CN103313825A

CN103313825A - Super hard alloy baseplate outer circumference cutting blade and manufacturing method thereof

Info

Publication number: CN103313825A
Application number: CN2011800656087A
Authority: CN
Inventors: 笠岛匡树; 美浓轮武久; 前川治和; 长崎欣史
Original assignee: Shin Etsu Chemical Co Ltd
Current assignee: Shin Etsu Chemical Co Ltd
Priority date: 2010-11-29
Filing date: 2011-11-28
Publication date: 2013-09-18
Anticipated expiration: 2031-11-28
Also published as: EP2647469A1; TW201238715A; SG190924A1; PH12018500478A1; KR20140005911A; EP2647469B1; TWI556913B; MY193556A; MY170393A; US20130252521A1; PH12018500478B1; WO2012073855A1; CN103313825B; MY193551A; EP2647469A4

Abstract

The disclosed super hard alloy baseplate outer circumference cutting blade is formed from a super hard alloy and has a cutting blade part on the outer circumferential edge of a thin circular ring-shaped baseplate. The cutting blade part contains: cBN abrasive grains and/or diamond abrasive grains formed by pre-coating with a magnetic material; a metal or alloy formed by electroplating or electroless plating which connects between the abrasive grains and between the abrasive grains and the baseplate; and a thermoplastic resin with a melting point no greater than 350 DEG C impregnated between the abrasive grains and between the abrasive grains and the baseplate, or a thermosetting resin formed by curing a liquid-state thermosetting resin composition with a curing temperature no greater than 350 DEG C impregnated between the abrasive grains and between the abrasive grains and the baseplate. Also disclosed is the manufacturing method of said super hard alloy baseplate outer circumference cutting blade.

Description

Cement carbide substrate outside cutting wheel and manufacture method thereof

Technical field

The present invention relates to a kind of cement carbide substrate outside cutting wheel that is applicable to cut rare-earth sintering magnet with and manufacture method.

Background technology

Cutting processing for rare earth permanent magnets piece (or sintered magnet piece) has realized multiple cutting technique, for example external diameter cutting, internal diameter cutting and scroll saw cutting.Wherein, external diameter sword cutting wheel uses the most extensive.External diameter sword cutting technique has many advantages, comprises cheap cutting tool, relatively low cutting surplus, cutting member good dimensional accuracy and the relatively high process velocity relevant with the carbide alloy sword.Because the mass production of these advantages and improvement, external diameter sword cutting technique is widely used in the cutting of rare-earth sintering magnet piece.

The external diameter sword cutting wheel that is used for the cutting rare-earth sintering magnet is disclosed in JP-AH09-174441, JP-A H10-175171, in JP-A H10-175172, these outside cutting wheels comprise cement carbide substrate, and described substrate has with phenolic resins, nickel plating etc. diamond or cBN abrasive particle bonding outer rim thereon.Because the substrate of being made by carbide alloy is improved at alloy tool steel or the high-speed steel with respect to prior art aspect the mechanical strength, has therefore realized the raising on the machining accuracy, realized by using thin sword to reduce the raising on the productive rate of the sheet that surplus brings and having realized the reduction of the processing cost that High-speed machining is brought.

Although aspect cutting and processing characteristics, the external diameter sword cutting wheel of use cement carbide substrate is improved than the external diameter sword cutting wheel of prior art, yet market constantly proposes to reduce the requirement of cost.Wish to have a kind of can be with the high performance cutting wheel of high accuracy and high-speed processing.

Reference listing

Patent document

Patent document 1:JP-A H09-174441

Patent document 2:JP-A H10-175171

Patent document 3:JP-A H10-175172

Patent document 4:JP-A2005-193358

Patent document 5:JP-A H07-207254

Patent document 6:JP2942989

Patent document 7:JP-A2005-219169

Patent document 8:WO96/23630

Patent document 9:JP-A2009-172751

Summary of the invention

Technical problem

The applicant proposed a kind of technology that diamond abrasive grain is bonded in the outer rim of Circular Hard Alloy substrate with resin such as phenolic resins in the past, and diamond or cBN abrasive particle was bonded in the technology (JP-A2009-172751) of the outer rim of Circular Hard Alloy substrate with the metal bond material with suitable Young's modulus.

Be used for the outside cutting wheel of cutting rare-earth sintering magnet piece by two parts, substrate and blade form.Therefore made by the carbide alloy of high-modulus because account for the most substrate of cutting wheel, cutting wheel is improved aspect mechanical strength, and cutting accuracy is higher than the cutting wheel at the bottom of alloy tool steel and the high-speed steel-base of having of prior art.Because the metal bond material with suitable Young's modulus of being combined with cement carbide substrate, improved the mechanical strength of whole cutting wheel, thereby with comparing as the resin mating-type outside cutting wheel of abrasive particle bond material with phenolic resins or polyimide resin of prior art, obtain the raising of three performances, the raising of machining accuracy, the raising of the material productive rate with thin land and the reduction of the processing cost that high cutting speed is brought.

Cement carbide substrate outside cutting wheel can be made by produce magnetic field near the outer rim of cement carbide substrate, magnetic fields is on the abrasive particle of precoating magnetic material, so that the coating on the magnetization abrasive particle, thereby based outer rim attracts abrasive particle, and carry out in this state plating, thereby abrasive particle is bonded in outer rim.The method has reduced the manufacturing cost of outside cutting wheel.

Cement carbide substrate outside cutting wheel by said method production is a kind of outside cutting wheel take high-performance as feature.But when using this outside cutting wheel that the rare-earth sintering magnet piece is cut into magnetic sheet, sometimes can be cut tiltedly because of magnet block, or stay the cutting vestige of cutting wheel and dimensional accuracy is worsened at the magnetic sheet cutting surfaces.Particularly, when example such as the external diameter with 80-200mm, the aperture of 30-80mm and the cement carbide substrate outside cutting wheel of 0.1-1.0mm thickness, and with 200mm at least ³When the time per unit processing volume of/min operated to carry out high speed, high load capacity cutting, dimensional tolerance can surpass 50 μ m.If dimensional accuracy worsens, then need some remedial measures.For example, magnetic sheet must pass through as pass through the additional step of the smooth grinding cutting surfaces of polishing.The outside cutting wheel must use the abrasive wheel finishing, perhaps changes the cutting condition.

This becomes the obstacle of magnetic sheet processing, this magnetic sheet need to be applicable to the motor in the gap between strict control yoke and the magnet, such as linear electric machine and hard disk voice coil motor (VCM), they all need the reduction of high dimensional accuracy (comprising the cut surface flatness) and manufacturing cost.

The purpose of this invention is to provide a kind of cement carbide substrate outside cutting wheel that the rare-earth sintering magnet piece can be cut into the sheet with high dimensional accuracy, and a kind of method with this outside cutting wheel of low cost fabrication.

