Processing method of overflow brick chamfer

Abstract

The invention relates to the technical field of overflow brick manufacturing, and discloses an overflow brick chamfer machining method which comprises the following steps: horizontally placing an overflow brick blank on a cushion brick; selecting a diamond cutter with a proper model; feeding, grinding and chamfering at the corners of the outer walls of the large end and the small end on one side of the green brick; hoisting the green brick by using an upender and then rotating the green brick; and feeding, grinding and chamfering at the corners of the outer walls of the large end and the small end on the other side of the green brick. According to the invention, a feeding mode for vertically processing the side line chamfers of the large and small ends of the front and turn-over surfaces of the overflow brick is adopted, so that the surface abrasion loss of the cutter is reduced, the service life of the cutter is prolonged, and the purchase cost of the cutter is saved on the premise of ensuring the processing quality.

Description

Technical Field

[0001] The invention relates to the technical field of overflow brick manufacturing, and in particular to a processing method for chamfering overflow bricks. Background Art

[0002] Overflow bricks occupy a critical position as core components in substrate glass and cover glass production lines. Their performance and quality are directly related to the quality and production efficiency of glass products. Overflow bricks are made of dense zirconium, a material with extremely unique physical properties. Their extremely high hardness, far exceeding that of many common materials, endows overflow bricks with excellent wear resistance and stability, enabling them to operate stably for long periods in harsh production environments such as high temperature and high pressure. However, this also poses significant challenges to processing. Due to their high hardness, ordinary machining tools are unable to cope with them. Diamond tools of various models and grit sizes must be used, and fine processing on CNC machine tools is required to meet the dimensional accuracy and surface quality requirements of the overflow bricks.

[0003] The machining of overflow bricks is complex and time-consuming, especially during the horizontal chamfering process for the large and small ends of the bricks, which places particularly stringent demands on the tool. This process requires the tool to move frequently up and down to precisely chamfer the brick edges. However, this up-and-down motion can easily lead to tool jamming, where the tool suddenly penetrates too deeply into the workpiece during machining, causing damage or reduced machining quality. While ball-end cutters can alleviate the jamming problem to some extent, the extremely hard material of overflow bricks, with an HBS value between 600 and 800, subjects the tool to significant cutting forces and wear during machining. Therefore, in actual production, machining a single brick requires replacing two or three diamond chamfering tools. This not only increases production time and costs but also places extremely high demands on the tool's durability, strength, and rigidity.

[0004] Due to the special tooling requirements and high wear rates during overflow brick processing, tool procurement costs have become a significant expense in the production process. Diamond tools are inherently expensive, and the frequent tool changes required for overflow brick processing contribute to the high tooling procurement costs. Summary of the Invention

[0005] In order to solve the existing problems, the present invention aims to provide a method for processing overflow brick chamfers, which adopts a vertical tool path method for processing the chamfers of the large and small end edges of the front and flip sides of the overflow bricks, so as to reduce the surface wear of the tool, extend the service life of the tool, and save the procurement cost of the tool while ensuring the processing quality.

[0006] In order to achieve the above objectives, the present invention provides the following technical solutions.

[0007] The invention provides a method for processing overflow brick chamfers, comprising the following steps: placing an overflow brick blank horizontally on a pad brick; selecting a diamond tool of a suitable type; grinding and chamfering the outer wall corners of the large end and the small end on one side of the brick blank; hoisting the brick blank with a turning machine and rotating it; and grinding and chamfering the outer wall corners of the large end and the small end on the other side of the brick blank.

[0008] As a further improvement of the present invention, the pad bricks are made of refractory bricks.

[0009] As a further improvement of the present invention, the diamond tool is selected from 180*φ20*φ10*R5-25*120#.

[0010] As a further improvement of the present invention, the feed grinding and chamfering includes using PFC80 water-soluble cutting fluid during the grinding process.

[0011] As a further improvement of the present invention, the feed grinding chamfer includes tangential feed and normal feed.

