阅读说明：本技术 高速超重负荷磨削固结磨具及其制备方法 (High-speed overweight load grinding consolidation grinding tool and preparation method thereof ) 是由 陈沈萍 刘小磐 孙玉凤 陈瑞和 刘总堂 陈瑞平 王友堂 吴祝艳 于 2021-07-20 设计创作，主要内容包括：本发明提出的一种高速超重负荷磨削固结磨具及其制备方法,磨削功能部采用酚醛树脂、聚酰亚胺树脂、缩丁醛树脂、硼酸锌、二硫化钼、硫化亚铁、冰晶石、碳化硅、氧化钙以及二盐基亚磷酸铅组成改性高聚合物基酚醛树脂结合剂,使结合剂具有高强度、耐高温的优异特性；聚酰亚胺树脂韧性较好,力学性能较高,能与酚醛树脂发生共固化反应或形成部分互穿网络结构,提高结合剂的力学性能；进一步通过硫化亚铁、二硫化钼、冰晶石改性,使改性后的结合剂兼具高韧性和高耐热性,改性效果明显提高；同时,缩丁醛树脂固化后在砂轮的磨料上会形成包膜,大幅度提高结合剂与磨料的把持力,参与组织复合成核,能够有效避免烧伤工件,并提高了磨具内部的硬度均匀性指标。(According to the high-speed overweight load grinding consolidation grinding tool and the preparation method thereof, the grinding function part adopts phenolic resin, polyimide resin, butyral resin, zinc borate, molybdenum disulfide, ferrous sulfide, cryolite, silicon carbide, calcium oxide and dibasic lead phosphite to form a modified high polymer-based phenolic resin binding agent, so that the binding agent has excellent characteristics of high strength and high temperature resistance; the polyimide resin has good toughness and high mechanical property, can perform co-curing reaction with phenolic resin or form a partial interpenetrating network structure, and improves the mechanical property of the binding agent; the modified binding agent has high toughness and high heat resistance and the modification effect is obviously improved by further modifying ferrous sulfide, molybdenum disulfide and cryolite; meanwhile, after the butyral resin is cured, a coating film can be formed on the grinding material of the grinding wheel, the holding force of the bonding agent and the grinding material is greatly improved, the tissue recombination nucleation is participated, the workpiece can be effectively prevented from being burnt, and the hardness uniformity index in the grinding tool is improved.)

1. The high-speed overweight load grinding and consolidation grinding tool is characterized by comprising a grinding functional part, wherein the grinding functional part comprises an abrasive, a bonding agent, a wetting agent and a reinforcing material, and the bonding agent comprises the following components in parts by weight:

2. the high speed super heavy load grinding bonded abrasive tool according to claim 1, wherein the binder comprises the following components in parts by weight:

3. the high speed super heavy load grinding bonded abrasive tool according to claim 1 or 2, wherein the grinding function comprises the following components in parts by weight:

4. the high-speed super-heavy-load grinding and bonding abrasive tool according to claim 3, wherein the abrasive is selected from any one or more of ceramic microcrystalline zirconia corundum, ceramic microcrystalline sintered corundum and silicon carbide.

5. The high speed super heavy load grinding bonded abrasive tool according to claim 4, wherein the wetting agent comprises the following components in parts by weight:

0.20-2.20 parts by weight of furfural; and the number of the first and second groups,

0.35 to 0.40 part by weight of dibutyl ester.

6. The high speed super heavy load grinding and bonding abrasive tool of claim 5 wherein the reinforcing material is fiberglass or carbon fiber.

7. The high speed super heavy load grinding bonded abrasive tool of claim 5 further comprising a reinforcement function.

8. A method of making a high speed super heavy load grinding bonded abrasive tool according to any of claims 1 to 7, comprising the steps of:

preparing a binding agent, namely providing components of the binding agent according to the proportion of the binding agent and mixing the components to prepare the binding agent;

a molding material preparation step, wherein the components of the grinding functional part are provided according to the proportion of the grinding functional part and are mixed to prepare the molding material;

a cold press molding step, namely placing the molding material in a grinding wheel mold and performing cold press treatment to prepare a cold press molding blank assembly, wherein the pressure of the cold press treatment is 17.0-20.0 MPa;

a pre-curing step, namely performing pre-curing treatment on the cold-pressed formed blank assembly to obtain a pre-cured formed blank assembly; wherein the pre-curing treatment is heating pre-curing in stages;

hot-press molding and curing, namely, carrying out hot-press treatment and curing treatment on the pre-cured molded blank assembly, and demolding to obtain a hot-press molded cured blank;

and a consolidation hardening step, namely, carrying out consolidation hardening treatment on the hot-press molding solidified blank to prepare the high-speed overweight load grinding and consolidation grinding tool.

9. The preparation method according to claim 8, wherein in the binder preparation step, the components of the binder are provided according to the proportion of the binder and are mixed, and the components are stirred and mixed for 3-5 min; adding ferrous sulfide, cryolite and calcium oxide according to the formula ratio, and stirring and mixing for 3-5 min; adding silicon carbide and dibasic lead phosphite in the formula ratio, stirring and mixing for 3-5 min.

10. The preparation method according to claim 9, wherein in the molding material preparation step, the components of the grinding functional part are provided according to the proportion of the grinding functional part and are mixed, after the grinding material and the wetting agent in the formula ratio are stirred and mixed for 3min to 7min, the components are stirred for 0.5min to 1.5min by a fly cutter; adding the bonding agent and the reinforcing material in the formula ratio, stirring and mixing for 3-7 min, and stirring for 0.5-1.5 min by using a fly cutter.

Technical Field

The invention relates to the technical field of billet grinding equipment, in particular to a high-speed overweight load grinding consolidation grinding tool and a preparation method thereof.

Background

The steel industry special steel billet grinding needs to use a high-speed overweight load grinding and consolidation grinding tool, the working line speed needs to reach 80-100 m/s, the tolerance temperature reaches the high temperature of more than 600 ℃ of the hot rolled billet, and the grinding pressure reaches 15000-20000N, thereby realizing high-speed and high-efficiency grinding. At present, the load and temperature resistance of the traditional resin grinding wheel which is used in a large amount in the steel industry can not meet the grinding requirement of special steel billets.

