metal processing, materials such as titanium alloys, superalloys, and stainless steels have the characteristics of good thermal stability, high thermal strength, good corrosion resistance and wear resistance, and are widely used in the fields of aviation, aerospace, and navigation. These materials have put forward higher requirements for the heavy-duty abrasive belts dedicated to metal processing. However, the existing abrasive implanting process of the abrasive belts limits the use of the working abrasive layer. The existing abrasive implanting process of the abrasive belts mainly adopts a combination of gravity and electrostatic abrasive implanting. The gravity abrasive implanting forms the bottom abrasive layer, and the electrostatic abrasive implanting forms the working abrasive layer. The existing electrostatic abrasive implanting structure includes a conveyor belt, an upper electrode plate, and a lower electrode plate; wherein, the upper electrode plate is arranged above the lower electrode plate and is used to generate an electric field that makes the abrasive grains move upward; the conveyor belt is arranged between the upper electrode plate and the lower electrode plate and is used to convey the abrasive grains, which can only meet the production of one-time electrostatic abrasive implanting. Therefore, the arrangement of the working abrasive layer on the abrasive belt is only one layer. As a result, the existing heavy-duty abrasive belts on the market perform well under the conventional pressure of 20 - 35 KN and the linear speed of 60 m / s, and can exert good grinding performance in the field of metal grinding. However, under higher pressure (≥35 KN) and higher rotational speed (≥60 m / s), problems such as fast abrasive shedding, later slipping and dullness, and short grinding life are likely to occur. This affects the processing efficiency of the products, requires frequent replacement of the abrasive belts, and causes waste of human resources and time resources.

[0003] In view of the above problems, the present invention provides a super-high-life heavy-duty abrasive belt for grinding metals and a manufacturing method thereof. Summary of the Invention

[0004] The purpose of the present invention is to provide a super-high-life heavy-duty abrasive belt for grinding metals and a manufacturing method thereof to solve the problems raised in the above background art.

[0005] To achieve the above purpose, the present invention provides the following technical solutions: A super-high-life heavy-duty abrasive belt for grinding metals includes a base material. A bottom glue is coated on the front surface of the base material to form a first bottom glue layer. Abrasives are implanted on the first bottom glue layer to form a gravity-implanted abrasive layer. And a bottom glue is sprayed on the first bottom glue layer and the gravity-implanted abrasive layer to form a second bottom glue layer. Abrasives are continuously implanted on the second bottom glue layer to form a first-time electrostatic-implanted abrasive layer and a second-time electrostatic-implanted abrasive layer. And the first-time electrostatic-implanted abrasive layer and the second-time electrostatic-implanted abrasive layer form a multi-layer all-standing structure. A top coat is coated on the second bottom glue layer, and a super coat is coated on the top coat.

[0006] A manufacturing method for a super-high-life heavy-duty abrasive belt dedicated to grinding metals, comprising the following steps: Step S1: Unroll the large roll of the base material and print the trademark; Step S2: Coat the front surface of the base material with a primer to form a first primer layer, and the amount of the first primer is 50-65% of the total primer amount; Step S3: Use the gravity sand planting and electrostatic sand planting processes to implant abrasives on the first primer layer. The amount of gravity sand planting is 100-400 g / m 2 , and the amount of electrostatic sand planting is 200-500 g / m 2 , and then perform a first drying. The drying temperature is 100-130 °C, and the drying time is 20-40 min to form a gravity sand-implanted abrasive layer; Step S4: After the drying is completed, spray a primer on the surface of the abrasive cloth. The viscosity of the sprayed primer is half of the viscosity of the coated primer to form a second primer layer; Step S5: Use the electrostatic sand planting process to implant abrasives on the second primer layer. The amount of sand planting is 400-1000 g / m 2 , and then perform a second drying to form a first electrostatic sand-implanted abrasive layer and a second electrostatic sand-implanted abrasive layer. The drying temperature is 100-130 °C, and the drying time is 40-60 min; Step S6: Coat a sizing layer on the second primer layer after the second electrostatic sand planting, and perform a main drying. The main drying temperature is 90-120 °C, and the drying time is 4 h; Step S7: Coat a super coating on the sizing layer, dry and cure the super coating. The drying temperature is 90-110 °C, and the drying time is 4 h; Step S8: Perform a flexing and humidifying operation to obtain the final abrasive belt product, and wind it up and put it into the large roll storage.

