Ceramic hollow sphere resin grinding wheel and preparation method thereof
By preparing a ceramic hollow ball resin grinding wheel, the binder and superhard abrasive are wrapped with carbon microspheres and then sintered at high temperature to form a hollow structure, which solves the problems of insufficient grinding efficiency, life and thermal stability of traditional grinding wheels and achieves efficient and stable grinding performance.
Patent Information
- Application Number
- CN202510959585.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-11
- Publication Date
- 2025-09-12
AI Technical Summary
Traditional grinding wheels are difficult to meet the high-precision, high-speed and dry processing requirements of modern industry in terms of grinding efficiency, service life and thermal stability. Vitrified bonded grinding wheels are brittle and require external dressing, while resin bonded grinding wheels have poor thermal stability and the abrasive grains are easily detached.
Ceramic hollow ball resin grinding wheel is prepared by mixing ceramic hollow ball abrasive with resin binder through hot pressing or cold pressing process. The binder and super-hard abrasive are wrapped with carbon microspheres and then sintered at high temperature to form a hollow structure, achieving self-sharpening, thermal stability and progressive shedding.
It improves the grinding efficiency and service life, avoids the decline of grinding efficiency and overheating, ensures stable grinding performance, and extends the service life of the grinding wheel.
Smart Images
Figure CN120620097A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of mechanical processing, and in particular to a ceramic hollow ball resin grinding wheel and a preparation method thereof. Background Art
[0002] Modern machining is moving towards high precision, high speed, hard machining, dry machining (no coolant), and cost reduction, placing considerable demands on the performance of grinding wheels. Traditional grinding wheels typically use a single type of binder to hold the abrasive together. However, with advancements in industrial technology, the demands for grinding wheel efficiency and service life continue to increase, and the performance of traditional grinding wheels is no longer able to meet the demands of modern industry.
[0003] In recent years, vitrified bond grinding wheels have excelled in grinding high-precision, high-hardness materials due to their high hardness and superior thermal stability. However, their brittle nature makes them difficult to self-sharpen during the grinding process, but they are easily dressed, requiring external dressing to create a new grinding edge for continued use. Resin bonds, due to their excellent elasticity, strength, and impact resistance, excel in rough grinding, cutting, or other grinding operations requiring less precise precision. However, their poor thermal stability makes them more susceptible to shedding when the abrasive grains are not completely blunt. While they can be used without dressing, they are not suitable for high-intensity, high-precision grinding applications. Summary of the Invention
[0004] In view of this, the present invention provides a ceramic hollow ball resin grinding wheel and a preparation method thereof, so as to achieve the purpose of solving the shortcomings of traditional grinding wheels in grinding efficiency, service life and thermal stability.
[0005] To achieve the above object, the present invention provides a method for preparing a ceramic hollow ball resin grinding wheel, comprising the following steps: After mixing the ceramic hollow ball abrasive with the resin binder, fillers are added and mixed evenly. The mixed material is pressed into a grinding wheel shape through a hot pressing or cold pressing process, and then cured to form a stable grinding wheel structure. Finally, after post-processing, a ceramic hollow ball resin grinding wheel is obtained.
[0006] Optionally, the preparation of the ceramic hollow ball abrasive comprises the following steps: S1, mixing superhard micro-powder abrasive and vitrified binder, adding organic solvent and mixing evenly to obtain slurry; S2, evenly coating the slurry on the surface of the carbon microspheres, drying and removing the organic solvent to form a preliminary abrasive-carbon microsphere composite structure; S3. Sintering, cooling, cleaning and screening the preliminary abrasive-carbon microsphere composite structure to obtain ceramic hollow sphere abrasive with uniform particle size.
[0007] Optionally, the weight of the carbon microspheres in S2 is 5-10% of the weight of the slurry, and the diameter of the carbon microspheres is 50 μm-200 μm.
[0008] Optionally, the sintering conditions in S3 are a temperature of 900-1200° C. and a time of 1-3 hours.
[0009] Optionally, the superhard micro-powder abrasive is one of CBN and diamond.
[0010] Optionally, the weight percentages of the ceramic hollow ball abrasive, resin binder and filler are as follows: 70-90% ceramic hollow ball abrasive, 8-18% resin binder and 0-20% filler.
