Resin coating combined grinding wheel and preparation method thereof

Abstract

The invention relates to the technical field of non-woven fabric materials, in particular to a resin coating combined grinding wheel which is characterized by comprising a base body, a grinding material layer and a resin coating. Wherein the surface of the grinding material layer is covered with the resin coating, the surface of the resin coating is provided with a bionic micro-nano composite structure, the bionic micro-nano composite structure is composed of nano-particles in the resin coating and a micron-sized groove array, and the surface of the bionic micro-nano composite structure is modified through low-surface-energy substances. The cooling liquid can be instantly spread to form a film and rapidly permeate into a grinding area to take away heat; and the abrasive dust automatically rolls down in the grinding process, the residual quantity is reduced by more than 80%, pores of the grinding wheel are prevented from being blocked, and the stable grinding efficiency is maintained.

Description

Technical Field

[0001] The present invention relates to the technical field of grinding wheels, and particularly relates to a resin-coated bonded grinding wheel and a preparation method thereof. Background Art

[0002] For the grinding process of metal surfaces, resin grinding discs are still one of the most widely used tools due to their high grinding volume and good durability.

[0003] In wet grinding, the surface of traditional resin grinding wheels is hydrophobic (contact angle > 90°), making it difficult for the coolant to quickly spread and form a uniform liquid film. This leads to uneven heat dissipation in the grinding area, with local temperatures reaching over 350 °C (refer to the reference "Research on the Mechanism of Thermal Damage in Grinding Process"), causing workpiece surface burns (burn rate > 10%) and thermal deformation of the grinding wheel. At the same time, abrasive debris easily adheres to the pores on the surface of the grinding wheel, forming a "debris layer" that clogs the cutting edges of the abrasives (residual amount > 30%), significantly reducing the grinding efficiency (volume removal rate < 1000 mm 3 / min). In view of this, we propose a resin-coated bonded grinding wheel and a preparation method thereof. Summary of the Invention

[0004] The purpose of the present invention is to solve the deficiencies mentioned in the above background art and provide a resin-coated bonded grinding wheel and a preparation method thereof.

[0005] To solve the above technical problems, the present invention adopts the following technical solutions:

[0006] A resin-coated bonded grinding wheel includes a substrate, an abrasive layer, and a resin coating;

[0007] Among them, the resin coating covers the surface of the abrasive layer, and its surface has a biomimetic micro-nano composite structure. The biomimetic micro-nano composite structure is composed of nano-particles and micron-scale groove arrays in the resin coating, and the surface is modified with a low surface energy substance.

[0008] Preferably, the mass fraction of the resin coating is specifically:

[0009]

[0010] Preferably, the micron-scale groove arrays on the surface of the abrasive layer are formed by laser etching or template imprinting processes, and the groove width is 5 - 50 μm, the depth is 1 - 10 μm, and the spacing between adjacent grooves is 10 - 100 Um.

[0011] Preferably, the abrasive in the abrasive layer is diamond, cubic boron nitride, or corundum, the abrasive particle size is 10 - 500 μm, and the surface of the abrasive is pretreated with a silane coupling agent.

[0012] Preferably, the nanoparticles are at least one of silica, silicon carbide or zinc oxide, and the particle size range of the nanoparticles is 20-200 nm.

[0013] Preferably, the low surface energy modifier is at least one of fluorosilane or polytetrafluoroethylene.

[0014] A preparation method of a resin-coated bonded grinding wheel, the specific steps of the preparation method are as follows:

[0015] S1. Substrate pretreatment: Sandblast the metal or ceramic substrate to make the surface roughness Ra reach 1-5 μm;

[0016] S2. Abrasive layer preparation: Mix the abrasive and the resin binder in a mass ratio of 3:1-5:1, coat it on the surface of the substrate, and pre-cure at 80-120 °C for 1-3 hours;

[0017] S3. Resin coating application: Mix epoxy resin, nanoparticles, low surface energy modifier and adhesion enhancer, and then spray the mixed resin slurry onto the surface of the abrasive layer to form a coating with a thickness of 10-100 μm;

[0018] S4. Structure forming: Form a microgroove array on the surface of the resin coating by template imprinting or laser etching;

[0019] S5. Functionalization treatment: Under an inert gas environment, perform plasma treatment on the resin coating, impregnate with a low surface energy modifier solution after activating the surface activity, and finally cure at 150-200 °C for 2-4 hours.

[0020] Preferably, in step S5, the power of the plasma treatment is 50-200 W, the treatment time is 1-10 minutes, and the gas is argon or nitrogen.

[0021] Preferably, in step S3, the viscosity of the resin slurry is 500-2000 mPa·s, the spraying pressure is 0.2-0.8 MPa, and the spraying distance is 10-30 cm.

