Manufacturing method of high-surface-activity ceramic corundum abrasive

Abstract

The invention belongs to the technical field of ceramic corundum abrasives, and particularly relates to a high-surface-activity ceramic corundum abrasive manufacturing method which comprises the following steps: step 1, infiltrating a ceramic corundum abrasive for 1-2 hours by using a coupling agent diluent, continuously stirring the ceramic corundum abrasive in the infiltrating process to enable the ceramic corundum abrasive to be uniformly infiltrated, adhesion of the ceramic corundum abrasive is avoided; secondly, the infiltrated ceramic corundum abrasive is dried through a dryer at the set temperature of 80-85 DEG C, the ceramic corundum abrasive needs to be continuously stirred in the drying process, and adhesion of the ceramic corundum abrasive is avoided; and thirdly, the dried ceramic corundum abrasive is screened, bonded large particles are removed, and the high-surface-activity ceramic corundum abrasive is obtained.The high-surface-activity ceramic corundum abrasive has the beneficial effects that the wrapping capacity of a binding agent on the ceramic corundum abrasive is improved, and the service life of a grinding tool is prolonged.

Description

Technical Field

[0001] This invention belongs to the field of ceramic corundum abrasive technology, and in particular, a method for manufacturing highly surface-active ceramic corundum abrasive. Background Technology

[0002] Ceramic corundum abrasives have higher hardness, greater toughness, and finer crystal structure. These three factors determine that grinding tools made from ceramic corundum abrasives have better grinding efficiency, more accurate grinding dimensions, and more precise geometric tolerances.

[0003] Ceramic corundum grinding wheels are highly durable and have a long service life, which can be 2 to 10 times that of ordinary corundum grinding wheels. They have a low replacement frequency, which reduces auxiliary processing time and downtime. This is beneficial for the use of CNC automatic machine tools and the realization of automated production. Therefore, ceramic corundum grinding tools are increasingly widely used in bearing grinding, roll grinding and high-precision grinding.

[0004] However, because ceramic corundum abrasive is 5-10 times more expensive than ordinary corundum, it is generally added in the production of abrasives at a ratio of 20%-50%. The production process of ceramic corundum abrasive results in a smooth surface, poorer hydrophilicity than ordinary abrasive, and weaker adhesion to binders. This leads to uneven distribution of binders in the abrasive and inconsistent binder bridge thickness between ceramic corundum abrasive and ordinary abrasive, thereby reducing the performance of ceramic corundum abrasive.

[0005] Our company has over 20 years of experience in abrasive production and possesses strong technical capabilities. We have conducted effective chemical and physical analyses of ceramic corundum abrasives and developed a ceramic corundum abrasive with strong hydrophilicity and adhesion to binders. This allows for consistent binder bridge thickness between the ceramic corundum abrasive and ordinary abrasives in the grinding wheel, fully leveraging the advantages of ceramic corundum abrasives and improving the performance of ceramic corundum grinding wheels. Summary of the Invention

[0006] This method for manufacturing highly surface-active ceramic corundum abrasive is characterized by the following steps: The first step is to soak the ceramic corundum abrasive with a coupling agent dilution for 1-2 hours. During the soaking process, the ceramic corundum abrasive should be stirred continuously to ensure that it is evenly soaked and to prevent it from sticking together.

[0007] The second step is to dry the impregnated ceramic corundum abrasive in a dryer at a set temperature of 80-85℃. During the drying process, the ceramic corundum abrasive must be constantly stirred to prevent it from sticking together.

[0008] The third step involves sieving the dried ceramic corundum abrasive to remove large, adhered particles, resulting in highly surface-active ceramic corundum abrasive.

[0009] Preferably, in the first step, the coupling agent is diluted with pure water at a ratio of 1:2 to obtain a diluted coupling agent solution.

[0010] Preferably, in the first step, the ceramic corundum abrasive is weighed and placed into a mixer, and a coupling agent diluent is added at different ratios of 2%-8% according to the particle size of the ceramic corundum abrasive (F24-F100).