[0012] As a further improvement of the present invention, the feed grinding chamfer includes the following steps: on the same chamfered processing surface, reciprocating feed, the feed process parameters are F=300mm / min, S=4500r / min, P=0.25mm.

[0013] As a further improvement of the present invention, the span of the turning machine is at least 600 mm.

[0014] As a further improvement of the present invention, the turning tonnage of the turning machine is at least 3 tons.

[0015] As a further improvement of the present invention, the turning machine lifts the brick blank, including wrapping a sling around the middle of the brick blank, and then connecting the two ends of the sling to the turning machine with two lifting rings respectively.

[0016] As a further improvement of the present invention, the sling has a minimum load-bearing capacity of 5 tons.

[0017] The present invention has the following beneficial effects: This patent proposes a method for chamfering overflow bricks, clarifying the basic operational process, including placing the brick blank, selecting a tool, grinding the chamfer, and flipping the brick blank for further processing. This method provides new ideas and operational specifications for overflow brick chamfering, helping to improve processing efficiency and quality, and ensuring the dimensional accuracy and surface quality of the overflow brick chamfer.

[0018] Preferably, the pad bricks are made of refractory bricks, which have good high-temperature resistance. During the overflow brick processing, they can withstand the heat generated by the processing and prevent the pad bricks from being damaged by high temperature, thereby ensuring the stability of the brick embryo during the processing and avoiding the displacement of the brick embryo position due to pad brick problems, which affects the chamfering processing quality.

[0019] Preferably, a diamond tool with the size of 180*φ20*φ10*R5-25*120# is used. This tool is specifically selected, and its size and parameters can better adapt to the material and processing requirements of overflow bricks, improve tool durability and processing efficiency, reduce tool replacement frequency, lower production costs, and at the same time ensure the accuracy and quality of chamfering.

[0020] Preferably, use PFC80 water-soluble cutting fluid during the grinding process. This fluid has excellent cooling, lubricating, and cleaning properties, effectively reducing temperatures during machining, reducing friction between the tool and the brick, and increasing tool life. It also promptly flushes away machining debris, ensuring surface cleanliness and improving chamfer quality.

[0021] Preferably, chamfer grinding involves both tangential and normal feeds. Different feed methods can be flexibly selected based on the specific shape of the overflow brick and processing requirements. Tangential feed better adapts to the curved corners of the brick's outer wall, ensuring smoother contact between the tool and the workpiece and reducing impact. Normal feed may improve processing efficiency in certain situations. Combining multiple feed methods helps improve processing flexibility and adaptability, optimizing chamfering results.

[0022] Optimally, the feed rate is F = 300 mm / min, the spindle speed is S = 4500 r / min, and the depth of cut is P = 0.25 mm. These parameters, derived through practical application and optimization, ensure reasonable cutting forces between the tool and the brick during machining. This not only ensures machining efficiency but also avoids tool damage or reduced machining quality due to excessive cutting forces, ensuring dimensional accuracy and surface quality during chamfering.

[0023] Prioritize the minimum span of the tilting machine to be 600mm. A sufficient span ensures that the tilting machine has sufficient space and stability when lifting and tilting the bricks, avoiding the bricks shaking or colliding with the tilting machine during the tilting process due to insufficient span, ensuring the safety of the bricks and smooth processing.

[0024] Preferably, the turning machine has a turning capacity of at least 3 tons. Overflow brick blanks are usually heavy, and sufficient turning capacity ensures that the turning machine can safely and stably lift and turn the blanks, avoiding malfunctions or accidents caused by insufficient tonnage, thus ensuring the safety of the production process.

[0025] Preferably, a lifting method is defined in which a sling is wrapped around the middle of the brick blank, and the two ends of the sling are connected to the turning machine via two lifting rings. This lifting method ensures that the brick blank is evenly stressed during the lifting process, preventing deformation or damage to the brick blank due to uneven stress. At the same time, it ensures the stability of the brick blank during the turning process, facilitating subsequent chamfering.

