阅读说明：本技术 一种金属超薄砂轮的绿色精密连续成型系统及工艺 (Green precise continuous forming system and process for metal ultrathin grinding wheel ) 是由 黎克楠 冯圆茹 陈锋 陈恩厚 赵赋 邴建立 王冻冻 王兵 于 2020-06-08 设计创作，主要内容包括：本发明公开一种金属超薄砂轮的绿色精密连续成型系统及工艺,属于机械加工中的超硬材料及制品技术领域,所述系统的组成为：以砂轮坯料的出口为上游,所述系统从上游至下游依次包括固定成型对辊、精密调节对辊、第一橡胶脱模辊、真空吸附装置、套料切割装置、第二橡胶脱模辊、烘箱和存放柜,精密调节对辊由第一精密调节辊和第二精密调节辊组成,第一橡胶脱模辊和第二橡胶脱模辊上设有用于对砂轮坯料进行运输的环形脱模带,第一橡胶脱模辊和和第二精密调节辊相切,第二橡胶脱模辊位于烘箱的进口处。本发明实现了连续生产,减少了目前单片模压断续生产批次质量的差异,提高了生产效率。(The invention discloses a green precise continuous molding system and a process of a metal ultrathin grinding wheel, belonging to the technical field of superhard materials and products in machining, wherein the system comprises the following components: the system comprises a fixed forming double-roll, a precise adjusting double-roll, a first rubber demoulding roll, a vacuum adsorption device, a jacking cutting device, a second rubber demoulding roll, an oven and a storage cabinet from upstream to downstream in sequence, wherein the precise adjusting double-roll consists of the first precise adjusting roll and the second precise adjusting roll, annular demoulding belts used for transporting the grinding wheel blanks are arranged on the first rubber demoulding roll and the second rubber demoulding roll, the first rubber demoulding roll and the second precise adjusting roll are tangent, and the second rubber demoulding roll is positioned at an inlet of the oven. The invention realizes continuous production, reduces the difference of batch quality of the current single-piece die pressing intermittent production and improves the production efficiency.)

1. The utility model provides a green accurate continuous forming system of ultra-thin emery wheel of metal which characterized in that, uses the export of emery wheel blank as the upper reaches, the system includes fixed shaping pair roller, accurate regulation pair roller, first rubber stripper roller, vacuum adsorption device, cover material cutting device, second rubber stripper roller, oven and storing compartment from the upper reaches to the low reaches in proper order, and accurate regulation pair roller comprises first accurate regulating roller and second accurate regulating roller, is equipped with the annular drawing of patterns area that is used for transporting the emery wheel blank on first rubber stripper roller and the second rubber stripper roller, and first rubber stripper roller is tangent with second accurate regulating roller, and second rubber stripper roller is located the import department of oven.

2. The green precise continuous molding system of the metal ultrathin grinding wheel as claimed in claim 1, wherein a scraper is arranged below the demolding belt between the second rubber demolding roller and the first rubber demolding roller and used for scraping the grinding wheel blank remained on the demolding belt after the grinding wheel blank is transported, and a residual material recycling hopper is arranged below the scraper.

3. The green precise continuous molding system of the ultrathin metal grinding wheel as claimed in claim 1, wherein the distance between the fixed molding pair rollers is 1 mm-2 mm, and the distance between the first precise regulating roller and the second precise regulating roller is 0.5 mm-0.6 mm.

4. The green precise continuous forming process of the metal ultrathin grinding wheel by using the system as claimed in any one of claims 1 to 3 is characterized by comprising the following steps:

(1) mixing: heating and stirring an organic binder until the organic binder is completely melted, adding a metal ultrathin grinding wheel raw material, and stirring for 30-90 minutes at 100-150 ℃, wherein the mass ratio of the organic binder to the metal ultrathin grinding wheel raw material is (1-3) to (7-9);

(2) pre-packaging: wrapping the mixed and matured dough by using a continuous protective film with the thickness of 0.1 mm-0.5 mm;