Disclosure of Invention

Therefore, the high-speed overweight load grinding consolidation grinding tool and the preparation method thereof are needed to be provided for solving the technical problem that the traditional resin high-speed heavy load grinding wheel cannot meet the grinding requirement of the special steel billet.

The invention provides a high-speed overweight load grinding and consolidating grinding tool which comprises a grinding functional part, wherein the grinding functional part comprises grinding materials, a bonding agent, a wetting agent and a reinforcing material, and the bonding agent comprises the following components in parts by weight:

in one embodiment, the binder comprises the following components in parts by weight:

in one embodiment, the grinding function part comprises the following components in parts by weight:

in one embodiment, the abrasive is selected from any one or more of ceramic microcrystalline zirconia corundum, ceramic microcrystalline sintered corundum and silicon carbide.

In one embodiment, the wetting agent comprises the following components in parts by weight:

0.20-2.20 parts by weight of furfural; and the number of the first and second groups,

0.35 to 0.40 part by weight of dibutyl ester.

In one embodiment, the reinforcing material is glass fiber or carbon fiber.

In one embodiment, the high speed super heavy load grinding bonded abrasive tool further comprises a reinforcement function.

The invention also provides a preparation method of the high-speed overweight load grinding and consolidation grinding tool, which comprises the following steps:

preparing a binding agent, namely providing components of the binding agent according to the proportion of the binding agent and mixing the components to prepare the binding agent;

a molding material preparation step, wherein the components of the grinding functional part are provided according to the proportion of the grinding functional part and are mixed to prepare the molding material;

a cold press molding step, namely placing the molding material in a grinding wheel mold and performing cold press treatment to prepare a cold press molding blank assembly, wherein the pressure of the cold press treatment is 17.0-20.0 MPa;

a pre-curing step, namely performing pre-curing treatment on the cold-pressed formed blank assembly to obtain a pre-cured formed blank assembly; wherein the pre-curing treatment is heating pre-curing in stages;

hot-press molding and curing, namely, carrying out hot-press treatment and curing treatment on the pre-cured molded blank assembly, and demolding to obtain a hot-press molded cured blank;

and a consolidation hardening step, namely, carrying out consolidation hardening treatment on the hot-press molding solidified blank to prepare the high-speed overweight load grinding and consolidation grinding tool.

In one embodiment, the components of the binding agent are provided according to the proportion of the binding agent and are mixed, namely, phenolic resin, polyimide resin, butyral resin, molybdenum disulfide and zinc borate in a formula ratio are stirred and mixed for 3-5 min; adding ferrous sulfide, cryolite and calcium oxide according to the formula ratio, and stirring and mixing for 3-5 min; adding silicon carbide and dibasic lead phosphite in the formula ratio, stirring and mixing for 3-5 min.

In one embodiment, the components of the grinding functional part are provided according to the proportion of the grinding functional part and are mixed, namely, after the grinding material and the wetting agent in the formula ratio are stirred and mixed for 3min to 7min, the grinding material and the wetting agent are stirred by a fly cutter for 0.5min to 1.5 min; adding the bonding agent and the reinforcing material in the formula ratio, stirring and mixing for 3-7 min, and stirring for 0.5-1.5 min by using a fly cutter.

According to the high-speed overweight load grinding and consolidation grinding tool, a modified high polymer-based phenolic resin binding agent is formed by phenolic resin, polyimide resin, butyral resin, zinc borate, molybdenum disulfide, ferrous sulfide, cryolite, silicon carbide, calcium oxide and dibasic lead phosphite, so that the binding agent has excellent characteristics of high strength and high temperature resistance; the polyimide resin has good toughness and high mechanical property, and can perform co-curing reaction with phenolic resin or form a partial interpenetrating network structure so as to improve the mechanical property of the binding agent; the modified binding agent has high toughness and high heat resistance and the modification effect is obviously improved by further modifying ferrous sulfide, molybdenum disulfide and cryolite; meanwhile, after the butyral resin is cured, a coating film can be formed on the grinding material of the grinding wheel, the holding force of the bonding agent and the grinding material is greatly improved, the tissue is involved in the compound nucleation, the workpiece can be effectively prevented from being burnt, and the hardness uniformity index in the grinding tool is improved; the invention improves the tensile strength of the grinding wheel by the composite technology of the modified high polymer-based phenolic resin and the ceramic microcrystalline abrasive, and can also effectively solve the interface problem between the ceramic abrasive and a polymer and the workpiece burning problem under the high-speed grinding condition, so that the grinding pressure of the prepared grinding wheel reaches 15000N-20000N, the temperature resistance during grinding reaches 600 ℃, the bonding strength of the grinding wheel is improved, and the working linear velocity can be improved to 80 m/s-100 m/s.

According to the preparation method of the high-speed overweight load grinding and consolidation grinding tool, the grinding wheel is preliminarily molded by adopting a cold press molding process, and then a stage type heating and pre-curing mode matched with the modified high polymer-based phenolic resin binding agent is adopted according to the characteristics of the modified high polymer-based phenolic resin binding agent, so that the gelation and crosslinking of the binding agent are consistent, the pre-curing of the binding agent and the grinding material is realized, the internal heights of grinding functional part tissues of the grinding wheel are ensured to be balanced and consistent, a multi-layer fine grinding material structure is formed, dense point-like grinding is realized, the high sharpness of the grinding wheel is realized, and the grinding ratio reaches 1: 160 above, the requirement of high-speed heavy-load grinding is met; meanwhile, the industrial production of the high-speed overweight load grinding consolidation grinding tool is optimized and designed in an overall structure according to the precision control technology, so that the unbalance coefficient of the prepared high-speed overweight load grinding consolidation grinding tool is not more than 0.40, the minimum diameter of the grinding wheel reaches 250mm, and the maximum diameter of the grinding wheel reaches 900 mm-1100 mm.

Drawings

FIG. 1 is a schematic flow chart of a method for manufacturing a high-speed super-heavy load grinding bonded abrasive tool according to the present invention;

FIG. 2 is a schematic structural diagram of a mold sleeve and a pressure head used in the method for preparing the high-speed super-heavy load grinding bonded abrasive tool of the invention;

FIG. 3 is a schematic structural view of a mold core used in the method for manufacturing a high-speed super-heavy-load grinding bonded abrasive tool according to the present invention;

FIG. 4 is a schematic diagram of a cold-pressed upper mold plate structure used in the method for manufacturing the high-speed super-heavy load grinding and consolidating grinding tool of the present invention;

fig. 5 is a schematic structural view of a hot upper template and a lower template used in the preparation method of the high-speed overweight load grinding consolidation grinding tool.