[0026] Preferably, the lifting straps are designed to bear a minimum load of 5 tons. Overflow bricks are heavy, and sufficient load-bearing capacity ensures that the lifting straps will not break during the lifting process, ensuring safe transportation and turnover of the bricks, and guaranteeing the safety and reliability of the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present invention in any way. In addition, the shapes and proportional dimensions of the components in the drawings are merely schematic and are used to facilitate understanding of the present invention. They are not intended to limit the shapes and proportional dimensions of the components of the present invention. In the drawings: Figure 1 This is a step diagram of a method for processing overflow brick chamfering in Example 1; Figure 2 A side view of a tangential feed method for processing overflow brick chamfers in Example 1; Figure 3 A side view of a tangential feed method for processing overflow brick chamfers in Example 1; Figure 4 A top view of a tangential feed method for processing overflow brick chamfers in Example 1; Figure 5 A cutting tool used in a method for processing overflow brick chamfers in Examples 1 and 2; Figure 6 This is a side view of the normal feed of a method for processing overflow brick chamfers in Example 2.

[0028] Among them, 1. Diamond tool; 2. Overflow brick; 3. Pad brick. DETAILED DESCRIPTION

[0029] In order to enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of the present invention.

[0030] It should be noted that when an element is referred to as being "disposed on" another element, it may be directly on the other element or there may be an element centered thereon. When an element is referred to as being "connected to" another element, it may be directly connected to the other element or there may be an element centered thereon. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only embodiments.

[0031] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one skilled in the art to which this invention pertains. The terms used in this specification of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0032] Example 1 like Figure 1 As shown, this embodiment provides a method for processing the chamfer of an overflow brick 2, comprising the following steps: Place the overflow brick 2 horizontally on the pad brick; Select the appropriate type of diamond tool 1; At the outer corners of the large and small ends of one side of the brick, grind the chamfers with a tangential feed; Use a turning machine to lift the bricks and rotate them; At the outer wall corners of the large end and the small end on the other side of the brick, chamfers are ground with a tangential feed.

[0033] Specifically, the spacer bricks are made of refractory bricks. Refractory bricks have good high-temperature resistance and can withstand the heat generated during the processing of the overflow bricks 2, preventing the spacer bricks from being damaged by high temperatures. This ensures the stability of the brick embryo during processing and prevents the position of the brick embryo from being shifted due to spacer problems, thereby affecting the quality of chamfering.

[0034] Specifically, chamfer grinding with tangential feed includes using PFC80 water-soluble cutting fluid during the grinding process.

[0035] Specifically, tangential feed grinding chamfers involves the following steps: A reciprocating feed is made parallel to the chamfered surface. Because overflow bricks are made of high-density, hard material, they are heavy and brittle, making frequent adjustments difficult. Furthermore, the milling cutter can easily damage the tool itself and destroy the overflow bricks. To achieve optimal cutting results and maintain a certain level of efficiency, this method has undergone extensive cutting trials.

[0036] Table 1 Three-element test parameters and effects

[0037] As shown in the table above, for the three selected test parameters, when F300mm / min+S2000r / min+P0.1mm, the cutting depth is too shallow (0.1mm) and the spindle speed is low, resulting in the tool being unable to effectively cut into the material, resulting in a "cutting motion" phenomenon; when F300mm / min+S2000r / min+P0.5mm, the cutting depth is increased to 0.5mm, although cutting is possible, the efficiency is still low, indicating that the current speed and feed speed are not well matched, and the spindle speed needs to be increased or the feed rate needs to be adjusted. To improve the material removal rate; when F300mm / min+S3600r / min+P0.1mm, the cutting depth is insufficient at high speed, resulting in unstable contact between the tool and the workpiece, resulting in the surface quality problem of "slow plane unevenness", and it is necessary to balance the speed and cutting depth parameters; when F300mm / min+S3600r / min+P0.5mm, the high speed and large cutting depth combination induce vibration, and the feed rate is not synchronously optimized (still 300mm / min), resulting in cutting force fluctuations and "plane ripples." Preferably, the process parameters for feed are F=300mm / min, S=4500r / min, and P=0.25mm. F=300mm / min is the feed speed, S=4500r / min is the spindle speed, and P=0.25mm is the cutting depth. These parameters are obtained through practice and optimization, and can ensure that the cutting force between the tool and the brick is reasonable during the processing, which can not only ensure processing efficiency, but also avoid tool damage or processing quality degradation due to excessive cutting force, and ensure the dimensional accuracy and surface quality of chamfering. Figure 2-4 As shown, a side view and a top view of a tangential feed in a method for chamfering an overflow brick 2 in Example 1.

