Orderly-arranged vacuum brazing diamond grinding tool and production process thereof

Abstract

The invention provides an orderly-arranged vacuum brazing diamond grinding tool and a production process thereof. The grinding tool comprises a metal base body, and a mounting hole coaxial with the axis of the base body is formed in the center of the base body; a grinding surface is arranged on the base body, and diamond particles are fixedly arranged on the grinding surface through a brazing layer; the production process comprises the following steps: coating a low-temperature volatile adhesive on a substrate and adhering brazing filler metal alloy powder, then coating the brazing filler metal alloy powder with the low-temperature volatile adhesive again, covering the brazing filler metal alloy powder with a high-temperature-resistant ceramic plate provided with a plurality of through holes with the diameter D of 1.05 d5d (d is the diamond particle size), and quickly spreading diamond particles with corresponding specifications, and finally, a profiling pressing plate is pressed and covered, and precise positioning of the base body, the brazing filler metal and the diamond is formed. According to the technical scheme provided by the invention, the problem of uneven distribution of grinding materials in the grinding tool is fundamentally solved, and then real uniform and patterned distribution is realized, so that each diamond is uniformly stressed in the grinding process of the grinding tool, and local overheating and abnormal wear are avoided.

Description

Technical Field

[0001] This invention belongs to the field of abrasive technology, specifically relating to an ordered arrangement of vacuum brazed diamond abrasives and its manufacturing process. Background Technology

[0002] Diamond tools occupy an irreplaceable position in the machining of hard and brittle materials due to their excellent grinding performance. Currently, the vast majority of diamond tools are manufactured using processes with randomly arranged abrasive particles, such as electroplating, sintering, or brazing, to randomly fix diamond particles onto the tool's working surface. This traditional method of random arrangement has a series of inherent drawbacks: 1. Unstable grinding performance: Uneven abrasive distribution results in "dense" and "sparse" areas on the tool's working surface. During grinding, dense areas are prone to overheating and burning the workpiece surface, while sparse areas experience increased wear and shedding due to excessive force on individual abrasive grains, making it difficult to control machining accuracy and surface quality. 2. Low material utilization: To ensure sufficient abrasive coverage on the working surface, excessive diamonds need to be spread during production, resulting in a large amount of diamonds being wasted in ineffective working areas or overlapping, leading to high costs. 3. Short tool life: Disordered arrangement makes the chip space between abrasive grains irregular, easily causing chip blockage. More importantly, when a piece of abrasive falls off, it immediately causes adjacent abrasive grains to bear several times the additional load, thus triggering a chain reaction of shedding, causing the tool to fail rapidly and significantly shortening its service life. 4. Poor process controllability: The distribution, exposure height, and spacing of abrasive grains are random, making it impossible to optimize the design according to specific machining conditions (such as rough grinding and fine grinding). Tool performance is highly dependent on operating experience, resulting in poor consistency.

[0003] Therefore, there is an urgent need in this field for a new grinding wheel and device that is compatible with high-temperature brazing processes and can achieve efficient, precise, and uniform diamond arrangement. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing technologies by providing an orderly arranged vacuum brazed diamond abrasive tool and its manufacturing process, the specific solution of which is as follows: An ordered arrangement of vacuum brazed diamond abrasives includes a metal substrate with a mounting hole coaxial with its axis at the center; a grinding surface is provided on the substrate, and diamond particles are fixed on the grinding surface through a brazing layer.

[0005] Based on the above, the substrate is disc-shaped, with a mounting hole coaxial with its axis at the center, and a grinding surface on one side of the substrate, on which multiple diamond particles are fixed in an orderly arrangement through a brazing layer.

[0006] Based on the above, the substrate is a cylindrical shape with one end open, and a mounting hole coaxial with its axis is provided at the center of the other end of the substrate. The side of the substrate is a grinding surface, and multiple diamond particles arranged in an orderly manner are fixed on the grinding surface through a brazing layer.

[0007] The production process of vacuum brazed diamond abrasives with orderly arrangement, as described above, is characterized by the following steps: Step 1: First, apply a low-temperature volatile adhesive to the grinding surface; Step 2: Evenly adhere the brazing alloy powder to the adhesive layer, and then coat the brazing powder with a low-temperature volatile adhesive again; Step 3: Based on the shape of the substrate, cover the brazing alloy powder with one or more alumina / alumina nitride-based high-temperature resistant ceramic templates. The high-temperature resistant ceramic templates are evenly distributed with multiple orderly arranged through holes. The diameter of the through holes is D=1.05d-5d, where d is the diamond abrasive particle size. In addition, the spacing between the through holes in the high-temperature resistant ceramic templates is P=3*D, and the thickness T of the high-temperature resistant ceramic templates satisfies T=m*d, where m is in the range of 1.2-5.2. Step 4: Sprinkle diamonds on the surface of the high-temperature ceramic template, so that the diamonds fall into the through holes and adhere to the adhesive on the surface of the brazing filler powder. Then rotate the substrate and the high-temperature ceramic template to allow the excess diamond particles to fall off naturally. Step 5: Cover one or more contouring plates on the high-temperature resistant ceramic template and apply appropriate pressure to make them fit together with the high-temperature resistant ceramic template to obtain the fired part; Step 6: Place the product obtained in Step 5 into a vacuum brazing furnace to complete the "substrate-brazing filler metal-diamond" welding; Step 7: Take out the product obtained in Step 6, and then remove the contour plate and the high-temperature ceramic contour template in sequence to obtain the final mold product.

