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CN-121973116-A - Impact-resistant high-strength composite abrasive cutting wheel and preparation method thereof

CN121973116ACN 121973116 ACN121973116 ACN 121973116ACN-121973116-A

Abstract

The invention discloses an impact-resistant high-strength composite abrasive cutting wheel which is characterized in that the impact-resistant high-strength composite abrasive cutting wheel is of a sandwich composite structure of a ceramic abrasive layer, a glass fiber net reinforcing layer and an elastic buffer layer, wherein the ceramic abrasive layer, the glass fiber net reinforcing layer and the elastic buffer layer are sequentially formed from outside to inside, the ceramic abrasive layer, the glass fiber net reinforcing layer and the elastic buffer layer are formed by compounding adhesives, the overall thickness is 3-8mm, the diameter is 100-300mm, the glass fiber net reinforcing layer is formed by high-toughness glass fiber mesh cloth modified by silane coupling agents, the elastic buffer layer is formed by polyurethane elastomer materials, and the ceramic abrasive layer is formed by compound abrasive materials formed by nanometer silicon carbide, sheet corundum, phenolic resin adhesives, steel slag micro powder, abrasive particles and auxiliary materials. A corresponding preparation method is also disclosed.

Inventors

  • JI BAOFENG
  • MA YONGBING
  • LIU CONG

Assignees

  • 河北双羊砂轮制造有限公司

Dates

Publication Date
20260505
Application Date
20260309

Claims (10)

