新型金属结合剂金刚石工具技术的基础研究
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摘要
热压烧结的金属结合剂金刚石磨料工具经过长达四十多年的生产运用实践,其固有弊病和缺陷已有了较为充分的暴露,其中最为根本和核心的问题是:对磨料结合把持强度低,磨料易脱落;磨料出刃难,出刃后出露程度保持难;磨料随机分布导致工作面上磨料负荷与磨削过程失衡。
本文在总结综合吸收消化国内外关于金属结合剂金刚石工具研究所取得进步与不足的基础上,围绕对磨料的结合把持强度、钎焊磨料的热损伤、孔隙结构及磨料有序分布等几个工艺关键问题开展了相关的基础及应用研究,所研制的新型金属结合剂金刚石工具在加工性能对比试验中表现了显著的优势。
本文完成的具有创新意义的研究工作主要包括:
(1)从钎焊金刚石形态与界面微观结构、界面结合强度以及金刚石磨料加工中的行为三个角度研究了金刚石钎焊效果的评价体系,获得了对金刚石磨料具有高把持强度同时又无附加损伤的金刚石钎焊技术。
(2)提出了松装液相烧结制备多孔金属结合剂金刚石固结磨料工具的新工艺方法。该工艺方法通过松装获取相对稳定的固相骨架结构,采用造孔剂调节孔隙率与孔隙大小,以专用于金刚石磨料钎焊的活性钎料作为液相在烧结过程中润湿、铺展、充填于固相骨架表面,将金刚石磨料和形成固相骨架的粉末互相钎接形成具有一定强度、在一定范围内孔隙含量和大小可控且金刚石磨料与结合剂界面为化学结合的多孔烧结体。相比于现有的多孔金属结合剂金刚石磨料工具制造工艺,该工艺方法制作的多孔金属结合剂金刚石节块在强度相当的条件下孔隙率和磨料把持强度得到了极大的提高。
(3)利用松装液相烧结新工艺,成功制备了适于高效精密加工用多孔金属结合剂金刚石镶块砂轮。试验研究表明,采用140/170粒度金刚石磨料制作的新型砂轮可在很低的磨料浓度条件下,精密磨削Al2O3工程陶瓷获得较低的表面粗糙度,且具有磨削力小、砂轮锋利且寿命长、材料有效去除率高的特点。
(4)将有序排布金刚石高温钎焊技术与常规的金刚石节块热压技术有效结合在一起,制作成功了能够实现难加工材料高效重负荷加工的新型多层金属结合剂金刚石工具。通过与专业生产厂家的同规格锯片的对比试验,已确证论文提供的典型样品工具—φ350金刚石圆锯片具有金刚石用量少、锋利,锯切效率高、寿命长的突出优点。
论文围绕金属基多层金刚石固结磨料工具所完成的具有开创意义的上述基础与应用研究工作,对推动国内外金刚石固结磨料工具的换代改造具有重要意义。
The metal-bonded diamond abrasive tools fabricated by hot-press sintering technique have been applied for over forty years. The inherent shortcomings and disadvantages have also appeared, and the most important points are as follows: the low bonding strength to the abrasive grains and the induced easy pullout of the grains from the matrix, the difficult outcrop and holding capacity of the cutting edge in the machining process, the unmatched grain load to the grinding practice owing to the stochastic grain distribution.
On the basis of the research on the metal-bonded diamond abrasive tools in recent years, new investigation are conducted from the following aspects, including the joining strength to the grains, the thermal damage of the abrasive, the hole structure and the optimum distribution of grains. The new-type metal-bonded diamond abrasive tools with multi-hole structure are fabricated and show outstanding advantages over the traditional tools in the machining experiments.
The main creative concepts are summarized as follows:
(1) The brazing effect of the diamond grains is analyzed from three aspects, such as the diamond shape and the interfacial microstructure, the joining strength, the behavior of the grains during machining. The key brazing technology is acquired to ensure the high joining strength and avoid the thermal damage of the diamond grain.
(2) The new technology is put forward to fabricate the multi-hole metal-bonded diamond abrasive tools in the loose liquid-phase sintering process. The steady solid framework forms through the loose technique. The ratio and size of the hole are adjusted by the pore producer. At the same time, the filler alloy, which has ever been utilized to braze diamond grain, is applied to wet and spread on the solid framework. The diamond grain could join hard with the framework. The sintered specimens are accomplished. Compared with the traditional technology of the metal-bonded diamond abrasive tools, the diamond tools fabricated using the new technology in this investigation could improve the pore ratio and the joining strength under the condition of the identical specimen strength.
(3) The slotted multi-hole metal-bonded diamond grinding wheels for high efficiency precision grinding are fabricated using the loose liquid phase sintering technology. The machining experiments detect that this new diamond tool with rather low density of the grains could grind precisely Al2O3 engineering ceramics. The low surface roughness reaches. Moreover, the characteristics, i.e. the low grinding force, the sharp edge and long tool life, the high material removal rate is also evident.
(4) The multi-layer metal-bonded diamond sawing blades for cutting difficult-to-machine materials are fabricated using the comprehensive technology of both the uniform distribution of the diamond grain and the conventional hot-press sintering technology. The machining experiments are carried out between the new blades and the merchant counterparts with diameter of 350mm. The result indicates that the new tools have some topping merits, including small quantity of grains, shape edge, high machining efficiency and long tool life.