[0022] Compared with the prior art, the beneficial effects of the present invention are:

[0023] The contact angle of the coolant on the surface of the resin coating of this application is <10°, and the coolant can be instantaneously spread into a film (spreading time <0.5 s), quickly penetrate into the grinding area, and take away heat; it is superhydrophobic to grinding chips (metal / ceramic particles) (contact angle >150°), and the grinding chips automatically roll off during the grinding process, and the residual amount is reduced by more than 80% (the residual amount of the traditional grinding wheel >30%), avoiding clogging of the grinding wheel pores, maintaining a stable grinding efficiency. Compared with the traditional grinding wheel that needs to frequently stop to clean the grinding chips, the present invention can extend the continuous operation time by 2-3 times.

[0024] The surface of the resin coating in this application is designed with micron-scale grooves (width 5 - 50 μm) and nano-scale protrusions (particle size 20 - 200 nm). Through mechanical interlocking and intermolecular forces, the bonding strength of the abrasive is ≥ 200 N / cm 2 (The traditional resin bonding strength ≤ 120 N / cm 2 ), the abrasive shedding rate < 5% (traditional grinding wheel > 15%), and the service life of the grinding wheel is increased to 150 hours (traditional grinding wheel ≤ 80 hours). BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings forming a part of this application are used to provide a further understanding of the present invention. The schematic embodiments and descriptions thereof of the present invention are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0026] Figure 1 It is a flowchart of a preparation method for a resin-coated bonded grinding wheel. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0027] The following will describe clearly and completely the technical solutions in the embodiments of the present invention in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Without conflict, the embodiments and features in the present application can be combined with each other. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of protection of the present invention.

[0028] Please refer to Figure 1 , the present invention details the above technical solutions through the following embodiments:

[0029] Embodiment 1

[0030] A resin-coated bonded grinding wheel includes a base body, an abrasive layer, and a resin coating; the resin coating covers the surface of the abrasive layer, and its surface has a bionic micro-nano composite structure, enabling the resin coating to have superwetting properties, specifically manifested as:

[0031] (1) The contact angle with the coolant is less than 10°, enabling the coolant to spread rapidly during grinding and carry the grinding debris to slide off;

[0032] (2) The adhesion force to the abrasive is greater than 200 N / cm 2 , strengthening the bonding between the abrasive and the base body through intermolecular forces and mechanical interlocking effects;

[0033] The bionic micro-nano composite structure consists of nano-particles and micron-scale groove arrays in the resin coating, and the surface is modified with low-surface-energy substances.

[0034] Among them, the mass fraction of the resin coating is specifically as follows:

[0035]

[0036] Among them, the micron-level groove array on the surface of the abrasive layer is formed by laser etching or template imprinting process, and the groove width is 50 μm, the depth is 10 μm, and the spacing between adjacent grooves is 100 μm.

[0037] Among them, the abrasive in the abrasive layer is diamond, the abrasive particle size is 500 μm, and the surface of the abrasive is pretreated with a silane coupling agent.

[0038] Among them, the nanoparticles are silicon carbide, and the particle size range of the nanoparticles is 200 nm.

[0039] A preparation method of a resin-coated bonded grinding wheel, the specific steps of the preparation method are as follows: First, perform sandblasting on the metal matrix to make the surface roughness Ra reach 5 μm; then mix the abrasive and the resin binder in a mass ratio of 5:1, coat it on the surface of the matrix, and pre-cure it at 120 °C for 3 hours; then mix epoxy resin, silicon carbide, fluorosilane and adhesion enhancer, and nano-silicon carbide in the resin coating can be uniformly dispersed through the silane coupling agent KH-550 to form a "resin-whisker" three-dimensional network structure, and then spray the mixed resin slurry onto the surface of the abrasive layer to form a coating with a thickness of 100 μm, the viscosity of the resin slurry is 2000 mPa·s, the spraying pressure is 0.8 MPa, and the spraying distance is 30 cm; then form a micron-level groove array on the surface of the resin coating by template imprinting or laser etching; finally, in an inert gas environment, perform plasma treatment on the resin coating, impregnate the fluorosilane solution after activating the surface activity, and finally cure it at 200 °C for 4 hours, the power of the plasma treatment is 200 W, the treatment time is 10 minutes, and the gas is argon.

[0040] It should be explained that the superwetting property is verified by the following methods: the spreading time of the coolant (water-based or oil-based) on the surface of the resin coating is less than 0.5 seconds; the residual amount of grinding chips during the grinding process is reduced by more than 60% compared with the traditional grinding wheel; the abrasive shedding rate in the grinding wheel life test is lower than 5%.

[0041] Example 2

[0042] The difference between this example and Example 1 is only that: in this example, there are 15 parts of silicon carbide; 10 parts of fluorosilane, and other conditions are the same.

[0043] Example 3

[0044] The difference between this example and Example 1 is only that: in this example, there are 20 parts of silicon carbide; 15 parts of fluorosilane, and other conditions are the same.

[0045] Example 4

[0046] The difference between this example and Example 1 is only that: in this example, there are 25 parts of silicon carbide; 15 parts of fluorosilane, and other conditions are the same.

[0047] Comparative Example 1

[0048] The difference between this comparative example and Example 1 is only that: this comparative example is a blank control group, directly using a grinding wheel purchased on the market, and other conditions are the same.

[0049] Comparative Example 2

[0050] The difference between this comparative example and Example 1 is only that: in this comparative example, the resin slurry purchased on the market is sprayed on the metal matrix, and other conditions are the same.