[0007] Preferably, the particle size of the abrasive is 20-180 mesh. The abrasives in the bottom sand layer generated by gravity sand planting include brown fused alumina, white fused alumina, semi-brittle fused alumina and high-temperature calcined fused alumina, and the abrasives in the working sand layer generated by electrostatic sand planting include zirconium corundum and ceramic microcrystalline corundum abrasives.

[0008] Preferably, the base material is a heat-resistant cloth base and is treated with a polyester cloth. High-temperature resistant resin is introduced into the cloth base impregnation formula. The high-temperature setting temperature of the cloth base is 220 °C, the elongation rate of the cloth base reaches 8%, and the cloth base treatment slurry is a mixture of polyvinyl alcohol, polyacrylate, polyacrylamide and boron-modified phenolic resin; Based on the resin addition amount as the standard, the specific ratio is as follows: Emulsion 100 Boron-modified phenolic resin 30-50 Inorganic filler 80-120 Dispersant 0.1-1 Gradually add and mix, adjust the viscosity to 2000 - 3000 CPS, the pH value > 7, continuously stir evenly and inject into the impregnation tank. The fabric base passes through the nip roller of the impregnation tank and is fully impregnated under extrusion pressure, so that the sizing material fully enters the polyester fiber, and then it is dried and enters the drying oven for high-temperature shaping and winding.

[0009] Preferably, the adhesive of the primer is a fast-curing resin. Based on the usage amount of the resin binder, the specific formulation is as follows: Phenolic resin 100 Filler 90 Defoamer 0.25 Dispersant 2 Silane coupling agent 0.5 The drying temperature of the primary primer is 100 - 130 °C, and the drying time is 20 - 40 min. The formulation of the secondary sprayed primer is the same as that of the primary coated primer, and the viscosity is adjusted to half of the primary primer by adding a diluent. The drying temperature is 100 - 130 °C, and the drying time is 40 - 60 min.

[0010] Preferably, the abrasive grain planting process is a multi-layer composite abrasive grain planting process, specifically: primary primer → gravity abrasive grain planting → primary electrostatic abrasive grain planting → primary drying → secondary sprayed primer → secondary electrostatic abrasive grain planting composite abrasive grain planting process; First, apply the primary primer and then plant the abrasive grains in the normal way of gravity first and then electrostatic. After the primary drying, spray the secondary primer and then plant the abrasive grains electrostatically again to ensure a multi-layer and full-standing distribution of the working abrasive grain layer.

[0011] Preferably, fluoride and aluminum hydroxide are added to the adhesive of the topcoat. The specific formulation is as follows: Phenolic resin 100 Epoxy resin 50 Calcium fluoride 120 Aluminum hydroxide 10 The drying temperature of the topcoat is 90 - 120 °C, and the drying time is 4 hours.

[0012] Preferably, high-strength modified epoxy resin, nano-silica, and aluminum hydroxide are added to the supercoat. The specific formulation is as follows: Epoxy resin 100 Aluminum fluoride 120 Polyacrylamide 20 Nano-silica 10 Aluminum hydroxide 10 The drying temperature of the coating is 90 - 110 °C, and the drying time is 4 hours.

[0013] Compared with the prior art, the beneficial effects of the present invention are: 1. The product fabric base prepared by the present invention has a low heat elongation rate and does not deform during grinding; 2. The product prepared by the present invention has good grinding life. When grinding stainless steel workpieces, the number of workpieces polished can be increased by 50 - 70% compared with the existing abrasive belts.

[0014] 3. The abrasive of the working sand layer of the product prepared by the present invention can maintain a multi-level all-standing structure, solving the conflict problem between grinding life and grinding sharpness. The sharpness in the later stage of grinding can basically be the same as that in the early stage, and there is no phenomenon of difficult grinding or slipping of the abrasive belt. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic flow chart of the manufacturing method of the heavy-duty abrasive belt for ultra-high life grinding of metals according to the present invention.

