Preparation of zirconia composite ceramic ball and polishing method thereof

Abstract

The application provides a zirconia composite ceramic ball preparation and polishing method. The zirconia composite ceramic ball has a self-abrasion of 0.001-0.1 g / kg·h, and Ra=0.02-0.5, and the abrasion resistance and service life of the grinding medium in product application are improved. The application also provides a preparation method of the high-performance zirconia composite ceramic ball, which adopts front-end zirconia ceramic surface polishing during the green body stage, and the polishing process is simple and the polishing effect is obvious, and the production efficiency is improved. The polishing material is convenient and easy to obtain, can achieve good surface polishing effect, will not damage the green body ball, and the polishing material can be repeatedly used to greatly reduce the production cost.

Description

Technical Field

[0001] This invention belongs to the field of materials, specifically relating to zirconia composite ceramic materials, and in particular, the preparation and polishing methods of zirconia composite ceramic spheres. Background Technology

[0002] The technological development of zirconia composite ceramic balls has always revolved around optimizing material performance, innovating processes, and expanding application scenarios. Zirconia ceramic beads stand out among many ceramic grinding media due to their outstanding advantages such as high strength, high hardness, excellent wear resistance, and corrosion resistance. They are highly favored by the ceramic industry and belong to high-end grinding materials. Their potential in new energy, biomedicine and other fields will be further released in the future.

[0003] Traditional process: The rolling forming method is used, but the surface of the green ball is uneven, which leads to a long polishing time in the later process, causing the zirconia material to age at low temperature, resulting in an increased wear rate of the grinding media.

[0004] Modern process: Titration molding method. The German titration process uses precise titration and high-temperature sintering (1300℃~1600℃) to make the porosity of zirconium beads less than 0.1% and the density more than 6.0g / cm³, and to form a "core-shell" gradient structure to balance wear resistance and toughness. However, the surface of titration molding has the disadvantage of pits, and it is also limited by the inability to produce large-size grinding media.

[0005] Isostatic pressing: Cold isostatic pressing can produce grinding media of any size with a diameter of 1 mm or more, and can control the consistency of size. However, the grinding media has poor sphericity and obvious burrs. The sintering density is relatively low. After sintering, the surface polishing causes low-temperature aging, which leads to an increase in wear rate.

[0006] To improve the grinding performance of zirconia composite ceramic balls, researchers have made some corresponding improvements. For example, after the zirconia composite ceramic balls are sintered at high temperature, a series of polishing methods are used, such as replacing the original polishing equipment with a sand mill and adjusting the type and ratio of polishing materials. After high-temperature sintering, the zirconia composite ceramic balls have high hardness. If the surface of the ceramic balls is smooth, the surface polishing time will be greatly reduced, thereby avoiding low-temperature aging and significantly reducing the wear of the zirconia composite ceramic balls. Summary of the Invention

[0007] Based on the problems existing in the prior art, the present invention polishes the green zirconia composite ceramic balls, which not only improves polishing efficiency, but also improves the sphericity of the zirconia composite ceramic balls, and enhances the wear resistance of the grinding media, thereby increasing production efficiency and meeting higher customer requirements.

[0008] The objective of this invention is achieved through the following measures:

[0009] A zirconia composite ceramic ball with a self-wear rate of 0.001-0.1 g / kg·h.

[0010] The zirconia composite ceramic spheres described above have a roughness Ra of 0.02 to 0.5. Preferably, the particle size of the zirconia composite ceramic spheres is 0.1-20.0 mm.

[0011] Another object of the present invention is to provide a polishing method for the above-mentioned zirconia composite ceramic balls.