Detailed Description

The present invention is further described with reference to specific examples to enable those skilled in the art to better understand the present invention and to practice the same, but the examples are not intended to limit the present invention.

The invention provides a high-speed overweight load grinding and consolidation grinding tool, which comprises a grinding functional part and optionally a reinforcing functional part. The grinding functional part comprises an abrasive, a bonding agent, a wetting agent and a reinforcing material, wherein the bonding agent comprises the following components in parts by weight:

according to the high-speed overweight load grinding and consolidation grinding tool, a modified high polymer-based phenolic resin binding agent is formed by phenolic resin, polyimide resin, butyral resin, zinc borate, molybdenum disulfide, ferrous sulfide, cryolite, silicon carbide, calcium oxide and dibasic lead phosphite, so that the binding agent has excellent characteristics of high strength and high temperature resistance; the polyimide resin has good toughness and high mechanical property, and can perform co-curing reaction with phenolic resin or form a partial interpenetrating network structure so as to improve the mechanical property of the binding agent; the modified binding agent has high toughness and high heat resistance and the modification effect is obviously improved by further modifying ferrous sulfide, molybdenum disulfide and cryolite; meanwhile, after the butyral resin is cured, a coating film can be formed on the grinding material of the grinding wheel, the holding force of the bonding agent and the grinding material is greatly improved, the tissue is involved in the compound nucleation, the workpiece can be effectively prevented from being burnt, and the hardness uniformity index in the grinding tool is improved; the invention improves the tensile strength of the grinding wheel by the composite technology of the modified high polymer-based phenolic resin and the ceramic microcrystalline abrasive, and can also effectively solve the interface problem between the ceramic abrasive and a polymer and the workpiece burning problem under the high-speed grinding condition, so that the grinding pressure of the prepared grinding wheel reaches 15000N-20000N, the temperature resistance during grinding reaches 600 ℃, the bonding strength of the grinding wheel is improved, and the working linear velocity can be improved to 80 m/s-100 m/s.

Further preferably, the binding agent comprises the following components in parts by weight:

as an alternative embodiment, the grinding function part comprises the following components in parts by weight:

as an alternative embodiment, the abrasive material of the high-speed super-heavy load grinding bonded abrasive tool is selected from one or more of ceramic microcrystalline zirconia corundum, ceramic microcrystalline sintered corundum and silicon carbide.

Optionally, the grain size composition of the abrasive is selected according to the grinding purpose of the high-speed super-heavy load grinding bonded abrasive tool, and may be, for example: 6# 50%, 8# 25%, 10# 25%, or 6# 25%, 8# 50%, 10# 25%, or 10# 25%, 16# 50%, 20# 25%. In the embodiment, the composition of the abrasive grain size is determined according to the requirement of grinding special steel billets, wherein the grain size label accords with the grain size number and the composition thereof described in GB2477-83 abrasive grain size and composition thereof.

As an alternative embodiment, the wetting agent comprises the following components in parts by weight

0.20-2.20 parts by weight of furfural; and the number of the first and second groups,

0.35 to 0.40 part by weight of dibutyl ester.

As a further alternative embodiment, the reinforcing material is glass fiber or carbon fiber. Optionally, the specification of the glass fiber is 3-9 μm in diameter and 0.5-5.0 mm in length, and the type of the carbon fiber is as follows: t400 chopped carbon fiber with diameter of 1-2 μm and length-diameter ratio greater than 20.

As an alternative embodiment, the high speed super heavy load grinding bonded abrasive tool includes a reinforcement function. Optionally, the structure of the reinforcement function part is annular. Optionally, the reinforcement function portion may further include a fixing portion for fixing the grinding wheel, for example, a bolt hole provided in the ring structure, or a fixing portion extending from the ring structure.

In a second broad aspect of the present invention, a method for preparing a high-speed super-heavy-load bonded abrasive tool is further provided, as shown in fig. 1, the method comprises the following steps:

a binding agent preparation step S100, wherein the components of the binding agent are provided according to the proportion of the binding agent and are mixed to prepare the binding agent;

a molding material preparation step S200, wherein the components of the grinding functional part are provided according to the proportion of the grinding functional part and are mixed to prepare a molding material;

a cold press molding step S300, namely placing the molding material in a grinding wheel mold and performing cold press treatment to obtain a cold press molding blank assembly, wherein the pressure of the cold press treatment is 17.0-20.0 MPa;

a pre-curing step S400, in which the cold-pressed formed blank assembly is subjected to pre-curing treatment to obtain a pre-cured formed blank assembly; wherein the pre-curing treatment is heating pre-curing in stages;

a step S500 of hot-press molding and curing, in which the pre-cured molded blank assembly is subjected to hot-press treatment and curing treatment, and a hot-press molded cured blank is prepared after demolding;

and a consolidation hardening step S600, namely, carrying out consolidation hardening treatment on the hot-press molding solidification blank to obtain the high-speed overweight load grinding and consolidation grinding tool.

Optionally, after the step S600 of solidification hardening, a step S700 of finishing and inspecting the manufactured high-speed super-heavy load grinding and solidifying grinding tool is further included, so that the high-speed super-heavy load grinding and solidifying grinding tool meets the national standard inspection.

According to the preparation method of the high-speed overweight load grinding and consolidation grinding tool, the grinding wheel is preliminarily molded by adopting a cold press molding process, and then a stage type heating and pre-curing mode matched with the modified high polymer-based phenolic resin binding agent is adopted according to the characteristics of the modified high polymer-based phenolic resin binding agent, so that the gelation and crosslinking of the binding agent are consistent, the pre-curing of the binding agent and the grinding material is realized, the internal heights of grinding functional part tissues of the grinding wheel are ensured to be balanced and consistent, a multi-layer fine grinding material structure is formed, dense point-like grinding is realized, the high sharpness of the grinding wheel is realized, and the grinding ratio reaches 1: 160 above, the requirement of high-speed heavy-load grinding is met; meanwhile, the industrial production of the high-speed overweight load grinding consolidation grinding tool is optimized and designed in an overall structure according to the precision control technology, so that the unbalance coefficient of the prepared high-speed overweight load grinding consolidation grinding tool is not more than 0.40, the minimum diameter of the grinding wheel reaches 250mm, and the maximum diameter of the grinding wheel reaches 900 mm-1100 mm.

