Because the super-hard material belt has the characteristics of high efficiency, precision, energy saving, material saving and environmental protection. In addition, China is both a super-hard material country and a large machinery manufacturing country. It has the advantage of developing and applying super-hard material coated abrasives. At present, China's super-hard material abrasive belt has been successfully developed and mass-produced for the development of difficult-to-machine materials and complex types. The grinding test and processing of the surface created conditions to promote the development of China's high-end equipment manufacturing industry.
1. High efficiency, precision, energy saving, material saving and environmental protection are the general trends of modern manufacturing development.
Superhard materials (diamond and cubic boron nitride) tools, including superhard material abrasive belts, will play an important role in this development. The application of superhard materials to coated abrasives has just begun in China. I have been fortunate to be one of its pioneers. Diamonds and cubic boron nitride are used as abrasives to successfully produce abrasive belts, sand discs and sand sleeves, and page wheels. , grinding discs, etc., and began to scale production and application. This article discusses the importance, necessity and feasibility of developing superhard material coated abrasives.
Diamond and cubic boron nitride (CBN) are the two materials with the highest hardness known in the world. Due to its high hardness, good wear resistance and high thermal conductivity, it is unmatched by ordinary abrasives (corundum and silicon carbide). When using hard abrasives to process hard and brittle and hard tough workpieces, the consumption is extremely small, and the sharpness and the shape of the abrasive can be maintained for a long time, which not only ensures the machining accuracy of the workpiece, but also greatly improves the processing efficiency. At the same time, it solves the problem of environmental pollution and conforms to the development strategies of energy conservation, material conservation, environmental protection and low carbon implemented by the state in the manufacturing industry.
Western developed countries have developed the use of superhard materials to manufacture coated abrasives from the perspective of solving the grinding process of difficult-to-machine materials, improving grinding efficiency and human health and environmental protection. At present, the United States, Germany, the United Kingdom, Switzerland and other countries have the production and sales of related products, and form a series of superhard material coated abrasive products.
2. Status of superhard material abrasive belt
Superhard material coated abrasive refers to an abrasive tool that adheres superhard material (synthetic diamond or cubic boron nitride) abrasive particles to a flexible flexible substrate with an adhesive.
With the rapid development of China's metallurgical industry and modern mechanical processing industry, the emergence of various new materials, high-end equipment manufacturing requirements for processing accuracy and surface finish are getting higher and higher, coated abrasives are also high efficiency, long life and super The direction of precision is developing. Therefore, the development and application of superhard material coated abrasives are quietly emerging in cemented carbide, electronics, stone, engineering ceramics, glass, gemstones, building materials, stainless steel, hardened steel, high speed tool steel, high temperature alloy (titanium alloy, nickel). The special processing fields of difficult-to-machine materials such as base and cobalt-based alloys and composite materials (carbon fiber reinforced plastics, special glass fiber reinforced plastics) have been widely used. It is particularly noteworthy that in the grinding of difficult-to-machine materials such as cemented carbide, stone, ceramics, iron-based alloys, etc., super-hard material abrasive belts show their unique advantages, from the grinding of workpieces used as general precision requirements. Developed to the grinding of high-precision, ultra-high-precision parts. Due to the application of super-hard material abrasive belt, the working life of the abrasive belt is greatly improved, and the abrasive belt grinding field is rapidly expanding, which can be used for wet grinding, dry grinding, high-speed grinding, heavy-duty grinding and high-precision precision parts grinding and polishing. It greatly enriches the application range of coated abrasives that enjoy the reputation of "universal grinding".
3. Structure of superhard material coated abrasives
The four elements of superhard material coated abrasives consist of an array of substrates, abrasives, binders, and abrasives.
3.1 substrate:
3.1.1 Substrate is the carrier of abrasive and binder, which is the main factor to make the belt flexible. The main performance indicators of the substrate are: radial tensile strength, latitudinal tensile strength, radial (latitudinal) elongation, mesh density of the textile fabric, and the like.