[0008] This invention has outstanding substantive features and significant progress compared to the prior art. Specifically, this invention has the following advantages: 1. The grinding wheel produced by the technical solution of this invention fundamentally solves the problem of uneven abrasive distribution in the grinding wheel: through the arrangement of precision through holes on the high-temperature resistant ceramic template, the diamond is forced to be positioned in the preset position, thereby achieving true uniform and patterned arrangement. This makes each diamond uniformly stressed during the grinding process, avoiding local overheating and abnormal wear, and ensuring grinding accuracy and surface quality of the workpiece.

[0009] 2. The abrasive produced by the technical solution of this invention greatly improves the diamond utilization rate: because each abrasive can be precisely arranged, the accumulation and waste of diamonds are avoided, and the material utilization rate can be increased from about 70% of disordered arrangement to more than 95%, which significantly reduces the production cost. 3. The abrasives produced by the technical solution of this invention significantly extend the tool life: uniform arrangement means uniform load distribution and reasonable chip space. When a diamond abrasive wears, the surrounding abrasives will not be severely impacted, effectively suppressing the chain-reaction shedding effect. Experiments show that the life of the grinding wheel manufactured by this method can be extended by 30%-50% compared with the disordered arrangement of grinding wheels; 4. The grinding tools produced by the technical solution of this invention have customizable performance: By changing the through hole spacing P of the high-temperature resistant ceramic template, the distribution density of diamond can be flexibly designed, thereby manufacturing special tools for different application scenarios such as coarse grinding (low density) and fine grinding (high density), which cannot be achieved by disordered arrangement. 5. The abrasive produced by the technical solution of this invention is highly efficient and compatible with existing production lines: the entire arrangement process is fast and can be operated in batches, with efficiency far exceeding that of robot arrangement of each piece, and it is fully adapted to the standard vacuum brazing process, making it easy to industrialize. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of the structure of Embodiment 1 of the present invention; Figure 2 This is a schematic diagram of the structure of Embodiment 2 of the present invention; In the figure: 1. Substrate; 1-1. Mounting hole; 2. High temperature resistant ceramic template; 2-1. Through hole; 3. Template pressure plate. Detailed Implementation

[0011] The technical solution of the present invention will be further described in detail below through specific embodiments.

[0012] Example 1 like Figure 1 As shown, the present invention provides an ordered arrangement of vacuum brazed diamond abrasive, including a base 1 made of 45# steel, wherein the base 1 has a mounting hole 1-1 coaxial with its axis at the center position; the base 1 has a grinding surface, and diamond particles are fixed on the grinding surface through a brazing layer.

[0013] The aforementioned substrate 1 is disc-shaped, with a mounting hole 1-1 coaxial with its axis at the center of the substrate 1. One side of the substrate 1 has an annular surface that is a grinding surface, and multiple diamond particles arranged in an orderly manner are fixed on the grinding surface through a brazing layer. Here, the diameter of the substrate 1 is 150mm.

[0014] The production process of vacuum brazed diamond abrasives with orderly arrangement, as described above, is characterized by the following steps: Step 1: First, ultrasonically clean the substrate 1 for 15 minutes to remove oil stains. Then, use brown corundum that has passed through a 120-mesh sieve to sandblast the grinding surface of the substrate 1 to increase the surface roughness, Ra=3.2μm. Apply a low-temperature volatile adhesive to the grinding surface with a thickness of 0.1mm. Step 2: Evenly adhere the brazing alloy powder to the adhesive layer. Here, the brazing alloy powder used is Ag-Cu-Ti alloy with a particle size of 200 mesh. The specific adhesion method is to press the substrate 1 coated with adhesive onto the brazing powder with a pressure of 0.05 MPa and hold the pressure for 10 seconds to make the brazing alloy evenly embedded in the adhesive layer; then coat the brazing powder with a low-temperature volatile adhesive again. Step 3: Based on the shape of the substrate 1, cover the brazing alloy powder with one or more alumina / alumina nitride-based high-temperature resistant ceramic templates 2. The high-temperature resistant ceramic template 2 has multiple orderly arranged through holes 2-1, the diameter of which is D=1.05d-5d, where d is the diamond abrasive particle size. In addition, the spacing P of the through holes 2-1 in the high-temperature resistant ceramic template 2 is 3*D, and the thickness T of the high-temperature resistant ceramic template 2 satisfies T=m*d, where m is in the range of 1.2-5.2. Here, the diamond particle size is d=0.355mm, the diameter D of the through holes 2-1 is designed to be 0.42mm, the thickness T of the high-temperature resistant ceramic template 2 is designed to be 2.1mm, and the size of the spacing P of the through holes 2-1 is designed to be 1.278mm. Step 4: Sprinkle diamonds on the surface of the high-temperature ceramic template 2, so that the diamonds fall into the through hole 2-1 and adhere to the adhesive on the surface of the brazing filler powder. Then rotate the substrate 1 and the high-temperature ceramic template 2 to allow the excess diamond particles to fall off naturally. Step 5: Cover one or more contouring pressure plates 3 on the high-temperature resistant ceramic contour template 2, and apply appropriate pressure to make them fit together with the high-temperature resistant ceramic contour template 2 to obtain the fired part; Step 6: Place the product obtained in Step 5 into a vacuum brazing furnace to complete the "substrate 1-brazing filler metal-diamond" welding; Step 7: Take out the product obtained in Step 6, and then remove the contour plate 3 and the high-temperature ceramic contour template 2 in sequence to obtain the final mold product.