[0016] Figure 2 It is a cross-sectional view of the heavy-duty abrasive belt for ultra-high life grinding of metals according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0017] Example 1 Referring to Figure 1 shown, a manufacturing method of a heavy-duty abrasive belt for ultra-high life grinding of metals, the general process route is: large roll of base material → uncoiling → printing trademark → first bottom glue → gravity abrasive implantation → first electrostatic abrasive implantation → first drying → second spraying of bottom glue → second electrostatic abrasive implantation → second drying → compound glue → main drying → winding and parking → super coating → drying and curing → parking → flexing and humidifying → winding → entering the large roll warehouse; Specifically, it includes the following steps: Step S1: Uncoil the large roll of base material and print the trademark; Step S2: Coat the bottom glue on the front surface of the base material to form a first bottom glue layer, and the amount of the first bottom glue is 50 - 65% of the total bottom glue amount; Step S3: Use the gravity abrasive implantation and electrostatic abrasive implantation processes to implant abrasives on the first bottom glue layer. The amount of gravity abrasive implantation is 100 - 400 g / m 2 , and the amount of electrostatic abrasive implantation is 200 - 500 g / m 2 , and then perform the first drying. The drying temperature is 100 - 130 °C, and the drying time is 20 - 40 min to form a gravity abrasive implanted layer; Step S4: After drying, spray the bottom glue on the surface of the abrasive cloth. The viscosity of the sprayed bottom glue is half of the viscosity of the coated bottom glue to form a second bottom glue layer; Step S5: Use the electrostatic abrasive implantation process to implant abrasives on the second bottom glue layer. The amount of abrasive implantation is 400 - 1000 g / m 2 , and then perform the second drying to form a first electrostatic abrasive implanted layer and a second electrostatic abrasive implanted layer. The drying temperature is 100 - 130 °C, and the drying time is 40 - 60 min; Step S6: Coat a secondary adhesive layer on the second primer layer after secondary electrostatic abrasive planting, and perform primary drying at a temperature of 90 - 120°C for 4 hours; Step S7: Coat a supercoat on the secondary adhesive layer, and dry and cure the supercoat at a drying temperature of 90 - 110°C for 4 hours; Step S8: Perform a flexing and humidifying operation to obtain the final abrasive belt product, which is wound and then placed in a large roll storage.

[0018] The particle size of the abrasive is 20 - 180 mesh. The abrasives in the bottom abrasive layer produced by gravity abrasive planting mainly include brown fused alumina, white fused alumina, semi-brittle fused alumina, and high-temperature calcined fused alumina, etc. The abrasives in the working abrasive layer produced by electrostatic abrasive planting mainly include zirconium corundum and ceramic microcrystalline corundum abrasives.

[0019] The base material is a cloth base with good heat resistance and is treated with a special polyester cloth treatment method. As an ultra-high-life abrasive belt, a longer grinding life places more stringent requirements on the base material. In addition to high strength, good stiffness, and high bonding strength between the base material, the primer, and the abrasive, the thermal stability of the base material also needs to be ensured during the cloth base treatment. High-temperature resistant resins are mainly introduced into the cloth base impregnation formula to improve the heat resistance of the cloth base. The high-temperature setting temperature of the cloth base is 220°C, and the elongation rate of the cloth base reaches 8%, reducing the elongation rate to ensure the grinding life in the later stage. The cloth base material is polyester cloth, and the cloth base treatment slurry is a mixture of polyvinyl alcohol, polyacrylate, polyacrylamide, and boron-modified phenolic resin; Based on the resin addition amount as the standard, the specific proportions are as follows: Emulsion 100 Boron-modified phenolic resin 30 - 50 Inorganic filler 80 - 120 Dispersant 0.1 - 1 Gradually add and mix, adjust the viscosity to 2000 - 3000 CPS, the pH value > 7, continuously stir evenly and inject into the impregnation tank. The cloth base is fully impregnated under a certain extrusion pressure through the impregnation tank nip roller, so that the sizing agent fully enters the polyester fiber, and then dried and enters the drying oven for high-temperature setting and winding. Using boron-modified phenolic resin in the sizing agent can effectively improve the thermal stability of the base material.

[0020] For the primer adhesive, a fast-curing resin is selected to ensure that the multi-layer composite abrasive planting process can be carried out, avoid the sagging phenomenon caused by the imbalance of the glue-to-abrasive ratio, and ensure the high viscosity and high room-temperature adhesiveness of the primer. Based on the resin binder usage amount as the standard, the specific proportions are as follows: Phenolic resin 100 Filler 90 Defoamer 0.25 Dispersant 2 Silane coupling agent 0.5 The drying temperature of the primary base glue is 100 - 130°C, and the drying time is 20 - 40 min. The formula of the secondary sprayed base glue is the same as that of the primary coated base glue. The viscosity is adjusted to half of the primary base glue by adding a diluent. The drying temperature is 100 - 130°C, and the drying time is 40 - 60 min.

