Additive Composition And Composition Binding Agent For Superhard Material And Preparation Thereof, And Self-Sharpening Diamond Grinding Wheel And Preparation Thereof

Abstract

Disclosed are an additive raw material composition and an additive for superhard material product, a method for preparing the additive, a composite binding agent, a superhard material product, a self-sharpening diamond grinding wheel and a method for manufacturing the same. The raw material composition consisting of components in following mass percentage: Bi2O3 25%40%, B2O3 25%40%, ZnO 5%25%, SiO2 2%10%, Al2O3 2%10%, Na2CO3 1%5%, Li2CO3 1%5%, MgCO3 0%5%, and CaF2 1%5%. The composite binding agent is prepared from the additive and a metal composite binding agent. The self-sharpening diamond grinding wheel prepared from the composite binding agent has high self-sharpness, high strength, and fine texture, is uniformly consumed during the grinding process, does not need to be trimmed during the process of being used, and maintains good grinding force all the time, fundamentally solving the problems of long trimming time and high trimming cost of the diamond grinding wheel.

Claims

1. An additive raw material composition for a superhard material product, consisting of components in a mass percentage as follows: Bi.sub.2O.sub.3 25%40%, B.sub.2O.sub.3 25%40%, ZnO 5%25%, SiO.sub.2 2%10%, Al.sub.2O.sub.3 2%10%, Na.sub.2CO.sub.3 1%5%, Li.sub.2CO.sub.3 1%5%, MgCO.sub.3 0%5%, and CaF.sub.2 1%5%.

2. An additive for a superhard material product, made from raw materials in a mass percentage as follows: Bi.sub.2O 25%40%, B.sub.2O.sub.3 25%40%, ZnO 5%25%, SiO.sub.7 2%10%, Al.sub.2O.sub.3 2%10%, Na.sub.2CO.sub.3 1%5%, Li.sub.2CO.sub.3 1%5%, MgCO.sub.3 0%5%, and CaF.sub.2 1%5%.

3. A method for preparing the additive according to claim 2, comprising steps of: 1) mixing Bi.sub.2O.sub.3, B.sub.2O.sub.3, ZnO, SiO.sub.2, Al.sub.2O.sub.3, Na.sub.2CO.sub.3, Li.sub.2CO.sub.3, and MgCO.sub.3 of the mass percentages, heating up to 12001400 C. and keeping temperature for 13 h to provide a mixture; 2) cooling the mixture obtained in Step 1) to 850950 C., adding CaF.sub.2 of the formula ratio and mixing, and keeping temperature for 12 h to provide a sinter; 3) quenching the sinter obtained in Step 2) and then crushing the quenched sinter to have a particle size of D90<200 nm to provide the additive.

4. The method for preparing the additive according to claim 3, wherein in Step 1), a rate of raising the temperature is 812 C./min; and in Step 2), a rate of cooling is 46 C./min.

5. (canceled)

6. The method for preparing the additive according to claim 3, wherein in Step 3), the quenching refers to quenching the obtained sinter in water, to provide a bulk material.

7. The method for preparing the additive according to claim 6, wherein the crushing refers to mixing the obtained bulk material with ethanol to provide a mixture and ball-milling the mixture.

8. A composite binding agent, consisting of a metal binding agent and the additive according to claim 2, and the metal binding agent is a bronze binding agent or a Co-based binding agent.

9. (canceled)

10. A superhard material product produced by using the composite binding agent according to claim 8.

11. A self-sharpening diamond grinding wheel, comprising an abrasive block, wherein raw materials of the abrasive block comprise a metal binding agent, MoS.sub.2, SG abrasive, diamond and additive; a content of mass percentage of the additive in the raw materials of the abrasive block is 1%10%; the additive is made from raw materials in a mass percentage as follows: Bi.sub.2O.sub.3 25%35%, B.sub.2O.sub.3 25%35%, ZnO 5%10%, SiO.sub.2 5%10%, Al.sub.2O.sub.3 5%10%, Na.sub.2CO.sub.3 1%5%, Li.sub.2CO.sub.3 1%5%, MgCO.sub.3 1%5%, and CaF.sub.2 1%5%.

12. The self-sharpening diamond grinding wheel according to claim 11, wherein the additive is prepared by a method comprising steps of: 1) mixing Bi.sub.2O.sub.3, B.sub.2O.sub.3, ZnO, SiO.sub.2, Al.sub.2O.sub.3, Na.sub.2CO.sub.3, Li.sub.2CO.sub.3, and MgCO.sub.3 of a formula ratio, raising a temperature to 12001400 C. and keeping temperature for 13 h to provide a mixture; 2) cooling the mixture obtained in Step 1) to 850950 C., adding CaF.sub.2 of the formula ratio and mixing, and keeping temperature for 12 h to provide a sinter; 3) quenching the sinter obtained in Step 2) and then crushing the quenched sinter to make the quenched sinter in a particle size of D90<200 nm to provide the additive.