As an optional implementation manner, in the binder preparation step S100, the components of the binder are provided according to the mixture ratio of the binder and are mixed by stirring and mixing the phenolic resin, the polyimide resin, the butyral resin, the molybdenum disulfide and the zinc borate in the formula ratio for 3min to 5 min; adding ferrous sulfide, cryolite and calcium oxide according to the formula ratio, and stirring and mixing for 3-5 min; adding silicon carbide and dibasic lead phosphite in the formula ratio, stirring and mixing for 3-5 min. And finally, screening the mixed binding agent by a 80# sieve for later use. Optionally, the binder preparation step S100 uses a counter-current mixer to mix the binders.

As an optional embodiment, in the molding material preparation step S200, the components of the grinding functional part are provided according to the proportion of the grinding functional part and are mixed, after the grinding material and the wetting agent in the formula ratio are stirred and mixed for 3min to 7min, the mixture is stirred for 0.5min to 1.5min by a fly cutter; adding the bonding agent and the reinforcing material in the formula ratio, stirring and mixing for 3-7 min, and stirring for 0.5-1.5 min by using a fly cutter.

Preferably, the molding material preparation step S200 uses an upper and lower double-pot counter-current mixer to mix the molding material. Particularly preferably, the grinding material with the formula ratio is added into an upper pot of an upper-pot and lower-pot counter-current mixer, a stirrer is started, a wetting agent is added and stirred for 5min, and a fly cutter of the stirrer is started and stirred for 1 min; pouring into a lower pot, starting a stirrer, adding the bonding agent and the reinforcing material according to the formula ratio, stirring for 5min, and starting a fly cutter of the stirrer to stir for 1min to finish the preparation of the molding material.

As an alternative embodiment, in the cold press molding step S300, the molding material is cold press molded by a fixed die method according to a certain single weight.

In the cold press molding step S300, a mold suitable for fixed mold molding is designed according to the size of the prepared bonded mold, and a mold meeting the structural characteristics of the high-speed overweight load grinding bonded mold and the fixed mold molding conditions is selected first. Referring to fig. 2 to 5, preferably, the mold comprises a pressing head 100, a mold sleeve and a mold core adapted to a fixed mold for forming a cold and hot pressing two-layer structure, an upper mold plate, and a lower mold plate. The die sleeve with the cold-hot pressing two-layer structure is divided into a cold-pressing die sleeve 210 and a hot-pressing die sleeve 220, the die core is divided into a cold-pressing die core 310 and a hot-pressing die core 320, the cold-pressing die sleeve 210, the hot-pressing die sleeve 220, the cold-pressing die core 310 and the hot-pressing die core 320 are respectively connected through a concave-convex end face machined at a connector, the upper cold-pressing die sleeve 210 and the cold-pressing die core 310 are moved out after cold-pressing molding is finished, the lower hot-pressing die sleeve 220 and the hot-pressing die core 320 are reserved, and demolding is finished until molding, curing and demolding are finished. The upper template is divided into a cold upper template 400 and a hot upper template 500, the cold upper template 400 and the hot upper template 500 are composed of two metal templates with different structures and the same diameter, the lower part of the cold upper template 400 is pasted with an elastic part 410 made of polyurethane elastic material, and the hot upper template 500 is not provided with the polyurethane elastic material; in addition, the lower plate and the upper hot-pressing plate 500 may have the same structure, and the polyurethane elastic material is not provided. After cold press molding is finished, scraping off unbalance due to slight material scraping during material feeding, wherein the contact end face of the cold press upper template 400 and the grinding wheel blank is an elastic surface 410 made of elastic polyurethane material during pressing, and the unbalance of material scraping is left on the elastic surface 410, so that the internal tissue density of the grinding wheel is kept uniform; and after the cold press molding is finished, the upper cold press die sleeve 210 and the cold press die core 310 are moved out, the cold press upper die plate 400 is changed into a hot press upper die plate 500, and the cold press molded blank in the die consisting of the lower hot press die sleeve 220, the hot press die core 320, the lower die plate and the lower die plate is transferred to the next working procedure.

In the cold press molding step S300, a die sleeve is arranged on an operation table of a molding unit, a lower template is positioned at the bottom of the die sleeve, a die core is positioned at the center of the die sleeve, molding materials are filled between the die core and the die sleeve, and a cold press upper template 400 is arranged at the upper part of the die sleeve; when in cold pressing, the cold pressing upper template 400 is abutted with the molding material by the elastic surface 410 with a polyurethane structure, the upper part of the cold pressing upper template 400 is provided with a pressure head 100, and the pressure head 100 is connected with a press.

When the molding materials are filled, calculating the weight of the grinding wheel according to the specific specification of the prepared grinding wheel, weighing the corresponding molding materials, performing die pressing molding on a grinding wheel molding unit, controlling the feeding speed by adopting a computer for feeding materials, and synchronizing the feeding amount with a feeding turntable device which drives a mold to rotate on the molding unit to realize uniform feeding; the material spreading rotary disc of the grinding wheel forming machine of the forming unit adopts a friction transmission mode, avoids adopting gear transmission or other transmission modes, eliminates transmission jitter to enable the formed material to generate uneven tissue density, enables the formed material to be uniformly distributed in the die, installs the cold upper die plate 400 after the filling is finished, and enables the upper surface and the lower surface of the formed blank to be uniformly pressed together with the grinding wheel forming die to enter a press machine for press forming, so that the density of the cold-pressed formed blank is uniform, and the quality requirement is met.

