新型金刚石砂轮的制备及其磨削性能研究
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摘要
本文主要针对传统砂轮磨削温度高、磨粒容易脱落、加工塑性材料时容易堵塞、需定期修锐等问题,提出和研制了一种新型结构的金刚石砂轮。利用粉末注射成型技术和真空钎焊技术制备出长径比大、金刚石把持力大的金刚石微刃来取代传统砂轮的磨粒,并将金刚石微刃在砂轮胎体材料中进行定向有序排布制备出新型金刚石砂轮,同时通过选用合适的砂轮胎体材料及配方的优化,使其孔隙率增大,便于砂轮修整、修锐。新型金刚石砂轮制备后,开展了其与普通树脂结合剂金刚石砂轮及有序化超硬微刃刀具在相同实验条件下的对比试验,进一步分析了其磨削性能和磨削机理。
金刚石微刃的制备是开发新型金刚石砂轮的关键一步。实验利用粉末注射成形技术将复合镀金刚石、Cu-10Sn-5Ti钎料粉末和蜡基粘结剂组成的均匀混合料制备出纤维状的成型坯,在这个过程中,通过控制注射成型参数以获得无缺陷、组织均匀的注射生坯；采用溶剂脱脂和热脱脂二步脱脂工艺进行脱脂处理；脱脂后对其进行真空钎焊烧结,使金刚石微刃具有一定的强度和良好的机械物理性能。实验结果表明：当烧结温度为920℃,保温时间为10min,升降温速度为5℃/min时,金刚石微刃的烧结性能最好。考察了单根金刚石微刃加工WC/12Co涂层的切削性能和金刚石主要破损形式,结果表明制备的金刚石微刃具有良好的加工性能。金刚石颗粒在磨削过程中主要经历了小块破碎、大块破碎及磨平等状态,很少看到整颗脱落的情况。
金刚石微刃制备后,实验采用节块形式的方法以实现新型金刚石砂轮的制备。首先制备出节块模具并根据设计的排布方式在其周向开孔；然后将金刚石微刃——人为均匀排布在周向小孔中并粘结固定；通过选取一定配比的胎体材料压制成型制备出金刚石节块；将制备的多个金刚石节块在模具中整体热压成型制备出新型金刚石砂轮,并对其进行二次固化处理,使金刚石砂轮具有更高的强度、硬度和良好的磨削性能。
新型金刚石砂轮制备后,考察了其与普通树脂结合剂金刚石砂轮及有序化超硬微刃刀具在相同实验条件下的磨削性能,并分析了其磨削机理。实验结果表明：相对于传统树脂结合剂金刚石砂轮,新型金刚石砂轮的磨削力要小,磨削温度要低,加工质量好于传统树脂结合剂金刚石砂轮。随着磨削的进行,普通树脂结合剂砂轮的工作表面留有许多金刚石磨粒的脱落坑,且在金刚石颗粒与颗粒之间出现了磨屑堵塞现象。而新型金刚石砂轮中的金刚石磨粒主要经历了小块破碎、大块破碎、磨耗等正常磨损阶段,很少发现金刚石整颗脱落的情况。同时金刚石微刃的人为均匀排布,使其容屑、排屑能力大幅度提高,砂轮发生堵塞的情况也得到了有效改善。与有序化超硬微刃刀具加工WC/12Co涂层的对比实验发现：新型金刚石砂轮的加工表面形貌和表面质量要好于有序化超硬微刃刀具,其磨削力大于有序化超硬微刃刀具的切削力。有序化超硬微刃刀具在加工过程中会产生崩刃等破坏形式,需对其刃磨,其刃磨工艺较为烦琐且需重新整体装配,刃磨效率低；而新型金刚石砂轮在磨削过程中主要经历完整-小块破碎-大块破碎-磨耗等正常磨损形式,砂轮使用寿命较长,且由于砂轮胎体材料具有一定的孔隙,也便于其修整、修锐。
制备的新型金刚石砂轮是对传统砂轮的一种有益创新和改进,在工艺上是对传统砂轮的一种突破。其一方面克服了传统固结金刚石磨粒砂轮的金刚石容易脱落,金刚石存在大量浪费的问题；另一方面也有效克服了目前单层钎焊砂轮存在的工作层过薄,使用寿命有限的不足。在磨削过程中,新型金刚石砂轮中上层金刚石磨粒失去切削能力后,下层金刚石磨粒又可出露继续发挥其磨削能力,实现了在三维意义上的钎焊分布。同时,金刚石微刃的有序排布,使得其容屑空间增大,散热能力提高,加工表面质量和加工效率也能进一步改善。
The random nature of the abrasives geometries and their distribution in conventional wheel results in high temperature and high specific energy. It can cause the abrasives to fall off the grinding wheel prematurely, leading to inefficient use of the abrasives. Moreover, grinding wheel wear and loading problems become more severe when grinding "sticky" materials, which requires more frequent wheel truing and dressing and thus reduces grinding efficiency. This paper is aimed at developing a new diamond wheel in order to overcome these shortages of conventional diamond wheels. The diamond cutting edges are fabricated by combining powder injection molding with vacuum brazing, which have a large aspect ratio and diamonds grits pullouts cannot happen due to the presence of the chemical bonding. These diamond cutting edges can be artificially ordered so as to have the desired arrange pattern and space among themselves, and then suppressed with resin bond materials to prepare a new diamond wheel. The appropriate pore inducer is chosen to improve the self-sharpening ability and increase the clearance for debries of wheel. The paper compares the machining performance of the new diamond wheel with that of conventional resin bond diamnd wheel in machining the Al2O3ceramic, the machining performance of the new diamond wheel with that of the engineered cutter in machining the WC/12Co coating, respectively, and further discusses the grinding mechanism.