13. The self-sharpening diamond grinding wheel according to claim 11, wherein the metal binding agent consists of components in parts by weight as follows: Cu 2545 parts, Sn 520 parts, Co 2035 parts, Al 310 parts, Fe 15 parts, Cr 13 parts, and Ti 13 parts.

14. The self-sharpening diamond grinding wheel according to claim 11, wherein in the raw materials of the abrasive block, a mass ratio of the SG abrasive to the diamond is (26):(515).

15. The self-sharpening diamond grinding wheel according to claim 14, wherein the abrasive block is made from raw materials in a mass percentage as follows: Cu 25%45%, Sn 5%20%, Co 20%35%, Al 3%10%, Fe 1%5%, Cr 1%3%, Ti 1%3%, MoS.sub.2 1%3%, SG abrasive 2%6%, diamond 5%15%, and additive 1%10%.

16. The self-sharpening diamond grinding wheel according to claim 11, further comprising a grinding wheel substrate, wherein the abrasive block is adhered onto the grinding wheel substrate.

17. A method for manufacturing the self-sharpening diamond grinding wheel according to claim 11, comprising steps of: a) mixing a metal binding agent, MoS.sub.2 powder, SG abrasive, diamond and additive to provide a mixture; b) placing the mixture obtained in Step a) in a mold and pressing the mixture to provide a semifinished product; c) placing the semifinished product obtained in Step b) in a mold, raising a temperature to 580620 C. and keeping temperature for 410 min for sintering, followed by quenching, to provide the abrasive block.

18. The method for manufacturing the self-sharpening diamond grinding wheel according to claim 17, wherein in Step b), a pressure of the pressing is 150200 MPa.

19. The method for manufacturing the self-sharpening diamond grinding wheel according to claim 17, wherein in Step c), the raising temperature refers to firstly raising the temperature to 350450 C. at a heating rate of 100 C./min and keeping temperature for 13 min, and then raising the temperature to 580620 C. at a heating rate of 50 C./min.

20. The method for manufacturing the self-sharpening diamond grinding wheel according to claim 17, further comprising adhering the obtained abrasive block on a grinding wheel substrate to provide the self-sharpening diamond grinding wheel.

21. A self-sharpening diamond grinding wheel, comprising an abrasive block, wherein raw materials of the abrasive block comprise a metal binding agent, MoS.sub.2, SG abrasive, diamond and the additive according to claim 2; and the content of mass percentage of the additive in the raw materials of the abrasive block is 1%10%.

22. The additive according to claim 2, wherein the additive has a microcrystalline structure.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0037] In order to more clearly illustrate technical solutions of examples of the present invention, figures which are needed in the examples will be introduced briefly below. It should be understood that the figures below merely show some examples of the present invention, and therefore should not be considered as limiting the scope. A person ordinarily skilled in the art still can obtain other relevant figures according to these figures, without expending inventive effort.

[0038] FIG. 1 is a diagram of distribution of particle size of an additive for a superhard material product obtained in Example 1;

[0039] FIG. 2 is a schematic diagram of distribution of the additive obtained in Example 1 in a composite binding agent,

[0040] Wherein the legends are 1skeleton material, 2additive.

DETAILED DESCRIPTION OF EMBODIMENTS

[0041] Below, the present invention is further described with reference to several embodiments.

[0042] An additive raw material composition for superhard material product consists of components in a mass percentage as follows:

[0043] Bi.sub.2O.sub.3 25%40%, B.sub.2O.sub.3 25%40%, ZnO 5%25%, SiO.sub.2 2%10%, Al.sub.2O.sub.3 2%10%, Na.sub.2CO.sub.3 1%5%, Li.sub.2CO.sub.3 1%5%, MgCO.sub.3 0%5%, and CaF.sub.2 1%5%.

[0044] In the above raw material composition, the purity of respective raw materials is analytically pure.

[0045] An additive for superhard material product is made from raw materials in a mass percentage as follows:

[0046] Bi.sub.2O.sub.3 25%40%, B.sub.2O.sub.3 25%40%, ZnO 5%25%, SiO.sub.2 2%10%, Al.sub.2O.sub.3 2%10%, Na.sub.2CO.sub.3 1%5%, Li.sub.2CO.sub.3 1%5%, MgCO.sub.3 0%5%, and CaF.sub.2 1%5%.

[0047] Optionally, the particle size of the additive is D90<200 nm.