(3) rolling: the pre-wrapped forming aggregate passes through a conveying belt and sequentially passes through a fixed forming double-roller, a precision adjusting double-roller and a first rubber demolding roller, the roller speed is 0.5-3 m/min, the precision of the distance between the double-roller is adjusted through hydraulic control of a dial indicator, and finally the pre-wrapped forming aggregate is rolled into a strip-shaped green body with the thickness of 0.5-0.6 mm;

(4) and (3) transmission: the strip-shaped green body passes through a first rubber demolding roller, is attached to a demolding belt and is conveyed to the next procedure along with the demolding belt;

(5) uncovering the film: the rolled strip-shaped green body enters a freezing film uncovering area through a demoulding belt, the temperature of the area is minus 5 ℃ to 5 ℃, and a protective film in the surface pre-packaging process is uncovered through adsorption by a vacuum sucker with the adsorption force of 3N to 5N;

(6) enabling the strip-shaped green body after film uncovering to enter a slitting area at a speed of 0.5-3 m/min, and obtaining an annular ultrathin grinding wheel green body meeting the required size through a jacking cutting device;

(7) degreasing: sending the cut annular ultrathin grinding wheel green body into an oven through a demolding belt for degreasing, wherein the degreasing temperature is 120-400 ℃, and the degreasing time is 10-300 min;

(8) and (4) packaging and storing: and (3) putting the degreased and qualified green bodies into a stainless steel box, filling protective gas, and putting the green bodies into a storage cabinet for storage at the temperature of 15-30 ℃ and the humidity of 5-10% RH.

5. The green precise continuous molding process of the metal ultrathin grinding wheel as claimed in claim 4, wherein the organic binder comprises the following components: 25-35 wt% of low-density polyethylene, 55-65 wt% of paraffin and 5-15 wt% of stearic acid.

6. The green precise continuous forming process of the metal ultrathin grinding wheel as claimed in claim 4, wherein the metal ultrathin grinding wheel is prepared from the following raw materials: 70-80 wt% of copper powder, 3-8 wt% of iron powder, 5-15 wt% of tin powder, 3-8 wt% of cobalt powder and 5-6 wt% of diamond, wherein the granularity of the copper powder, the iron powder, the tin powder and the cobalt powder is 500 meshes or finer, and the granularity of the diamond is 600 meshes.

7. The green precise continuous forming process of the metal ultrathin grinding wheel as claimed in claim 4, wherein the outer diameter of the metal ultrathin grinding wheel is 58.3mm, the inner diameter of the metal ultrathin grinding wheel is 39.2mm, and the thickness of the metal ultrathin grinding wheel is 0.55 mm.

Technical Field

The invention belongs to the field of superhard materials and products in machining, and particularly relates to a green precise continuous forming system and process for a metal ultrathin grinding wheel.

Background

The ultrathin grinding wheel is mainly used for the precise cutting and processing of key parts such as optical filters, semiconductor chips, optical fiber splitters, LEDs and the like in the fields of optics, electronics, optical communication and the like, and is widely used for the procedures of chip scribing, packaging cutting, LED cutting, optical fiber array slotting, ceramic sleeve cutting, precious material cutting and the like. The materials have high requirements on cutting precision and processing quality, and have strict control on workpiece chipping, cracks, scratches, burrs, peeling and the like. The thickness of the ultrathin grinding wheel can be as thin as 0.015mm, the outer diameter is 50 mm-125 mm, the diameter-thickness ratio is high, the cutting depth is 0.05 mm-3 mm, the feeding speed is 0.05 mm/s-300 mm/s, the cutting rotating speed is 10000 rpm/min-60000 rpm/min, and the ultrathin grinding wheel belongs to the field of high-speed/ultrahigh-speed grinding, and is high in rotating speed, fast in feeding, narrow in cutting joint and long in continuous operation time. Under the high-speed strong heat-force coupling effect, the defects of asymmetrical distribution, component segregation, uneven density, poor precision and the like of the abrasive materials such as diamond, CBN, SiC and the like on the two side surfaces of the ultrathin grinding wheel easily cause uneven stress distribution of the ultrathin grinding wheel, generate multi-order irregular vibration, and further cause low high-speed movement precision, unqualified processing quality and high product rejection rate.