3.1.2 Composite substrate: In the past ten years, the base tape (high-speed transmission belt) has been developed in large-area strong grinding, because of its thickness adjustability (from 0.5-3.0mm), better tensile strength And lower elongation (less than 1.5%), good heat resistance, water resistance, and smooth surface. Therefore, it is currently a trend to use it as a belt and other coated abrasive substrates.
3.2 Abrasive: diamond, cubic boron nitride (CBN). China's superhard material coated abrasives are high-tech products developed in recent years. At present, there is no systematic complete product classification. According to the different abrasive materials, it can be divided into two types: diamond coated abrasives and cubic boron nitride coated abrasives.
3.3 Binder: There are two kinds of resin binder and metal binder.
3.3.1 Resin Superhard Material The abrasive belt is basically the same in structure as the ordinary abrasive belt. It is made by mixing the adhesive with the abrasive by means of dispensing or pre-forming the template.
3.3.2 Metal bond abrasive belts are manufactured by electroplating or other special processes.
3.4 Arrangement of abrasive: This is a major feature different from ordinary abrasive coated abrasives. The form (pattern) has a dot type, an X type, an arrow type, a V type, and the like. The reason why the form (pattern) of the sand-sand arrangement is listed as a major element of the super-hard material belt is because it plays a very important role in the grinding process: a single abrasive grain itself is used as a grinding unit, and several grinding The granules together form a grinding unit in the sand pattern, and the grinding unit is evenly distributed on the surface of the abrasive cloth. During the working process, a plurality of sharp edges are formed, the sharpness is sharpened, and the uniform gap between the small units is formed to form a large gap. The chip space, not only the grinding debris is taken away with the belt rotation, the chip removal is good, the blockage caused by the grinding debris is avoided, and the grinding temperature is lowered, and the sharpness of the grinding tool and the grinding force are maintained for a long time.
The grinding efficiency of the super-hard material belt is not only due to the super-hard abrasive itself, but also because of the particularity of the abrasive distribution. For the grinding process with the grinding amount requirement, the abrasive belt with the particle size of 40#~240# can be used. The distribution pattern of the sand surface abrasive grain is arrow-shaped, and the substrate adopts X-WT, Y-WT and PU. Sharp grinding, high efficiency, good chip removal, low noise and less dust;
For fine grinding and polishing process, 320#~2000# fine-grained abrasive belt can be used. The sand surface abrasive distribution pattern adopts dot-shaped distribution. The substrate adopts J-WT, and its abrasive belt product has softness and chip removal. Good, low grinding temperature, low noise, less dust, high processing accuracy and high finish.
The particle size of the abrasive used in the superhard material abrasive belt must be considered comprehensively for the processing conditions, processing requirements and optimum particle size range. Generally, the three factors of processing surface roughness, processing efficiency and belt life are considered.
4, the application of superhard material coated abrasives
Abrasive belt grinding is a kind of flexible grinding technology, which has multiple processing functions of grinding, grinding and polishing. With "cold state" effect, the grinding precision can reach 0.1μm.
Diamond abrasive belt is especially suitable for the processing of hard and brittle non-metallic materials and non-ferrous metals. Therefore, it is widely used in hard and brittle materials such as stone, building materials, glass, special ceramics, monocrystalline silicon, polycrystalline silicon, gemstone and silicon-aluminum alloy, hard alloy. Grinding and polishing of complex shapes of products.
The hardness of CBN is second only to diamond, and the grinding belt has the advantages of small grinding force, low grinding temperature, high grinding ratio and good chemical stability. It is especially suitable for the processing of hard and tough iron-based alloys, such as rough grinding of special high-speed steel tools such as vanadium-titanium alloy steel; heat-resistant steel (titanium alloy, nickel-based alloy, cobalt-based alloy), stainless steel and high Fine grinding and final grinding of precision parts made of alloy structural steel; because of its small grinding force and low grinding temperature, it is an ideal grinding tool for titanium alloy grinding, because it does not cause deformation of the machine guide rail. It is more suitable for the finishing and final grinding of machine tool guides, instruments and miniature bearing parts; the processing of complex profile workpieces (pinion cutters, high-precision gears, blades, etc.); the finishing of other quenching tool steels and the local thermal stress and Grinding of various material parts sensitive to thermal shock.