[0048] A method for preparing the above additive includes the steps of:

[0049] 1) mixing Bi.sub.2O.sub.3, B.sub.2O.sub.3, ZnO, SiO.sub.2, Al.sub.2O.sub.3, Na.sub.2CO.sub.3, Li.sub.2CO.sub.3, and MgCO.sub.3 of a formula ratio, heating up to 12001400 C. and keeping the temperature for 13 hours to provide a mixture;

[0050] 2) cooling the mixture obtained in Step 1) to 850950 C., adding CaF.sub.2 of the formula ratio to the mixture, and keeping the temperature for 12 hours to provide a sinter;

[0051] 3) quenching the sinter obtained in Step 2) and then crushing the quenched sinter to make the quenched sinter in a particle size of D90<200 nm to obtain the additive.

[0052] Optionally, in Step 1), a rate of the heating is 812 C./min. The mixed raw materials are put in a quartz crucible, and placed in a high-temperature resistance furnace to be heated.

[0053] Optionally, in Step 2), a rate of the cooling is 46 C./min.

[0054] Optionally, in Step 3), the quenching refers to quenching the obtained sinter in water, to provide a bulk material. The water preferably is water at a room temperature.

[0055] Optionally, the crushing in Step 3) refers to mixing the obtained bulk material with ethanol and ball-milling them. The bulk material is put into a ball-mill tank together with ethanol to be ball-milled on a high-energy ball-milling machine; they are ball-milled until the obtained powder has a particle size of D90<200 nm; optionally, the ball-milling time is 4060 hours. Optionally, a volume ratio of the material to ethanol is 1:3.

[0056] The composite binding agent consists of a metal binding agent and the above additive. The content of mass percentage of the additive in the composite binding agent is no more than 30%. In one embodiment, the content of mass percentage of the additive in the composite binding agent is 1.1%30%.

[0057] Optionally, the metal binding agent is a bronze binding agent or a Co-based binding agent.

[0058] A superhard material product uses the above composite binding agent; the superhard material product is a grinding wheel. In the grinding wheel, the weight of the additive is 1%10% of the total weight of the raw materials of the grinding wheel. The raw materials of the grinding wheel include the composite binding agent and an abrasive. Preferably, the abrasive is a diamond abrasive.

[0059] The self-sharpening diamond grinding wheel includes an abrasive block. Raw materials of the abrasive block include a metal binding agent, MoS.sub.2, SG abrasive, diamond and the above additive; the content of mass percentage of the above additive in the raw materials of the abrasive block is 1%10%.

[0060] A method for manufacturing the above self-sharpening diamond grinding wheel includes the steps of:

[0061] a) mixing the metal binding agent, the MoS.sub.2 powder, the SG abrasive, the diamond and the additive to provide a mixture;

[0062] b) loading the mixture obtained in Step a) in a mold and pressing the mixture to provide a semi-finished product;

[0063] c) placing the semi-finished product obtained in Step b) in a mold, heating up to 580620 C. and keeping the temperature for 410 min for sintering, followed by quenching, to provide the abrasive block.

[0064] Optionally, in Step a), the mixing includes pouring the raw materials in a three-dimensional mixer to mix the materials for 24 hours.

[0065] Optionally, in Step b), a pressure of the pressing is 150200 MPa. The mold used in the pressing preferably is a steel mold; the device used in the pressing preferably is an oil hydraulic press.

[0066] Optionally, in Step c), the heating refers to firstly heating up to 350450 C. at a heating rate of 100 C./min and keeping the temperature for 13 min, and then heating up to 580620 C. at a heating rate of 50 C./min. The function of firstly heating up to 350450 C. and keeping the temperature is to promote the complete melting of Sn with a low melting point, so as to perform alloying reaction.

[0067] Optionally, in Step c), the mold used in the sintering preferably is a graphite mold; the device used in the sintering preferably is a hot pressed sintering machine. The sintering process can be carried out in an air atmosphere. After completing the sintering by keeping the temperature at 580620 C., the mold is placed in water to be quenched. The water preferably is water at a room temperature.

[0068] Optionally, the method for preparing the self-sharpening diamond grinding wheel further includes adhering the obtained abrasive block on a grinding wheel substrate to obtain the self-sharpening diamond grinding wheel.

[0069] In the embodiments, all the raw materials used in the raw material composition are analytically pure.

Example 1

[0070] An additive raw material composition for superhard material product in the present example consists of components of mass percentage as follows:

[0071] Bi.sub.2O.sub.3 35%, B.sub.2O.sub.3 35%, ZnO 10%, SiO.sub.2 5%, Al.sub.2O.sub.3 3%, Na.sub.2CO.sub.3 2%, Li.sub.2CO.sub.3 4%, MgCO.sub.3 2%, and CaF.sub.2 4%.