At present, the forming process adopted by the ultrathin grinding wheel is loose powder mould pressing intermittent forming, and the main steps are as follows: formulation design → powder mixing → tool selection → pressing parameter setting → powder spreading → single-mode pressing → manual die unloading. The existing forming process has strong dependence on human experience, poor product stability, large dust, low production efficiency, poor green body precision and environmental pollution, and belongs to intermittent forming. In addition, the traditional forming process is easy to have the defects of upward floating of grinding materials such as diamonds and the like, segregation of components with different densities, uneven density of the upper part and the lower part of a green body, over-poor precision and the like, so that the rejection rate of processed products in the high-speed cutting process is high.

With the continuous promotion of the global industry 4.0, the country pays more and more attention to environmental protection, the requirements of precision manufacturing such as photoelectricity on processing quality and efficiency are continuously improved, and a novel forming process of an ultrathin grinding wheel needs to be researched and proposed urgently. Therefore, the grinding wheel preparation process which is continuously prepared, green, environment-friendly and precisely formed is suitable for the requirement of national industrial development.

Disclosure of Invention

The invention develops a green precise continuous molding system and a process of the metal ultrathin grinding wheel aiming at the defects that the existing molding process of the ultrathin grinding wheel is easy to cause upward floating of grinding materials such as diamond and the like, segregation of components with different densities, uneven density of a green blank and an upper blank, over-poor precision and the like.

In order to achieve the purpose, the invention provides the following main technical scheme:

the utility model provides a green accurate continuous forming system of ultra-thin emery wheel of metal to emery wheel blank's export is the upper reaches, the system includes fixed shaping pair roller, accurate regulation pair roller, first rubber stripper roller, vacuum adsorption device, jacking cutting device, second rubber stripper roller, oven and storing compartment from upper reaches to low reaches in proper order, and accurate regulation pair roller comprises first accurate regulating roller and second accurate regulating roller, is equipped with the annular drawing of patterns area that is used for carrying out the transportation to emery wheel blank on first rubber stripper roller and the second rubber stripper roller, and first rubber stripper roller is tangent with the second accurate regulating roller, and second rubber stripper roller is located the import department of oven.

Furthermore, a scraping knife is arranged below the demolding belt between the second rubber demolding roller and the first rubber demolding roller and used for scraping the residual grinding wheel blanks on the demolding belt after the grinding wheel blanks are transported, and a surplus material recycling hopper is arranged below the scraping knife.

Furthermore, the distance between the fixed forming pair rollers is 1 mm-2 mm, the distance between the first precision adjusting roller and the second precision adjusting roller is 0.5 mm-0.6 mm, and the demolding belt is a canvas demolding belt.

The green precise continuous forming process of the metal ultrathin grinding wheel by using the system comprises the following steps:

(1) mixing: heating and stirring an organic binder until the organic binder is completely melted, adding a metal ultrathin grinding wheel raw material, and stirring for 30-90 minutes at 100-150 ℃, wherein the mass ratio of the organic binder to the metal ultrathin grinding wheel raw material is (1-3) to (7-9);

(2) pre-packaging: wrapping the mixed and matured dough by using a continuous protective film with the thickness of 0.1 mm-0.5 mm;

(3) rolling: the pre-wrapped forming aggregate passes through a conveying belt and sequentially passes through a fixed forming double-roller, a precision adjusting double-roller and a first rubber demolding roller, the roller speed is 0.5-3 m/min, the precision of the distance between the double-roller is adjusted through hydraulic control of a dial indicator, and finally the pre-wrapped forming aggregate is rolled into a strip-shaped green body with the thickness of 0.5-0.6 mm;

(4) and (3) transmission: the strip-shaped green body passes through a first rubber demolding roller, is attached to a demolding belt and is conveyed to the next procedure along with the demolding belt;