[0012] The polishing method for the above-mentioned zirconia composite ceramic balls includes rough polishing, fine polishing, and high-precision polishing of the zirconia ceramic green body;

[0013] For rough polishing, zirconia ceramic powder with D50 of 10-50um and calcined at high temperature is used as the polishing material;

[0014] Fine polishing uses zirconia ceramic powder with a D50 of less than 10um that has been calcined at high temperature as the polishing material;

[0015] The fine polishing process uses a fine polishing slurry prepared with a fine polishing material. The fine polishing material is zirconia ceramic powder with a diameter of less than 5 μm that has been calcined at high temperature. The fine polishing slurry includes 2-20 wt% ceramic binder (preferably one or more of PVA, PVB, and CMC), 2-20 wt% fine polishing material, 0.1-1 wt% ceramic dispersant (preferably one or more of PAA, sodium hexametaphosphate, Triton, or PEG), and 59-95.9 wt% water. The raw material for preparing the polishing material is zirconia ceramic green body that has been pulverized to obtain powder with a D50 of less than 50 μm, which is then calcined at high temperature for 0.5-4 hours and allowed to cool naturally before use.

[0016] Preferably, the weight ratio of the above-mentioned zirconia ceramic green body to coarse polishing powder and fine polishing powder is 10: (1~5), and the weight ratio of the fine polishing liquid to the green body is 10: (0.3~3).

[0017] The above polishing is performed using a sugar coating machine linkage device. Within the sugar coating machine system, three polishing processes are performed sequentially: coarse polishing, fine polishing, and finishing polishing. The speed of coarse and fine polishing is 30-60 revolutions per minute, and the time is 5-30 minutes; the speed of finishing polishing is 40-70 revolutions per minute, and the time is 2-15 minutes.

[0018] The above polishing method can be achieved using a sugar coating machine linkage device, which consists of three sugar coating machines connected in series via flexible hoses. Preferably, the flexible hoses connecting the front and rear sugar coating machines are detachable, and the sugar coating machines are installed at an angle of 30-65 degrees to facilitate material flow. Each sugar coating machine includes: a base (1), an upper and lower regulating valve (2), a drum pot (3), an automatic fine grinding liquid spraying device (4), a sugar coating machine switch (5), a pot speed adjustment button (6), and a pot body interface (7) for installing screens and pipes. Figure 5As shown.

[0019] The aforementioned pot body interface for installing the screen and pipes includes two usage modes: when the drum of the coating machine is rotating for polishing, the pot body interface for installing the screen and pipes is plugged with a flat cover; when it is necessary to separate the material from the green balls, the flat cover plugging the pot body interface for installing the screen and pipes is removed, and a suitable screen and pipe are installed. After polishing, the polished green balls can flow directly into the storage device through the pipes on the pot body. Discharge is not only convenient but also does not damage the green balls, greatly improving production efficiency.

[0020] The aforementioned polishing equipment comprises three specific coating machines connected by pipes and screens. Different sized screens filter polishing materials of varying particle sizes to achieve three processes: coarse polishing, fine polishing, and high-precision polishing. Because green balls have low strength, if traditional methods are used to remove the polished green balls from the coating machine after coarse polishing, and then the polishing material is sieved out before being placed in another coating machine for fine polishing, many uncontrollable factors can cause damage to the inside and outside of the green balls. This invention, by adding screens and pipes to the coating machines, allows the polished green balls to be directly separated from the polishing material without damage, thus achieving efficient and rapid polishing.

[0021] Specifically, the polishing methods mentioned above include:

[0022] (1) Take the powder of ceramic green balls after it has been processed by a pulverizer, sieve the powder with a screen to obtain powder with a size of less than 50 μm, calcine at 800~1200℃ for 0.5~4 hours and then let it cool naturally before it can be used as a polishing material;

[0023] (2) Use a sieve to sieve 10-50um of the above polishing material for use as coarse polishing material;

[0024] (3) Use a sieve to sieve 5~15um of the above polishing material for use as fine polishing material;

[0025] (4) The fine polishing liquid is a fine polishing liquid prepared from fine polishing material. The fine polishing material is zirconia ceramic powder with a diameter of less than 5 μm that has been calcined at high temperature. The fine polishing liquid includes 2~20wt% ceramic binder, 2~20wt% fine polishing material, 0.1~1wt% ceramic dispersant, and 59~95.9wt% water.

[0026] Polishing materials for green balls from different sources can be obtained by repeating the above steps and replacing the required crushed powder with the green balls themselves.

[0027] Another object of the present invention is to provide a method for preparing the above-mentioned zirconia composite ceramic spheres.