[0021] The abrasive planting method is a multi-layer composite abrasive planting process. Different from the traditional abrasive planting process, the present invention adopts a composite abrasive planting process of "primary base glue → gravity abrasive planting → primary electrostatic abrasive planting → primary drying → secondary sprayed base glue → secondary electrostatic abrasive planting". First, after applying the primary base glue, abrasive planting is carried out in the order of gravity first and then electrostatic. After primary drying, the secondary base glue is sprayed, and then electrostatic abrasive planting is carried out again to ensure a multi-layer and fully standing distribution of the working abrasive layer. Different from the traditional abrasive planting process, after the ordinary abrasive belt grinds the workpiece, the abrasive grains are passivated and lose the grinding ability; while for the product prepared by this invention, after a certain amount of workpiece is cut off by the abrasive grains and passivated, the tips of the abrasive grains in the primary electrostatic abrasive planting layer below the secondary electrostatic abrasive planting layer are exposed to participate in grinding. Therefore, sharp cutting edges are continuously generated during the grinding process of this product, so it has a long service life and can maintain the consistency of sharpness.

[0022] In the re-bonding adhesive, fluoride, aluminum hydroxide, etc. are added to increase the bonding force and improve the heat dissipation performance of the system. The specific formulation is as follows: Phenolic resin 100 Epoxy resin 50 Calcium fluoride 120 Aluminum hydroxide 10 The drying temperature of the re-bonding is 90 - 120°C, and the drying time is 4 hours.

[0023] In the super-coating, high-strength modified epoxy resin, nano-silica, aluminum hydroxide, etc. are added to improve the heat dissipation performance of the super-coating. The specific formulation is as follows: Epoxy resin 100 Aluminum fluoride 120 Polyacrylamide 20 Nano-silica 10 Aluminum hydroxide 10 The drying temperature of the coating is 90 - 110°C, and the drying time is 4 hours.

[0024] Example 2 Refer to Figure 2As shown in the figure, a heavy-duty abrasive belt dedicated to grinding metal with an ultra-high service life includes a base material 10. A base glue is coated on the front surface of the base material 10 to form a first base glue layer 11. Abrasives are implanted on the first base glue layer 11 to form a gravity-implanted abrasive layer 14. And a base glue is sprayed on the first base glue layer 11 and the gravity-implanted abrasive layer 14 to form a second base glue layer 12. Abrasives are continuously implanted on the second base glue layer 12 to form a primary electrostatic-implanted abrasive layer 15 and a secondary electrostatic-implanted abrasive layer 16. And the primary electrostatic-implanted abrasive layer 15 and the secondary electrostatic-implanted abrasive layer 16 form a multi-layer all-standing structure. A topcoat layer 13 is coated on the second base glue layer 12, and a supercoat layer 17 is coated on the topcoat layer 13.

[0025] In summary, the heavy-duty abrasive belt dedicated to grinding metal with an ultra-high service life prepared by the present invention has good grinding service life. When grinding stainless steel workpieces, compared with the existing abrasive belts, the number of workpieces polished can be increased by 50-70%. For the product prepared by the present invention, the abrasives in the working abrasive layer can maintain a multi-layer all-standing structure, solving the conflict problem between grinding service life and grinding sharpness. The sharpness in the later stage of grinding can be basically the same as that in the early stage, and there is no phenomenon of difficult grinding or slipping of the abrasive belt.

[0026] The above is only a preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution and inventive concept of the present invention, makes equivalent substitutions or changes, and should be covered by the protection scope of the present invention.

Claims

1. A heavy-duty abrasive belt specially designed for grinding metals with an ultra-long service life, characterized in that: It includes a substrate, a primer is coated on the front side of the substrate to form a first primer layer, abrasives are implanted on the first primer layer to form a gravity-implanted abrasive layer, and primer is sprayed on the first primer layer and the gravity-implanted abrasive layer to form a second primer layer, abrasives are further implanted on the second primer layer to form a primary electrostatic-implanted abrasive layer and a secondary electrostatic-implanted abrasive layer, and the primary electrostatic-implanted abrasive layer and the secondary electrostatic-implanted abrasive layer form a multi-level full-standing structure, a secondary primer layer is coated with a composite glue layer, and a super coating is coated on the composite glue layer.