Preferably, the specific implementation manner of the cold press molding step S300 is as follows:

according to the reinforcing steel ring quantity equal-portion forming material as the reinforcing function portion and feeding the material in multiple portions, applying pressure, installing a mold on a forming machine set operation platform according to the process, filling an equal-portion forming material, placing the reinforcing steel ring, then filling an equal-portion forming material, performing cold pressing treatment, performing cold pressing forming on a conventional low-tonnage cold pressing grinding wheel forming machine set operation platform, wherein the cold pressing forming adopts fixed mold forming, namely, pressing to a certain size of the thickness of a mold fixed mold under a certain pressure condition, and the thickness of the mold fixed mold is preferably 1.2 times of the specified thickness of a finished product and is kept for 1 min. The pressure is 17.0MPa to 20.0MPa, and may be, for example, 17.0MPa, 17.5MPa, 18.0MPa, 18.5MPa, 19.0MPa, 19.5MPa or 20.0 MPa. And after applying pressure, moving to an operation table, removing a die sizing block, unloading the cold-pressed upper die plate 400 formed by cold pressing, starting the operation table turntable again, scraping the uneven end surface of the blank body, which is in contact with the upper die plate, by using a knife edge ruler, leaving the uneven part of the polyurethane elastic structure of the upper die plate on the upper end surface of the grinding wheel blank due to uneven tissue density, and leaving for next feeding and putting. After the cold press molding step S300 is completed, the cold upper mold plate, the cold press mold sleeve, and the cold press mold core are removed, and the hot upper mold plate 500 is mounted for use.

As an alternative embodiment, in the pre-curing step S400, the conditions for heating the pre-curing in stages are as follows:

in the first stage, heating is carried out for 30-60 min at the temperature of 60-80 ℃;

in the second stage, the mixture is heated for 30 to 60 minutes at the temperature of between 80 and 100 ℃;

in the third stage, the mixture is heated for 30 to 60 minutes at the temperature of between 100 and 120 ℃;

in the fourth stage, the mixture is heated for 30-60 min at the temperature of 120-130 ℃.

Preferably, in this embodiment, the entire mold replaced with the hot-press upper mold plate is placed in a precuring furnace to be precured under the above-described condition of heating precuring in stages. Through designing preliminary solidification curve temperature according to the grinding wheel binder characteristic, adopt the segmentation heating precuring to make the binder in the cold pressing shaping base subassembly complete gelation, binder gelation cross-linking is compound to realize binder and abrasive material precuring, slowly discharge reaction gas in the precuring process in advance, guaranteed that the inside high equilibrium of emery wheel tissue is unanimous, thereby form the fine abrasive material structure of multilayer, realize intensive punctiform grinding, realized the emery wheel high sharpness, the grinding ratio reaches 1: 160 above, the requirement of high-speed heavy-load grinding is met.

As an optional embodiment, in the step S500 of hot press molding and curing, the hot pressing treatment is carried out from 18MPa to 20MPa to 25MPa, the temperature is increased from 120 ℃ to 130 ℃ to 180 ℃ to 190 ℃ at the temperature increasing rate of 0.5 ℃/min to 1.5 ℃/min, and the exhaust treatment is carried out at intervals in the temperature increasing and pressure increasing process. Preferably, in the hot pressing process, when the temperature rises by 10-20 ℃, the pressurization is stopped and the exhaust treatment is started for 5min, the pressing system of the press is closed, the pressurization is stopped for 5min, so that the solidified reaction gas is conveniently discharged from the die template and the die ring, the exhaust procedure is repeatedly started for three times, and more preferably, in the hot pressing process, when the temperature rises by 15 ℃, the pressurization is stopped and the exhaust treatment is started for 5min, and the exhaust procedure is repeatedly started for three times.

More preferably, in the hot press molding and curing step S500, the curing treatment is carried out at a temperature of 180 to 190 ℃ and a pressure of 20 to 25MPa for 1.0 to 3.0 hours.

Specifically, optionally, the mold with the hot pressing template after the pre-curing step S400 is integrally placed in a hot press, the pressure is increased to 18 Mpa-20 Mpa, the temperature is gradually increased from the initial 120 ℃ to 130 ℃ to 180 ℃ to 190 ℃, the temperature is increased at the rate of 0.5 ℃ to 1.5 ℃ per minute, and the temperature is increased by 15 ℃ per minute, an exhaust program is started, a press pressurization system is closed, pressurization is stopped, and the curing reaction gas is conveniently exhausted from the mold plate and the mold sleeve of the grinding tool, so that the exhaust program is repeatedly started three times until the highest hot pressing curing temperature of 180 ℃ to 190 ℃ is reached, and hot pressing is finished. And (3) entering a curing treatment stage after hot pressing, keeping the temperature of 180-190 ℃ and the pressure of 20-25 MPa at the end of hot pressing, and keeping the temperature and pressure for 1.0-3.0 h to realize the curing of the grinding wheel. After the grinding wheel is solidified, stopping pressurizing, closing the heating system, starting the mold discharging system of the hot-press forming machine set, taking out the mold from the hot-press machine, unloading the mold, placing the hot-press formed solidified blank on a supporting plate, checking that the blank meets the forming technical conditions, and then transferring to the next procedure while the blank is hot.

As an optional embodiment, in the step of solidification hardening, the solidification hardening treatment is to gradually increase the temperature from 180 ℃ to 190 ℃ to 220 ℃ to 230 ℃ within the time range of 5.0h to 7.0h, and keep the temperature at 220 ℃ to 230 ℃ for 5.0h to 7.0 h. In the embodiment, the low-temperature curing process is adopted, so that the cost can be reduced, the energy consumption is saved, the environment is protected, and the method is suitable for industrialization.

Consolidation hardening is the final process of the forming of the grinding wheel blank, and the hot-press forming solidification blank is subjected to heating treatment after demoulding to realize final complete solidification, so that certain hardness strength and heat resistance are finally realized, and the quality requirement is met. In the process of solidification and hardening, a hardening curve is a 12-hour hardening curve with a temperature rise curve with the highest temperature of 220-230 ℃, namely, a hot-press molding solidified blank is placed in a curing furnace, the temperature is gradually raised from 180-190 ℃ to 220-230 ℃ within the time range of 5.0-7.0 hours, and the temperature is kept at 220-230 ℃ for 5.0-7.0 hours. Optionally, when the furnace temperature is cooled to 100-120 ℃, opening the furnace door, continuously cooling to 60-80 ℃ and discharging.

In the finishing and inspection step S700, the high-speed overweight loaded grinding and consolidation grinding tool after the consolidation hardening is finished

Machining is carried out to reach the dimension and line tolerance specified by the standard. The equipment used in the step comprises a metal processing lathe, a grinding wheel surface grinder, a multifunctional grinding wheel lathe and the like, and the qualified products after finish machining are inspected according to the national specified standard.