The creative work on the multi-layer metal-bonded diamond abrasive tools in this investigation could accelerate markedly the research and the application of the diamond tools around the world.
本文在总结综合吸收消化国内外关于金属结合剂金刚石工具研究所取得进步与不足的基础上,围绕对磨料的结合把持强度、钎焊磨料的热损伤、孔隙结构及磨料有序分布等几个工艺关键问题开展了相关的基础及应用研究,所研制的新型金属结合剂金刚石工具在加工性能对比试验中表现了显著的优势。
本文完成的具有创新意义的研究工作主要包括:
(1)从钎焊金刚石形态与界面微观结构、界面结合强度以及金刚石磨料加工中的行为三个角度研究了金刚石钎焊效果的评价体系,获得了对金刚石磨料具有高把持强度同时又无附加损伤的金刚石钎焊技术。
(2)提出了松装液相烧结制备多孔金属结合剂金刚石固结磨料工具的新工艺方法。该工艺方法通过松装获取相对稳定的固相骨架结构,采用造孔剂调节孔隙率与孔隙大小,以专用于金刚石磨料钎焊的活性钎料作为液相在烧结过程中润湿、铺展、充填于固相骨架表面,将金刚石磨料和形成固相骨架的粉末互相钎接形成具有一定强度、在一定范围内孔隙含量和大小可控且金刚石磨料与结合剂界面为化学结合的多孔烧结体。相比于现有的多孔金属结合剂金刚石磨料工具制造工艺,该工艺方法制作的多孔金属结合剂金刚石节块在强度相当的条件下孔隙率和磨料把持强度得到了极大的提高。
(3)利用松装液相烧结新工艺,成功制备了适于高效精密加工用多孔金属结合剂金刚石镶块砂轮。试验研究表明,采用140/170粒度金刚石磨料制作的新型砂轮可在很低的磨料浓度条件下,精密磨削Al2O3工程陶瓷获得较低的表面粗糙度,且具有磨削力小、砂轮锋利且寿命长、材料有效去除率高的特点。
(4)将有序排布金刚石高温钎焊技术与常规的金刚石节块热压技术有效结合在一起,制作成功了能够实现难加工材料高效重负荷加工的新型多层金属结合剂金刚石工具。通过与专业生产厂家的同规格锯片的对比试验,已确证论文提供的典型样品工具—φ350金刚石圆锯片具有金刚石用量少、锋利,锯切效率高、寿命长的突出优点。
论文围绕金属基多层金刚石固结磨料工具所完成的具有开创意义的上述基础与应用研究工作,对推动国内外金刚石固结磨料工具的换代改造具有重要意义。
The metal-bonded diamond abrasive tools fabricated by hot-press sintering technique have been applied for over forty years. The inherent shortcomings and disadvantages have also appeared, and the most important points are as follows: the low bonding strength to the abrasive grains and the induced easy pullout of the grains from the matrix, the difficult outcrop and holding capacity of the cutting edge in the machining process, the unmatched grain load to the grinding practice owing to the stochastic grain distribution.
On the basis of the research on the metal-bonded diamond abrasive tools in recent years, new investigation are conducted from the following aspects, including the joining strength to the grains, the thermal damage of the abrasive, the hole structure and the optimum distribution of grains. The new-type metal-bonded diamond abrasive tools with multi-hole structure are fabricated and show outstanding advantages over the traditional tools in the machining experiments.
The main creative concepts are summarized as follows:
(1) The brazing effect of the diamond grains is analyzed from three aspects, such as the diamond shape and the interfacial microstructure, the joining strength, the behavior of the grains during machining. The key brazing technology is acquired to ensure the high joining strength and avoid the thermal damage of the diamond grain.
(2) The new technology is put forward to fabricate the multi-hole metal-bonded diamond abrasive tools in the loose liquid-phase sintering process. The steady solid framework forms through the loose technique. The ratio and size of the hole are adjusted by the pore producer. At the same time, the filler alloy, which has ever been utilized to braze diamond grain, is applied to wet and spread on the solid framework. The diamond grain could join hard with the framework. The sintered specimens are accomplished. Compared with the traditional technology of the metal-bonded diamond abrasive tools, the diamond tools fabricated using the new technology in this investigation could improve the pore ratio and the joining strength under the condition of the identical specimen strength.
(3) The slotted multi-hole metal-bonded diamond grinding wheels for high efficiency precision grinding are fabricated using the loose liquid phase sintering technology. The machining experiments detect that this new diamond tool with rather low density of the grains could grind precisely Al2O3 engineering ceramics. The low surface roughness reaches. Moreover, the characteristics, i.e. the low grinding force, the sharp edge and long tool life, the high material removal rate is also evident.
(4) The multi-layer metal-bonded diamond sawing blades for cutting difficult-to-machine materials are fabricated using the comprehensive technology of both the uniform distribution of the diamond grain and the conventional hot-press sintering technology. The machining experiments are carried out between the new blades and the merchant counterparts with diameter of 350mm. The result indicates that the new tools have some topping merits, including small quantity of grains, shape edge, high machining efficiency and long tool life.
The creative work on the multi-layer metal-bonded diamond abrasive tools in this investigation could accelerate markedly the research and the application of the diamond tools around the world.
引文
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