[0028] In the above-mentioned method for preparing zirconia composite ceramic balls, the polishing is performed before the zirconia ceramic powder is greened.

[0029] The preparation method of the above-mentioned zirconia composite ceramic balls includes polishing material preparation, polishing, high-temperature sintering, and sand polishing.

[0030] The aforementioned zirconia composite ceramic powder can be prepared by various methods, including roll forming, dry pressing, and titration forming.

[0031] Specifically, the preparation method of the above-mentioned zirconia composite ceramic spheres includes the following steps:

[0032] S1. Polishing material preparation:

[0033] Step 1: Take the powder from the ceramic green balls after they have been processed by a pulverizer, sieve the powder with a diameter of less than 50 μm, calcine it at 800~1200℃ for 0.5~4 hours, and let it cool naturally before using it as a polishing material.

[0034] Step 2: Use a sieve to sieve 10-50µm of the above polishing material for use as coarse polishing material;

[0035] Step 3: Use a sieve to sieve 5~15um of the above polishing material for use as fine polishing material;

[0036] Step 4: The fine polishing liquid is a fine polishing liquid formulated with fine polishing material. The fine polishing material is zirconia ceramic powder with a diameter of less than 5 μm that has been calcined at high temperature. The fine polishing liquid includes 2~20wt% ceramic binder, 2~20wt% fine polishing material, 0.1~1wt% ceramic dispersant, and 59~95.9wt% water.

[0037] S2, Polishing:

[0038] Step 1: Take 40-80 kg of zirconia composite ceramic green pellets and place them in... Figure 4 Add 5-20 kg of the coarse polishing material mentioned above to the first sugar coating machine, adjust the speed of the sugar coating machine to 30-60 revolutions per minute, and rotate for 5-30 minutes;

[0039] Step 2: The coarse polishing material from the first sugar coating machine is transferred through pipes and screens to a second identical sugar coating machine for material separation.

[0040] Step 3: Add 5-15 kg of the fine polishing material mentioned above to the first coarse polishing sugar coating machine, adjust the speed of the sugar coating machine to 30-60 revolutions per minute, and rotate for 5-30 minutes;

[0041] Step 4: The fine polishing material from the sugar coating machine in step 3 is passed through pipes and screens to a third identical sugar coating machine for material separation.

[0042] Step 5: Add 0.5-3 kg of fine grinding liquid to the automatic spraying device of the first finely polished sugar coating machine, turn on the automatic spraying device of fine grinding liquid, adjust the speed of the sugar coating machine to 40-70 rpm, and polish for 2-15 minutes;

[0043] S3. The polished green balls are sintered at high temperature;

[0044] S4. The sintered grinding media is loaded into a sand mill for polishing. The polishing time is 1 to 6 hours to obtain zirconia composite ceramic balls.

[0045] Preferably, the ceramic binder of the present invention is one or more of PVA, PVB, and CMC; and the ceramic dispersant is one or more of PAA, sodium hexametaphosphate, Triton, and PEG.

[0046] Beneficial effects

[0047] 1. In the field of zirconia ceramic processing, the different forming characteristics of green spheres result in uneven surfaces and burrs on some green spheres. Polishing these defective green spheres after high-temperature sintering is time-consuming and labor-intensive, requiring more complex polishing processes and more polishing materials, and significantly increasing polishing time. This leads to low-temperature aging of the polishing media during the polishing process, thereby increasing wear. This invention achieves surface polishing of green spheres by formulating polishing materials with different particle sizes and proportions and using multiple polishing processes, such as adjusting the speed of the coating machine. Surface polishing of green spheres after sintering becomes easier, shortening the polishing time, thus avoiding low-temperature aging, resulting in lower wear on the finished product and significantly improved quality.

[0048] 2. The polishing material of the present invention is obtained by calcining zirconia composite ceramic green balls at 800~1200℃ after crushing. The material is readily available and the same chemical composition will not contaminate the material. The hardness of the polishing material is not too high for the green balls, so it can achieve a good surface polishing effect without damaging the green balls. Moreover, the polishing material can be reused, which greatly reduces the production cost.