The fabrication of diamond cutting edges is a key step for the successful preparation of the new diamond wheel. The typical fabrication process of the diamond cutting edges are mixing, injection molding, debinding and vacuum brazing. Initially, a suitable formulation of binder is mixed with the coated diamonds and copper based alloy powders. The injection green parts are molded on a reciprocating screw injection molding machine. The binder must be removed from the molded parts, a two-step debinding process is selected. Brazing is the last stage of the process, it is essentially a removal of pores, accompanied by strong bonding strength between the diamonds and copper based alloy. The test indicated that the diamond cutting edges with no defects were prepared by vacuum brazing process (brazing temperature is920℃, holding time is10min, heating/cooling rate is5℃/min). The paper investigates the machining performance of the single diamond cutting edge in machining the WC/12Co coating. The test indicated that diamond cutting edge has good cutting properties, the diamonds mainly occurred micro-fracture and fracture, diamonds pull-out cannot easily happen during the grinding processing owe to the presence of strong adhesion between the diamond grits and brazing alloy, the diamond grits were used efficiently.
Because the diamond cutting edges have high transverse-rupture strength and large aspect ratio, they can been artificially distributed in the matrix material in accordance with array parameters, and further fabricate the new diamond wheel through autoclave process. The production process flow of the new diamond wheel is as follow:Initially, produce diamond segment die and oval open in the cylindrical in accordance with array parameters. Secondly, put the diamond cutting edges into the hole and hold them immovably, Then embeds into resin bond materials and porosity inducer to fabricate diamond segments. Finally, prepare the new diamond wheel through autoclave process and further make the bond matrix higher strength through curing process
After the preparation of the new diamond wheel, it discusses the grinding performances of the new diamond wheel and the conventional resin bond diamond wheel machining Al2O3ceramic at the same conditions. The test indicated that the grinding force and grinding temperature of the new diamond wheel are smaller than that of the conventional wheel, and the machining quality of the former is better than that of the latter. The changes of morphologies of diamond grits in grinding are observed, the worn states of diamond grits of the new diamond wheel are intact, micro-fractured, macro-fractures, and the diamond grits are difficult to be pulled out because of the strong bonding strength, in addition, the blockage of wheel is decreased through the controlled distributing of diamond cutting edges. In contrast, diamond grits falling off from conventional grinding wheel are observed, and the surface easy to block, which would result in grinding temperature rise even thermal damage. The machining performance of the new diamond wheel with the engineered cutter in machining the WC/12Co coating was compared, the test indicated that the machining quality of the former is better than that of the latter, And the wear test showed that the cutting edges of the engineered cutter appear tipping, they need to be sharpened again, but the sharpening technology is complex and time-consuming. In contrast, The primary wearing way of the diamond grits of the new diamond wheel are intact, micro-fractured and macro-fractured, and it was easy dressed.