[0072] An additive for superhard material product in the present example is made from the above raw material composition, and a method for preparing the additive includes the steps of:

[0073] 1) mixing Bi.sub.2O.sub.3, B.sub.2O.sub.3, ZnO, SiO.sub.2, Al.sub.2O.sub.3, Na.sub.2CO.sub.3, Li.sub.2CO.sub.3, and MgCO.sub.3 of a formula ratio and evenly mixing them, then pouring the mixture in a quartz crucible, and placing the quartz crucible in a high-temperature resistance furnace to be heated at a rate of 10 C./min to 1250 C. and keeping the temperature for 2 hours to provide a mixture;

[0074] 2) cooling the mixture obtained in Step 1) to 850 C. at a rate of 5 C./min, adding CaF.sub.2 of the formula ratio to the mixture and stirring, and keeping the temperature for 2 hours to provide a sinter;

[0075] 3) pouring the sinter obtained in Step 2) into cold water to be quenched to provide a bulk material; putting the obtained bulk material and ethanol, at a volume ratio of 1:3 of the material to ethanol, into a ball-mill tank to be ball-milled on a high-energy ball-milling machine for 60 hours, to obtain a powder, i.e. the additive, having a particle size of D90<200 nm (the particle size of the powder was detected via a laser particle analyzer, and the particle size distribution was as shown in FIG. 1).

[0076] The composite binding agent in the present example consists of a metal binding agent and the above additive. The content of mass percentage of the additive in the composite binding agent is 10%. The metal binding agent is a bronze binding agent, and consists of components of mass percentage as follows: Cu powder 71%, Sn powder 21% Co powder 7%, and Ni powder 1%.

[0077] The grinding wheel in the present example was made by evenly mixing the above composite binding agent with a diamond abrasive, followed by pressing the mixture at 150 MPa into a semi-finished product, and then placing the semi-finished product in a corresponding mold to be subjected to sintering at 580 C. The weight of the additive is 8% of the total weight of the raw materials of the grinding wheel the composite binding agent and the diamond abrasive).

[0078] FIG. 2 is a schematic diagram of distribution of the additive in the composite binding agent. It can be seen from FIG. 2 that the additive shows uniformly diffused radial distribution of a submicron level in the composite binding agent, and the distribution of the additive in the superhard material product is also consistent. In FIG. 2, the skeleton material refers to a refractory component in the metal binding agent, and is a part of the composite binding agent.

[0079] The grinding wheel obtained in Example 1 is used for grinding of hard alloy, and the grinding effect thereof is as listed in Table 1, where Comparative Example 1 uses a diamond grinding wheel of bronze binding agent without the additive, and the rest is the same as that in Example 1.

[0080] Table 1 Comparison Table of Grinding Effects of the Grinding Wheel Obtained in Example 1

TABLE-US-00001 Removal Trimming Grinding Strength Rate Frequency (Kg Service Life of Wheel (MPa) (g/min) each time) Grinding Wheel Comparative 280 3 2.5 30 Example 1 Example 1 260 4 4 42

Example 2

[0081] An additive raw material composition for superhard material product in the present example consists of components of mass percentage as follows:

[0082] Bi.sub.2O.sub.3 30%, B.sub.2O.sub.3 40%, ZnO 10%, SiO.sub.2 5%, Al.sub.2O.sub.3 3%, Na.sub.2CO.sub.3 4%, Li.sub.2CO.sub.3 4%, and CaF.sub.2 4%.

[0083] An additive for superhard material product in the present example is made from the above raw material composition, and a method for preparing the additive includes the steps of:

[0084] 1) mixing Bi.sub.2O.sub.3, B.sub.2O.sub.3, ZnO, SiO.sub.2, Al.sub.2O.sub.3, Na.sub.2CO.sub.3, and Li.sub.2CO.sub.3 of a formula ratio and evenly mixing them, then pouring the mixture in a quartz crucible, and placing the quartz crucible in a high-temperature resistance furnace to be heated at a rate of 10 C./min to 1300 C. and keeping the temperature for 1 hour to provide a mixture;

[0085] 2) cooling the mixture obtained in Step 1) to 850 C. at a rate of 5 C./min, adding CaF.sub.2 of the formula ratio to the mixture and stirring, and keeping the temperature for 2 hours to provide a sinter;

[0086] 3) pouring the sinter obtained in Step 2) into cold water to be quenched to provide a bulk material; putting the obtained bulk material and ethanol, at a volume ratio of 1:3 of the material to ethanol, into a ball-mill tank to be ball-milled on a high-energy ball-milling machine for 50 hours, to obtain a powder, i.e. the additive, having a particle size of D90<200 nm (the particle size of the powder was detected via a laser particle analyzer).

[0087] The composite binding agent in the present example consists of a metal binding agent and the above additive. The content of mass percentage of the additive in the composite binding agent is 3.8%. The metal binding agent is a Co-based binding agent, and consists of components of mass percentage as follows: Co 64%, Cu 21%, Sn 10%, and WC 5%.