[0049] 3. The structural properties of zirconia ceramic beads directly affect their performance in industrial production. Excessive surface roughness can impair the grinding performance of zirconia ceramic beads and significantly reduce their service life. As the application fields of zirconia ceramic beads continue to expand and deepen, the requirements for surface roughness in industrial production will become increasingly stringent. This invention employs front-end zirconia ceramics for surface polishing during the greening process, which not only simplifies the polishing process but also significantly improves the polishing effect. This is a concrete implementation of continuous improvement and optimization of the processing technology of zirconia ceramic beads, aiming to control and reduce surface roughness and improve the processing quality of zirconia ceramic beads. Attached Figure Description

[0050] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0051] Figure 1 , Figure 2 , Figure 3 SEM images of the green spheres of zirconia composite ceramic microspheres formed by three different molding methods of the present invention are shown respectively.

[0052] Figure 4 The invention illustrates a sugar coating machine linkage device consisting of three sugar coating machines connected in series.

[0053] Figure 5 A schematic diagram of a sugar coating machine with an automatic water spraying device according to the present invention is shown;

[0054] Figure 6 This is a flowchart of the preparation process;

[0055] Figure 7 The roughness test results of zirconia composite ceramic microspheres are shown. Detailed Implementation

[0056] The endpoints and any values ​​of the ranges disclosed in this invention are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed in this invention.

[0057] The technical solutions of the present invention will be clearly and completely described below with reference to specific embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0058] The following examples illustrate three different molding methods for zirconia composite ceramic green balls: green ball A prepared by rolling molding of a zirconia composite ceramic powder, green ball B prepared by dry pressing of a zirconia composite ceramic powder, and green ball C prepared by titration molding of a zirconia composite ceramic powder, were subjected to surface polishing tests.

[0059] Furthermore, the preparation method of the polishing material includes:

[0060] A certain amount of powder from type A, type B, and type C green pellets is processed by a pulverizer. The powder with a diameter of less than 50 μm is sieved through a sieve and then calcined at 800~1200℃ for 0.5~4 hours and naturally cooled before being used as a polishing material.

[0061] Furthermore, 10-50 μm of the above polishing material is sieved through a sieve and used as a coarse polishing material;

[0062] Further: Use a sieve to sieve 5~15um of the above polishing material for use as a fine polishing material;

[0063] Furthermore: the composition of the polishing slurry is a polishing slurry formulated with polishing material. The polishing material is zirconia ceramic powder with a diameter of less than 5 μm that has been calcined at high temperature. The polishing slurry includes 2~20wt% ceramic binder (PVA: 20~50%, PVB: 15~45%, CMC: 20~50%), 2~20wt% polishing material, 0.1~1wt% ceramic dispersant (PAA: 30~50%, sodium hexametaphosphate: 10~15%, Triton: 10~40%, PEG: 20~50%), and 59~95.9wt% water.

[0064] This embodiment also provides the following: green spheres A, B, and C prepared by rolling molding of a zirconia composite ceramic powder; green sphere B, B, and C prepared by dry pressing of a zirconia composite ceramic powder; and green sphere C prepared by titration molding of a zirconia composite ceramic powder. The embodiments also include zirconia composite ceramic spheres A, B, and C after polishing and sintering, and A1, B1, and C1 after sintering without polishing. Furthermore, the zirconia composite ceramic spheres A, B, C, and A1, B1, and C1 after sintering were polished using the same method, and their surface roughness and wear were compared and analyzed.

[0065] Example 1

[0066] The polishing steps for green sphere A, prepared from zirconia composite ceramic powder by roll forming, are as follows:

[0067] S1. Polishing material preparation:

[0068] Step 1: Take 50 kg of self-produced green balls A, process them into powder using a pulverizer, sieve the powder with a median diameter D50 of 20 μm, calcine it at 1000℃ for two hours, and then let it cool naturally. The resulting powder can be used as a polishing material.

[0069] Step 2: Use a sieve to sift 15 kg of the above-mentioned polishing material with a D50 of 10-20 μm, and use it as coarse polishing material;

[0070] Step 3: Use a sieve to sieve 15 kg of the above polishing material with a D50 of less than 10 μm, and use it as a fine polishing material.