The super-hard material abrasive belt products have an annular abrasive belt, a sand ring, a grinding disc, a hand rubbing block, a grinding disc, a grinding wheel, and the like, and can process workpieces of various shapes with high surface quality and high precision. Not only has a long service life, but also high grinding efficiency. For example, the 100# electroplated diamond coated abrasive soft-grinding disc developed by our company, the service life of the processed stone is 8-10 times that of the resin diamond soft-grinding disc; the CBN abrasive belt produced by our company is used by Chongqing Sanmao Haida with six-axis linkage sand. With a grinding machine for processing heat-resistant stainless steel steam turbine blades, a CBN abrasive belt can be processed continuously for 18-20 hours, and the surface quality of the workpiece is good. The German VSM produces 718 ordinary stacked abrasive belts, one can only be processed continuously for 2 hours; Shanghai Baosteel uses the diamond belts produced by our company and its products to polish the surface and spray the workpieces such as tungsten carbide materials, and the polishing efficiency is high. The surface roughness of the workpiece is uniform.
5. Development trend of superhard material abrasive belt
5.1. Development of special binders. Due to the different performance requirements of adhesives for different fields of use of superhard material abrasive belts, it will be necessary to develop special binders for specific fields of use;
5.2. Research and development of micro-powder superhard abrasive sand. The distribution uniformity and orientation of the abrasive must be effectively controlled. American 3M Company uses a dispenser to manufacture resin-dispensing abrasive belts, which can better solve the problems of uniformity of abrasive distribution, softness of abrasive belts, etc., and can save the amount of super-hard abrasives and reduce costs.
5.3. Development of high precision and ultra precision super abrasive abrasive belts. At present, precision grinding usually refers to machining technology with a machining accuracy of 3~0.3μm and a surface roughness of Ra0.3~0.03μm. Ultra-precision grinding requires a machining accuracy of 0.3~0.03μm and a roughness of 0.03~0.05. Mm. Due to the basic characteristics of superhard material abrasive belts, its application to precision and ultra-precision grinding is one of the main directions in the future.
6 Conclusion
6.1. Superhard material abrasive belt has the dual characteristics of "hard" superhard material and "soft" coated abrasive, which is the best combination of "just" and "soft". In line with the strategic requirements of modern high-speed, high-efficiency, precision, material-saving, energy-saving and environmentally-friendly processing technology, it has important technical and economic value to push coated abrasives to the peak.
6.2. Superhard material abrasive belt is not only a high-tech coated abrasive product, but also a high value-added and high-efficiency product. Its quality and level often mark the production and processing level of a national coated abrasive tool, and vigorously develop super hard material coating. Attachment of abrasive tools is feasible and necessary.
6.3. China is a world's largest producer of super-hard materials. In 2010, the output of synthetic diamond was 9.2 billion carats and the annual output of CBN was 260 million carats. The variety is complete, the price is low, and the supply is sufficient. It has laid a reliable material for the development of super-hard material abrasive belt products. Foundation and security.
6.4 China has a huge stone mining and processing, optical glass, gem processing industry, engineering ceramic processing, photovoltaic industry, aerospace, nuclear power wind power, high-end equipment manufacturing. It is believed that the successful development and mass production of superhard material coated abrasives in China will certainly promote the rapid development of the above-mentioned industries in China.
6.5. Superhard materials are much more expensive than ordinary abrasives, but from the standpoint of high performance, long life and high cost performance, the use of superhard material abrasive belts is a highly efficient, cost-effective and cost-effective tool. The so-called high price of super-hard materials should not be an obstacle to the development of super-hard material abrasive belt products, but should make full use of the advantages of low-cost super-hard materials that are unmatched by other countries. Applying superhard materials to coated abrasives is one of the development directions of China's coated abrasives industry, and it will surely have a bright future!
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Tag: superhard material super hard abrasive hard and brittle material coated abrasive grinding
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