In the preparation method of the high-speed overweight load grinding consolidation grinding tool, the composite technology of the high-strength double-phase reinforced composite material is innovatively realized by the composite structure design of combining the grinding functional part and the reinforcing functional part according to the special proportion of the binding agent and the grinding functional part and by the preparation processes of material feeding cold press molding, pre-curing and hot press molding curing in different times. The special cold and hot pressing device arranged on the grinding wheel forming unit is adopted to be pressed to the specified height of a forming die under the specified pressure, firstly, a grinding wheel blank body with the specified height is preliminarily pressed in a cold pressing state, and then, the blank body is pre-cured and then is subjected to high-pressure low-temperature hot pressing in a heating state to form a blank body with the consistent tissue density of a final finished product, so that the grinding wheel is ensured to have higher tissue density and uniformity.

The grinding wheel prepared by the preparation method of the high-speed overweight load grinding consolidation grinding tool not only improves the tensile strength of the grinding wheel, can prepare a larger-size grinding wheel, but also can effectively solve the interface problem between a ceramic grinding material and a polymer and the workpiece burning problem under the high-speed grinding condition, so that the grinding pressure of the prepared grinding wheel reaches 15000N-20000N, the temperature resistance during grinding reaches 600 ℃, the bonding strength of the grinding wheel is improved, the working linear speed can be improved to 80 m/s-100 m/s, and the grinding ratio reaches 1: the unbalance coefficient is more than 160, the unbalance coefficient is not more than 0.40, the minimum diameter of the grinding wheel reaches 250mm, the maximum diameter of the grinding wheel reaches 900 mm-1100 mm, and the requirements of large specification, high speed, high efficiency, overload and high temperature resistance of the grinding wheel in the special steel billet grinding process are well met.

Furthermore, the preparation method of the high-speed overweight load grinding consolidation grinding tool breaks through the technical problems that the solid phase aggregate with a ceramic structure has large size and low strength and cannot meet the technical problem of precision grinding, adopts the microstructure design and the self-sharpening control technology, prepares the ceramic material with the inorganic high-molecular high-strength nano structure and the submicron microparticle grinding material into the large-particle and high-strength ceramic microcrystal stacking grinding material by adopting the composite forming process, and uses the ceramic material as the grinding material of the consolidation grinding tool, so that the durability and the service life of the grinding wheel can be stably improved, and the degree of finish can reach the nanometer level.

The ceramic microcrystal stacking abrasive grinding material is a bulk abrasive prepared by an alumina abrasive and a silicon carbide abrasive by a special method. The novel ceramic abrasive with the microcrystalline structure is a sintered ceramic abrasive which is manufactured by adopting a sol-gel process, a low-temperature curing technology and an in-situ crystallization technology, the crystal size of the sintered ceramic abrasive is about 1-3 micrometers, multiple layers of small abrasive particles are bonded together to form a point type grinding of abrasive particle group abrasive (the abrasive particles are mainly alumina (brown corundum) or silicon carbide), the sintered ceramic abrasive is hard and tough, tiny crystals gradually fall off during grinding to expose new crystals, and the sharpness of the whole abrasive particles is kept. The abrasive is bonded by a large number of small particles of abrasive, and has a rougher appearance than a conventional abrasive. The point grinding of the abrasive grain group abrasive is formed by bonding a plurality of layers of small abrasive grains together, the small abrasive grains continuously fall off in a passivation mode, and new abrasive grains are continuously exposed in the grinding process of the grinding tool. The grains of the abrasive grain group abrasive are slightly worn in the grinding process of the grinding tool, so that the formed multilayer abrasive keeps consistent cutting rate, consistent roughness and consistent smoothness in the whole grinding process, and simultaneously provides stable grinding, the service life is greatly prolonged, the technology for preparing high-strength microcrystal structural ceramics by adopting series of inorganic high polymer materials breaks through the technical problems that solid phase aggregate with a ceramic structure is large in size and low in strength, cannot meet the technical requirement of precise grinding, and the multilayer fine abrasive grain group abrasive is formed to be in a structure and point-like grinding, and the durability can reach 8-23 times that of a common abrasive belt. The fineness can reach nanometer level. The abrasive groups also belong to ceramic sintered corundum, and the only difference is in the existence form of the abrasive particle shape, the unique form not only can solve the problem of use under the condition of high grinding force, but also can generate better self-sharpening under the condition of lower grinding force, when the abrasive is subjected to the grinding force, the passivated part of the abrasive can be decomposed along the crystal face, a new sharp edge is immediately generated and participates in the cutting action, and the self-sharpening effect is reflected. The speed and the smoothness of workpiece grinding are greatly improved, and the workpiece is always in an excellent grinding state under the high-speed grinding condition, so that high-speed precise grinding is realized.

Example 1

Finished specification (mm) of the high-speed super-heavy load grinding consolidation grinding tool of the embodiment: 610 × 75 × 203.4 (grinding wheel outer diameter × thickness × bore diameter); granularity: 8 #; the line speed was used: 80 m/s; hardness of the finished product: y level; feeding single weight: 63.6 kg; reinforcing the steel ring: two, two. The feed composition is shown in table 1.

Table 1 example 1 feed composition table

Wherein, the grinding material is ceramic microcrystal zirconium corundum and ceramic microcrystal sintering corundum.

The preparation process of the high-speed overweight load grinding consolidation grinding tool comprises the following steps:

preparing a bonding agent by using a 150L counter-current mixer, weighing raw materials of the bonding agent according to a formula, adding phenolic resin, polyimide resin, butyral resin, molybdenum disulfide and zinc borate into the counter-current mixer, starting a stirrer to mix for 3-5 min, continuously adding ferrous sulfide, cryolite and calcium oxide into the counter-current mixer, starting the stirrer to mix for 3-5 min, sequentially adding black silicon carbide (400#), dibasic lead phosphite into the counter-current mixer, starting the stirrer to mix for 3-5 min, and sieving by a 80# sieve for later use.