  1. 1. The shock-resistant high-strength composite abrasive cutting wheel is characterized by being of a sandwich composite structure of a ceramic abrasive layer, a glass fiber net reinforcing layer and an elastic buffer layer, wherein the ceramic abrasive layer, the glass fiber net reinforcing layer and the elastic buffer layer are sequentially formed from outside to inside, the ceramic abrasive layer, the glass fiber net reinforcing layer and the elastic buffer layer are formed by compounding adhesives, the overall thickness is 3-8mm, the diameter is 100-300mm, the glass fiber net reinforcing layer is composed of high-toughness glass fiber mesh cloth modified by silane coupling agents, the elastic buffer layer is composed of polyurethane elastomer materials, and the ceramic abrasive layer is composed of compound abrasive materials formed by nanometer silicon carbide, sheet corundum, phenolic resin adhesives, steel slag micropowder, abrasive particles and auxiliary materials.
  2. 2. The anti-impact high-strength composite abrasive cutting wheel sheet according to claim 1, wherein the thickness of the ceramic abrasive layer is 1.5-4.0mm, the thickness of the glass fiber net reinforcing layer is 0.5-1.5mm, the thickness of the glass fiber net reinforcing layer is 15-25% of the total thickness of the abrasive sheet, the thickness of the elastic buffer layer is 0.5-2.0mm, the thickness of the elastic buffer layer is 15-25% of the total thickness of the abrasive sheet, the hardness of the abrasive sheet is HRB 85-95, the impact strength is more than or equal to 12kJ/m < 2 >, the preparation method of the high-toughness glass fiber net cloth modified by the silane coupling agent comprises immersing the glass fiber net cloth in a silane coupling agent solution, drying and curing after padding treatment, the mass concentration of the silane coupling agent solution is 2.0-5.0%, the silane coupling agent is KH-550, the padding pressure is 0.2-0.4MPa, the padding speed is 8-15m/min, the drying temperature is 80℃ -100%, the aging resistance is more than or equal to 1.85%, the elongation of the elastic buffer layer is more than or equal to 1.5% of the butyl phosphate, the elastic buffer layer is more than or equal to 1.85%, the elongation rate is more than or equal to 1.5% of the elastic buffer layer is more than or equal to 1.5% and the elongation rate is more than or equal to 1.85%.
  3. 3. The impact-resistant high-strength composite abrasive cutting wheel according to claim 2, wherein the composite abrasive of the ceramic abrasive layer comprises, by mass, 45-65% of abrasive particles, 3.0-8.0% of nano silicon carbide, 5.0-12.0% of sheet-like corundum, 15-25% of phenolic resin binder, 5.0-15.0% of steel slag micropowder and 0.4-1.1% of auxiliary materials, wherein the auxiliary materials comprise a dispersing agent and an antifoaming agent, the mass fraction of the dispersing agent is 0.3-0.8%, the mass fraction of the antifoaming agent is 0.1-0.3%, the particle size ratio of the abrasive particles is coarse particles (80-120 meshes) 15%, medium particles (120-200 meshes) 60%, fine particles (200-320 meshes) 25%, the particle size of the nano silicon carbide is 30-80nm, the particle size is more than or equal to 99.5%, the particle size of the sheet-like corundum is 1-5 μm, the purity is more than or equal to 99.0%, the steel slag is industrial solid waste, the activity index is more than or equal to 75%, the viscosity of the phenolic resin binder is 100-1500℃, and the viscosity of the phenolic resin is 500-1500℃.
  4. 4. A method for preparing an impact-resistant high-strength composite abrasive cut-off wheel according to any one of claims 1 to 3, comprising the steps of: S1, preparing a glass fiber mesh reinforcing layer, which comprises the steps of selecting glass fiber mesh cloth, and performing silane coupling agent modification treatment to obtain modified high-toughness glass fiber mesh cloth serving as the glass fiber mesh reinforcing layer; S2, preparing an elastic buffer layer, which comprises the steps of uniformly mixing polyurethane elastomer raw materials, an anti-aging agent and a dispersing agent, and obtaining the elastic buffer layer through melting and forming; S3, preparing a raw material of the ceramic abrasive layer, wherein the raw material comprises abrasive particles, nano silicon carbide, flaky corundum, phenolic resin binder, steel slag micropowder, dispersing agent and defoamer, which are weighed according to mass fraction, and are uniformly mixed and then dispersed by ultrasonic to obtain a ceramic abrasive layer mixture; S4, performing composite molding, namely stacking the ceramic abrasive layer mixture, the glass fiber net reinforcing layer and the elastic buffer layer in the order of the ceramic abrasive layer, the glass fiber net reinforcing layer and the elastic buffer layer, putting the ceramic abrasive layer mixture, the glass fiber net reinforcing layer and the elastic buffer layer into a molding die, and performing compression molding to obtain a grinding wheel blank; S5, performing low-temperature curing, namely curing the grinding wheel blank by adopting a process of microwave pre-curing and constant temperature low pressure curing to obtain an impact-resistant high-strength composite cutting grinding wheel; S6, carrying out post-treatment on the impact-resistant high-strength composite type abrasive cutting wheel, namely trimming, polishing and checking the cured impact-resistant high-strength composite type abrasive cutting wheel, and removing unqualified products to obtain a finished product.
  5. 5. The method for manufacturing an impact resistant high strength composite abrasive cut-off wheel according to claim 4, wherein S1 comprises: S11, selecting raw materials, namely selecting glass fiber mesh cloth, and selecting a silane coupling agent, deionized water and a catalyst, wherein the catalyst is hydrochloric acid or ammonia water; S12, preparing a silane coupling agent solution, which comprises the steps of mixing the silane coupling agent and deionized water according to a mass ratio of 2:98-5:95, adding 0.1-0.2% of catalyst, starting a stirring device, stirring at a speed of 300-500r/min for 10-15min, uniformly stirring, standing for 10-20min, and fully hydrolyzing the silane coupling agent to obtain a silane coupling agent solution with a mass concentration of 2.0-5.0%, wherein the solution is uniform and has no precipitate; S13, performing modification treatment, namely immersing the glass fiber mesh cloth into the prepared silane coupling agent solution for 5-10min to ensure that the glass fiber mesh cloth fully absorbs the solution, then conveying the glass fiber mesh cloth into a two-roller padding machine for padding treatment, wherein the padding pressure is 0.2-0.4MPa, the padding speed is 8-15m/min, the padding amount is controlled to ensure that the silane coupling agent solution is uniformly adhered to the surface of the glass fiber mesh cloth, and no redundant effusion exists; S14, drying and curing, namely placing the padded glass fiber mesh cloth into a drying oven, drying and curing for 1-2 hours at 80-100 ℃, and obtaining the modified high-toughness glass fiber mesh cloth as a glass fiber mesh reinforcing layer for later use after drying and curing.