[0088] The grinding wheel in the present example was made by evenly mixing the above composite binding agent with a diamond abrasive, followed by pressing the mixture at 200 MPa into a semi-finished product, and then placing the semi-finished product in a corresponding mold to be subjected to sintering at 620 C. The weight of the additive is 3% of the total weight of the raw materials of the grinding wheel (the composite binding agent and the diamond abrasive).

[0089] The grinding wheel obtained in Example 2 is used for grinding of iron-based powder metallurgical workpiece, which is assembly line work, and the grinding effect thereof is as listed in Table 2, where Comparative Example 2 uses a diamond grinding wheel of Co-based binding agent without the additive, and the rest is the same as that in Example 2.

[0090] Table 2 Comparison Table of Grinding Effects of the Grinding Wheel Obtained in Example 2

TABLE-US-00002 Service Trimming Life of Processing Frequency Grinding Grinding Strength Cycle Time (piece Wheel Wheel (MPa) (sec) each time) (piece) Comparative 260 18 3200 28000 Example 2 Example 2 250 14 5800 42000

[0091] The composition of the additive raw material compositions for superhard material product in Examples 3-6 is as listed in Table 3.

[0092] Table 3 Composition of the Additive Raw Material Compositions for Superhard Material Product in Examples 3-6 (mass percentage)

TABLE-US-00003 Component Example 3 Example 4 Example 5 Example 6 Bi.sub.2O.sub.3 25% 30% 40% 25% B.sub.2O.sub.3 40% 25% 30% 25% ZnO 5% 19% 5% 25% SiO.sub.2 2% 10% 8% 6% Al.sub.2O.sub.3 8% 2% 5% 10% NaCO.sub.3 1% 5% 3% 2% LiCO.sub.3 3% 1% 5% 2% MgCO.sub.3 5% 3% 1% 3% CaF.sub.2 1% 5% 3% 2%

[0093] The additives for superhard material product in Examples 3-6 are made from the above raw material compositions, respectively. Technical parameters of preparing methods are as listed in Table 4, and the rest is the same with that in Example 1.

[0094] Table 4 Table of Parameters of Methods for Preparing the Additives for Superhard Material Product in Examples 3-6

TABLE-US-00004 Step Parameter Example 3 Example 4 Example 5 Example 6 1) temperature being kept at, C. 1200 1300 1400 1350 temperature-keeping time, h 3 2 1 1.5 2) temperature being kept at, C. 850 950 900 900 temperature-keeping time, h 2 1 1.5 1 3) ball-milling time, h 40 45 50 55
Composite binding agents in Examples 3-6 consist of the above additives and metal binding agents, respectively, and the rest is the same as that in Example 1. The grinding wheels in Examples 3-6 are made from the above composite binding agents and diamond abrasives, respectively, and the rest is the same as that in Example 1.

[0095] Grinding effects of the grinding wheels in Examples 3-6 are detected, and results are as listed in Table 5.

[0096] Table 5 Detection Results of Grinding Effects of the Grinding Wheels Obtained in Examples 3-6

TABLE-US-00005 Removal Trimming Service Life of Grinding Strength Rate Frequency (Kg Grinding Wheel Wheel (MPa) (g/min) each time) (Kg) Comparative 280 3 2.5 30 Example 1 Example 3 277 3.9 3.9 40 Example 4 273 4 3.6 35 Example 5 270 4.2 3 33 Example 6 269 3.3 5 45

[0097] It can be seen from Table 5 that, while substantially maintaining the original strength, the grinding wheel products using the additive in the present invention have improved sharpness, service life, and grinding performance.

Example 7

[0098] A self-sharpening diamond grinding wheel in the present example includes a grinding wheel substrate and an abrasive block, and the abrasive block is made from raw materials in a mass percentage as follows: Cu 28%, Sn 12%, Co 30%, Al 5%, Fe 3%, Cr 2%, Ti 2%, MoS.sub.2 3%, SG abrasive 2%, diamond 10%, and additive 3%.

[0099] The additive is made from raw materials in a mass percentage as follows: Bi.sub.2O.sub.3 35%, B.sub.2O.sub.3 35%, ZnO 10%, SiO.sub.2 5%, Al.sub.2O.sub.3 3%, Na.sub.2CO.sub.3 2%, Li.sub.2CO.sub.3 4%, MgCO.sub.3 2%, and CaF.sub.2 4%.

