Preparation method of resin grinding roller grinding wheel for non-ferrous metal industry

Abstract

The present application is prepared by a new abrasive processing technology, using modified resin binder, adding multifunctional filler, and cooperating with special mixing, forming and step curing process, and is a special resin grinding roller grinding wheel with high surface precision, low scratch and long service life. The grinding wheel prepared by the method is suitable for precision grinding of high chromium forged steel, high speed steel and surface chromium plated roller, and the grinding surface roughness Ra can be stably controlled in 0.01-0.15 μm, the roller surface is scratch-free, the service life is equivalent to that of imported grinding wheel, and the imported product can be effectively replaced, thereby reducing the production cost of enterprises.

Description

Technical Field

[0001] This invention belongs to the field of abrasive preparation technology, specifically relating to a method for preparing a resin-bonded grinding wheel for the non-ferrous metals industry, which is a resin-bonded grinding wheel for precision grinding with a roller. Background Technology

[0002] Driven by the rapid development of industries such as new energy, electronics, and packaging, the demand for non-ferrous metal foils such as aluminum and copper foils continues to grow. Rolls used for foil rolling are mostly made of high-chromium forged steel and high-speed steel, requiring high surface hardness and extremely strict surface finish requirements, typically within 0.15μm. Currently, the industry mainly relies on imported grinding wheels for high-end roll grinding, which are expensive and have long delivery cycles. Domestic grinding wheels generally suffer from grinding scratches, unstable surface finish, and frequent clogging, making them unsuitable for high-end foil rolling.

[0003] Existing resin grinding wheels are mostly designed for ferrous metals. Their abrasive edges are sharp, the binder lacks sufficient heat resistance and toughness, and they lack lubricating and heat-dissipating fillers. When grinding non-ferrous metals, which have high thermal conductivity, high plasticity, and are prone to adhesion, they easily cause surface scratches and substandard roughness on the rolls. Therefore, developing a dedicated, stable, and low-cost method for manufacturing grinding wheels for non-ferrous metal rolls has significant engineering application value. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a method for preparing resin grinding rollers for the non-ferrous metals industry. Through formula optimization and precise process control, the method achieves high grinding wheel durability, long service life, and no scratches on the surface of the workpiece after grinding, with a roughness of 0.01-0.15um.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A resin grinding roller for the non-ferrous metals industry is mainly made of the following raw materials in the following weight ratio: 100 parts abrasive, 8-14 parts resin liquid, 8-12 parts cryolite, 0.5-1.5 parts oleamide, and 4-6 parts phenolic resin powder.

[0006] Specifically, the resin liquid includes, but is not limited to, liquid phenolic resin or liquid epoxy resin.

[0007] Specifically, the abrasive includes, but is not limited to, at least one of white corundum, chromium corundum, and green silicon carbide, and the abrasive particle size can be F150-F800.

[0008] A method for preparing the above-mentioned resin grinding roller for the non-ferrous metals industry includes the following steps: S1. The cleaned and dried abrasive is evenly placed into the chamber of the low-temperature plasma treatment equipment. The chamber is closed and a vacuum is drawn to ensure that there is no air interference in the chamber. A mixture of Ar2 and O2 gas is introduced into the chamber. The plasma generator is started and the surface of the abrasive is modified under stirring. During the treatment, the abrasive is evenly turned over by the stirring device to ensure that the surface modification of the abrasive is uniform. S2 Weigh the resin liquid, add the liquid-terminated carboxyl butadiene nitrile rubber, stir and mix well to toughen and modify the resin binder. S3 weighs the abrasive treated in S1 and the modified resin liquid in S2 in proportion, mixes them evenly using a roller mill mixer, and then adds oleic acid amide, cryolite and phenolic resin powder in sequence and mixes them evenly to obtain the molding material. S4 molding material is transferred to a constant temperature and humidity storage area for curing (temperature controlled at 15-25℃, relative humidity at 45-55%, and stored in a sealed container for 12-24 hours). After sieving, it is put into the mold for spreading, leveling, and then pressed at room temperature. S5. After the shaped grinding wheel blank has been air-dried at room temperature for 2-4 days, it is placed in a curing oven for curing to obtain the final product.

[0009] Furthermore, in step S1, anhydrous ethanol is used to ultrasonically clean the abrasive to remove surface oil and impurities. After cleaning, it is transferred to an oven for drying. During ultrasonic cleaning, the ultrasonic power is 100-300W and the ultrasonic time is 10-30min; the drying temperature is 100-120℃ and the drying time is 2-4h.