  6. 6. The method for manufacturing an impact resistant high strength composite abrasive cut-off wheel according to claim 5, wherein S2 comprises: S21, selecting raw materials, namely selecting polyurethane elastomer raw materials, wherein the mass ratio of the polyurethane elastomer raw materials is 1:1.2-1.5:0.1-0.3, and selecting an anti-aging agent and a dispersing agent, wherein the addition amount of the anti-aging agent is 0.5-1.5% of the total mass of the polyurethane elastomer raw materials, the addition amount of the dispersing agent is 0.3-0.5% of the total mass of the polyurethane elastomer raw materials, the polyurethane elastomer raw materials are isocyanate, polyether polyol and chain extender, the anti-aging agent is one of 2, 6-di-tert-butyl-p-cresol and triphenyl phosphite, and the dispersing agent is polycarboxylate sodium salt; S22, mixing and melting, wherein the steps of adding isocyanate, polyether polyol and chain extender into a melting kettle, starting a stirring device, heating to 120-150 ℃ at a stirring speed of 200-300r/min, melting for 20-40min to enable raw materials to be fully melted and mixed; S23, molding, namely pouring the polyurethane elastomer melt into a molding die, controlling the molding pressure to be 0.1-0.3MPa, the molding temperature to be 80-100 ℃, and the molding time to be 15-30min, cooling and molding the melt, and taking out the die after molding is finished to obtain the elastic buffer layer for standby.
  7. 7. The method for manufacturing an impact resistant high strength composite abrasive cut-off wheel according to claim 6, wherein S3 comprises: S31, weighing raw materials, wherein the raw materials comprise, by mass, 45-65% of abrasive particles, 3.0-8.0% of nano silicon carbide, 5.0-12.0% of flaky corundum, 15-25% of phenolic resin binder, 5.0-15.0% of steel slag micropowder, 0.3-0.8% of dispersing agent and 0.1-0.3% of defoaming agent, wherein the abrasive particles are weighed according to the proportion of 15% of coarse particles, 60% of medium particles and 25% of fine particles, the coarse particles are 80-120 meshes, the medium particles are 120-200 meshes, the fine particles are 200-320 meshes, the particle size of nano silicon carbide is 30-80nm, the purity is more than or equal to 99.5%, the particle size of flaky corundum is 1-5 mu m, the purity is more than or equal to 99.0%, the steel slag micropowder is local industrial solid waste, the particle size is 100-300nm, the activity index is more than or equal to 75%, the phenolic resin binder is thermosetting phenolic resin, the softening point is 80-100 ℃, the viscosity is 500-1500 mPa.s, the dispersing agent is polycarboxylic acid sodium salt and the defoaming agent is an organic defoaming agent in dodecyl benzene sulfonate; S32, mixing, namely adding the weighed coarse, medium and fine abrasive particles, nano silicon carbide, flaky corundum and steel slag micro powder into a stirring tank, starting a stirring device, stirring at a stirring speed of 300-500r/min for 10-20min to fully and uniformly mix the solid raw materials, then adding a dispersing agent and a defoaming agent, continuously stirring for 10-15min to uniformly disperse the dispersing agent and the defoaming agent into the solid raw materials to prevent solid particles from agglomerating, and finally adding a phenolic resin binder, adjusting the stirring speed to 600-800r/min, and stirring for 20-30min to uniformly wrap the phenolic resin binder on the surfaces of the solid particles to obtain a primarily mixed mixture; S33, performing ultrasonic dispersion, namely placing the primarily mixed mixture into ultrasonic dispersion equipment, wherein the ultrasonic power is 400-600W, the ultrasonic time is 20-40min, the ultrasonic temperature is 30-45 ℃, and further breaking the agglomeration of solid particles through ultrasonic dispersion to uniformly disperse the components, so as to obtain the ceramic abrasive layer mixture which is uniform and free of agglomeration and good in fluidity for later use.
  8. 8. The method for manufacturing an impact resistant high strength composite abrasive cut-off wheel according to claim 7, wherein S4 comprises: S41, preparing a mold, namely selecting a forming mold matched with the size of a target grinding wheel, smearing a release agent on the inner wall of the mold, facilitating subsequent demolding, and cleaning impurities and dust on the inner wall of the mold to ensure the cleanliness and flatness of the mold; S42, stacking the spreading materials, namely stacking the ceramic grinding material layer mixture, the glass fiber net reinforcing layer and the elastic buffer layer into a forming die according to the sequence of the ceramic grinding material layer, the glass fiber net reinforcing layer and the elastic buffer layer, wherein the spreading thickness of the ceramic grinding material layer mixture is 1.5-4.0mm, the spreading thickness of the glass fiber net reinforcing layer is 0.5-1.5mm, the spreading thickness of the elastic buffer layer is 0.5-2.0mm, and the total spreading thickness is consistent with the target thickness of a grinding wheel; s43, press molding, namely putting a die with spreading in a hydraulic molding machine, controlling the pressure of the press molding to be 1.0-2.5MPa, the molding temperature to be 60-80 ℃ and the molding time to be 15-30min, and tightly combining all layers by pressing to form a grinding wheel blank with uniform structure, no layering and no bubble; s44, demolding, namely closing the hydraulic forming machine after the pressing is finished, and taking out the grinding wheel blank from the die after the die is cooled to the room temperature of 25+/-5 ℃.
  9. 9. The method for manufacturing an impact resistant high strength composite abrasive cut-off wheel according to claim 8, wherein S5 comprises: S51, performing microwave pre-curing, namely placing the demoulded grinding wheel blank into a microwave curing oven, controlling the microwave power to be 300-500W, the pre-curing temperature to be 70-90 ℃ and the pre-curing time to be 10-20min; s52, carrying out constant-temperature low-pressure curing, namely placing the pre-cured grinding wheel blank into a constant-temperature curing box, controlling the curing temperature to be 80-100 ℃, the curing pressure to be 0.3-0.8MPa, and the curing time to be 2-4 hours; and S53, cooling, namely closing the constant temperature curing box after curing is finished, taking out the grinding wheel from the curing box, and naturally cooling to the room temperature of 25+/-5 ℃.
  10. 10. The method for manufacturing an impact resistant high strength composite abrasive cut-off wheel according to claim 9, wherein S6 comprises: S61, trimming, namely placing the cooled grinding wheel into a trimmer, and trimming the edge of the grinding wheel; s62, polishing, namely putting the trimmed grinding wheel into a polisher, polishing the cutting surface of the grinding wheel, and removing uneven parts of the surface; S63, performing inspection, namely performing comprehensive inspection on the polished grinding wheel, wherein the inspection items comprise dimensional accuracy, hardness, impact strength, wear resistance, strong combination and appearance; S64, packaging and storing, wherein the step of packaging the qualified grinding wheel finished product.