[0038] Specifically, the minimum span of the turning machine is 600mm. This minimum span is a minimum limit based on the dimensions of common overflow bricks 2. A sufficient span ensures the turning machine has sufficient space and stability when lifting and turning the brick blanks, preventing the brick blanks from shaking or colliding with the turning machine during the turning process due to insufficient span, thereby ensuring the safety of the brick blanks and smooth processing.

[0039] Specifically, the turning tonnage of the turning machine is at least 3 tons.

[0040] Specifically, the turning machine lifts the brick blank by wrapping a sling around the middle of the brick blank and then connecting the two ends of the sling to the turning machine with two lifting rings. This lifting method ensures that the brick blank is evenly stressed during the lifting process, preventing deformation or damage to the brick blank or the processed chamfered portion due to uneven force. It also ensures the stability of the brick blank during the turning process, facilitating subsequent chamfering.

[0041] Specifically, the slings must be able to bear a minimum load of 5 tons.

[0042] Specifically, the diamond tool 1 uses 180*φ20*φ10*R5-25*120#. This tool was specifically selected, with dimensions and parameters that best suit the material and processing requirements of the overflow brick 2. This improves tool durability and processing efficiency, reduces tool replacement frequency, and lowers production costs, while ensuring chamfer accuracy and quality. In actual processing, the tool type is optimized based on the workpiece shape, selecting a tool with a shorter shank, a shorter cutting section, and a smaller diamond particle size. For concave surfaces, ball-end cutters are preferred.

[0043] Example 2 The difference between this embodiment and embodiment 1 is that: Grind chamfers with normal infeed.

[0044] Specifically, the chamfer was ground with a normal feed, including the use of PFC80 water-soluble cutting fluid during the grinding process.

[0045] Specifically, if Figure 6 As shown in FIG, normal feed grinding chamfer includes the following steps: on the same chamfer processing surface, reciprocating feed is performed perpendicular to the chamfer processing surface, and the process parameters of feed are F=300mm / min, S=4500r / min, and P=0.25mm.

[0046] During the processing of various types of overflow bricks, after each process is completed, the wear of the diamond tool and the quality of the processed surface must be observed to determine whether the particle size of the tool's diamond surface meets the requirements for continued processing.

[0047] The comparison between the two embodiments is summarized as follows: Table 2 Comparison of parameters and effects of Examples 1 and 2

[0048] As shown in the table above, while tangential feed processing time is significantly shorter than normal feed, in Example 1, tangential feed took 69 minutes, while normal feed took 124 minutes, an efficiency improvement of approximately 44%. This is because tangential feed reduces the impact load on the tool and workpiece, making the cutting process smoother. However, it requires a longer tool path and is more time-consuming. Furthermore, observation of the chamfered edges of the G6 generation cover plate overflow bricks shows that both meet the requirements of subsequent processing.

[0049] Tools with a tangential feed (perpendicular to the work surface) can remain usable after machining, while tools with a normal feed require replacement. This is because tangential feed distributes cutting forces more evenly, avoiding severe localized wear. If abnormal tool wear occurs during machining, the steel of the toolholder can break, and the high-speed operation of the toolholder can contact the dense zirconium overflow brick, potentially posing a safety hazard. However, it should be noted that actual tool life is also affected by factors such as material hardness and cooling conditions.

[0050] According to the above analysis, both embodiments use the same cutting parameters (F=300mm / min, S=4500r / min, P=0.25mm), which shows that the difference in results mainly comes from the choice of feed method.