[0010] Furthermore, in step S1, the volume ratio of Ar to O2 is (80~95):(5~20), the power of the plasma generator is 50~400W, the temperature inside the control chamber is maintained at 30~80℃, and the processing time is 5~30min.

[0011] Furthermore, in step S2, the amount of liquid-terminated carboxyl-terminated nitrile rubber added is 5-10% of the weight of the resin liquid.

[0012] Furthermore, in step S4, the sieve number is 12# to 16#, the molding pressure is 7 to 12 MPa, and the holding time is 30 to 90 seconds.

[0013] Furthermore, in step S5, the curing process is as follows: heat preservation at 60-80℃ for 4-6 hours, heat preservation at 100-120℃ for 2-4 hours, and heat preservation at 140-160℃ for 2-4 hours.

[0014] Compared with existing technologies, the method for preparing resin grinding rollers for the non-ferrous metals industry provided by this invention has the following advantages and beneficial effects: This invention employs a novel abrasive treatment technology. First, ultrasonic cleaning removes impurities from the abrasive surface. Then, low-temperature plasma generates hydroxyl and oxygen-containing polar groups on the abrasive surface, improving its bonding performance with resin. This avoids the environmental pollution caused by traditional silane coupling agent treatments. Carboxyl-terminated nitrile rubber is used to toughen and modify the resin solution, improving the grinding wheel's impact resistance, reducing noise and vibration during grinding, and preventing scratches and vibration marks on the workpiece surface. A specialized mixing process ensures uniform mixing of the molding materials, improving the uniformity of the grinding wheel's structure. A three-stage curing process ensures a high yield rate and extends the grinding wheel's lifespan. The grinding wheels prepared by this invention can meet the requirements of the non-ferrous metals industry for high surface precision, long lifespan, and high durability in grinding wheels. Detailed Implementation

[0015] The technical solution of the present invention will be further described in detail below with reference to the embodiments, but the scope of protection of the present invention is not limited thereto.

[0016] The present invention discloses a method for preparing a resin grinding roller for the non-ferrous metals industry, comprising the following steps: S1. Anhydrous ethanol is used to ultrasonically clean the abrasive to remove surface oil and impurities. After cleaning, it is transferred to an oven for drying. The dried abrasive is then evenly placed into the chamber of the low-temperature plasma treatment equipment. The chamber is closed and a vacuum is drawn to ensure that there is no air interference in the chamber. A mixture of Ar2 and O2 gas is introduced into the chamber, and the plasma generator is started to perform surface modification treatment on the abrasive. During the treatment, the abrasive is evenly turned over by a stirring device to ensure uniform surface modification of the abrasive. Specifically, anhydrous ethanol is used to ultrasonically clean one of white corundum, chromium corundum, or green silicon carbide, with an abrasive particle size of F150-F800, for 10-20 minutes at an ultrasonic power of 100-300W to remove surface oil and impurities. After cleaning, the abrasive is transferred to an oven at 100-120℃ and dried for 2-4 hours. The dried abrasive is then evenly placed into the chamber of a low-temperature plasma treatment device, the chamber is closed and evacuated to ensure no air interference. A mixture of Ar2 and O2 is introduced into the chamber, with a volume ratio of (80~95):(5~20). The plasma generator is started and the power is set to 50-400W to perform surface modification treatment on the abrasive for 5-30 minutes. During the treatment, the abrasive is stirred evenly by a stirring device to ensure uniform surface modification. S2, weigh a certain amount of resin liquid, add liquid-terminated carboxyl butadiene nitrile rubber, stir evenly, and toughen and modify the resin binder. Specifically, a certain amount of liquid phenolic resin or liquid epoxy resin is weighed, and 5-10% of liquid carboxyl-terminated butadiene-acrylonitrile rubber is added and stirred evenly to toughen and modify the resin binder. S3: Weigh the abrasive treated in S1 and the modified resin liquid in S2 according to the proportion, mix them evenly using a roller mill mixer, and then add oleic acid amide, cryolite and phenolic resin powder in sequence and mix evenly to obtain the molding material. Specifically, 100 parts of the abrasive treated in S1 and 8-14 parts of the modified resin liquid in S2 are weighed out and mixed evenly using a roller mill mixer. Then, 0.5-1.5 parts of oleic acid amide, 8-12 parts of cryolite, and 4-6 parts of phenolic resin powder are added in sequence and mixed evenly to obtain the molding material. S4, after the molding material is sifted and sieved, it is fed into the mold for spreading, leveling, and then pressed at room temperature; Specifically, the molding material is transferred to a constant temperature and humidity storage area for curing, with the temperature controlled at 15-25℃ and the relative humidity at 45-55%, and stored in a sealed environment for 12-24 hours. After passing through a 12-16# sieve, it is put into the mold for spreading and leveling. Then, it is molded under constant pressure at room temperature with a molding pressure of 7-12MPa and a holding time of 30-90S. S5. Allow the formed grinding wheel blank to air dry at room temperature for 3 days, then place it in a curing oven to cure, and you will get the desired result. Specifically, the formed grinding wheel blank is air-dried at room temperature for 3 days, then placed in a curing oven for curing. The curing curve is 60-80℃ for 4-6 hours, 100-120℃ for 2-4 hours, and 140-160℃ for 2-4 hours.