[0011] Optionally, the hot pressing conditions are a temperature of 100-200° C. and a pressure of 10-20 MPa.
[0012] Optionally, the filler is one of aluminum oxide and silicon carbide.
[0013] In order to achieve the above-mentioned purpose, the present invention also provides a ceramic hollow ball resin grinding wheel prepared by a preparation method of the ceramic hollow ball resin grinding wheel.
[0014] The above technical solution of the present invention includes at least the following beneficial effects: The technical solution provided by this invention mixes sintered ceramic hollow sphere abrasive with a resin binder to produce a grinding wheel abrasive. The hollow ceramic sphere structure not only retains the high hardness and thermal stability of the vitrified binder, but also reduces the weight of the grinding wheel through the hollow structure, improving grinding efficiency and service life.
[0015] The technical solution provided by the present invention uses a ceramic binder and superhard abrasives (such as CBN, diamond, etc.) to wrap carbon microspheres. The carbon microspheres inside are gasified through high-temperature sintering to form a ceramic hollow ball structure. During the grinding process, the ceramic hollow ball abrasive falls off in the following way: Self-sharpening shedding: During the grinding process, as the cutting edge of the ceramic hollow ball abrasive gradually wears away, the resin bond, due to its excellent elasticity, allows the abrasive to fall off under appropriate pressure, exposing a new grinding edge and achieving a self-sharpening effect. This shedding method avoids the problem of reduced grinding efficiency caused by excessive abrasive wear in traditional grinding wheels.
[0016] Thermally Stable Shedding: Because the ceramic hollow spheres are composed of a vitrified binder and highly thermally conductive superhard abrasives, they exhibit excellent thermal conductivity, effectively dissipating heat generated during the grinding process and preventing localized overheating of the grinding wheel. As grinding temperatures rise, the thermal stability of the resin binder improves, preventing premature shedding of the abrasive due to overheating. Furthermore, the ceramic hollow spheres' structural stability at high temperatures ensures that the abrasive is shed at the appropriate time, extending the life of the grinding wheel.
[0017] Progressive shedding: The bond strength between the hollow ceramic ball abrasive and the resin bond has been optimized to achieve progressive shedding during the grinding process. This means the abrasive does not shed all at once, but rather gradually as the grinding force changes, ensuring stable grinding performance. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 Schematic diagram of the structure of the ceramic hollow ball abrasive in Example 1 of the present invention; Figure 2 Schematic diagram of the structure of the ceramic hollow ball resin grinding wheel in Example 1 of the present invention. DETAILED DESCRIPTION
[0019] To make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the following will be combined with the appended drawings of the embodiments of the present invention. Figures 1 and 2 , clearly and completely describing the technical solutions of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the described embodiments of the present invention, all other embodiments derived by ordinary technicians in this field fall within the scope of protection of the present invention.
[0020] Example 1 Preparation of ceramic hollow ball abrasive: Mix superhard micronized abrasive (CBN) with a vitrified bond, then add an organic solvent (ethanol) as a dispersing medium to ensure uniform mixing to create a slurry. The weight percentages of superhard micronized abrasive, vitrified bond, and organic solvent are as follows: 70% superhard abrasive, 20% vitrified bond, and 10% organic solvent.
[0021] A mixed slurry of superhard micropowder abrasive and ceramic binder is evenly coated on the surface of the carbon microspheres. The diameter of the carbon microspheres is selected based on the desired hollow sphere size, 100 μm. The weight of the carbon microspheres is 5% of the slurry weight. The coated carbon microspheres are dried at room temperature to remove the organic solvent, forming a preliminary abrasive-carbon microsphere composite structure.
[0022] The dried composite structure is placed in a high-temperature furnace for sintering at 900°C for 3 hours. At high temperatures, the carbon microspheres are gasified to form a hollow structure, and the ceramic binder and superhard abrasive are tightly combined to form a stable ceramic hollow ball abrasive. After sintering, it is cooled to room temperature, cleaned and sieved to ensure that the particle size of the ceramic hollow ball abrasive is consistent and to remove unqualified particles. The schematic diagram of the obtained ceramic hollow ball abrasive structure is shown in Figure 1 .