(5) uncovering the film: the rolled strip-shaped green body enters a freezing film uncovering area through a demoulding belt, the temperature of the area is minus 5 ℃ to 5 ℃, and a protective film in the surface pre-packaging process is uncovered through adsorption by a vacuum sucker with the adsorption force of 3N to 5N;

(6) enabling the strip-shaped green body after film uncovering to enter a slitting area at a speed of 0.5-3 m/min, and obtaining an annular ultrathin grinding wheel green body meeting the required size through a jacking cutting device;

(7) degreasing: sending the cut annular ultrathin grinding wheel green body into an oven through a demolding belt for degreasing, wherein the degreasing temperature is 120-400 ℃, and the degreasing time is 10-300 min;

(8) and (4) packaging and storing: and (3) putting the degreased and qualified green bodies into a stainless steel box, filling protective gas, and putting the green bodies into a storage cabinet for storage at the temperature of 15-30 ℃ and the humidity of 5-10% RH.

Preferably, the organic binder has a composition of: 25-35 wt% of low-density polyethylene, 55-65 wt% of paraffin and 5-15 wt% of stearic acid.

Preferably, the metal ultrathin grinding wheel comprises the following raw materials: 70-80 wt% of copper powder, 3-8 wt% of iron powder, 5-15 wt% of tin powder, 3-8 wt% of cobalt powder and 5-6 wt% of diamond, wherein the granularity of the copper powder, the iron powder, the tin powder and the cobalt powder is 500 meshes or finer, and the granularity of the diamond is 600 meshes.

Preferably, the metal ultrathin grinding wheel has an outer diameter of 58.3mm, an inner diameter of 39.2mm and a thickness of 0.55mm

The invention has the following positive beneficial effects:

1. the invention is applied to the precise molding of the green body of the ultrathin grinding wheel in the field of superhard grinding tools in the mechanical industry, utilizes the characteristic of better wettability of organic matters and diamond, adopts organic binder to wrap the diamond and metal bond powder into a lump and roll the lump for molding, overcomes the defects that the existing loose powder compression molding diamond is easy to float upwards and different density components are easy to segregate, is beneficial to reducing the bad phenomena of high-speed tail swing, jumping, multi-step irregular movement and the like of the ultrathin grinding wheel, and is beneficial to improving the high-speed movement precision and the processing quality of the ultrathin grinding wheel;

2. the rolling gap is adjusted by adopting a dial indicator for hydraulic adjustment, and the precision of rolled green bodies can reach +/-0.005 mm, which is far higher than the precision (+/-0.03 mm) of the existing loose powder compression molding process;

3. the invention realizes continuous production, reduces the difference of batch quality of the current single-piece die pressing intermittent production and improves the production efficiency. The organic binder can effectively coat the diamond and the binder powder, thereby avoiding dust pollution, being beneficial to protecting the health of workers and realizing green manufacture. Meanwhile, the residual blanks after cutting can be returned to the bin for mixing again, so that the material utilization rate is greatly improved, non-renewable resources are saved, and the forming process is precise, continuous, green and sustainable.

Drawings

FIG. 1 is a schematic structural diagram of a green precision continuous molding system for a metal ultrathin grinding wheel; in the figure, 1, a pre-wrapped blank, 2, a fixed forming pair roller, 31, a first precision adjusting roller, 32, a second precision adjusting roller, 41, a first rubber demoulding roller, 42, a second rubber demoulding roller, 5, a canvas demoulding belt, 6, a vacuum adsorption device, 7, a jacking cutting device, 8, an annular ultrathin grinding wheel green body, 9, a scraping knife, 10, a residual material recovery hopper, 11, an oven and 12, a storage cabinet are arranged;

FIG. 2 is a process flow diagram of the present invention;

FIG. 3 is an SEM image of a green grinding wheel obtained after degreasing in example 1 at 400 times magnification;

FIG. 4 is an SEM image of a green grinding wheel obtained after degreasing in example 1, at 3000 times magnification.

Detailed Description

The invention will be further described with reference to the following drawings and specific examples: