Effects of binder content on preparation of spherical corundum stacked abrasive by spray drying method

The spraying drying method was used to prepare spherical corundum stacked abrasive, with inorganic sol and ordinary white corundum powder serving as the binder and single-grain abrasive, respectively. Using X-ray diffraction, scanning electron microscopy, single particle compressive strength tester, and integrated surface roughness tester, the effects of different binder dosages were characterized on the fronts of microstructure, strength, and polishing performance of spherical corundum stacked abrasive, respectively. Results show that the corundum stacked abrasive possesses better sphericity and uniform distribution. With a binder content of 8% (mass fraction, as below) and a sintering temperature of 820°C, the binder can be melted into a liquid phase, providing better coverage of the corundum abrasive and producing a stronger holding force. Polishing experiments show that the polishing rate of corundum stacked abrasive to stainless steel workpieces increases continuously with binder content increasing. When the binder content is 8%, the workpiece has the better surface consistency and the lowest surface roughness, which is 0.05 μm.