[0100] A method for preparing the additive includes the steps of:

[0101] 1) mixing Bi.sub.2O.sub.3, B.sub.2O.sub.3, ZnO, SiO.sub.2, Al.sub.2O.sub.3, Na.sub.2CO.sub.3, Li.sub.2CO.sub.3, and MgCO.sub.3 of a formula ratio and evenly mixing them, then pouring the mixture in a quartz crucible, and placing the quartz crucible in a high-temperature resistance furnace to be heated at a rate of 10 C./min to 1250 C. and keeping the temperature for 2 hours to provide a mixture;

[0102] 2) cooling the mixture obtained in Step 1) to 850 C. at a rate of 5 C./min, adding CaF.sub.2 of the formula ratio to the mixture and stirring, and keeping the temperature for 2 hours to provide a sinter;

[0103] 3) pouring the sinter obtained in Step 2) into cold water (room temperature) to be quenched to provide a bulk material; putting the obtained bulk material and ethanol into a ball-mill tank to be ball-milled on a high-energy ball-milling machine for 60 hours, to obtain a powder, i.e. the additive, having a particle size of D90<200 nm.

[0104] A method for manufacturing the self-sharpening diamond grinding wheel in the present example includes the steps of:

[0105] a) mixing Cu powder, Sn powder, Co powder, Al powder, Fe powder, Cr powder, Ti powder, MoS.sub.2 powder, SG abrasive, diamond and additive of a formula ratio, pouring them into a three-dimensional mixer to be mixed for 2 hours, to provide a mixture;

[0106] b) loading the mixture obtained in Step a) into a steel mold, shaving and flattening the mixture, and placing the steel mold on an oil hydraulic press to be pressed at a pressure of 150 MPa, to provide a semi-finished product.

[0107] c) loading the semi-finished product obtained in Step b) in a graphite mold, and placing the graphite mold in a hot pressing sintering machine in an air atmosphere to be sintered, specifically: heating up to 400 C. at a heating rate of 100 C./min and keeping the temperature for 2 min, to promote the complete melting of Sn with a low melting point, so as to perform alloying reaction, and then heating up to 600 C. at a heating rate of 50 C./min and keeping the temperature for 8 min; after completing the sintering, placing the mold in cold water (room temperature) to be quenched, to provide the abrasive block;

[0108] d) adhering the abrasive block obtained in Step c on a grinding wheel substrate to obtain the self-sharpening diamond grinding wheel.

Example 8

[0109] A self-sharpening diamond grinding wheel in the present example includes a grinding wheel substrate and an abrasive block, and the abrasive block is made from raw materials in a mass percentage as follows: Cu 44%, Sn 10%, Co 25%, Al 3%, Fe 2%, Cr 1%, Ti 3%, MoS.sub.2 1%, SG abrasive 5%, diamond 5%, and additive 1%.

[0110] The additive is made from raw materials in a mass percentage as follows: Bi.sub.2O.sub.3 25%, B.sub.2O.sub.3 40%, ZnO 5%, SiO.sub.2 2%, Al.sub.2O.sub.3 8%, Na.sub.2CO.sub.3 1%, Li.sub.2CO.sub.3 3%, MgCO.sub.3 5%, and CaF.sub.2 1%.

[0111] A method for preparing the additive includes the steps of:

[0112] 1) mixing Bi.sub.2O.sub.3, B.sub.2O.sub.3, ZnO, SiO.sub.2, Al.sub.2O.sub.3, Na.sub.2CO.sub.3, Li.sub.2CO.sub.3, and MgCO.sub.3 of a formula ratio and evenly mixing them, then pouring the mixture in a quartz crucible, and placing the quartz crucible in a high-temperature resistance furnace to be heated at a rate of 10 C./min to 1300 C. and keeping the temperature for 1 hour to provide a mixture;

[0113] 2) cooling the mixture obtained in Step 1) to 850 C. at a rate of 5 C./min, adding CaF.sub.2 of the formula ratio to the mixture and stirring, and keeping the temperature for 2 hours to provide a sinter;

[0114] 3) pouring the sinter obtained in Step 2) into cold water (room temperature) to be quenched to provide a bulk material; putting the obtained bulk material and ethanol into a ball-mill tank to be ball-milled on a high-energy ball-milling machine for 50 hours, to obtain a powder, i.e. the additive, having a particle size of D90<200 nm.

[0115] A method for manufacturing the self-sharpening diamond grinding wheel in the present example includes the steps of:

[0116] a) mixing Cu powder, Sn powder, Co powder, Al powder, Fe powder, Cr powder, Ti powder, MoS.sub.2 powder, SG abrasive, diamond and additive of a formula ratio, pouring them into a three-dimensional mixer to be mixed for 3 hours, to provide a mixture;

[0117] b) loading the mixture obtained in Step a) into a steel mold, shaving and flattening the mixture, and placing the steel mold on an oil hydraulic press to be pressed at a pressure of 200 MPa, to provide a semi-finished product.