[0071] Step 4: The fine polishing slurry consists of 10% PVA, 10% powder with a median diameter D50 of 5µm (green pellet A is crushed and then calcined at 1000℃), 79.9% industrial pure water by mass, and 0.1% ceramic dispersant PAA.

[0072] S2, in Figure 4 Polishing is performed in the linked equipment of the sugar coating machine shown:

[0073] Step 1: Take another 50 kg of green clay ball A and place it in... Figure 4 Add 15 kg of the coarse polishing material mentioned above to the first sugar coating machine, adjust the speed of the sugar coating machine to 50 rpm, and rotate for 10 minutes;

[0074] Step 2: Separate the coarse polishing material from the first sugar coating machine and flow it through pipes and screens to the second sugar coating machine;

[0075] Step 3: Add 15 kg of the fine polishing material mentioned above to the first coarse polishing sugar coating machine, adjust the speed of the sugar coating machine to 50 rpm, and rotate for 10 minutes.

[0076] Step 4: Separate the fine polishing material from the sugar coating machine in step 3, and let the fine polishing material flow through pipes and screens to the third sugar coating machine;

[0077] Step 5: Add an appropriate amount of fine grinding liquid to the automatic spraying device of the first finely polished sugar coating machine, turn on the automatic spraying device of fine grinding liquid, adjust the speed of the sugar coating machine to 50 revolutions per minute, and polish for 5 minutes.

[0078] S3. Take out the polished green balls from the first sugar coating machine and sinter them at 1450℃ for 2 hours;

[0079] S4. Polish the sintered green balls in a sand mill for 3 hours to obtain zirconia composite ceramic balls A;

[0080] S5. The zirconia composite ceramic ball A was subjected to a wear test in a sand mill.

[0081] Example 2

[0082] The polishing steps for green sphere B, prepared from zirconia composite ceramic powder by dry pressing, are as follows.

[0083] S1. Polishing material preparation:

[0084] Step 1: Take 50 kg of self-produced green balls B, process them into powder using a crusher, sieve the powder with D50 at 20 μm, calcine it at 1000℃ for two hours, and then let it cool naturally. The resulting powder can be used as a polishing material.

[0085] Step 2: Use a sieve to sift 15 kg of the above-mentioned polishing material with a D50 of 10-20 μm, and use it as coarse polishing material;

[0086] Step 3: Use a sieve to sieve 15 kg of the above polishing material with a D50 of less than 10 μm, and use it as a fine polishing material.

[0087] Step 4: The fine polishing slurry consists of 10% PVA, 10% powder with a median diameter D50 of 5µm (green pellet A is crushed and then calcined at 1000℃), 79.9% industrial pure water by mass, and 0.1% ceramic dispersant PAA.

[0088] S2, in Figure 4 Polishing is performed in the linked equipment of the sugar coating machine shown:

[0089] Step 1: Take another 50 kg of green clay ball A and place it in... Figure 4 Add 15 kg of the coarse polishing material mentioned above to the first sugar coating machine, adjust the speed of the sugar coating machine to 50 rpm, and rotate for 10 minutes;

[0090] Step 2: Separate the coarse polishing material from the first sugar coating machine and flow it through pipes and screens to the second sugar coating machine;

[0091] Step 3: Add 15 kg of the fine polishing material mentioned above to the first coarse polishing sugar coating machine, adjust the speed of the sugar coating machine to 50 rpm, and rotate for 10 minutes.

[0092] Step 4: Separate the fine polishing material from the sugar coating machine in step 3, and let the fine polishing material flow through pipes and screens to the third sugar coating machine;

[0093] Step 5: Add an appropriate amount of fine grinding liquid to the automatic spraying device of the first finely polished sugar coating machine, turn on the automatic spraying device of fine grinding liquid, adjust the speed of the sugar coating machine to 50 revolutions per minute, and polish for 5 minutes.

[0094] S3. The polished green balls are sintered at 1450℃ for 2 hours.

[0095] S4. Polish the sintered green balls in a sand mill for 3 hours to obtain zirconia composite ceramic balls B.

[0096] S5. The zirconia composite ceramic ball B was subjected to wear test in a sand mill.