[0011] Preferably, the speed of the mixer is controlled so that the temperature of the ceramic corundum abrasive is 10-40℃ during mixing, ensuring uniform mixing and avoiding severe sticking of the abrasive due to overheating.

[0012] Preferably, in the second step, the dryer rotates at a speed of 30-35 RPM, which can dry the ceramic corundum evenly and prevent it from sticking together.

[0013] Furthermore, the coupling agent is a silane coupling agent.

[0014] The beneficial effect of this invention is to improve the binding ability of the binder on ceramic corundum abrasive, thereby increasing the service life of the abrasive. Detailed Implementation Example 1

[0015] A method for manufacturing highly surface-active ceramic corundum abrasive, characterized by comprising the following steps: The first step is to dilute the silane coupling agent with pure water at a ratio of 1:2 to obtain a coupling agent dilution. Weigh the ceramic corundum abrasive F100 and put it into a mixer. Add 8% of the coupling agent dilution and soak the ceramic corundum abrasive with the coupling agent dilution for 2 hours. During the soaking process, the ceramic corundum abrasive is continuously stirred by the mixer. The mixer speed is controlled to ensure that the temperature of the ceramic corundum abrasive is 10℃ during stirring, so as to ensure uniform stirring and avoid the abrasive from overheating and sticking.

[0016] The second step is to dry the impregnated ceramic corundum abrasive in a dryer set at 80°C. During the drying process, the ceramic corundum abrasive must be constantly stirred, and the dryer speed is 35 RPM to prevent the abrasive from sticking together.

[0017] The third step involves sieving the dried ceramic corundum abrasive to remove large, adhered particles, resulting in highly surface-active ceramic corundum abrasive.

[0018] A grinding wheel manufacturing company compared the performance of high surface activity ceramic corundum abrasive and grinding wheels made of ceramic corundum.

[0019] High surface activity ceramic corundum abrasive F100 Ceramic Corundum F100 Grinding mold specifications 1-500*26*203SG / WA F100 M V-50M / S 3 pieces 1-500*26*203 SG / WA F100 M V-50M / S 3 pieces Repair frequency 100 pieces / 110 pieces / 115 pieces 80 pieces / 80 pieces / 75 pieces Reasons for increased repair frequency Inconsistent abrasive shedding results in workpiece roughness exceeding the standard. workpiece quality Five workpieces are inspected every 50 pieces, and the dressing frequency and correction amount are set according to the pass rate of dimensional accuracy, tolerance range, and roughness. Five workpieces are inspected every 50 pieces, and the dressing frequency and correction amount are set according to the pass rate of dimensional accuracy, tolerance range, and roughness. trim amount 0.2 mm 0.2 mm Service life A total of 50,000 / 55,000 / 57,500 pieces were ground. A total of 40,000 pieces / 40,000 pieces / 37,500 pieces were ground. Example 2

[0020] A method for manufacturing highly surface-active ceramic corundum abrasive, characterized by comprising the following steps: The first step is to dilute the silane coupling agent with pure water at a ratio of 1:2 to obtain a coupling agent dilution. Weigh the ceramic corundum abrasive F80 and put it into a mixer. Add 6% of the coupling agent dilution and soak the ceramic corundum abrasive in the coupling agent dilution for 2 hours. During the soaking process, the ceramic corundum abrasive is continuously stirred by the mixer. The mixer speed is controlled to ensure that the temperature of the ceramic corundum abrasive is 15℃ during stirring, so as to ensure uniform stirring and avoid the abrasive from overheating and sticking.

[0021] The second step is to dry the impregnated ceramic corundum abrasive in a dryer set at 80°C. During the drying process, the ceramic corundum abrasive must be constantly stirred, and the dryer speed is 35 RPM to prevent the abrasive from sticking together.

[0022] The third step involves sieving the dried ceramic corundum abrasive to remove large, adhered particles, resulting in highly surface-active ceramic corundum abrasive.