2. A method for manufacturing a heavy-duty abrasive belt for grinding metal with an ultra-long service life as claimed in claim 1, characterized in that: The steps include: Step S1, unwinding the large roll of substrate and printing the trademark; Step S2, coating the front surface of the substrate with a primer to form a first primer layer, wherein the amount of the primer is 50-65% of the total amount of the primer; Step S3: Gravity sand planting and electrostatic sand planting are used to plant abrasives on the first base glue layer, and the amount of gravity sand planting is 100-400g / m 2 , the amount of electrostatic sand planting is 200-500g / m 2 , and then carry out a drying process, the drying temperature is 100-130℃, the drying time is 20-40min, to form a gravity-planted abrasive layer; Step S4: after drying, spraying a primer on the surface of the abrasive cloth, wherein the viscosity of the sprayed primer is half of the viscosity of the coated primer, to form a second primer layer; Step S5: Use electrostatic sand implantation to implant abrasives on the second primer layer, with the amount of implanted sand being 400-1000 g / m 2 , and then perform secondary drying to form a primary electrostatic sand-planting abrasive layer and a secondary electrostatic sand-planting abrasive layer, the drying temperature is 100-130°C, and the drying time is 40-60min; Step S6, coating a second adhesive layer on the second base adhesive layer after the second electrostatic sand planting, and performing main drying, the main drying temperature is 90-120° C., and the drying time is 4 hours; Step S7, coating the super coating on the adhesive layer, drying and curing the super coating, the drying temperature is 90-110° C., and the drying time is 4 hours; Step S8: Perform a soft bending and humidification operation to obtain a final abrasive belt product, which is then wound and placed in a large roll warehouse.

3. The method for manufacturing a heavy-duty abrasive belt for grinding metal with ultra-long service life according to claim 2, characterized in that: The particle size of the abrasive is 20-180 meshes. The bottom sand layer abrasive produced by gravity sand planting includes brown corundum, white corundum, semi-brittle corundum and high-temperature calcined corundum. The working sand layer abrasive produced by electrostatic sand planting includes zirconium corundum and ceramic microcrystalline corundum abrasive.

4. The method for manufacturing a heavy-duty abrasive belt for grinding metal with ultra-long service life according to claim 2, characterized in that: The substrate is a heat-resistant cloth base and is treated with polyester cloth. A high-temperature resistant resin is introduced into the cloth base impregnation formula. The high-temperature setting temperature of the cloth base is 220° C. The cloth base elongation reaches 8%. The cloth base treatment slurry is a mixture of polyvinyl alcohol, polyacrylate, polyacrylamide and boron-modified phenolic resin. Based on the amount of resin added, the specific ratio is as follows: Lotion 100 Boron modified phenolic resin 30-50 Inorganic filler 80-120 Dispersant 0.1-1 Gradually add and mix, adjust the viscosity to 2000CPS-3000CPS, PH value>7, continuously stir and evenly inject into the impregnation tank, the cloth base passes through the impregnation tank and is fully impregnated under the extrusion pressure, so that the rubber material fully enters the polyester fiber, and then dries and enters the drying room for high-temperature setting and winding.

5. The method for manufacturing a heavy-duty abrasive belt for grinding metal with ultra-long service life according to claim 2, characterized in that: The adhesive of the primer is a fast-curing resin, with the amount of resin binder used as the standard, and the specific ratio is as follows: Phenolic resin 100 Filling 90 Defoamer 0.25 Dispersant 2 Silane coupling agent 0.5 The drying temperature of the first primer is 100-130℃, and the drying time is 20-40min. The formula of the second spray primer is the same as that of the first coating primer. The viscosity is adjusted to half of the first primer by adding diluent. The drying temperature is 100-130℃, and the drying time is 40-60min.

6. The method for manufacturing a heavy-duty abrasive belt for grinding metal with ultra-long service life according to claim 2, characterized in that: The sand planting process is a multi-layer composite sand planting process, specifically: a composite sand planting process of primary primer → gravity sand planting → primary electrostatic sand planting → primary drying → secondary spraying of primer → secondary electrostatic sand planting; firstly, apply the primary primer and then perform normal sand planting in a gravity-first and then electrostatic sand planting manner, after primary drying, spray the secondary primer and perform electrostatic sand planting again to ensure that the working sand layer is distributed in a multi-layered and fully standing manner.

7. The method for manufacturing a heavy-duty abrasive belt for grinding metal with an ultra-long service life according to claim 2, characterized in that: Fluoride and aluminum hydroxide are added to the adhesive of the composite glue, and the specific proportion is as follows: Phenolic resin 100 Epoxy Resin 50 Calcium Fluoride 120 Aluminum hydroxide 10 The drying temperature of the glue coating is 90-120℃ and the drying time is 4 hours.

8. The method for manufacturing a heavy-duty abrasive belt for grinding metal with ultra-long service life according to claim 2, characterized in that: High-strength modified epoxy resin, nano-silicon dioxide and aluminum hydroxide are added to the super coating, and the specific proportion is as follows: Epoxy resin 100 Aluminum fluoride 120 Polyacrylamide 20 Nano Silica 10 Aluminum hydroxide 10 The coating drying temperature is 90-110°C and the drying time is 4 hours.

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