[0097] Example 3

[0098] The polishing steps for green sphere C obtained by titration molding of zirconia composite ceramic powder are as follows.

[0099] S1. Polishing material preparation:

[0100] Step 1: Take 50 kg of self-produced raw embryo balls C, process them into powder using a pulverizer, sieve the powder with D50 at 20 μm, calcine it at 1000℃ for two hours, and then let it cool naturally. The resulting powder can be used as a polishing material.

[0101] Step 2: Use a sieve to sift 15 kg of the above-mentioned polishing material with a D50 of 10-20 μm, and use it as coarse polishing material;

[0102] Step 3: Use a sieve to sieve 15 kg of the above polishing material with a D50 of less than 10 μm, and use it as a fine polishing material.

[0103] Step 4: The fine polishing slurry consists of 10% PVA, 10% powder with a median diameter D50 of 5µm (green pellet A is crushed and then calcined at 1000℃), 79.9% industrial pure water by mass, and 0.1% ceramic dispersant PAA.

[0104] S2, in Figure 4 Polishing is performed in the linked equipment of the sugar coating machine shown:

[0105] Step 1: Take another 50 kg of green clay ball A and place it in... Figure 4 Add 15 kg of the coarse polishing material mentioned above to the first sugar coating machine, adjust the speed of the sugar coating machine to 50 rpm, and rotate for 10 minutes;

[0106] Step 2: Separate the coarse polishing material from the first sugar coating machine and flow it through pipes and screens to the second sugar coating machine;

[0107] Step 3: Add 15 kg of the fine polishing material mentioned above to the first coarse polishing sugar coating machine, adjust the speed of the sugar coating machine to 50 rpm, and rotate for 10 minutes.

[0108] Step 4: Separate the fine polishing material from the sugar coating machine in step 3, and let the fine polishing material flow through pipes and screens to the third sugar coating machine;

[0109] Step 5: Add an appropriate amount of fine grinding liquid to the automatic spraying device of the first finely polished sugar coating machine, turn on the automatic spraying device of fine grinding liquid, adjust the speed of the sugar coating machine to 50 revolutions per minute, and polish for 5 minutes.

[0110] S3. The polished green balls are sintered at 1450℃ for 2 hours.

[0111] S4. Polish the sintered green balls in a sand mill for 3 hours to obtain zirconia composite ceramic balls C.

[0112] S5. The zirconia composite ceramic ball C was subjected to wear test and roughness test in a sand mill.

[0113] Zirconia composite ceramic green sphere A, with a relatively rough surface, such as Figure 1 As shown, the surface of the zirconia composite ceramic green sphere B has relatively obvious pressed burrs, such as... Figure 2 As shown, the zirconia composite ceramic green sphere C has an uneven surface. Figure 3 As shown.

[0114] Comparative Example 1

[0115] A green sphere A prepared by rolling molding of zirconia composite ceramic powder is basically the same as that in Example 1, except that the green sphere prepared by rolling molding of zirconia composite ceramic powder does not require a green sphere polishing step.

[0116] S1. A green ball A, prepared by rolling molding of a zirconia composite ceramic powder, is sintered at 1450℃ for hours.

[0117] S2. Polish the sintered green balls in a sand mill for 3 hours to obtain zirconia composite ceramic balls A1.

[0118] S3. The zirconia composite ceramic ball A1 was subjected to wear test in a sand mill.

[0119] Comparative Example 2

[0120] A green sphere B prepared by dry pressing of a zirconia composite ceramic powder is basically the same as that in Example 1, except that the green sphere prepared by dry pressing of the zirconia composite ceramic powder does not require a green sphere polishing step.

[0121] S1. A green ball B prepared by dry pressing of a zirconia composite ceramic powder is sintered at 1450℃ for 2 hours.

[0122] S2. Polish the sintered green balls in a sand mill for 3 hours to obtain zirconia composite ceramic balls A1.

[0123] S3. The zirconia composite ceramic ball B1 was subjected to wear test in a sand mill.

[0124] Comparative Example 3

[0125] The green sphere C prepared by titration molding of a zirconia composite ceramic powder is basically the same as that in Example 1, except that the green sphere prepared by titration molding of a zirconia composite ceramic powder does not require a green sphere polishing step.

[0126] S1. Green pellets C, prepared by titration molding of a zirconia composite ceramic powder, are sintered at 1450℃ for 2 hours.

[0127] S2. Polish the sintered green balls in a sand mill for 3 hours to obtain zirconia composite ceramic balls A1.

[0128] S3. The zirconia composite ceramic ball C1 was subjected to wear test in a sand mill.

[0129] The self-wear test of the zirconia composite ceramic microspheres prepared in the examples and comparative examples was carried out in accordance with the standard JC / T 2136-2012 "Microcrystalline Zirconia Abrasive Media Balls"; the surface roughness of the zirconia beads was determined by using national standard marking and observing the surface roughness under a scanning electron microscope; these results are shown in Table 1.

[0130] Table 1. Wear test results of zirconia composite ceramic microspheres

[0131] ,

[0132] from Figure 7 The test results show that the zirconia composite ceramic microspheres prepared in Examples 1 to 3 of the present invention have lower self-wear compared with Comparative Examples 1 to 3. Figure 7 The roughness test results of zirconia composite ceramic microspheres show that, under the same polishing conditions, the surfaces of zirconia ceramic beads A, B, and C that were polished from green spheres are smoother, while the surfaces of comparative examples A1, B1, and C1 are rougher.

[0133] Zirconia ceramic beads directly impact their performance in industrial production. Excessive surface roughness can affect the grinding performance of zirconia ceramic beads and significantly reduce their service life. In future industrial production, as the application fields of zirconia ceramic beads continue to expand and deepen, the requirements for surface roughness will become increasingly stringent. This invention utilizes front-end zirconia ceramics for surface polishing during the greening process, which not only simplifies the polishing process but also yields significant polishing results. This is a concrete implementation of continuous improvement and optimization of the processing technology of zirconia ceramic beads, aiming to control and reduce surface roughness and improve the processing quality of zirconia ceramic beads. This represents an important technical challenge and a direction for development.

[0134] Zirconia ceramic beads are commonly used in ink production to grind ink raw materials to the required particle size. After the wear of zirconia ceramic beads is reduced, impurities introduced into the ink due to the wear of the grinding media can be significantly reduced, thereby improving the purity of the ink. (The ink products were ground to the same particle size under the same conditions using zirconia beads from Example 1 and Comparative Example 1. The ink purity was tested as follows: the ink purity using zirconia beads from Example 1 was 99.98%, and the ink purity using zirconia beads from Comparative Example 1 was 99.37%).

[0135] Zirconia ceramic beads can also be used in ceramic bearings. When the wear resistance of the ceramic beads is improved, the service life of the bearing can be increased.

[0136] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A polishing method for preparing zirconia composite ceramic spheres, characterized in that: The self-wear of the zirconia composite ceramic balls is 0.001-0.1 g / kg·h; the roughness Ra of the zirconia composite ceramic balls is 0.02~0.5; the particle size of the zirconia composite ceramic balls is 0.1-20.0 mm. The polishing method includes rough polishing, fine polishing, and high-precision polishing of the zirconia ceramic green body; The coarse polishing material uses zirconia ceramic powder with a D50 of 10-50um that has been calcined at high temperature; The fine polishing material uses zirconia ceramic powder with a D50 of less than 10um that has been calcined at high temperature; The polishing fluid is formulated with zirconia ceramic powder with a D50 of less than 5µm that has been calcined at high temperature. The raw material for preparing the polishing material is zirconia ceramic green balls that have been crushed by a pulverizer and have a D50 of 20 μm or less. The powder is then calcined at high temperature for 2 hours and cooled. The weight ratio of the zirconia ceramic green balls to the coarse polishing powder and the fine polishing powder is 10:(1~5), and the weight ratio of the zirconia ceramic green balls to the fine polishing liquid is 10:(0.3~3).

2. The polishing method for the zirconia composite ceramic balls as described in claim 1, characterized in that: The polishing process employs a sugar coating machine linkage device, which sequentially performs three polishing stages: coarse polishing, fine polishing, and high polishing. The coarse and fine polishing stages involve rotation speeds of 30-60 revolutions per minute and a time of 5-30 minutes; the high polishing stages involve rotation speeds of 40-70 revolutions per minute and a time of 2-15 minutes.