[0023] A grinding wheel manufacturing company compared the performance of high surface activity ceramic corundum abrasive and grinding wheels made of ceramic corundum.

[0024] High surface activity ceramic corundum abrasive F80 Ceramic Corundum F80 Grinding mold specifications 1-50*40*20 SG / WA F80 L V-60M / S 3 pieces 1-50*40*20 SG / WA F80 L V-60M / S 3 pieces Repair frequency 150 pieces / 145 pieces / 150 pieces 100 pieces / 110 pieces / 100 pieces Reasons for increased repair frequency Inconsistent abrasive shedding causes workpieces to exceed tolerance limits and roughness standards. workpiece quality If all 5 pieces pass the initial inspection after each overhaul, mass production can begin. Every 20 pieces, 2 pieces are inspected. The overhaul frequency and correction amount are set based on the passability of dimensional accuracy, tolerance range, and roughness. If all 5 pieces pass the initial inspection after each overhaul, mass production can begin. Every 20 pieces, 2 pieces are inspected. The overhaul frequency and correction amount are set based on the passability of dimensional accuracy, tolerance range, and roughness. trim amount 0.2 mm 0.2 mm Service life A total of 20,000 / 19,500 / 20,000 pieces were ground. A total of 13,500 / 14,800 / 13,500 pieces were ground. Example 3

[0025] A method for manufacturing highly surface-active ceramic corundum abrasive, characterized by comprising the following steps: The first step involves diluting the silane coupling agent with pure water at a ratio of 1:2 to obtain a coupling agent dilution. Weigh the ceramic corundum abrasive F36 and place it in a mixer. Add 4% of the coupling agent dilution and soak the ceramic corundum abrasive in the dilution for 1.3 hours. During the soaking process, continuously stir the ceramic corundum abrasive with the mixer and control the mixer speed to ensure that the temperature of the ceramic corundum abrasive is maintained at 20°C during stirring, thus ensuring uniform stirring and preventing the abrasive from overheating and sticking together.

[0026] The second step is to dry the impregnated ceramic corundum abrasive in a dryer set at 80°C. During the drying process, the ceramic corundum abrasive must be constantly stirred, and the dryer speed is 32 RPM to prevent the abrasive from sticking together.

[0027] The third step involves sieving the dried ceramic corundum abrasive to remove large, adhered particles, resulting in highly surface-active ceramic corundum abrasive.

[0028] A grinding wheel manufacturing company compared the performance of high surface activity ceramic corundum abrasive and grinding wheels made of ceramic corundum.

[0029] High surface activity ceramic corundum abrasive F36 Ceramic Corundum F36 Grinding mold specifications 1-900*100*305 SG / PA F36 M B-50M / S 2 pieces 1-900*100*305 SG / PA F36 M B-50M / S 2 pieces Repair frequency Continuous trimming Continuous trimming workpiece quality For each inspection, the amount of trimming is set based on the pass / fail status of dimensional accuracy, tolerance range, and roughness. For each inspection, the amount of trimming is set based on the pass / fail status of dimensional accuracy, tolerance range, and roughness. trim amount 0.25 mm 0.3 mm Service life A total of 248 pieces / 256 pieces were ground. A total of 180 pieces / 176 pieces were ground. Example 4

[0030] A method for manufacturing highly surface-active ceramic corundum abrasive, characterized by comprising the following steps: The first step involves diluting the silane coupling agent with pure water at a ratio of 1:2 to obtain a diluted coupling agent solution. Weigh the ceramic corundum abrasive F24 and place it in a mixer. Add 2% of the diluted coupling agent solution and soak the ceramic corundum abrasive in the diluted coupling agent solution for 1.0 hour. During the soaking process, continuously stir the ceramic corundum abrasive with the mixer and control the mixer speed to ensure that the temperature of the ceramic corundum abrasive is 40℃ during stirring, thus ensuring uniform stirring and preventing the abrasive from overheating and sticking together.

[0031] The second step is to dry the impregnated ceramic corundum abrasive in a dryer set at 80°C. During the drying process, the ceramic corundum abrasive must be constantly stirred, and the dryer speed is 35 RPM to prevent the abrasive from sticking together.

[0032] The third step involves sieving the dried ceramic corundum abrasive to remove large, adhered particles, resulting in highly surface-active ceramic corundum abrasive.

[0033] A grinding wheel manufacturing company compared the performance of high surface activity ceramic corundum abrasive and grinding wheels made of ceramic corundum.

[0034] High surface activity ceramic corundum abrasive F24 Ceramic Corundum F24 Grinding mold specifications 1-750*75*305 SG / GC F24 M B-40M / S 3 pieces 1-750*75*305 SG / GC F24 M B-40M / S 3 pieces Repair frequency 6 pieces / 6 pieces / 5 pieces 4 pieces / 4 pieces / 3 pieces Reasons for increased repair frequency Inconsistent abrasive shedding caused the workpiece to exceed tolerance limits. workpiece quality For each inspection, the frequency of finishing and the amount of correction are set according to the pass rate of dimensional accuracy, tolerance range, and roughness. For each inspection, the frequency of finishing and the amount of correction are set according to the pass rate of dimensional accuracy, tolerance range, and roughness. trim amount 0.35 mm 0.35 mm Service life A total of 2072 / 2068 / 1750 pieces were ground. A total of 1560 / 1555 / 1200 pieces were ground. As can be seen from Examples 1 to 4 above, abrasives made with highly surface-active ceramic corundum abrasives have a longer service life.

Claims

1. A method for manufacturing a highly surface-active ceramic corundum abrasive, characterized in that, Includes the following steps: The first step is to soak the ceramic corundum abrasive with a coupling agent dilution for 1-2 hours. During the soaking process, the ceramic corundum abrasive should be stirred continuously to ensure that it is evenly soaked and to prevent it from sticking together. The second step is to dry the impregnated ceramic corundum abrasive by setting the temperature to 80-85℃ in a dryer. During the drying process, the ceramic corundum abrasive must be stirred continuously to prevent it from sticking together. The third step involves sieving the dried ceramic corundum abrasive to remove large, adhered particles, resulting in highly surface-active ceramic corundum abrasive.

2. The method for manufacturing a high surface activity ceramic corundum abrasive according to claim 1, characterized in that, In the first step, the coupling agent is diluted with pure water at a ratio of 1:2 to obtain a diluted coupling agent solution.

3. The method for manufacturing a high surface activity ceramic corundum abrasive according to claim 2, characterized in that, In the first step, weigh the ceramic corundum abrasive and put it into the mixer. Depending on the particle size of the ceramic corundum abrasive (F24-F100), add the coupling agent diluent at different ratios of 2%-8%.

4. The method for manufacturing a high surface activity ceramic corundum abrasive according to claim 3, characterized in that, Control the mixer speed to keep the temperature of the ceramic corundum abrasive at 10-40℃ during mixing, ensuring uniform mixing and preventing the abrasive from overheating and sticking together.

5. The method for manufacturing a highly surface-active ceramic corundum abrasive according to claim 4, characterized in that, In the second step, the dryer rotates at a speed of 30-35 RPM, which can dry the ceramic corundum evenly and prevent it from sticking together.

6. The method for manufacturing a high surface activity ceramic corundum abrasive according to claim 5, characterized in that, The coupling agent is a silane coupling agent.

7. The method for manufacturing a high surface activity ceramic corundum abrasive according to claim 6, characterized in that, Includes the following steps: The first step is to dilute the silane coupling agent with pure water at a ratio of 1:2 to obtain a coupling agent dilution. Weigh the ceramic corundum abrasive F100 and put it into a mixer. Add 8% of the coupling agent dilution and use the coupling agent dilution to wet the ceramic corundum abrasive for 2 hours. During the wettation process, the ceramic corundum abrasive is continuously stirred by the mixer. The speed of the mixer is controlled to keep the temperature of the ceramic corundum abrasive at 10°C during stirring, ensuring uniform stirring and avoiding severe adhesion of the abrasive due to overheating. The second step is to dry the impregnated ceramic corundum abrasive by setting the temperature to 80°C in a dryer. During the drying process, the ceramic corundum abrasive must be constantly stirred. The dryer speed is 35 RPM to prevent the abrasive from sticking together. The third step involves sieving the dried ceramic corundum abrasive to remove large, adhered particles, resulting in highly surface-active ceramic corundum abrasive.

8. The method for manufacturing a highly surface-active ceramic corundum abrasive according to claim 6, characterized in that, Includes the following steps: The first step is to dilute the silane coupling agent with pure water at a ratio of 1:2 to obtain a coupling agent dilution. Weigh the ceramic corundum abrasive F80 and put it into a mixer. Add 6% of the coupling agent dilution and use the coupling agent dilution to wet the ceramic corundum abrasive for 2 hours. During the wettation process, the ceramic corundum abrasive is continuously stirred by the mixer. The speed of the mixer is controlled so that the temperature of the ceramic corundum abrasive is maintained at 15℃ during stirring to ensure uniform stirring and avoid severe adhesion of the abrasive due to overheating. The second step is to dry the impregnated ceramic corundum abrasive by setting the temperature to 80°C in a dryer. During the drying process, the ceramic corundum abrasive must be constantly stirred. The dryer speed is 35 RPM to prevent the abrasive from sticking together. The third step involves sieving the dried ceramic corundum abrasive to remove large, adhered particles, resulting in highly surface-active ceramic corundum abrasive.

9. The method for manufacturing a high surface activity ceramic corundum abrasive according to claim 6, characterized in that, Includes the following steps: The first step is to dilute the silane coupling agent with pure water at a ratio of 1:2 to obtain a coupling agent dilution. Weigh the ceramic corundum abrasive F36 and put it into a mixer. Add 4% of the coupling agent dilution and use the coupling agent dilution to wet the ceramic corundum abrasive for 1.3 hours. During the wetting process, the ceramic corundum abrasive is continuously stirred by the mixer. The mixer speed is controlled to ensure that the temperature of the ceramic corundum abrasive is 20℃ during stirring, so as to ensure uniform stirring and avoid the abrasive from overheating and sticking. The second step is to dry the impregnated ceramic corundum abrasive by setting the temperature to 80℃ in a dryer. During the drying process, the ceramic corundum abrasive must be constantly stirred. The dryer speed is 32RPM to prevent the abrasive from sticking together. The third step involves sieving the dried ceramic corundum abrasive to remove large, adhered particles, resulting in highly surface-active ceramic corundum abrasive.

10. A method for manufacturing a highly surface-active ceramic corundum abrasive according to claim 6, characterized in that, Includes the following steps: The first step is to dilute the silane coupling agent with pure water at a ratio of 1:2 to obtain a coupling agent dilution. Weigh the ceramic corundum abrasive F24 and put it into a mixer. Add 2% of the coupling agent dilution and use the coupling agent dilution to wet the ceramic corundum abrasive for 1.0 hour. During the wetting process, the ceramic corundum abrasive is continuously stirred by the mixer. The speed of the mixer is controlled to ensure that the temperature of the ceramic corundum abrasive is 40℃ during stirring, so as to ensure uniform stirring and avoid the abrasive from overheating and sticking. The second step is to dry the impregnated ceramic corundum abrasive by setting the temperature to 80°C in a dryer. During the drying process, the ceramic corundum abrasive must be constantly stirred. The dryer speed is 35 RPM to prevent the abrasive from sticking together. The third step involves sieving the dried ceramic corundum abrasive to remove large, adhered particles, resulting in highly surface-active ceramic corundum abrasive.