Solution of problem

By inference, what the rare-earth sintered magnet piece was cut oblique phenomenon is because the outside cutting wheel has the not tooth shape shape of lateral symmetry, cutting operation is carried out in easy cut direction, and because when being installed in the outside cutting wheel on the machining tool, outside cutting wheel generation warpage.Also infer, stay at magnetic sheet the cutting vestige phenomenon be because when for above-mentioned reasons magnet block being cut oblique outside cutting wheel on the cutting operation path during flip-flop traffic direction, the cutting surfaces of new cutting does not engage smoothly with the cutting surfaces that has cut, and has formed step.

During cutting operation, the flip-flop of the traffic direction of outside cutting wheel has occured, for example, when the part of the sword of outside cutting wheel is out of shape for a certain reason or is peeled off; When sword edge its shape of flip-flop; When because the feed speed of cutting wheel is higher than the grinding rate of sword, and the internal stress that is caused in sword by this distortion becomes larger than the external force that puts on the sword from workpiece, result, the power that causes the sword distortion are released and when sword is out of shape; Fill up with the foreign matter that is cut chip that operating period forms or external source when cutting groove or smoothing and when causing the operation of outside cutting wheel disturbed.In order to eliminate any cutting vestige that under this condition, can form, sword edge its shape of flip-flop not effectively, with be applied to when any power during cutting operation on the sword when changing its traffic direction, sword deform such degree so that the cutting surfaces before and after changing engage smoothly.

Abrasive particle is bonded to by plating or electroless plating and produces the space problem in the outside cutting wheel that forms blade in the substrate therein.Because abrasive particle has certain particle size, between the abrasive particle and between abrasive particle and the substrate, the only part contact of the abrasive particle of bonding, and the space between them can not be fully by the coating landfill.As a result, even behind plating, also leave the space in the blade.That is, blade comprises the space that is communicated with the surface.

As long as low at the load that is applied to during the cutting operation on the outside cutting wheel, even there is such space to exist, hi-precision cutting also is possible, because blade does not stand the substantial deformation that caused by the power that applies during the cutting.Yet, under so high load, cutting so that the place of cement carbide substrate distortion, the sword edge can partly be out of shape or come off.One prevents that blade edge deformation or the effective ways that come off from being by strengthening the intensity at sword edge.Will describe such as the back, because blade should have enough elasticity to allow the blade distortion to make it possible to the smooth engagement cutting surfaces, the intensity that only strengthens sword comes resistance to deformation to address this problem.

By the edging structure that satisfies high strength, elasticity and the required mechanical performance of blade has been done further investigation, the inventor have been found that by utilize between the abrasive particle and abrasive particle and substrate between the space, can obtain effective blade by allowing resin infiltrate the space specifically.The resin infiltrate is to form by melting heat plastic resin, infiltration and sclerosis, or by the liquid thermosetting resin combination being infiltrated and solidifying to form.The outside cutting wheel that comprises cement carbide substrate and such blade is effective in the dimensional accuracy that improves with the magnetic sheet of its cutting.The technology of melting heat plastic resin, infiltration and sclerosis or the technology of infiltrating liquid compositions of thermosetting resin and curing are effective for making take high cutting accuracy and low-cost outside cutting wheel as feature.The present invention is based on these discoveries and finishes.

On the one hand, the invention provides a kind of cement carbide substrate outside cutting wheel, it comprises the substrate of annular thin discs form of carbide alloy of the Young's modulus with 450-700GPa and the blade on this substrate outer rim, and this substrate has external diameter, the internal diameter of 30-80mm and the thickness of 0.1-1.0mm of the 80-200mm that limits outer rim.

This blade comprises diamond and/or the cBN abrasive particle of precoating magnetic material; By electroplating or electroless plating forms is used for abrasive particle is bonded together and is bonded to suprabasil metal or alloy bond material; And penetrate between the abrasive particle and abrasive particle and substrate between resin.Described resin is the thermosetting resin that has the thermoplastic resin of the highest 350 ℃ fusing point or have the liquid thermosetting resin combination acquisition of the highest 350 ℃ solidification temperature by curing.

In a preferred embodiment, resin is to be selected from least a in the modified resin of acrylic resin, epoxy resin, phenolic resins, polyamide, polyimide resin and aforementioned resin.Also preferred resin has the Poisson's ratio of 0.3-0.48.

In a preferred embodiment, substrate has at least 40kA/m(0.05T) saturation magnetization.

In a preferred embodiment, abrasive particle has the average particle size particle size of 10-300 μ m, and also preferred abrasive particle has at least 0.2 mass susceptibility χ g.

On the other hand, the invention provides a kind of method of making cement carbide substrate outside cutting wheel, may further comprise the steps:

Provide by the Young's modulus with 450-700GPa, limit the external diameter of the 80-200mm of outer rim, the internal diameter of 30-80mm, and the substrate of the annular thin discs form of the carbide alloy of the thickness of 0.1-1.0mm,

Diamond and/or the cBN abrasive particle of precoating magnetic material are provided,

Permanent magnet is placed near the substrate outer rim so that the magnetic field that is produced by permanent magnet can have an effect with the abrasive particle magnetic attraction through applying and remain on the substrate outer rim near,

Metal or alloy electroplated or electroless plating to the substrate outer rim with by on the abrasive particle through applying of magnetic attraction and maintenance, be used for abrasive particle is bonded together and is bonded to substrate, form blade abrasive particle is fixedly secured in the substrate outer rim, and

Allow the thermoplastic resin with the highest 350 ℃ fusing point infiltrate between the abrasive particle and any space between abrasive particle and the substrate, or allow the liquid thermosetting resin combination with the highest 350 ℃ solidification temperature infiltrate between the abrasive particle and any space between abrasive particle and the substrate, and be cured there.

In a preferred embodiment, resin is modified resin at least a that is selected from acrylic resin, epoxy resin, phenolic resins, polyamide, polyimide resin and aforementioned resin.Also preferably infiltrate the Poisson's ratio that resin has 0.3-0.48.

In a preferred embodiment, abrasive particle has the average particle size particle size of 10-300 μ m.Also preferred abrasive particle has at least 0.2 mass susceptibility χ g.

In a preferred embodiment, permanent magnet produces at least magnetic field of 8kA/m in the space of extending 10mm or less distance from the outer rim of substrate.

Beneficial effect of the present invention

Use cement carbide substrate outside cutting wheel, rare earth magnet block is cut into magnetic sheet.Only adopting cutting operation is high dimensional accuracy with magnetic sheet fine finishining just.Fine finishining behind any cutting operation can be omitted.Obtain to have the rare earth magnetic sheet of high dimensional accuracy with low cost.

This method of making the outside cutting wheel is that cost is effective.

Brief description of drawings

Outside cutting wheel in the schematically illustrated one embodiment of the invention of Fig. 1, Fig. 1 (A) is plane, Fig. 1 (B) is the profile along Fig. 1 (A) center line B-B, Fig. 1 (C) is circle C(blade among Fig. 1 (B)) enlarged drawing.

Fig. 2 is the decomposition diagram of an exemplary clamp using in this method.

Fig. 3 is the outside amplification view that clips the holder of substrate among Fig. 2.

Fig. 4 (A) is to 4(D) be formed in the cutaway view of the different embodiments of suprabasil blade.

Fig. 5 is the microphoto of the blade side surface of outside cutting wheel among the embodiment 1.

Fig. 6 is the curve map that shows cutting accuracy and the relation of the magnetic sheet number of the outside cutting wheel cutting of using embodiment 1 to 4 and Comparative Examples 1.

Fig. 7 is the curve map of the relation that shows that the blade of stress and the outside cutting wheel of embodiment 1 to 4 and Comparative Examples 1 is out of shape.

The embodiment explanation

With reference to Fig. 1, the cement carbide substrate outside cutting wheel that illustrates in one embodiment of the invention comprises substrate 10 and blade 20, and substrate 10 is annular thin discs forms that carbide alloy is made, and blade 20 is arranged on the outer rim of substrate 10.This blade 20 comprises by diamond and/or the cBN abrasive particle electroplated or electroless plating bonds with the metal or metal alloy bond material.

Substrate 10 is annular thin discs (thin slice with annular of centre bore 12) forms, have the 80-200mm that limits outer rim, the external diameter of preferred 100-180mm, the thickness of the internal diameter of the 30-80mm of limiting hole 12, preferred 40-70mm, 0.1-1.0mm, preferred 0.2-0.8mm.

It is noted that as shown in Figure 1, the disk of this substrate 10 has centre bore and excircle.Therefore term " radially " and " axially " use with respect to the disk center, so thickness is axial dimension, and length (or highly) is radial dimension.Term " inside " or " inwardly " and " outside " or " outwards " use with respect to the center of disk or the rotating shaft of cutting wheel similarly.

This substrate has the thickness and the external diameter that is no more than in the 200mm scope in 0.1 to the 1.0mm scope, because the substrate of size can be made accurately like this, and guarantee to cut off processing work with high dimensional accuracy uniformity ground for a long time, typically be the rare-earth sintering magnet piece.Thickness causes possibility with the irrelevant obvious warpage of external diameter less than 0.1mm, and makes substrate so that be difficult to high accuracy.Thickness surpasses 1.0mm and shows the increase of cutting surplus.Consider the size of can the technology by existing production and processing rigid alloy making, external diameter is up to 200mm.The aperture is arranged in 30 to 80mm the scope to adapt to the axle that cuts off machining tool.

The example of the carbide alloy of preparation substrate comprises the carbide powder with the metal in the IVB in the periodic table, VB and the group vib, such as WC, TiC, MoC, NbC, TaC and Cr ₃C ₂By sinter bonded those carbide alloy in the binder matrix of Fe, Co, Ni, Mo, Cu, Pb, Sn or its metal alloy.In these carbide alloy, preferred typical WC-Co, WC-Ti, C-Co and WC-TiC-TaC-Co system.They should have the Young's modulus of 450-700GPa.Also preferred those have the carbide alloy that the carbide alloy of the electric conductivity that is easy to electroplate or those can enough palladium catalysts etc. give such electric conductivity.When giving carbide conductive with palladium catalyst etc., can adopt known agent, as being used for the metallized metalating agent of ABS resin.

About the magnetic property of substrate, preferably larger saturation magnetization is to remain on substrate by magnetic attraction with abrasive particle.Yet, even in the situation that low saturation magnetization also can will apply the basad magnetic attraction of abrasive particle of magnetic material by position and the magnetic field intensity of control permanent magnet.For this reason, having at least, the substrate of the saturation magnetization of 40kA/m (0.05T) is gratifying.

By downcutting the square sample of 5mm from the substrate with given thickness, and utilize vibration sample magnetometer (VSM) to determine the saturation magnetization of substrate at the magnetization curve (4 π I-H) of 24-25 ℃ temperature survey sample.The upper limit of the intensity of magnetization value of first quartile is designated as saturation magnetization.

Can advantageously carry out chamfering (bevelling or rounding) to the outer rim of substrate, in order to strengthen the bond strength between substrate and the blade, blade is by being formed in the substrate with metal bond material bound abrasive grains.The chamfering of substrate outer rim is favourable, even because when mistakenly the sword overmastication being surpassed border between substrate and the abrasive grain layer for the purpose of adjusting sword thickness during grinding, it is separated to prevent blade that the metal bond material is left on boundary.The angle of chamfering and amount can be determined according to the thickness of substrate and the average particle size particle size of abrasive particle, because be suitable for the thickness that the scope of chamfering depends on substrate.

Abrasive particle used herein is diamond particles and/or cBN particle.Abrasive particle should apply with magnetic material.Size and the hardness that should be used for determining to apply magnetic material abrasive particle before according to expection.

For example, can use separately diamond particles (comprising natural diamond and industrial diamond synthesis) or cubic boron nitride (cBN) particle.The mixture of diamond particles and cBN particle also is acceptable.According to workpiece, every type abrasive particle can be selected from single crystal grain and polycrystalline particle, and can use separately or mix and use in order to adjust fragility.In addition, in order to strengthen the bond strength to the magnetic material that applies subsequently, approximately the metal of 1 μ m such as Fe, Co or Cr are effective at abrasive particle surface sputtering thickness.

Although particle size depends on the thickness of substrate, preferred abrasive particle has the average particle size particle size of 10-300 μ m.If average particle size particle size can stay less space less than 10 μ m between abrasive particle, so that during cutting operation, occur as smoothing and the problem filling up, and the loss cutting power.If, can producing the magnetic sheet that for example cuts by its greater than 300 μ m, average particle size particle size has the problem of rough surface.Consider cutting efficiency and life-span, can use separately or use as the mixture of different size particle the abrasive particle of the certain size in this scope.

Use in advance the magnetic material coated grits, abrasive particle through applying can be attracted magnetically at short notice even have in the substrate of carbide alloy of low saturation magnetization like this, and is fixedly secured and coming off during the adhesion step by plating preventing in the substrate.Particularly, preferably the abrasive particle through applying has at least 0.2, more preferably at least 0.39 mass susceptibility χ g.Typically, magnetic material is at least a metal that is selected among Ni, Fe and the Co, the alloy of two or more these metalloids, or a kind of such metal or alloy and at least a alloy that is selected among P and the Mn.Can be by any known technology, for example sputter, plating or electroless plating are with such magnetic material coated grits, until coating layer thickness reaches the 0.5-100% of abrasive particle diameter, preferred 2-80%.

Because the magnetic susceptibility of the abrasive particle through applying depends on magnetic susceptibility and the magnetic material coating thickness of the magnetic material of coating, should select the type of magnetic material, to obtain for the required attraction of the abrasive particle of certain size.Yet, also can magnetic susceptibility be brought up to a certain degree by heat treatment even have the nickel phosphor coating of the electroless plating of low magnetic susceptibility because of high content of phosphorus.Have different magnetic susceptibility the layer multiple coating also be possible, for example, comprise have low magnetic susceptibility the layer and thereon have high magnetic susceptibility the layer coating.Therefore, the magnetic susceptibility of the abrasive particle through applying can be adjusted according to special status.

As long as the abrasive particle through applying has at least 0.2, preferred at least 0.39 mass susceptibility χ g, the abrasive particle through applying just can be magnetized rapidly by near the magnetic field that produces the substrate periphery.Then abrasive particle on 64 interior arbitrary positions, space that the permanent magnet holder of substrate shown in Figure 3 and anchor clamps limits substantially equally by magnetic attraction.If the mass susceptibility χ g of the abrasive particle through applying is less than 0.2, the abrasive particle in that space can not attracted fully so.Under so weak attraction, some abrasive particles can come off during plating, can not form abrasive grain layer (or blade) or form the abrasive grain layer of porous, thereby have low mechanical strength.

The mass susceptibility χ g of abrasive particle can determine by the following method, the plastic holding device of height of internal diameter, the 5mm of external diameter with 8mm, 6mm is provided, with uniform particles and distribute thinly in container, to form one or two layer of stratum granulosum, to take out in the particulate from reservoir device, measure the weight of particle, they are put back in the container, place the paraffin of the fusing point have approximately 50 ℃ at stratum granulosum, and in 60 ℃ baking oven heating container.In case melted paraffin wax, with lid with container closure and cooling.Utilize vibration sample magnetometer (VSM) at the initial magnetization curve (4 π I-H) of the temperature survey sample of 24-25 ° of C.The slope at initial magnetization curve flex point place has provided differential magnetic susceptibility, comes to obtain the mass susceptibility χ g of abrasive particle except this differential magnetic susceptibility with sample weight.It should be noted that with standard Ni sample calibration magnetic field, and abrasive grain density is used as jolt ramming bulk density (tap bulk density) and measures.

The coating thickness of magnetic material should fall into suitable scope, because coating thickness can affect the size in the space that produces during blade forms.Preferred minimum coating thickness is 2.5 μ m, can and substantially not have the space to produce by the plating coating at all abrasive particles of this thickness.For example, for the abrasive particle of the average particle size particle size of the maximum 300 μ m with preferred average particle size particle size scope, coating thickness can be at least 0.5%, more preferably at least 0.8% of particle size.As long as the coating of magnetic material has the thickness in this scope, it just can be provided at the confining force that can reduce Grain Falling Off when using the outside cutting wheel in the cutting operation.As long as select the magnetic material of suitable type to be used for applying, near abrasive particle during the plating step will be attracted and be maintained at by magnetic field the outer rim of substrate or its and do not come off.

Abrasive particle for the average particle size particle size of 10 μ m of the minimum of a value with preferred average particle size particle size scope, preferred maximum coating thickness reaches 100% of abrasive particle average particle size particle size, because otherwise the abrasive particle that can not effectively play a role during cutting operation partly increases, hinder the part from sharpening of abrasive particle to increase, and working ability descend.

The metal bond material that abrasive particle is bonded together is coating metal or alloy.When forming blade, must near the outer rim of substrate, permanent magnet be set and produce magnetic field.For example, having two or more at least, the permanent magnet of the remanent magnetism of 0.3T (or residual magnetic flux density) is arranged on the side surface of the substrate that is positioned at substrate outer rim inboard, or it is inboard and be no more than in the space of 20mm distance from the side surface interval of substrate to be arranged on the substrate outer rim, thereby produces at least magnetic field of 8kA/m in the space of extending 10mm or less distance from the substrate outer rim.Magnetic fields is on the diamond and/or cBN abrasive particle of precoating magnetic material, to produce magnetic attracting force.By this magnetic attracting force, abrasive particle is by magnetic attraction and fixedly secure near substrate outer rim or its.In the situation that abrasive particle fixedly secures, carry out plating or the electroless plating of metal or alloy in the substrate outer rim, thereby abrasive particle is bonded to the substrate outer rim.

The anchor clamps that this method is used comprise a pair of holder, and each holder comprises external diameter greater than the insulating cove of substrate external diameter, and arrange and fixedly secure the permanent magnet on the lid of substrate outer rim inboard.When being fixed between the holder, substrate carries out the plating operation.

With reference to figure 2 and 3, shown an exemplary clamp that is used for the plating process.These anchor clamps comprise a pair of

holder

50,50, and each adds gripping member and comprises insulating cove 52 and be installed in the permanent magnet 54 that covers on 52.Substrate 1 is sandwiched between holder 50 and 50.Permanent magnet 54 preferably is embedded in and covers in 52.Perhaps, thus permanent magnet 54 is installed in and covers on 52 that permanent magnet 54 can dock with substrate 1 when assembling.

The permanent magnet of packing in the anchor clamps should have enough magnetic force, attracts to suprabasil abrasive particle in order to keep during the plated metal bond material is with the plating process of bound abrasive grains.Although required magnetic force depends on the distance between substrate outer rim and the magnet, and the intensity of magnetization and the magnetic susceptibility that are coated in the magnetic material on the abrasive particle, desirable magnetic force can obtain from permanent magnet, this permanent magnet has the remanent magnetism of 0.3T at least and the coercivity of 0.2MA/m at least, the remanent magnetism of preferred at least 0.6T and at least coercivity of 0.8MA/m, the more preferably at least remanent magnetism of 1.0T and at least coercivity of 1.0MA/m.

The remanent magnetism that permanent magnet has is larger, and the magnetic field gradient that it produces is larger.Therefore the permanent magnet that has larger residual induction when wishing local attraction's abrasive particle suits.In this sense, preferably with remanent magnetism at least the permanent magnet of 0.3T prevent that the vibration that the oscillating motion owing to the anchor clamps of the stirring of plating solution in the plating process and clamping substrate produces from causing abrasive particle to separate from substrate.

When coercivity is larger, even when being exposed to the high temperature plating solution, magnet also can with abrasive particle for a long time more strongly magnetic attraction in substrate.So the selection free degree of the position of employed magnet, shape and size has just increased, and has made things convenient for the manufacturing of anchor clamps.Magnet with higher coercivity is selected from the magnet that those satisfy required remanent magnetism.

Consider that magnet contacts with the potential of plating solution, preferably permanent magnet is applied so that magnet can be more anticorrosive.Under such condition, select coating material so that in the plating solution replacement of the solubility of coating material and the metal species in the plating solution minimize.In an embodiment that wherein the metal bond material is deposited from nickel plating bath, the coating material that is preferred for magnet is for example for example epoxy resin or acrylic resin of Cu, Sn or Ni or resin of metal.

