加工电熔锆刚玉砖用电镀金刚石磨轮的研制和应用

电熔锆刚玉砖是玻璃熔窑最重要的耐火材料，该砖结构致密、热稳定性高、耐磨性好、抗蚀能力强，只有超硬磨料才能对锆刚玉砖表面进行有效磨削。本文通过复合电镀方法研制和生产金刚石磨轮，并给出了复合电镀金刚石磨轮的工艺流程。在研制过程中，对金刚石磨轮的基体和胎体进行了优化设计，分析了金刚石质量、金刚石浓度、金刚石粒度对磨削过程的影响，采用两种品级、四种粒度的金刚石按一定比例混合使用，扩大了磨轮的适用范围，提高了磨轮的自锐性，研制的电镀金刚石磨轮用于磨削锆刚玉砖耐火材料，其平均使用寿命达到168．36m^2，与热压焊接金刚石磨轮比较，平均寿命和磨削效率分别提高16．5％和20％。使用结果表明：电镀金刚石磨轮是最适合磨削加工电熔锆刚玉砖的金刚石工具，加工后的锆刚玉砖具有精确的几何形状和高光洁度的表面，同时，选择合适的金刚石磨轮和合理的磨削参数，对电镀金刚石磨轮的使用寿命和磨削效率以及锆刚玉砖的加工质量有重要影响。

DEVELOPMENT AND APPLICATION OF ELECTROPLATED DIAMOND GRINDING WHEEL FOR MACHINING FUSED CAST ZIRCON-CORUNDUM REFRACTORY BRICKS

Fused-cast zircon-corundum bricks are the most commonly used refractory for glass tank fumace.Because of dense structure, thermal stability, wear-resistance and good-resistance to the corrosion, grinding with super abrasive tool is the primary choice. In this paper, diamond-grinding wheel is developed and produced by adopting composite electroplating technology. The procedure and method for manufacturing the diamond grinding wheel are introduced. The optimization design of matrix alloy components is carried out. The effect of diamond parameters such as grade, grit size and concentration upon the grinding process is analyzed. An amount of diamond consisted of 2 grades and 4 grit sizes in a certain proportion are used. The grinding wheel can be used in wider area and its sharpness is increased. Its average service life is 168.30m 2 when processing AZS bricks. In comparison with those of heat-press sintering and welding the electroplated diamond grinding wheel service life and grinding efficiency increased by 16.5% and 20%, respectively. The results show that it is suitable for processing fused-cast zircon-corundum refractory. In order to further increase the service life and grinding efficiency and improve the processing quality of AZS bricks, it is important to reasonably select the grinding wheel and grinding parameters.