[0017] The invention will be further described below with specific examples.

[0018] In the following examples, all raw materials used are commercially available products that can be directly purchased or prepared using conventional techniques in the art. For example, liquid phenolic resin, model: 2124 thermosetting phenolic resin liquid, viscosity 400-1200 mPa·s@25℃, free phenol ≤3%, commercially available product. Liquid carboxyl-terminated nitrile butadiene rubber, model: 1300×8 CTBN; acrylonitrile content 18%-22%, commercially available product. Phenolic resin powder, model: JM939, free phenol ≤3%, commercially available product.

[0019] In the embodiments, unless otherwise specified, all measurements are in parts by weight. Example 1

[0020] This embodiment describes a method for preparing resin grinding rollers for the non-ferrous metals industry. The specific process is as follows: 1) Use anhydrous ethanol to ultrasonically clean white corundum with a particle size of F800 for 10 minutes at an ultrasonic power of 300W to remove surface oil and impurities. After cleaning, transfer it to a 100℃ oven to dry for 4 hours. Place the dried abrasive evenly into the chamber of the low-temperature plasma treatment equipment, close the chamber and evacuate it to ensure that there is no air interference in the chamber. Introduce a mixture of Ar2 and O2 into the chamber with a volume ratio of Ar2 to O2 of 80:20. Start the plasma generator and control the temperature in the chamber to be maintained at 30℃. Set the power to 400W to perform surface modification treatment on the abrasive for 5 minutes. During the treatment, use a stirring device to drive the abrasive to turn evenly to ensure uniform surface modification of the abrasive. 2) Weigh a certain amount of 14 parts of liquid phenolic resin, add 10% of the weight of liquid resin of liquid carboxyl-terminated butadiene-acrylonitrile rubber, stir evenly, and toughen and modify the resin binder. 3) Weigh 100 parts of the white corundum abrasive treated in step 1) and the modified liquid phenolic resin in step 2), mix them evenly using a roller mill mixer, and then add 1.5 parts of oleic acid amide, 12 parts of cryolite and 4 parts of phenolic resin powder in sequence and mix evenly to obtain the molding material. 4) The molding material is subjected to a curing process (the molding material is transferred to a constant temperature and humidity storage area for curing, with the temperature controlled at 15℃ and the relative humidity at 45%, and stored in a sealed environment for 24 hours), and after passing through a 16# sieve, it is fed into the mold for spreading and leveling. Then, it is subjected to constant pressure molding at room temperature, with a molding pressure of 7MPa and a holding time of 90S. 5) Allow the formed grinding wheel blank to air dry at room temperature for 3 days, then place it in a curing oven for curing. The curing curve is 60℃ for 6 hours, 120℃ for 2 hours, and 160℃ for 2 hours, which yields resin grinding rollers for the non-ferrous metals industry.

[0021] The resin grinding wheel for non-ferrous metals industry prepared using this method was used to perform grinding tests on a Φ280mm high-chromium forged steel work roll. The results are shown in the table below.