Shape, size and the quantity of the permanent magnet in the anchor clamps of packing into depends on the size of cement carbide substrate and position, the direction and intensity in desirable magnetic field.For example, when hope evenly is bonded in the substrate outer rim with abrasive particle, the magnet ring corresponding with the substrate external diameter can be set, or along the substrate outer rim continuously and sealing ground arrange the arc magnet piece corresponding with the substrate external diameter or have the cuboid magnet piece of several millimeters long side.In order to reduce the cost of magnet, can magnet block is spaced apart to reduce the quantity of magnet block.

Although depend on the remanent magnetism of used magnet block, can increase the space between the magnet block.Because magnet block is spaced apart, another group particle that the abrasive particle that is coated with magnetic material is divided into the one group of particle that is attracted and is not attracted.So abrasive particle is not glued to other zone of substrate outer rim to some zones of substrate outer rim by alternately bonded.Formation is by isolated blade that consists of.

About near the magnetic field that the substrate outer rim, produces, be installed in the position of the permanent magnet on two holders of clamping substrate and the combination of the direction of magnetization by change and can produce various magnetic fields.By repeatedly carrying out magnetic field analysis and the layout of magnet is determined in experiment, so that extending 10mm from the substrate outer rim or more producing at least 8kA/m in the space of small distance, the preferred magnetic field of 40kA/m at least.When magnetic field intensity during less than 8kA/m; it has the abrasive particle that little magnetic force attracts to be coated with magnetic material; if carry out in this state plating; abrasive particle can be removed in the plating process; as a result of form and have very lacunose blade; perhaps abrasive particle bonds with dendroid, causes the size of blade greater than desired value.Finishing subsequently can cause separation or the longer time of cost of blade.These all can improve the cost of manufacturing.

Preferably, permanent magnet is placed on the part that is attracted from the abrasive particle place close to more.In general, permanent magnet is placed on the base side surface of substrate outer rim inboard, or to be positioned at the substrate outer rim inboard and extend not more than the space of 20mm distance from the base side surface, preferably to be positioned at the substrate outer rim inboard and extend not more than the space of 10mm distance from the side surface of substrate.At least two have at least that the permanent magnet of 0.3T remanent magnetism (particularly at least one magnet of each holder) is placed on the ad-hoc location in the described space, so that magnet is positioned at described space all or in part, in the space that extends not more than the 10mm distance from the substrate outer rim, can produces thus and have at least magnetic field of 8kA/m intensity.So, no matter substrate is by having high saturation and magnetic intensity and the material that may cause magnetic force such as alloy tool steel or high-speed steel preparation, or by having low saturation magnetization and the less material of magnetic force such as the carbide alloy of may causing prepares, can both near the substrate outer rim, produce the magnetic field with suitable magnetic force.When supplying with in magnetic field when being coated with the abrasive particle of magnetic material, coating is magnetized, and abrasive particle is attracted and remains near substrate outer rim or its as a result.

About the position of magnet with respect to the substrate outer rim, if magnet is not placed in the space defined above, if particularly magnet is placed on the outside of substrate outer rim, although near the substrate outer rim, for example, in the distance of the outside 0.5mm of substrate outer rim, very high near near the magnetic field intensity the substrate outer rim so, but the zone that may exist a magnetic field gradient to put upside down.So abrasive particle tends to show the behavior of upwards floating and coming off from substrate.If the position of magnet is inboard in the substrate outer rim, but in the distance that surpasses 20mm from the substrate outer rim, magnetic field in the space that extends not more than the 10mm distance from the substrate outer rim is tending towards having the intensity less than 8kA/m so, has the danger that the power of magnetic attraction abrasive particle diminishes.In this case, magnetic field intensity can improve by increasing magnet size.Yet large-sized magnet is not only near the position that abrasive particle attracted to, and the zone produces strengthened magnetic field around, and this is undesirable, because some abrasive particles can attracted to the position that abrasive particle is not attracted.The large scale magnet is unrealistic, because the anchor clamps of the magnet of packing into also become very large.

The shape of anchor clamps (holder) meets the shape of substrate.The size of anchor clamps (holder) is such, and when substrate was clipped between the holder, the permanent magnet in the holder can be on the position with respect to the hope of substrate.For substrate and the permanent magnet piece that row 2.5mm is long, 2mm is wide, 1.5mm is thick of the thickness of the external diameter with 125mm and 0.26mm, for example, use external diameter with 125mm at least and approximately the disk of the thickness of 20mm as holder.

Particularly, the external diameter of anchor clamps or holder is chosen as is equal to or greater than { external diameter of substrate+(height of abrasive grain layer) * 2 }, in order to guarantee the height of abrasive grain layer or overhang (H2 among Fig. 1 (C)) radially, and select the thickness of anchor clamps or holder in order to provide enough intensity to prevent because shift-in or shift out hot dip and bathe the warpage that the unexpected variation of the temperature of generation causes.The thickness of the part that holder contacts with abrasive particle can be reduced to less than remainder, in order to guarantee the axial overhang (T3 among Fig. 1 (C)) of the abrasive grain layer on the substrate thickness direction.The masking tape that thickness is equaled axial overhang sticks to this part, so that thickness can equate with the thickness of remainder.

The material of preparation anchor clamps or holder does not preferably have the insulating materials of coating deposition thereon, because be dipped into during hot dip bathes for the whole anchor clamps that the metal bond material are deposited in the substrate, have the substrate that is clipped between the holder.Even more wish this insulating materials should have chemical resistance, the highest approximately 90 ℃ heat resistance and when being exposed to shift-in and shift out the repeatedly fast thermal cycle of plating bath, still have the resistance to heat shocks that is enough to keep size constancy.Also wish this insulating materials should have be enough to prevent holder by internal stress (accumulation in moulding and the processing) generation warpage, make when immerse hot dip when bathing between holder and substrate the dimensional stability in generation space.Certainly, this insulating materials should be machinable, so as can the high accuracy free from flaw and breach ground be used for receiving the groove of permanent magnet in the processing of any position.

Particularly, holder is by the engineering plastics of for example PPS, PEEK, POM, PAR, PSF and PES with such as the pottery preparation of aluminium oxide.Holder is selected suitable material by being prepared as follows, and the consideration mechanical strength is determined thickness and other size, is this size with forming materials, and processing is for the groove that receives permanent magnet with for the recess that receives the current electrode that needs when electroplating.During use, the holder of assembling a pair of such preparation is clipped in substrate therebetween.When holder was assembled together with the electrode that can electroplate for the substrate power supply, this assembling process both provided power supply that mechanical banding also is provided, and produced compact package as a whole.Certainly, preferably a plurality of anchor clamps are coupled together as shown in Figure 2, thus a plurality of substrate plating simultaneously, because production process becomes more efficient.

Particularly, as shown in Figure 2, be used for to electroplate and be installed in as the negative electrode 56 of substrate keeper and cover 52 center recess.By with a pair of holder 50 and substrate 1 combination, the back shaft 58 of conduction is inserted the hole of holder and substrate, and their bandings are come assembling fixture together.Under assembled state, negative electrode 56 contacts with axle 58, allows 56 power supplies from axle 58 to negative electrode.In Fig. 2, use

separator

60 and 62, two anchor clamps of end cap to be installed on the axle 58 with suitable interval, each anchor clamps is made of a pair of holder 50,50.Be appreciated that the anchor clamps that show among Fig. 2 are for plating.In the situation that electroless plating does not need negative electrode, can replace with non-conductive keeper, and back shaft also needs not be conduction.

Use anchor clamps, plating is performed as follows.Come assembling fixture by clamping substrate 1 between the permanent magnet in the

holder

50,50 of packing into.At this state, as shown in Figure 3, stretching out by

holder

50,50

lid

52,52 outer

peripheral portion

52a, 52a(exceeds substrate) and the outer rim of substrate 1 define space 64.The abrasive particle of the precoating magnetic material of the appropriate amount that weighs with scale also supplies to it in space 64, and abrasive particle is by magnetic attraction and maintenance in space 64.

The amount that remains on the abrasive particle in the space depends on height and the width of the hope of the size of the external diameter of substrate and thickness, abrasive particle and blade to be formed.The process that also preferably repeatedly repeats to keep abrasive particle and carry out plating so that the amount of per unit volume abrasive particle equates on any position of substrate outer rim, and can be passed through securely (tenaciously) bound abrasive grains of plating technology.

Form by this way blade.Preferably, blade comprises 10-80 volume %, the more preferably abrasive particle of the volume fraction of 30-75 volume %.Mean the less abrasive particle that cuts of helping less than the volume fraction of 10 volume %, cause resistance increment in cutting operation process.The volume fraction that surpasses 80 volume % means that the cut edge deflection reduces during cutting operation, stays the cutting vestige and makes dimensional accuracy and the cutting blade degraded appearance at cutting surfaces.Owing to these reasons, cutting speed must slow down.Therefore preferably change particle size by the thickness that changes the magnetic material coating on abrasive particle, thereby adjust the volume fraction of abrasive particle for application-specific.

Shown in Fig. 1 (C), blade 20 is made of a pair of

leg lock

22a, 22b and main body 20, clamps in the axial direction the outer rim of substrate 10 between leg lock 22a, the 22b, and main body 20 outward radials extend beyond the outside (edge) of substrate 10.It should be noted that such division is the convenience in order to describe, because the integrally formed blade of leg and main body.The thickness of blade 20 is greater than the thickness of substrate 10.In order to form the blade of this design, preferably construct as shown in Figure 3 space 64.

More specifically, for leg lock 22a, the 22b of the blade 20 of the outer rim of clamping substrate 10 between it, each preferably has 0.1-10mm, the more preferably length H1 of 0.5-5mm.Each

leg

22a, 22b preferably have at least 5 μ m(=0.005mm), more preferably 5-2000 μ m even the more preferably thickness T 3 of 10-1000 μ m.The gross thickness of

leg

22a, 22b is preferably at least 0.01mm, more preferably 0.01-4mm, even more preferably 0.02-2mm.The gross thickness of blade 20 is thicker than substrate 10.If the length H1 of

leg lock

22a, 22b is less than 0.1mm, they are preventing that the cement carbide substrate outer rim from occurring on breach and the crack or effectively, but to strengthen aspect the substrate effect little, and sometimes can not prevent the distortion that substrate is caused by Cutting Drag.If length H1 surpasses 10mm, the enhancing of substrate obtains under the sacrifice expense.If the thickness T of leg lock 3 is less than 5 μ m, so thin leg can not strengthen the mechanical strength of substrate or effectively discharge metal fragment.

Shown in Fig. 4 (A)-4(D),

leg lock

22a, 22b can be comprised of metal bond material 24 and abrasive particle 26 (Fig. 4 (A)), form (Fig. 4 (B)) by metal bond material 24, or comprise the superimposed layer (Fig. 4 (C)) that covers the bottom in the substrate 10 and formed by metal bond material 24 and abrasive particle 26 that is formed by metal bond material 24.Merit attention, in order to center on whole outer surface shown in Fig. 4 (D), the intensity of blade can further improve by plated metal bond material on the structure of Fig. 4 (C).

In the embodiment that Fig. 4 (B)-4(D) shows, the inside portion that leg lock contacts with substrate 10 is only formed by metal bond material 24.For this reason, substrate is covered, so that only have the part that will form the substrate of leg lock in the above to expose, carries out plating in the base part that is not covered.Then substrate is installed on the anchor clamps, with abrasive particle 26 packing spaces 64, and carries out plating.After electroplating abrasive particle, can substrate 10 be covered with the

lid

52,52 of Fig. 2, this lid 52 has less external diameter so that the part of electroplating comes out, and again carries out plating, layer outermost layer as blade that formation is comprised of metal bond material 24 is shown in Fig. 4 (D).

Again with reference to Fig. 1 (C), the main body of blade 20 that outward radial extends beyond the outer rim of substrate 10 has length H2, although can change along with the size of abrasive particle to be bonded, this length is preferably 0.1-10mm, more preferably 0.3-8mm.If the length H2 of this main body is less than 0.1mm, because impact and wearing and tearing in the cutting operation, blade can consume at short notice, and this life-span that shows cutting wheel is short.If the length H2 of main body surpasses 10mm, it is easily deformable that blade can become, although the thickness (T2 among Fig. 1 (C)) of blade is depended in distortion, this magnetic sheet that causes cutting out has wavy cutting surfaces, therefore makes the dimensional accuracy variation.The main body of blade is comprised of abrasive particle 26, metal bond material 24 and resinoid bond substantially.

The metal bond material is the metal or alloy by the plating deposition.Metal bond material used herein is at least a metal that is selected among Ni, Fe, Co, Cu and the Sn, the alloy that is formed by at least two kinds of above-mentioned metals, or by one or both alloys that form at least a above-mentioned metal or alloy and phosphorus (P) and the manganese (Mn).This metal or alloy deposits by plating, so that forming interconnection between the abrasive particle and between abrasive particle and the substrate.

Method by plating plated metal bond material is divided into two kinds, galvanoplastic and electroless plating process usually.In practice of the present invention, it is low that galvanoplastic are easily controlled the internal stress and the production cost that remain in the metal bond material, and electroless plating (or chemical plating) method is guaranteed the relatively uniformly deposition of metal bond material, as long as the plating solution infiltration.Two kinds of methods can be used alone or in combination, so that blade can comprise the space of the OK range that will be described later.

Can control stress in the plated film by suitable mode.For example, at single metal-plated such as copper or nickel plating, typically be in the nickel sulfamic acid plating, the temperature of concentration that can be by in suitable scope, selecting active component or nickel sulfamic acid, the current density during the plating, plating bath, and add organic additive such as adjacent benzenesulfonimide (o-benzenesulfonimide) or para toluene sulfonamide (p-toluenesulfonamide) or element such as Zn, S or Mn and come proof stress.In addition, in alloy plated such as Ni-Fe alloy, Ni-Mn alloy, Ni-P alloy, Ni-Co alloy or Ni-Sn alloy, can come proof stress by Fe, Mn, P, Co or the content of Sn, temperature and other parameter of plating bath in the selection alloy in suitable scope.In the situation that alloy plated, certainly adding organic additive is effective to proof stress.