[0118] c) loading the semi-finished product obtained in Step b) in a graphite mold, and placing the graphite mold in a hot pressing sintering machine in an air atmosphere to be sintered, specifically: heating up to 450 C. at a heating rate of 100 C./min and keeping the temperature for 1 min, to promote the complete melting of Sn with a low melting point, so as to perform alloying reaction, and then heating up to 580 C. at a heating rate of 50 C./min and keeping the temperature for 10 min; after completing the sintering, placing the mold in cold water (room temperature) to be quenched, to provide the abrasive block;

[0119] d) adhering the abrasive block obtained in Step c on a grinding wheel substrate to obtain the self-sharpening diamond grinding wheel.

Example 9

[0120] A self-sharpening diamond grinding wheel in the present example includes a grinding wheel substrate and an abrasive block, and the abrasive block is made from raw materials in a mass percentage as follows: Cu 25%, Sn 5%, Co 30%, Al 7%, Fe 1%, Cr 2%, Ti 1%, MoS.sub.2 2%, SG abrasive 6%, diamond 15%, and additive 6%.

[0121] The additive is made from raw materials in a mass percentage as follows: Bi.sub.2O.sub.3 30%, B.sub.2O.sub.3 25%, ZnO 19%, SiO.sub.2 10%, Al.sub.2O.sub.3 2%, Na.sub.2CO.sub.3 5%, Li.sub.2CO.sub.3 1%, MgCO.sub.3 3%, and CaF.sub.2 5%. A method for preparing the additive is the same as that in Example 7.

[0122] A method for manufacturing the self-sharpening diamond grinding wheel in the present example includes the steps of:

[0123] a) mixing Cu powder, Sn powder, Co powder, Al powder, Fe powder, Cr powder, Ti powder, MoS.sub.2 powder, SG abrasive, diamond and additive of a formula ratio, pouring them into a three-dimensional mixer to be mixed for 4 hours, to provide a mixture;

[0124] b) loading the mixture obtained in Step a) into a steel mold, shaving and flattening the mixture, and placing the steel mold on an oil hydraulic press to be pressed at a pressure of 170 MPa, to provide a semi-finished product.

[0125] c) loading the semi-finished product obtained in Step b) in a graphite mold, and placing the graphite mold in a hot pressing sintering machine in an air atmosphere to be sintered, specifically: heating up to 400 C. at a heating rate of 100 C./min and keeping the temperature for 1 min, to promote the complete melting of Sn with a low melting point, so as to perform alloying reaction, and then heating up to 620 C. at a heating rate of 50 C./min and keeping the temperature for 4 min; after completing the sintering, placing the mold in cold water (room temperature) to be quenched, to provide the abrasive block;

[0126] d) adhering the abrasive block obtained in Step c on a grinding wheel substrate to obtain the self-sharpening diamond grinding wheel.

Example 10

[0127] A self-sharpening diamond grinding wheel in the present example includes a grinding wheel substrate and an abrasive block, and the abrasive block is made from raw materials in a mass percentage as follows: Cu 25%, Sn 20%, Co 20%, Al 5%, Fe 5%, Cr 3%, Ti 1%, MoS.sub.2 2%, SG abrasive 3%, diamond 7%, and additive 9%.

[0128] The additive is made from raw materials in a mass percentage as follows: Bi.sub.2O.sub.3 40%, B.sub.2O.sub.3 30%, ZnO 5%, SiO.sub.2 8%, Al.sub.2O.sub.3 5%, Na.sub.2CO.sub.3 3%, Li.sub.2CO.sub.3 5%, MgCO.sub.3 1%, and CaF.sub.2 3%. A method for preparing the additive is the same as that in Example 7.

[0129] A method for manufacturing the self-sharpening diamond grinding wheel in the present example includes the steps of:

[0130] a) mixing Cu powder, Sn powder, Co powder, Al powder, Fe powder, Cr powder, Ti powder, MoS.sub.2 powder, SG abrasive, diamond and additive of a formula ratio, pouring them into a three-dimensional mixer to be mixed for 4 hours, to provide a mixture;

[0131] b) loading the mixture obtained in Step a) into a steel mold, shaving and flattening the mixture, and placing the steel mold on an oil hydraulic press to be pressed at a pressure of 160 MPa, to provide a semi-finished product.

[0132] c) loading the semi-finished product obtained in Step b) in a graphite mold, and placing the graphite mold in a hot pressing sintering machine in an air atmosphere to be sintered, specifically: heating up to 350 C. at a heating rate of 100 C./min and keeping the temperature for 3 min, to promote the complete melting of Sn with a low melting point, so as to perform alloying reaction, and then heating up to 610 C. at a heating rate of 50 C./min and keeping the temperature for 3 min; after completing the sintering, placing the mold in cold water (room temperature) to be quenched, to provide the abrasive block;

[0133] d) adhering the abrasive block obtained in Step c on a grinding wheel substrate to obtain the self-sharpening diamond grinding wheel.