[0051] It is worth noting that both of the above-mentioned embodiments utilize traditional three-axis boring and milling equipment, eliminating the need for four- or five-axis equipment for chamfering. Furthermore, while the tangential feed method is limited to three axes in terms of feed path selection, the feed programming is simpler, making this processing method less challenging to apply. Previously, the chamfering procedures for the large and small ends of various overflow brick models involved cutting-line milling within the surface machining process within the programming software. The principle of diamond tool entry and exit was to reciprocate up and down through the gap outside the brick body. However, the tool would become stuck on the inclined surface during the descending step, and the upward machining step did not exist.

[0052] The technical challenge addressed by this patented invention lies in horizontally machining the chamfers at the front and flip sides of overflow bricks. Previously, these chamfers were processed using a φ10 x R5 diamond ball-end tool that moved back and forth along the outside of the product. This resulted in tool snagging during the lowering process. While the ball-end tool could achieve this, the hard and brittle nature of overflow bricks led to significant wear on the diamond tool. Once the diamond grit was reduced, contact between the base steel and the brick body could occur, posing a safety hazard.

[0053] Based on long-term machining experience and analysis of left-right tool paths for chamfering the four edges of the weir crest during vertical brick machining, this paper presents a new method for horizontally machining the upper surfaces of the front and flip sides of the large and small ends of G6-generation overflow cover bricks using a reciprocating tool path, without changing the machining area. Comparison of the finished product surface quality and performance demonstrated that the two tool paths achieved comparable machining times. However, observation of the finished surface of a φ10 x R5 diamond ball-end tool revealed that the reciprocating tool path reduced tool surface wear, extending tool life and reducing tool procurement costs. This new method for horizontally machining the chamfers of the large and small ends, front, and flip sides of overflow bricks with a reciprocating tool path eliminates the tool-jamming problem associated with vertical reciprocating tool paths and reduces the incidence of abnormal tool wear. It can be applied to all future overflow brick models for horizontal machining of the chamfers of the large and small ends, front, and flip sides of overflow bricks.

[0054] The above embodiment is only one of the implementation methods that can realize the technical solution of the present invention. The scope of protection claimed by the present invention is not limited only to this embodiment, but also includes changes, replacements and other implementation methods that can be easily thought of by any technician familiar with this technical field within the technical scope disclosed by the present invention.

Claims

1. A method for processing overflow brick chamfers, characterized in that: The following steps are involved: Place the overflow bricks horizontally on the pad bricks; Choose the right type of diamond tool; At the outer corners of the large and small ends of one side of the brick, grind the chamfers with a knife; Use a turning machine to lift the bricks and rotate them; At the outer corners of the large and small ends on the other side of the brick, the knife is fed in to grind and chamfer.

2. A method for processing overflow brick chamfers according to claim 1, characterized in that: The pad bricks are made of refractory bricks.

3. A method for processing overflow brick chamfers according to claim 2, characterized in that: The diamond tool is 180*φ20*φ10*R5-25*120#.

4. The method for processing overflow brick chamfers according to claim 1, characterized in that: The feed grinding and chamfering includes using PFC80 water-soluble cutting fluid during the grinding process.

5. The method for processing overflow brick chamfers according to claim 1, characterized in that: The feed grinding chamfer includes tangential feed and normal feed.

6. The method for processing overflow brick chamfers according to claim 1, characterized in that: The feed grinding and chamfering process comprises the following steps: On the same chamfering processing surface, the reciprocating feed is used, and the feed process parameters are F=300mm / min, S=4500r / min, and P=0.25mm.

7. The method for processing overflow brick chamfers according to claim 1, characterized in that: The span of the turning machine is at least 600 mm.

8. The method for processing overflow brick chamfers according to claim 1, characterized in that: The turning tonnage of the turning machine is at least 3 tons.

9. The method for processing overflow brick chamfers according to claim 1, characterized in that: The turning machine lifts the brick embryo, which includes wrapping a sling around the middle of the brick embryo, and then connecting the two ends of the sling with the turning machine through two lifting rings.

10. A method for processing overflow brick chamfers according to claim 9, characterized in that: The sling has a minimum load-bearing capacity of 5 tons.

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