Can deposit single metal or alloy by selecting in the known plating bath any, and adopt the plating condition commonly used of this plating bath to carry out plating.

The example of preferred electroplating bath comprises sulfamate watt (Watts) nickel electroplating bath, and it comprises the nickel sulfamic acid of 250-600g/L, the nickelous sulfate of 50-200g/L, the nickel chloride of 5-70g/L, the boric acid of 20-40g/L and an amount of adjacent benzenesulfonimide; With the cupric pyrophosphate electroplating bath, it comprises 25% the ammoniacal liquor of potassium pyrophosphate, 1-20mL/L of cupric pyrophosphate, the 100-450g/L of 30-150g/L and the potassium nitrate of 5-20g/L.Typical electroless plating bath is the nickel-phosphorus alloy electroless plating bath, and it comprises the nickelous sulfate of 10-50g/L, the sodium hypophosphite of 10-50g/L, the sodium acetate of 10-30g/L, the natrium citricum of 5-30g/L and an amount of thiocarbamide.

By the plating method, abrasive particle is bonded in together and is bonded to the outer rim of substrate, forms accurately the blade that has near the size of net shape, and wherein abrasive particle can be the mixture of diamond abrasive grain, cBN abrasive particle or diamond and cBN abrasive particle.

The blade that forms is like this comprising the space between the abrasive particle and between abrasive particle and the substrate.According to the present invention, the thermoplastic resin that will have the highest 350 a ℃ fusing point infiltrates in this space and in this sclerosis, and the liquid thermosetting resin combination that perhaps will have the highest 350 a ℃ solidification temperature infiltrates in this space and in this curing.Therefore, the feature of the blade of outside cutting wheel is, there is thermoplastic resin with the highest 350 ℃ fusing point between the abrasive particle and between abrasive particle and the substrate in whole blade from the surface to inside or from the thermosetting resin of the liquid thermosetting resin combination with the highest 350 ℃ solidification temperature.

Suitable infiltration resin comprises thermoplastic resin and thermosetting resin, typically is the modified resin of epoxy resin, acrylic resin, phenolic resins, polyamide resin, polyimide resin and aforementioned resin, and they can use separately or mix use.

This thermoplastic resin or thermosetting resin can infiltrate blade; for example; thermoplastic resin is processed into have 0.1-2.0mm, line, particle or the film ring of the diameter of preferred 0.8-1.5mm; this film ring has the shape and size identical with blade; thickness is 0.05-1.5mm, and this line, particle or ring are placed on the blade, and this blade of heating is to the temperature that is higher than fusing point on heater such as heating plate or in the baking oven; keep this temperature to allow the resin of melting infiltrate blade, Slow cooling is to room temperature afterwards.Can form the liquid thermosetting resin combination by resin is mixed with organic solvent, curing agent etc., said composition is cast in blade, allows said composition infiltrate blade, in solidification temperature or be higher than the temperature heating of solidification temperature, solidify thus, Slow cooling infiltrates thermosetting resin to room temperature afterwards.Perhaps by the outside cutting wheel being placed near blade in the gapped female die of tool, fill this half module with the resin that claimed weight or resin combination, upper mold section is cooperated with female die, when mould applies certain pressure, heat the mould after this cooperation, allow resin or resin combination infiltrate blade and infiltrate.Cooling frame afterwards, then release pressure and cutting wheel taken out from mould.Then the cooling step of heating steps should be slowly to avoid any overstrain.

When use has the resin of relatively good wetability, can be by substrate being clipped between the metal parts of stainless steel, iron or copper, switch on to metal parts, make metal parts produce heat, thereby heat substrate and blade, and the blade of heating is contacted to infiltrate with resin or the liquid resin composition of melting.

In the blade that obtains, abrasive particle, the resin that covers magnetic material on the abrasive particle, metal bond material and infiltrate the space are suitably disperseed.

The resin that infiltrates blade should preferably have following physical property.Fusing point preferably is not higher than 350 ℃.In the situation that thermoplastic resin, fusing point is not higher than 350 ℃, preferably be not higher than 300 ℃, purpose is to prevent cement carbide substrate distortion and make the dimensional accuracy variation or change mechanical strength, and prevents the blade distortion or owing to the marked difference of thermal expansion between cement carbide substrate and the blade produces strain.In the situation that thermosetting resin, fusion temperature preferably is at least 10 ℃, has enough flowabilities and at room temperature infiltrates because this can satisfy compositions of thermosetting resin.

Resin preferably has elasticity, is expressed as 0.3-0.48 with Poisson's ratio, more preferably 0.33-0.44.The resin that has less than 0.3 Poisson's ratio lacks pliability and is difficult to engage smoothly cutting surfaces.The resin that has greater than 0.48 Poisson's ratio does not reach standard in other physical property such as hardness, has the sword edge the significantly danger of distortion occurs.Poisson's ratio can use the infiltration resin sample of 15 * 15 * 15mm to measure by the impulse ultrasound method.

The hardness of resin can not be too high, hardness is too high can hinder when abrasive wear during cutting operation, destroy or when coming off abrasive particle from sharpening (new abrasive particle appearance, the phenomenon that helps cutting operation), and the hardness of resin be lower than for bound abrasive grains and be coated in the hardness of the metal bond material of the magnetic material on the abrasive particle.Even in the time of in the working fluid that also preferably uses in being exposed to process or the cooling fluid, variation or the corrosion of intensity should not occur in resin.

If necessary, will infiltrate the size that the blade that resin is arranged is adjusted into hope within it by grinding or the discharge processing of using aluminium oxide, carborundum or adamantine abrasive wheel.In this; although depend on the thickness of blade; but the edge of blade can chamfering (bevelling or rounding) to the degree of C0.1 or R0.1 at least, because such chamfer machining is effective to reducing the cutting vestige on the cutting surfaces or alleviating the cracked of final magnetic sheet.

The outside cutting wheel of the application of the invention can cut various workpiece.Typical workpiece comprises R-Co rare-earth sintering magnet and R-Fe-B rare-earth sintering magnet, and wherein R is rare earth element at least a that comprises Y.These magnets are by being prepared as follows.

The R-Co rare-earth sintering magnet comprises RCo ₅And R ₂Co ₁₇System.Wherein, R ₂Co ₁₇The composition of magnet (% by weight) comprises the Co of 20-28%R, 5-30%Fe, 3-10%Cu, 1-5%Zr and surplus.They form the weighing source material by being prepared as follows by this, with its fusing, cast melt, and the alloy fine powder are broken to the average particle size particle size of 1-20 μ m, produce R ₂Co ₁₇Magnet powder.Then in magnetic field, powder compressed and 1100-1250 ° of C sintering 0.5-5 hour.Sintered body is being lower than under sintering temperature 0-50 ℃ the temperature solution treatment 0.5-5 hour, and is keeping a period of time to carry out burin-in process at 700-950 ℃, then cooling.