Preparing molding materials by using an upper and lower double-pot countercurrent mixer, weighing raw materials of the molding materials according to a formula, adding grinding materials into an upper pot of the upper and lower double-pot countercurrent mixer, starting a stirrer, adding furfural and dibutyl ester resin, stirring for 5min, and then starting a flying cutter of the stirrer to stir for 1 min; and transferring the stirred material into a lower pot of an upper and lower double-pot countercurrent mixer, starting the stirrer, adding the bonding agent and the fibers, stirring for 5min, and then starting a fly cutter of the stirrer to stir for 1min to obtain a molding material for later use.

And (3) performing cold press molding by using a 500-ton grinding wheel molding machine set, sieving the prepared molding material by a 16# sieve to enable the molding material to be in a loose state, calculating the feeding amount of the molding material to be 63.6kg according to the specific specification of the prepared grinding wheel, and weighing the molding material with the corresponding weight. Dividing the molding material into three equal parts, adding 21.2kg of the molding material into a mold, leveling by a leveling device, placing a reinforcing steel ring, adding 21.2kg of the molding material into the mold, leveling by the leveling device, placing the rest reinforcing steel ring, adding 16.1521.2 kg of the molding material into the mold, loading a cold pressing template and applying pressure twice under 18MPa, wherein the first time is 1/3 of the total pressure, removing a sizing block on the upper part of the mold, applying pressure for the second time, pressing the molding material to a specified thickness of 90mm, keeping for 1 minute, after cold press molding, removing the sizing block of a grinding tool, unloading the cold pressing template, a cold pressing template sleeve, cold pressing an upper mold core part, scraping the concave-convex part left on the upper end surface of the grinding wheel blank by the cold pressing upper mold plate due to uneven tissue density by using a knife edge ruler, and (5) completing cold press molding. Installing a hot upper template and turning to the next procedure.

Pre-curing by using a curing furnace, placing the cold-pressed formed blank and the die into the curing furnace for sectional heating and pre-curing, and heating for 30min at the temperature of 60 ℃ in the first stage; in the second stage, heating is carried out for 30min at the temperature of 80 ℃; in the third stage, heating is carried out for 30min at the temperature of 100 ℃; in the fourth stage, the mixture is heated at 120 ℃ for 30 min.

The method comprises the steps of carrying out hot press molding and curing by using a 1500-ton grinding wheel molding unit, placing a precured grinding wheel blank communicated with a mold into a hot press, raising the pressure to 20Mpa, gradually raising the temperature from initial 120 ℃ to 180 ℃, raising the temperature at a speed of raising the temperature by 1 ℃ per minute, starting an exhaust program every time the temperature is raised by 15 ℃, closing a press development system, stopping pressurization, facilitating the discharge of curing reaction gas from a mold template and a mold ring, and repeatedly starting the exhaust program for three times until the temperature is raised to 180 ℃. Heating the hot-press molding to 180 ℃, immediately curing, keeping the temperature at 180 ℃ after hot-press molding, adjusting the pressure to 25Mpa, and maintaining for 1.0 h; and (3) finishing the grinding wheel solidification at a specified time, stopping pressurizing after the grinding wheel solidification, closing the heating system, starting a mold discharging system of the hot-press forming machine set, taking the mold out of the hot-press machine, wrapping the mold by adopting a heat-insulating material, slowly cooling the mold, unloading the mold after the mold is cooled, placing a hot-press forming solidification blank on a supporting plate, and transferring to the next procedure when the hot-press forming solidification blank is hot after the mold is checked to meet the technical conditions of a forming material.

Solidifying and hardening by using a curing furnace, placing the hot-press molded solidified blank in the curing furnace while the hot-press molded solidified blank is hot, feeding the hot-press molded solidified blank into a hot air circulation curing furnace for solidifying and hardening, regulating and controlling the curing furnace according to a heating and hardening curve 1 with the maximum temperature of 220 ℃ and the time of 12h, controlling the heating rate to gradually heat the temperature in the curing furnace from 180 ℃ to 220 ℃ for 6h, preserving the heat when the maximum temperature is 220 ℃ for 6h, stopping heating until the furnace temperature is cooled to 100 ℃, opening a furnace door, continuously cooling to 60 ℃, and taking out the furnace.

And finishing and inspecting the grinding wheel after the consolidation and hardening are finished. The prepared grinding wheel has the specification (mm) of 610 multiplied by 76 multiplied by 203.4 (the outer diameter multiplied by the thickness multiplied by the aperture of the grinding wheel), when the special steel billet of the gold steel is ground, the high temperature resistant temperature test of the hot-dressed billet is more than or equal to 600 ℃, the using linear speed is 80m/s, the grinding pressure reaches 15000N-20000N, the grinding ratio is more than or equal to 1:163.5, and the unbalance coefficient is 0.24.

Example 2

Finished specification (mm) of the high-speed super-heavy load grinding consolidation grinding tool of the embodiment: 915 × 125 × 304.8 (grinding wheel outer diameter × thickness × aperture); granularity: 16 #; the line speed was used: 90 m/s; hardness of the finished product: y level; feeding single weight: 234 kg; reinforcing the steel ring: two, two. The feed composition is shown in table 2.

Table 2 example 2 composition of the feed

Wherein, the grinding material is ceramic microcrystal zirconium corundum and ceramic microcrystal sintering corundum.

The preparation process of the high-speed overweight load grinding consolidation grinding tool comprises the following steps:

preparing a bonding agent by using a 150L counter-current mixer, weighing raw materials of the bonding agent according to a formula, adding phenolic resin, polyimide resin, butyral resin, molybdenum disulfide and zinc borate into the counter-current mixer, starting a stirrer to mix for 3-5 min, continuously adding ferrous sulfide, cryolite and calcium oxide into the counter-current mixer, starting the stirrer to mix for 3-5 min, sequentially adding black silicon carbide (400#), dibasic lead phosphite into the counter-current mixer, starting the stirrer to mix for 3-5 min, and sieving by a 80# sieve for later use.

Preparing molding materials by using an upper and lower double-pot countercurrent mixer, weighing raw materials of the molding materials according to a formula, adding grinding materials into an upper pot of the upper and lower double-pot countercurrent mixer, starting a stirrer, adding furfural and dibutyl ester resin, stirring for 5min, and then starting a flying cutter of the stirrer to stir for 1 min; and transferring the stirred material into a lower pot of an upper and lower double-pot countercurrent mixer, starting the stirrer, adding the bonding agent and the fibers, stirring for 5min, and then starting a fly cutter of the stirrer to stir for 1min to obtain a molding material for later use.