Description

Impact-resistant high-strength composite abrasive cutting wheel and preparation method thereof Technical Field The invention relates to the technical field of cutting tools, in particular to an impact-resistant high-strength composite cutting grinding wheel and a preparation method thereof, which are particularly suitable for industries such as machining, building materials and the like, can be widely used for cutting materials such as metal materials, stones, concrete and the like, can effectively solve the problems of poor impact resistance, easy cracking during high-speed cutting, insufficient durability and the like of the traditional cutting grinding wheel, improves the safety and efficiency of cutting operation, and meets the urgent requirements of related industries on high-safety cutting tools. Background The cutting grinding wheel is an indispensable core cutting tool in the industries of machining, building materials and the like, is mainly used for cutting and polishing various materials such as metal, stone, concrete, glass and the like, and the performance quality of the cutting grinding wheel is directly related to the cutting efficiency, the operation safety and the production cost. The cutting grinding wheel has huge requirements for a plurality of enterprises for manufacturing machines, building construction and stone materials in the industrial fields of machining and building materials, and with the improvement of industrial upgrading and safety management requirements, the requirements for the impact resistance, the strength, the wear resistance and the safety of the cutting grinding wheel are raised. At present, the traditional abrasive cutting wheel widely used in the market mainly has the following technical pain points, and the actual requirements of related industries are difficult to meet: 1. the traditional abrasive cutting wheel is mostly in a single abrasive layer structure, lacks effective enhancement and buffer design, has crisp texture and is not enough in impact resistance. In high-speed cutting operation (especially in a cutting scene with the rotating speed not less than 3000 r/min), the grinding wheel is subjected to larger impact load, edge breakage and cracking are easy to occur, the cutting efficiency is affected, safety accidents can be possibly caused, the personal safety of operators is threatened, and the cutting machine is one of the main potential safety hazards faced by current machining and building material enterprises. 2. The abrasive materials of the traditional abrasive cutting wheel have the defects of insufficient durability and high use cost, the formula of the abrasive materials of the traditional abrasive cutting wheel is single, common corundum and silicon carbide abrasive materials are mostly adopted, the hardness and the wear resistance are limited, the abrasive materials are easy to fall off and abrade in the cutting process, the service life of the abrasive cutting wheel is short, frequent replacement is required, and the production cost of enterprises is increased. Meanwhile, the adhesive of part of grinding wheels is poor in performance, delamination and falling off are easy to occur, and durability is further reduced. 3. The production process has high energy consumption and poor product stability, the traditional cutting grinding wheel is mostly cured at a temperature of between 150 and 200 ℃ under a pressure of between 3.0 and 5.0MPa, the energy consumption is high, the internal stress of the grinding wheel is easily generated, the impact resistance and the dimensional stability of the product are further affected, the problems of deformation, cracking and the like occur, and the product qualification rate is low. 4. The raw material cost is high, the resource utilization rate is low, the abrasive and the binder of the traditional abrasive cut-off wheel are mainly made of pure industrial raw materials, the cost is high, the local industrial solid waste resources are not fully utilized, and the policy guidance of national green development and resource recycling is not met. As industrial large countries, a large amount of industrial solid wastes such as steel slag are generated each year, if the industrial solid wastes cannot be effectively utilized, not only can the resource waste be caused, but also the environmental pressure can be brought. Related attempts to improve upon the above problems have also been made in the industry, but there are still a number of disadvantages. For example, part of the technology adopts a single glass fiber reinforced layer to improve the strength of the grinding wheel, but no buffer layer is arranged, so that the impact resistance is improved only limitedly, and the grinding wheel is easy to crack during high-speed cutting, the technology optimizes the formula of the grinding material, improves the wear resistance, but does not solve the problems of high energy consumption and large internal stress of the prod