[0022] Example 2

[0023] This embodiment describes a method for preparing resin grinding rollers for the non-ferrous metals industry. The specific process is as follows: 1) Use anhydrous ethanol to ultrasonically clean F380 chromium corundum for 15 minutes at an ultrasonic power of 200W to remove surface oil and impurities. After cleaning, transfer it to a 110℃ oven to dry for 3 hours. Place the dried abrasive evenly into the chamber of the low-temperature plasma treatment equipment, close the chamber and evacuate it to ensure that there is no air interference in the chamber. Introduce a mixture of Ar2 and O2 into the chamber with a volume ratio of Ar2:10. Start the plasma generator and control the temperature in the chamber to be maintained at 60℃. Set the power to 200W to perform surface modification treatment on the abrasive for 15 minutes. During the treatment, use a stirring device to drive the abrasive to turn evenly to ensure uniform surface modification of the abrasive. 2) Weigh 8 parts of liquid phenolic resin, add 8% of liquid carboxyl-terminated butadiene-acrylonitrile rubber by weight of the resin liquid, stir evenly, and toughen and modify the resin binder. 3) Weigh 100 parts of the chromium corundum abrasive treated in step 1) and the modified liquid phenolic resin in step 2), mix them evenly using a roller mill mixer, and then add 1 part of oleic acid amide, 10 parts of cryolite and 6 parts of phenolic resin powder in sequence and mix evenly to obtain the molding material. 4) The molding material is transferred to a constant temperature and humidity storage area for curing. The temperature is controlled at 20℃ and the relative humidity at 50%. It is stored in a sealed container for 18 hours. After passing through a 14# sieve, it is put into the mold for spreading and leveling. Then, it is molded at room temperature with a molding pressure of 10 MPa and a holding time of 60 seconds. 5) Allow the formed grinding wheel blank to air dry at room temperature for 3 days, then place it in a curing oven for curing. The curing curve is 80℃ for 4 hours, 100℃ for 4 hours, and 140℃ for 4 hours, which yields resin grinding rollers for the non-ferrous metals industry.

[0024] The resin grinding wheel for non-ferrous metals industry prepared using this method was used to perform grinding tests on a Φ350mm high-chromium forged steel work roll. The results are shown in the table below.

[0025] Example 3

[0026] This embodiment describes a method for preparing resin grinding rollers for the non-ferrous metals industry. The specific process is as follows: 1) Use anhydrous ethanol to ultrasonically clean F150 green silicon carbide for 30 minutes at an ultrasonic power of 100W to remove surface oil and impurities. After cleaning, transfer it to a 120℃ oven to dry for 2 hours. Place the dried abrasive evenly into the chamber of the low-temperature plasma treatment equipment, close the chamber and evacuate it to ensure that there is no air interference in the chamber. Introduce a mixture of Ar2 and O2 into the chamber with a volume ratio of Ar2 to O2 of 95:5. Start the plasma generator and control the temperature in the chamber to be maintained at 80℃. Set the power to 50W to perform surface modification treatment on the abrasive for 30 minutes. During the treatment, use a stirring device to drive the abrasive to turn evenly to ensure uniform surface modification of the abrasive. 2) Weigh 8 parts of liquid epoxy resin (Sinopec E-44, a common commercial product), add 5% of liquid carboxyl-terminated butadiene nitrile rubber by weight of the resin liquid, stir evenly, and toughen and modify the resin binder. 3) Weigh 100 parts of the green silicon carbide abrasive treated in step 1) and the modified liquid epoxy resin in step 2), mix them evenly using a roller mill mixer, and then add 0.5 parts of oleic acid amide, 8 parts of cryolite and 5 parts of phenolic resin powder in sequence and mix evenly to obtain the molding material. 4) The molding material is transferred to a constant temperature and humidity storage area for curing. The temperature is controlled at 25℃ and the relative humidity at 55%. It is stored in a sealed container for 12 hours. After passing through a No. 12 sieve, it is put into the mold for spreading and leveling. Then, it is molded at room temperature with a molding pressure of 12 MPa and a holding time of 30 seconds. 5) Allow the formed grinding wheel blank to air dry at room temperature for 3 days, then place it in a curing oven for curing. The curing curve is 70℃ for 5 hours, 110℃ for 3 hours, and 150℃ for 3 hours to obtain the resin grinding roller grinding wheel for the non-ferrous metals industry.

[0027] The resin grinding wheel for non-ferrous metals industry prepared using this method was used to perform grinding tests on a Φ280mm high-chromium forged steel work roll. The results are shown in the table below.

[0028]

[0029] Comparative Example

[0030] 1) Weigh 100 parts of green silicon carbide abrasive and 8 parts of epoxy resin liquid directly, mix them evenly using a roller mill mixer, and then add 0.5 parts of oleic acid amide, 8 parts of cryolite and 5 parts of phenolic resin powder in sequence and mix evenly to obtain the molding material. 2) The molding material is transferred to a constant temperature and humidity storage area for curing. The temperature is controlled at 25℃ and the relative humidity at 55%. It is stored in a sealed container for 12 hours. After passing through a No. 12 sieve, it is put into the mold for spreading and leveling. Then, it is molded at room temperature with a molding pressure of 12 MPa and a holding time of 30 seconds. 3) Allow the formed grinding wheel blank to air dry at room temperature for 3 days, then place it in a curing oven for curing. The curing curve is 70℃ for 5 hours, 110℃ for 3 hours, and 150℃ for 3 hours to obtain the resin grinding roller grinding wheel for the non-ferrous metals industry.

[0031] The resin grinding wheel for non-ferrous metals industry prepared using this method was used to perform grinding tests on a Φ280mm high-chromium forged steel work roll. The results are shown in the table below.

[0032]

[0033] The data in the table above shows that: after canceling the modification of the abrasive and the toughening modification of the resin liquid in this comparative example, the grinding wheel prepared was used to grind high-chromium forged steel work rolls. The workpiece surface showed obvious scratches of 3-5mm and spiral marks. The service life and durability were far lower than the grinding performance of the grinding wheel in the example.

[0034] In summary, this invention utilizes novel abrasive processing technology, modified resin binders, and multifunctional fillers, along with specialized mixing, molding, and stepped curing processes, to produce a specialized resin-based grinding wheel for rolling mill rolls. This wheel offers high surface precision, low scratches, and a long service life. The grinding wheel prepared by this method is suitable for precision grinding of high-chromium forged steel, high-speed steel, and chrome-plated rolling mill rolls. The surface roughness Ra can be stably controlled within 0.01-0.15 μm, with no scratches on the roll surface. Its service life is comparable to imported grinding wheels, effectively replacing imported products and reducing production costs for enterprises.

Claims

1. A resin-bonded grinding roller for the non-ferrous metals industry, characterized in that, It is mainly made of the following raw materials in the following weight ratio: 100 parts abrasive, 8-14 parts resin liquid, 8-12 parts cryolite, 0.5-1.5 parts oleamide, and 4-6 parts phenolic resin powder.

2. The resin grinding roller wheel for the non-ferrous metals industry as described in claim 1, characterized in that, The resin solution is liquid phenolic resin or liquid epoxy resin.

3. The resin grinding roller wheel for the non-ferrous metals industry as described in claim 1, characterized in that, The abrasive is at least one of white corundum, chromium corundum, and green silicon carbide, and the abrasive particle size is F150-F800.

4. The method for preparing resin grinding rollers / wheels for the non-ferrous metals industry according to any one of claims 1 to 3, characterized in that, Includes the following steps: S1. The cleaned and dried abrasive is evenly placed into the chamber of the low-temperature plasma treatment equipment. The chamber is closed and a vacuum is drawn to ensure that there is no air interference in the chamber. A mixture of Ar2 and O2 gas is introduced into the chamber. The plasma generator is started and the surface of the abrasive is modified under stirring. S2 Weigh out the resin liquid, add the liquid-terminated carboxyl butadiene-acrylonitrile rubber, and mix well; S3 weighs the abrasive treated in S1 and the modified resin liquid in S2 according to the proportion, mixes them evenly, and then adds oleic acid amide, cryolite and phenolic resin powder in sequence and mixes them evenly to obtain the molding material. After being pressed and sieved, the S4 molding material is fed into the mold for spreading, leveling, and then pressed at room temperature. S5. After the shaped grinding wheel blank has been air-dried at room temperature for 2-4 days, it is placed in a curing oven for curing to obtain the final product.

5. The preparation method according to claim 4, characterized in that, In step S1, ultrasonic cleaning is used with an ultrasonic power of 100-300W and an ultrasonic time of 10-30 minutes; the drying temperature is 100-120℃ and the drying time is 2-4 hours.

6. The preparation method according to claim 4, characterized in that, In step S1, the volume ratio of Ar to O2 is (80~95):(5~20), the power of the plasma generator is 50~400W, the temperature inside the control chamber is maintained at 30~80℃, and the processing time is 5~30min.

7. The preparation method according to claim 4, characterized in that, In step S2, the amount of liquid-terminated carboxyl-terminated nitrile rubber added is 5-10% of the weight of the resin liquid.

8. The preparation method according to claim 4, characterized in that, In step S4, the sieve number is 12# to 16#, the molding pressure is 7 to 12 MPa, and the holding time is 30 to 90 seconds.

9. The preparation method according to claim 4, characterized in that, In step S5, the curing process is as follows: heat preservation at 60-80℃ for 4-6 hours, heat preservation at 100-120℃ for 2-4 hours, and heat preservation at 140-160℃ for 2-4 hours.

Images