[0015] Example 2 like Figure 2 As shown, unlike Embodiment 1, the above-mentioned substrate 1 is a cylindrical shape with one end open. The other end of the substrate 1 has a mounting hole 1-1 coaxial with its axis at the center position. The side of the substrate 1 is a grinding surface, and multiple diamond particles arranged in an orderly manner are fixed on the grinding surface through a brazing layer.

[0016] The outer diameter of the substrate 1 is 300mm, the diamond particle size is d=0.71mm, the diameter D of the through hole 2-1 of the high temperature resistant ceramic template 2 is designed to be 0.85mm, the thickness T of the high temperature resistant ceramic template 2 is designed to be 2.55mm, and the spacing P of the through hole 2-1 is designed to be 1.275mm.

[0017] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them; although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications can still be made to the specific implementation of the present invention or equivalent substitutions can be made to some technical features without departing from the spirit of the technical solutions of the present invention, and all such modifications and substitutions should be covered within the scope of the technical solutions claimed in the present invention.

Claims

1. An ordered arrangement of vacuum brazed diamond abrasives, characterized in that: It includes a metal substrate (1), and a mounting hole (1-1) coaxial with its axis is provided at the center of the substrate (1); a grinding surface is provided on the substrate (1), and diamond particles are fixed on the grinding surface through a brazing layer.

2. The ordered arrangement of vacuum brazed diamond abrasives according to claim 1, characterized in that: The substrate (1) is disc-shaped, and a mounting hole (1-1) coaxial with its axis is provided at the center of the substrate (1). One side of the substrate (1) is an annular surface that is a grinding surface, and multiple diamond particles arranged in an orderly manner are fixed on the grinding surface through a brazing layer.

3. The ordered arrangement of vacuum brazed diamond abrasives according to claim 1, characterized in that: The substrate (1) is a cylindrical shape with one end open. The other end of the substrate (1) has a mounting hole (1-1) coaxial with its axis at the center. The side of the substrate (1) is a grinding surface, and multiple diamond particles arranged in an orderly manner are fixed on the grinding surface through a brazing layer.

4. The production process of vacuum brazed diamond abrasives with ordered arrangement according to claim 2 or 3, characterized in that... Includes the following steps: Step 1: First, apply a low-temperature volatile adhesive to the grinding surface; Step 2: Evenly adhere the brazing alloy powder to the adhesive layer, and then coat the brazing powder with a low-temperature volatile adhesive again; Step 3: Based on the shape of the substrate (1), cover the brazing alloy powder with one or more alumina / alumina nitride-based high-temperature ceramic templates (2). The high-temperature ceramic templates (2) are evenly distributed with multiple orderly arranged through holes (2-1). The diameter of the through holes (2-1) is D=1.05d-5d, where d is the diamond abrasive particle size. In addition, the spacing between the through holes (2-1) in the high-temperature ceramic templates (2) is P=3*D, and the thickness T of the high-temperature ceramic templates (2) satisfies T=m*d, where m is in the range of 1.2-5.

2. Step 4: Sprinkle diamonds on the surface of the high-temperature ceramic template (2) so that the diamonds fall into the through hole (2-1) and adhere to the adhesive on the surface of the brazing filler powder. Then rotate the substrate (1) and the high-temperature ceramic template (2) so that the excess diamond particles fall off naturally. Step 5: Cover one or more contour plates (3) on the high-temperature ceramic contour template (2) and apply appropriate pressure to make them fit together with the high-temperature ceramic contour template (2) to obtain the fired part; Step 6: Send the product obtained in step 5 into a vacuum brazing furnace to complete the "substrate (1) - brazing filler metal - diamond" welding; Step 7: Take out the product obtained in step 6, and then remove the contour plate (3) and the high-temperature ceramic contour template (2) in sequence to obtain the final mold product.

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