[0051] Comparative Example 3

[0052] The difference between this comparative example and Example 1 is only that: in this comparative example, silicon carbide is not added, and other conditions are the same.

[0053] Performance Test

[0054] Samples were prepared according to Examples 1 - 4 and Comparative Examples 1 - 2. The superwetting performance of each sample was tested with reference to the contact angle test (GB / T 30693 - 2014), and the abrasive binding strength of each sample was tested with reference to the tensile test (ASTM D4541). The specific data are shown in Table 1 and Table 2:

[0055] Table 1:

[0056] Performance Index Example 1 Example 2 Example 3 Example 4 Coolant Spreading Time (S) 0.4 0.5 0.3 0.6 <![CDATA[Abrasive bond strength (N / cm 2 )]]> 190 180 220 170 Grinding Temperature (℃) 200 210 180 220 Wheel Life (hours) 150 160 180 140 Chip Residue (%) 10 9 8 12

[0057] Table 2:

[0058] Performance Index Comparative Example 1 Comparative Example 2 Comparative Example 3 Coolant Spreading Time (S) 7 5 3 <![CDATA[Abrasive Bond Strength (N / cm 2 )]]> 110 120 135 Grinding Temperature (℃) 390 350 370 Wheel Life (hours) 90 110 100 Chip Residue (%) 40 30 35

[0059] It can be seen from the data in Table 1 and Table 2 that:

[0060] Through the bionic superwetting resin coating design, this application solves the core pain points such as traditional grinding wheel chip accumulation, easy abrasive shedding, and uneven heat dissipation, and has significant advantages in the precision machining fields such as aerospace high-strength alloys and semiconductor wafers, and has comprehensive benefits such as high efficiency, environmental protection, and long life.

[0061] It is obvious to those skilled in the art that the present invention is not limited to the details of the above-described exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, in all respects, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is defined by the appended claims rather than the above description. Accordingly, all changes that fall within the meaning and scope of the equivalent elements of the claims are intended to be embraced within the present invention.

Claims

1. A resin-bonded coated grinding wheel, characterized in that: It includes a substrate, an abrasive layer, and a resin coating; Among them, the resin coating covers the surface of the abrasive layer, and its surface has a biomimetic micro-nano composite structure. The biomimetic micro-nano composite structure is composed of nano-particles in the resin coating and a micron-scale groove array, and the surface is modified with a low surface energy substance.

2. The resin-bonded coated grinding wheel according to claim 1, wherein: The specific mass fraction of the resin coating is:

3. The resin-coated bonded grinding wheel according to claim 1, wherein: The micron-scale groove array on the surface of the abrasive layer is formed by laser etching or template imprinting process, and the groove width is 5 - 50 μm, the depth is 1 - 10 μm, and the distance between adjacent grooves is 10 - 100 μm.

4. The resin-coated bonded grinding wheel according to claim 2, wherein: The abrasive in the abrasive layer is diamond, cubic boron nitride or corundum, the abrasive particle size is 10 - 500 μm, and the surface of the abrasive is pretreated with a silane coupling agent.

5. The resin-coated bonded grinding wheel according to claim 2, wherein: The nano-particles are at least one of silicon dioxide, silicon carbide or zinc oxide, and the particle size range of the nano-particles is 20 - 200 nm.

6. The resin-bonded coated grinding wheel according to claim 2, wherein: The low surface energy modifier is at least one of fluorosilane or polytetrafluoroethylene.

7. A preparation method of a resin-coated bonded grinding wheel, applicable to the resin-coated bonded grinding wheel according to any one of claims 1-6, characterized in that: The specific steps of the preparation method are: S1. Substrate pretreatment: Sandblast the metal or ceramic substrate to make the surface roughness Ra reach 1 - 5 μm; S2. Abrasive layer preparation: Mix the abrasive and the resin binder in a mass ratio of 3:1 - 5:1, coat it on the surface of the substrate, and pre-cure at 80 - 120 °C for 1 - 3 hours; S3. Resin coating application: Mix epoxy resin, nano-particles, low surface energy modifier and adhesion enhancer, and then spray the mixed resin slurry onto the surface of the abrasive layer to form a coating with a thickness of 10 - 100 μm; S4. Structure forming: Form a micron-scale groove array on the surface of the resin coating by template imprinting or laser etching; S5. Functionalization treatment: In an inert gas environment, perform plasma treatment on the resin coating, activate the surface activity and then immerse it in a low surface energy modifier solution, and finally cure at 150 - 200 °C for 2 - 4 hours.

8. The preparation method of a resin-coated bonded grinding wheel according to claim 7, characterized in that: In step S5, the power of the plasma treatment is 50 - 200 W, the treatment time is 1 - 10 minutes, and the gas is argon or nitrogen.

9. The preparation method of a resin-coated bonded grinding wheel according to claim 7, characterized in that: In step S3, the viscosity of the resin slurry is 500 - 2000 mPa·s, the spraying pressure is 0.2 - 0.8 MPa, and the spraying distance is 10 - 30 cm.

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