And (3) performing cold press molding by using an 800-ton grinding wheel molding machine set, sieving the prepared molding material by a 16# sieve to enable the molding material to be in a loose state, calculating the feeding amount of the molding material to be 234kg according to the specific specification of the prepared grinding wheel, and weighing the molding material with the corresponding weight. Dividing the molding material into three equal parts, adding 78kg of molding material into a mold, placing a reinforcing steel ring, adding 78kg of molding material into the mold, placing the other reinforcing steel ring, adding 78kg of molding material into the mold, loading a cold pressing template, pressing twice with 18Mpa pressure, wherein the first time is 1/3 of total pressure, then removing a grinding tool sizing block, pressing with the second time to press the specified thickness of 150mm, keeping for 1 minute, removing the grinding tool sizing block after cold press molding, unloading the cold pressing template, cold pressing a die sleeve, cold pressing an upper die core part, scraping concave and convex parts left on the upper end surface of the grinding wheel blank through a polyurethane rubber elastic structure due to uneven tissue density by using a knife edge ruler, and completing cold press molding. Installing a hot upper template and turning to the next procedure.

And (2) performing pre-curing by using a curing furnace, placing the cold-pressed formed blank and the die into the curing furnace for sectional heating and pre-curing, wherein the first stage is heated at the temperature of 80 ℃ for 30min, the second stage is heated at the temperature of 100 ℃ for 30min, the third stage is heated at the temperature of 120 ℃ for 60min, and the fourth stage is heated at the temperature of 130 ℃ for 60 min.

Using a 3000-ton grinding wheel forming machine set to carry out hot press forming and curing, placing a precured grinding wheel blank communicated with a mould into a hot press, increasing the pressure to 20Mpa, gradually increasing the temperature from initial 120 ℃ to 180 ℃, increasing the temperature at a speed of increasing 1 ℃ per minute, starting an exhaust program every time the temperature is increased by 15 ℃, closing a press development system, stopping pressurization, facilitating the discharge of curing reaction gas from a mould template and a mould ring, and repeatedly starting the exhaust program for three times until the temperature is increased to 180 ℃. Heating the hot-press molding to 180 ℃, immediately carrying out curing treatment, keeping the temperature of 180 ℃ after hot-press molding, adjusting the pressure to 25Mpa, and maintaining for 3 hours; and (3) finishing the grinding wheel solidification at a specified time, stopping pressurizing after the grinding wheel solidification, closing the heating system, starting a mold discharging system of the hot-press forming machine set, taking the mold out of the hot-press machine, unloading the mold, placing the hot-press formed solidified blank on a supporting plate, and transferring to the next procedure when the hot-press formed solidified blank is hot after the mold meets the technical conditions of a forming material.

Solidifying and hardening by using a curing furnace, placing the hot-press formed solidified blank in the curing furnace while the hot-press formed solidified blank is hot, feeding the hot-press formed solidified blank into a hot air circulation curing furnace for solidifying and hardening, regulating and controlling the curing furnace according to a temperature rise hardening curve 1 with the maximum temperature of 230 ℃ and the time of 12h, controlling the temperature rise rate to gradually raise the temperature in the curing furnace from 180 ℃ to 230 ℃ for 6h, preserving the temperature when the maximum temperature is 230 ℃ for 6h, stopping heating until the furnace temperature is cooled to 100 ℃, opening a furnace door, continuously cooling to 60 ℃, and taking out the furnace.

And finishing and inspecting the grinding wheel after the consolidation and hardening are finished. The prepared grinding wheel has the specification (mm) of 915 multiplied by 125 multiplied by 305 (the outer diameter multiplied by the thickness multiplied by the aperture of the grinding wheel), when the special steel billet of the gold steel is ground, the high temperature resistant temperature test of the hot-dressed billet is more than or equal to 600 ℃, the using linear speed is 90m/s, the grinding pressure is more than 15000N, the grinding ratio is more than or equal to 1:164.65, and the unbalance coefficient is 0.22.

Examples 3 to 7

The finished specifications and preparation methods of the high-speed overweight loaded grinding and consolidation grinding tools of examples 3 to 7 are the same as those of example 1, except for the feeding composition, the feeding compositions of examples 3 to 7 are shown in table 3, and the prepared high-speed overweight loaded grinding and consolidation grinding tools grind special steel billets made of gold steel which are the same as those of example 1, and the performance indexes are shown in table 4.

Table 3 examples 3 to 7 feed composition table

Table 4 performance index of high-speed overweight loaded grinding bonded abrasive tool prepared in examples 3 to 7

Performance index	Example 3	Example 4	Example 5	Example 6	Example 7
						High temperature resistance (DEG C)	605	630	625	615	610
Using linear velocity (m/s)	80	80	80	80	80
						Grinding pressure (N)	15000	20000	20000	15000	15000
Grinding ratio	163.5	168	166.4	165.6	164.6
						Coefficient of unbalance	0.29	0.2	0.22	0.23	0.28
Rotary strength m/s	155.7	180	173.5	158.5	156.6

Comparative examples 1 to 5

The finished specifications and preparation methods of the high-speed overweight load grinding consolidation grinding tools of comparative examples 1 to 5 are the same as those of example 1, except that the feeding composition is the same, the feeding composition of comparative examples 1 to 5 is shown in table 5, and the prepared high-speed overweight load grinding consolidation grinding tools grind special steel billets made of gold steel which are the same as those of example 1, and the performance indexes are shown in table 6.

Table 5 comparative examples 1 to 5 feed composition table

Table 6 performance indexes of high-speed overweight loaded grinding consolidation abrasive tool prepared in comparative examples 1 to 5

Performance index	Comparative example 1	Comparative example 2	Comparative example 3	Comparative example 4	Comparative example 5
						High temperature resistance (DEG C)	585	580	595	605	615
Using linear velocity (m/s)	80	80	80	80	80
						Grinding pressure (N)	15000	15000	15000	15000	15000
Grinding ratio	138.8	155.4	158.8	160.5	162.1
						Coefficient of unbalance	0.25	0.36	0.25	0.23	0.29
Rotary strength m/s	138.6	138.4	138.8	138.8	138.4

The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the present invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.