The new diamond wheel has more superiority than conventional diamond wheels on grinding performance. On the one hand, the new diamond wheel overcome the shortage of diamond grits easy to fall off the surface of the conventional grinding wheel, on the other hand, the lifetime of the new diamond wheel is longer than that of the brazed monolayer wheel. When the diamonds of the new diamond wheel lose the cutting ability, the diamonds under-layer can expose and continue to cut. The chip-pocket space and cooling ability are increased because of the optical orientation of diamond cutting edges, which also affects the wheel life and machining quality.
金刚石微刃的制备是开发新型金刚石砂轮的关键一步。实验利用粉末注射成形技术将复合镀金刚石、Cu-10Sn-5Ti钎料粉末和蜡基粘结剂组成的均匀混合料制备出纤维状的成型坯,在这个过程中,通过控制注射成型参数以获得无缺陷、组织均匀的注射生坯；采用溶剂脱脂和热脱脂二步脱脂工艺进行脱脂处理；脱脂后对其进行真空钎焊烧结,使金刚石微刃具有一定的强度和良好的机械物理性能。实验结果表明：当烧结温度为920℃,保温时间为10min,升降温速度为5℃/min时,金刚石微刃的烧结性能最好。考察了单根金刚石微刃加工WC/12Co涂层的切削性能和金刚石主要破损形式,结果表明制备的金刚石微刃具有良好的加工性能。金刚石颗粒在磨削过程中主要经历了小块破碎、大块破碎及磨平等状态,很少看到整颗脱落的情况。
金刚石微刃制备后,实验采用节块形式的方法以实现新型金刚石砂轮的制备。首先制备出节块模具并根据设计的排布方式在其周向开孔；然后将金刚石微刃——人为均匀排布在周向小孔中并粘结固定；通过选取一定配比的胎体材料压制成型制备出金刚石节块；将制备的多个金刚石节块在模具中整体热压成型制备出新型金刚石砂轮,并对其进行二次固化处理,使金刚石砂轮具有更高的强度、硬度和良好的磨削性能。
新型金刚石砂轮制备后,考察了其与普通树脂结合剂金刚石砂轮及有序化超硬微刃刀具在相同实验条件下的磨削性能,并分析了其磨削机理。实验结果表明：相对于传统树脂结合剂金刚石砂轮,新型金刚石砂轮的磨削力要小,磨削温度要低,加工质量好于传统树脂结合剂金刚石砂轮。随着磨削的进行,普通树脂结合剂砂轮的工作表面留有许多金刚石磨粒的脱落坑,且在金刚石颗粒与颗粒之间出现了磨屑堵塞现象。而新型金刚石砂轮中的金刚石磨粒主要经历了小块破碎、大块破碎、磨耗等正常磨损阶段,很少发现金刚石整颗脱落的情况。同时金刚石微刃的人为均匀排布,使其容屑、排屑能力大幅度提高,砂轮发生堵塞的情况也得到了有效改善。与有序化超硬微刃刀具加工WC/12Co涂层的对比实验发现：新型金刚石砂轮的加工表面形貌和表面质量要好于有序化超硬微刃刀具,其磨削力大于有序化超硬微刃刀具的切削力。有序化超硬微刃刀具在加工过程中会产生崩刃等破坏形式,需对其刃磨,其刃磨工艺较为烦琐且需重新整体装配,刃磨效率低；而新型金刚石砂轮在磨削过程中主要经历完整-小块破碎-大块破碎-磨耗等正常磨损形式,砂轮使用寿命较长,且由于砂轮胎体材料具有一定的孔隙,也便于其修整、修锐。
制备的新型金刚石砂轮是对传统砂轮的一种有益创新和改进,在工艺上是对传统砂轮的一种突破。其一方面克服了传统固结金刚石磨粒砂轮的金刚石容易脱落,金刚石存在大量浪费的问题；另一方面也有效克服了目前单层钎焊砂轮存在的工作层过薄,使用寿命有限的不足。在磨削过程中,新型金刚石砂轮中上层金刚石磨粒失去切削能力后,下层金刚石磨粒又可出露继续发挥其磨削能力,实现了在三维意义上的钎焊分布。同时,金刚石微刃的有序排布,使得其容屑空间增大,散热能力提高,加工表面质量和加工效率也能进一步改善。
The random nature of the abrasives geometries and their distribution in conventional wheel results in high temperature and high specific energy. It can cause the abrasives to fall off the grinding wheel prematurely, leading to inefficient use of the abrasives. Moreover, grinding wheel wear and loading problems become more severe when grinding "sticky" materials, which requires more frequent wheel truing and dressing and thus reduces grinding efficiency. This paper is aimed at developing a new diamond wheel in order to overcome these shortages of conventional diamond wheels. The diamond cutting edges are fabricated by combining powder injection molding with vacuum brazing, which have a large aspect ratio and diamonds grits pullouts cannot happen due to the presence of the chemical bonding. These diamond cutting edges can be artificially ordered so as to have the desired arrange pattern and space among themselves, and then suppressed with resin bond materials to prepare a new diamond wheel. The appropriate pore inducer is chosen to improve the self-sharpening ability and increase the clearance for debries of wheel. The paper compares the machining performance of the new diamond wheel with that of conventional resin bond diamnd wheel in machining the Al2O3ceramic, the machining performance of the new diamond wheel with that of the engineered cutter in machining the WC/12Co coating, respectively, and further discusses the grinding mechanism.