[0023] The preparation of the ceramic hollow ball resin grinding wheel includes the following steps: Ceramic hollow ball abrasive is mixed with resin bond and filler (aluminum oxide) is added to enhance the mechanical properties of the grinding wheel. The weight percentages of ceramic hollow ball abrasive, resin bond and filler are as follows: ceramic hollow ball abrasive 80%, resin bond 10% and filler 10% The mixed material is pressed into the shape of a grinding wheel through a hot pressing process. The hot pressing temperature is 200°C and the pressure is 15MPa. The formed grinding wheel is cured to ensure that the resin bond is fully cured and a stable grinding wheel structure is formed. The grinding wheel is subjected to post-processing processes such as shaping and balancing to ensure that it meets the requirements of use. The structural diagram of the obtained ceramic hollow ball resin grinding wheel is shown in Figure 2 (The curing and post-processing steps are optional processes in the existing technology) Example 2 Preparation of ceramic hollow ball abrasive: Mix superhard micro-powder abrasive (diamond) with a vitrified binder, then add an organic solvent as a dispersing medium, ensuring uniform mixing, to create a slurry. The weight percentages of superhard micro-powder abrasive, vitrified binder, and organic solvent are as follows: 80% superhard abrasive, 10% vitrified binder, and 10% organic solvent.
[0024] A mixed superhard micropowder abrasive and ceramic binder slurry is evenly coated on the surface of the carbon microspheres. The diameter of the carbon microspheres is selected based on the desired hollow sphere size, 50 μm. The weight of the carbon microspheres is 10% of the slurry weight. The coated carbon microspheres are dried at room temperature to remove the organic solvent, forming a preliminary abrasive-carbon microsphere composite structure.
[0025] The dried composite structure is sintered in a high-temperature furnace at 1100°C for two hours. At this high temperature, the carbon microspheres vaporize, forming a hollow structure. The ceramic binder and superabrasive are tightly bonded, forming a stable ceramic hollow sphere abrasive. After sintering, the composite is cooled to room temperature, cleaned, and sieved to ensure uniform particle size and remove unqualified particles.
[0026] The preparation of the ceramic hollow ball resin grinding wheel includes the following steps: Ceramic hollow ball abrasive is mixed with resin bond and filler (aluminum oxide) is added to enhance the mechanical properties of the grinding wheel. The weight percentages of ceramic hollow ball abrasive, resin bond and filler are as follows: ceramic hollow ball abrasive 90%, resin bond 8% and filler 2% The mixed material is pressed into the shape of a grinding wheel through a hot pressing process. The hot pressing temperature is 100°C and the pressure is 20 MPa. The formed grinding wheel is then cured to ensure that the resin bond is fully cured and a stable grinding wheel structure is formed. The grinding wheel undergoes post-processing such as shaping and balancing to ensure that it meets the requirements for use. (Curing and post-processing are optional processes in existing technologies.) Example 3 Preparation of ceramic hollow ball abrasive: Mix superhard micro-powder abrasive (diamond) with a vitrified binder and add an organic solvent as a dispersing medium, ensuring uniform mixing to create a slurry. The weight percentages of superhard micro-powder abrasive, vitrified binder, and organic solvent are as follows: 75% superhard abrasive, 20% vitrified binder, and 5% organic solvent.
[0027] A mixed slurry of superhard micropowder abrasive and ceramic binder is evenly coated on the surface of the carbon microspheres. The diameter of the carbon microspheres is selected based on the desired hollow sphere size, 200 μm. The weight of the carbon microspheres is 8% of the slurry weight. The coated carbon microspheres are dried at room temperature to remove the organic solvent, forming a preliminary abrasive-carbon microsphere composite structure.
[0028] The dried composite structure is sintered in a high-temperature furnace at 1200°C for one hour. At this high temperature, the carbon microspheres vaporize, forming a hollow structure. The ceramic binder and superabrasive are tightly bonded, forming a stable hollow ceramic abrasive. After sintering, the composite is cooled to room temperature, cleaned, and sieved to ensure uniform particle size and remove unqualified particles.
[0029] The preparation of the ceramic hollow ball resin grinding wheel includes the following steps: Ceramic hollow ball abrasive is mixed with a resin bond, and filler (silicon carbide) is added to enhance the mechanical properties of the grinding wheel. The weight percentages of ceramic hollow ball abrasive, resin bond, and filler are as follows: ceramic hollow ball abrasive 82%, resin bond 18%.