3. The polishing method for the zirconia composite ceramic balls as described in claim 2, characterized in that: The sugar coating machine linkage equipment consists of three sugar coating machines connected in series via flexible hoses. The flexible hoses connecting the front and rear sugar coating machines are detachable, with an inclination angle of 30 to 65 degrees. Each sugar coating machine includes: a base (1), an upper and lower regulating valve (2), a drum pot (3), an automatic spraying device for fine grinding liquid (4), a sugar coating machine switch (5), a pot speed adjustment button (6), and a pot body interface (7) for installing screens and pipes. The pot body interface for installing screens and pipes has two usage modes: when the drum pot of the sugar coating machine is rotating and polishing, the inside of the pot body interface for installing screens and pipes is plugged with a flat cover; when it is necessary to separate the material from the raw balls, the flat cover plugging the pot body interface for installing screens and pipes is removed, and a suitable screen and pipe are installed.

4. The polishing method for the zirconia composite ceramic spheres as described in claim 1, characterized in that: include: (1) Take the powder of ceramic green balls after it has been processed by a pulverizer, sieve the powder with a screen to obtain powder with a size of less than 50 μm, calcine at 800~1200℃ for 0.5~4 hours and then let it cool naturally before it can be used as a polishing material; (2) Use a sieve to sieve 10-50um polishing material for use as coarse polishing material; (3) Use a sieve to sieve 5~15um polishing material for use as fine polishing material; (4) The polishing liquid is prepared from polishing material. The polishing material is zirconia ceramic powder with a diameter of less than 5 μm that has been calcined at high temperature and screened by a sieve. The polishing liquid includes 2~20wt% ceramic binder, 2~20wt% polishing material, 0.1~1wt% ceramic dispersant, and 59~95.9wt% water. The ceramic binder is one or more of PVA, PVB, and CMC. The ceramic dispersant is one or more of PAA, sodium hexametaphosphate, Triton, and PEG.

5. A method for preparing zirconia composite ceramic spheres, characterized in that: Polishing as described in claim 1 is performed before the zirconium oxide ceramic powder is greened.

6. The method for preparing zirconia composite ceramic spheres as described in claim 5, characterized in that: The process includes polishing material preparation, polishing, high-temperature sintering, and sand polishing; the zirconia composite ceramic powder is prepared by methods including rolling molding, dry pressing, or titration molding.

7. The method for preparing zirconia composite ceramic spheres as described in claim 5, characterized in that: Includes the following steps: S1. Polishing material preparation: Step 1: Take the powder from the ceramic green balls after they have been processed by a pulverizer, sieve the powder with a screen to obtain powder smaller than 50μm, and then calcine and let it cool naturally before using it as a polishing material; Step 2: Use a sieve to sift out 10-50µm polishing material for use as coarse polishing material; Step 3: Use a sieve to sift out 5~15um polishing material for use as fine polishing material; Step 4: The fine polishing liquid is a fine polishing liquid formulated with fine polishing material, which is zirconia ceramic powder with a diameter of less than 5μm that has been calcined at high temperature; S2, Polishing: Step 1: Place the zirconia composite ceramic green ball into the first sugar coating machine in the sugar coating machine linkage equipment, and add the coarse polishing material mentioned above; Step 2: Separate the coarse polishing material from the first sugar coating machine. The coarse polishing material is then transferred through pipes and screens to the second sugar coating machine for material separation. Step 3: Add the fine polishing material to the first coarsely polished sugar coating machine; Step 4: Separate the fine polishing material from the sugar coating machine in step 3. The fine polishing material is then transferred through pipes and screens to the third sugar coating machine for material separation. Step 5: Add polishing liquid to the automatic spraying device of the first finely polished sugar coating machine, and turn on the automatic spraying device for polishing liquid; S3. The polished green balls are sintered at high temperature; S4. The sintered grinding media is loaded into a sand mill for polishing to obtain zirconia composite ceramic balls.

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