The fabrication of diamond cutting edges is a key step for the successful preparation of the new diamond wheel. The typical fabrication process of the diamond cutting edges are mixing, injection molding, debinding and vacuum brazing. Initially, a suitable formulation of binder is mixed with the coated diamonds and copper based alloy powders. The injection green parts are molded on a reciprocating screw injection molding machine. The binder must be removed from the molded parts, a two-step debinding process is selected. Brazing is the last stage of the process, it is essentially a removal of pores, accompanied by strong bonding strength between the diamonds and copper based alloy. The test indicated that the diamond cutting edges with no defects were prepared by vacuum brazing process (brazing temperature is920℃, holding time is10min, heating/cooling rate is5℃/min). The paper investigates the machining performance of the single diamond cutting edge in machining the WC/12Co coating. The test indicated that diamond cutting edge has good cutting properties, the diamonds mainly occurred micro-fracture and fracture, diamonds pull-out cannot easily happen during the grinding processing owe to the presence of strong adhesion between the diamond grits and brazing alloy, the diamond grits were used efficiently.
Because the diamond cutting edges have high transverse-rupture strength and large aspect ratio, they can been artificially distributed in the matrix material in accordance with array parameters, and further fabricate the new diamond wheel through autoclave process. The production process flow of the new diamond wheel is as follow:Initially, produce diamond segment die and oval open in the cylindrical in accordance with array parameters. Secondly, put the diamond cutting edges into the hole and hold them immovably, Then embeds into resin bond materials and porosity inducer to fabricate diamond segments. Finally, prepare the new diamond wheel through autoclave process and further make the bond matrix higher strength through curing process
After the preparation of the new diamond wheel, it discusses the grinding performances of the new diamond wheel and the conventional resin bond diamond wheel machining Al2O3ceramic at the same conditions. The test indicated that the grinding force and grinding temperature of the new diamond wheel are smaller than that of the conventional wheel, and the machining quality of the former is better than that of the latter. The changes of morphologies of diamond grits in grinding are observed, the worn states of diamond grits of the new diamond wheel are intact, micro-fractured, macro-fractures, and the diamond grits are difficult to be pulled out because of the strong bonding strength, in addition, the blockage of wheel is decreased through the controlled distributing of diamond cutting edges. In contrast, diamond grits falling off from conventional grinding wheel are observed, and the surface easy to block, which would result in grinding temperature rise even thermal damage. The machining performance of the new diamond wheel with the engineered cutter in machining the WC/12Co coating was compared, the test indicated that the machining quality of the former is better than that of the latter, And the wear test showed that the cutting edges of the engineered cutter appear tipping, they need to be sharpened again, but the sharpening technology is complex and time-consuming. In contrast, The primary wearing way of the diamond grits of the new diamond wheel are intact, micro-fractured and macro-fractured, and it was easy dressed.
The new diamond wheel has more superiority than conventional diamond wheels on grinding performance. On the one hand, the new diamond wheel overcome the shortage of diamond grits easy to fall off the surface of the conventional grinding wheel, on the other hand, the lifetime of the new diamond wheel is longer than that of the brazed monolayer wheel. When the diamonds of the new diamond wheel lose the cutting ability, the diamonds under-layer can expose and continue to cut. The chip-pocket space and cooling ability are increased because of the optical orientation of diamond cutting edges, which also affects the wheel life and machining quality.
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