[0030] The mixed material is pressed into the shape of a grinding wheel through a hot pressing process. The hot pressing temperature is 150°C and the pressure is 10MPa. The formed grinding wheel is then cured to ensure that the resin bond is fully cured and a stable grinding wheel structure is formed. The grinding wheel undergoes post-processing such as shaping and balancing to ensure that it meets the requirements for use. (Curing and post-processing are optional processes in existing technologies.) Performance test comparison, the ceramic hollow ball resin grinding wheel prepared in Examples 1 to 3 and the traditional abrasive structure grinding wheel are compared in various indicators when processing 6203 bearing inner diameter workpieces. Under the condition that the grinding wheel linear speed, workpiece linear speed, and roller speed ratio are the same, 10 grinding wheels of Examples 1 to 3 and 10 grinding wheels with traditional abrasive structure are sampled, and the performance parameters are obtained by observing the entire grinding wheel processing process. The performance parameter data are shown in Table 1.
[0031] Table 1 Performance comparison of the ceramic hollow ball resin grinding wheel prepared by the present invention and the traditional abrasive structure grinding wheel
[0032] As can be seen from Table 1, the ceramic hollow ball resin grinding wheel prepared by the present invention reduces equipment power during processing, reduces dressing frequency, improves grinding efficiency, improves grinding accuracy, avoids overheating of grinding temperature, and increases service life.
[0033] The above is a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.
Claims
1. A method for preparing a ceramic hollow ball resin grinding wheel, characterized in that: The following steps are involved: After mixing the ceramic hollow ball abrasive with the resin binder, fillers are added and mixed evenly. The mixed material is pressed into a grinding wheel shape through a hot pressing or cold pressing process, and then cured to form a stable grinding wheel structure. Finally, after post-processing, a ceramic hollow ball resin grinding wheel is obtained.
2. The method for preparing a hollow ceramic ball resin grinding wheel according to claim 1, wherein: The preparation of the ceramic hollow ball abrasive comprises the following steps: S1, mixing superhard micro-powder abrasive and vitrified binder, adding organic solvent and mixing evenly to obtain slurry; S2, evenly coating the slurry on the surface of the carbon microspheres, drying and removing the organic solvent to form a preliminary abrasive-carbon microsphere composite structure; S3. Sintering, cooling, cleaning and screening the preliminary abrasive-carbon microsphere composite structure to obtain ceramic hollow sphere abrasive with uniform particle size.
3. The method for preparing a hollow ceramic ball resin grinding wheel according to claim 2, wherein: The weight percentages of the superhard micro-powder abrasive, the vitrified binder and the organic solvent in S1 are as follows: 60-80% superhard abrasive, 10-20% vitrified binder and 5-10% organic solvent.
4. The method for preparing a hollow ceramic ball resin grinding wheel according to claim 2, wherein: The weight of the carbon microspheres in S2 is 5-10% of the weight of the slurry, and the diameter of the carbon microspheres is 50 μm-200 μm.
5. The method for preparing a hollow ceramic ball resin grinding wheel according to claim 2, wherein: The sintering conditions in S3 are a temperature of 900-1200° C. and a time of 1-3 hours.
6. The method for preparing a hollow ceramic ball resin grinding wheel according to claim 3, wherein: The superhard micro-powder abrasive is one of CBN and diamond.
7. The method for preparing a hollow ceramic ball resin grinding wheel according to claim 1, wherein: The weight percentages of the ceramic hollow ball abrasive, resin binder and filler are as follows: 70-90% of the ceramic hollow ball abrasive, 8-18% of the resin binder and 0-20% of the filler.
8. The method for preparing a hollow ceramic ball resin grinding wheel according to claim 1, wherein: The hot pressing conditions are a temperature of 100-200° C. and a pressure of 10-20 MPa.
9. The method for preparing a hollow ceramic ball resin grinding wheel according to claim 1, wherein: The filler is one of aluminum oxide and silicon carbide.
10. A ceramic hollow ball resin grinding wheel produced by the method for producing a ceramic hollow ball resin grinding wheel according to any one of claims 1 to 9.