Example 11

[0134] A self-sharpening diamond grinding wheel in the present example includes a grinding wheel substrate and an abrasive block, and the abrasive block is made from raw materials in a mass percentage as follows: Cu 30%, Sn 5%, Co 35%, Al 10%, Fe 3%, Cr 3%, Ti 2%, MoS.sub.2 1%, SG abrasive 2%, diamond 5%, and additive 4%.

[0135] The additive is made from raw materials in a mass percentage as follows: Bi.sub.2O.sub.3 25%, B.sub.2O.sub.3 25%, ZnO 25%, SiO.sub.2 6%, Al.sub.2O.sub.3 10%, Na.sub.2CO.sub.3 2%, Li.sub.2CO.sub.3 2%, MgCO.sub.3 3%, and CaF.sub.2 2%. A method for preparing the additive is the same as that in Example 7.

[0136] A method for manufacturing the self-sharpening diamond grinding wheel in the present example includes the steps of:

[0137] a) mixing Cu powder, Sn powder, Co powder, Al powder, Fe powder, Cr powder, Ti powder, MoS.sub.2 powder, SG abrasive, diamond and additive of a formula ratio, pouring them into a three-dimensional mixer to be mixed for 2 hours, to provide a mixture;

[0138] b) loading the mixture obtained in Step a) into a steel mold, shaving and flattening the mixture, and placing the steel mold on an oil hydraulic press to be pressed at a pressure of 180 MPa, to provide a semi-finished product.

[0139] c) loading the semi-finished product obtained in Step b) in a graphite mold, and placing the graphite mold in a hot pressing sintering machine in an air atmosphere to be sintered, specifically: heating up to 450 C. at a heating rate of 100 C./min and keeping the temperature for 2 min, to promote the complete melting of Sn with a low melting point, so as to perform alloying reaction, and then heating up to 590 C. at a heating rate of 50 C./min and keeping the temperature for 8 min; after completing the sintering, placing the mold in cold water (room temperature) to be quenched, to provide the abrasive block;

[0140] d) adhering the abrasive block obtained in Step c on a grinding wheel substrate to obtain the self-sharpening diamond grinding wheel.

[0141] Self-sharpening diamond grinding wheels in Examples 12-16 use the abrasive blocks obtained in Examples 7-11 as the grinding blocks, respectively. It is also possible to omit the grinding wheel substrate.

Experimental Example

[0142] In the present Experimental Example, functional performances of the self-sharpening diamond grinding wheels obtained in Examples 7-11 are detected, and results are as listed in Table 6.

[0143] A conventional grinding wheel is provided wherein raw materials of an abrasive block consist of components of mass percentage as follows: Cu 50%, Sn 25%, Co 15%, and diamond 10%; the manufacturing method for the conventional grinding wheel is the same as that in Example 4.

[0144] Table 6 Detection Results of Functional Performances of Self-sharpening Diamond Grinding Wheels Obtained in Examples 7-11)

TABLE-US-00006 Spindle Motor Grinding Trimming Trimming Total Processing Current Item Object Mode Time Hours Amount Mean Value Yield Conventional sapphire manual 6 times/ 60 h 153 pieces 35 A 98.7% grinding trimming 120 min wheel Example 7 sapphire none 0 60 h 183 pieces 33 A 98.6% Example 8 sapphire none 0 60 h 189 pieces 34 A 98.8% Example 9 sapphire none 0 60 h 177 pieces 28 A 98.7% Example 10 sapphire none 0 60 h 180 pieces 27 A 98.9% Example 11 sapphire none 0 60 h 175 pieces 29 A 99.1% Notes: the bigger a spindle motor current, the bigger a load.

[0145] It can be seen from Table 6 that since the diamond grinding wheels in Examples 7-11 have good self-sharpening ability, the trimming step is omitted, thus the trimming cost is saved, and the trimming time is transferred to the processing of the workpiece; during the same period of time, the processing amount is increased by about 17%, and the processing efficiency is improved; moreover, during the grinding process, the grinding load (resistance) is decreased, the sharpness of the grinding wheel is improved, and the yield is comparable. The detection results show that the diamond grinding wheels in the present invention have high self-sharpness, high strength, and high processing efficiency, is uniformly consumed during the grinding process, and do not need to be trimmed during the operational life cycle. Moreover, during the grinding process, they maintain good grinding force all the time, fundamentally solving the problems of long trimming time and high trimming cost of the conventional diamond grinding wheel, and possessing good economic benefit.

[0146] Although the invention has been described and illustrated with a certain degree of particularity with reference to a number of invention embodiments, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the combination and arrangement of parts can be resorted to by those skilled in the art without departing from the spirit and scope of the invention, as hereinafter claimed.