Advances in fabrication of ceramic corundum abrasives based on sol–gel process |
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| Institution: | 1. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China;2. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China;3. Qingdao Sisa Abrasives Co., Ltd, Qingdao 266555, China;4. Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education & Zhejiang Province, Zhejiang University of Technology, Hangzhou 310032, China;5. School of Mechanical and Automotive Engineering, Shanghai University of Engineering Science, Shanghai 201620, China;6. Department of Mechanical Engineering, Curtin University, Miri 98009, Malaysia;7. School of Aerospace, University of Nottingham Ningbo China, Ningbo 315100, China;8. Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran 31261, Saudi Arabia;9. Key Lab High Efficiency and Clean Mech Manufacture, Shandong University, Jinan 250100, China;10. Department of Sustainable and Renewable Energy Engineering, University of Sharjah, Sharjah 27272, United Arab Emirates |
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| Abstract: | Corundum abrasives with good chemical stability can be fabricated into various free abrasives and bonded abrasive tools that are widely used in the precision machining of various parts. However, these abrasives cannot satisfy the machining requirements of difficult-to-machine materials with high hardness, high strength, and strong wearing resistance. Although superhard abrasives can machine the above-mentioned materials, their dressing and manufacturing costs are high. By contrast, ceramic corundum abrasives fabricated by sol–gel method is a cost-effective product between conventional and superhard abrasives. Ceramic corundum abrasives exhibit self-sharpening and high toughness. In this review, the optimization methods of ceramic corundum abrasive properties are introduced from three aspects: precursor synthesis, particle shaping, and sintering. Firstly, the functional mechanism of seeds and additives on the microstructural and mechanical properties of abrasives is analyzed. Specifically, seeds can reduce the phase transition temperature and improve fracture toughness. The grain size and uniformly dense structure can be controlled by applying an appropriate amount of multicomponent additives. Then, the urgent need of engineering application and machinability of special shape ceramic corundum abrasives is reviewed, and three methods of abrasive shaping are summarized. The micromold replication technique is highly advanced and can be used to prepare functional abrasives. Additionally, the influence of a new sintering method, namely, two-step sintering technique, on the microstructural and mechanical performance of ceramic corundum abrasives is summarized. Finally, the challenge and developmental trend of the optimization of ceramic corundum abrasives are prospected. |
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| Keywords: | Ceramic corundum abrasive Seed Shaping technique Sintering additive Sol–Gel Two-step sintering process |
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