The composition of R-Fe-B rare-earth sintering magnet (% by weight) comprises 5-40%R, 50-90%Fe and 0.2-8%B.In order to improve magnetic characteristic and corrosion resistance, can be to wherein adding additional element, additional elements is selected from C, Al, Si, Ti, V, Cr, Mn, Co, Ni, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Sn, Hf, Ta, W etc.The amount of additional elements is the highest 30 % by weight for Co, is the highest 8 % by weight for other element.This magnet forms the weighing source material by being prepared as follows by this, with its fusing, casts melt, and the alloy fine powder is broken to the average particle size particle size of 1-20 μ m, produces the R-Fe-B magnet powder.Then in magnetic field, powder is compressed and at 1000-1200 ℃ of sintering 0.5-5 hour, follow 400-1000 ℃ of maintenance a period of time and carry out burin-in process, then cooling.

Use outside cutting wheel of the present invention not stay cutting vestige ground at cutting surfaces with high dimensional accuracy rare earth magnet block is cut into magnetic sheet.Particularly this is real when the edge of blade has the compression shear stress of particular range.For example, this outside cutting wheel comprises blade, this blade have thickness, the 80-200mm of 0.1-1.0mm external diameter, edge chamfer (rounding or bevelling) is the degree of R0.1 or C0.1 at least.By cutting wheel being clipped between the thick round iron plate of 5mm, this cutting wheel flatly is installed on the anchor clamps, so that only have blade to expose.So keep cutting wheel so that substrate can be in warpage under the pressurized.In the position from the outside spaced apart 0.3mm of substrate outer rim, press edge pressing part with the linear velocity of 1mm/min with pressure head the rotating shaft of cutting wheel axial (or thickness direction of blade) is upper, the length of the contact area of pressure head equals that { the radially overhang (mm) of blade deducts 0.3mm}, and width is 10mm.Measurement is to the stress of movable press head distance.Continue to press until blade breaks.Along with the increase of movable press head distance, can confirm that curve map shows that linear zone is stress and the proportional zone of the displacement of pressure head.The slope of curve of calculating in stress zone proportional to deflection.As long as this slope is in the 100-10000N/mm scope, cutting wheel is exactly effective not staying at cutting surfaces that cutting vestige ground is cut into rare earth magnet block aspect the magnetic sheet with high dimensional accuracy.

Embodiment

Nonrestrictive mode provides embodiment and Comparative Examples to the below in the mode of explanation.

[embodiment 1]

To be processed into by the carbide alloy that 90wt%WC and 10wt%Co form the annular thin discs of thickness of internal diameter, 0.3mm of external diameter with 125mm, 40mm as substrate.This substrate has the Young's modulus of 600GPa, the saturation magnetization of 127kA/m (0.16T).

With adhesive tape this cement carbide substrate is covered, so that only will expose from the extend internally circumferential area on two surfaces of 1.0mm of outer rim.Water cleans with degreasing this substrate to be immersed in 40 ℃ the commercially available alkaline aqueous solution 10 minutes, immerses in 50 ℃, the aqueous solution of 30-80g/L sodium pyrophosphate, with 2-8A/dm ²Current density carry out electrolysis.In deionized water, this substrate carried out ultrasonic cleaning and immerse in 50 ℃ the sulfamate watt nickel plating bath, at 5-20A/dm ²Current density under the plating priming coat.In case after Covering adhesive tapes peelled off, water cleaned substrate.

Side surface to polyphenylene sulfide (PPS) resin disk of the thickness of external diameter with 130mm, 10mm is processed, and forms the groove of the degree of depth of internal diameter, the 1.5mm of external diameter with 123mm, 119mm.2.5mm is long, 2mm is wide equidistantly to arrange 75 in the groove of this dish, the permanent magnet piece that 1.5mm is thick (N39UH, Br=1.25T that Shin-Etsu rare-earth magnet Co., Ltd produces), and the thickness direction of permanent magnet piece aligns with the depth direction of groove.Come securely the permanent magnet piece to be fixed in the groove with the epoxy resin filling groove, finish the holder of the magnet of packing into.Substrate is clipped between the holder of a pair of such formation anchor clamps, magnet one side of holder to the inside.In clamp position, permanent magnet inwardly separates the distance of 1mm from the substrate outer rim along substrate surface.This permanent magnet produces magnetic field near the substrate outer rim, have at least intensity of 8kA/m (0.01T) according to analyzing this magnetic field in the space of extending the 10mm distance from the substrate outer rim.

In advance diamond abrasive grain is carried out the NiP plating forming the diamond abrasive grain through applying, it has 0.588 mass susceptibility χ g and the average particle size particle size of 135 μ m.At the recess that is limited by holder and substrate, supply with the diamond abrasive grain of 0.4g through applying, thus abrasive particle by magnetic attraction to and be evenly distributed in whole substrate outer rim.The anchor clamps that attract to have abrasive particle on it are immersed in 50 ℃ the sulfamate watt nickel plating bath, at 5-20A/dm ²Current density under electroplate.Taking out anchor clamps and water cleans.Repeat the step of diamond abrasive grain, plating and the washing of magnetic attraction 0.4g through applying.

The holder that replaces anchor clamps with the PPS resin disk holder of the thickness of the external diameter with 123mm, 10mm.Substrate is clipped between the holder, so that the side surface of abrasive grain layer exposes.With the sulfamate watt nickel plating bath of 50 ℃ of anchor clamps immersions, at 5-20A/dm ²Current density under switch on, with at whole blade deposition coating.Take out anchor clamps and water and clean, unload afterwards substrate and dry, obtain the outside cutting wheel.

Become component to be dissolved in the organic solution as main resin-shaped bisphenol A diglycidyl ether and dicyandiamide, thus obtained liquid epoxy resin composition is coated on the side surface of blade of outside cutting wheel, and kept 3 minutes.This outside cutting wheel is placed in 180 ℃ the baking oven and kept approximately 120 minutes.Turn off baking oven, allow the outside cutting wheel in baking oven, to cool down.The epoxy resin that it should be noted that curing has 0.34 Poisson's ratio.Fig. 5 is the microphoto of blade side surface.

The tool using grinding machinery grinds the outside cutting wheel, so that give prominence to the distance (T3) of cement carbide substrate 50 μ m at each abrasive grain layer.After the projection or thickness and external diameter of adjusting abrasive grain layer, the outside cutting wheel is repaired, produced cement carbide substrate outside cutting wheel, it has thickness (T2) is abrasive grain layer or the blade of 127mm for 0.4mm, external diameter.

[embodiment 2]

To be processed into by the carbide alloy that 90wt%WC and 10wt%Co form the annular thin discs of thickness of internal diameter, the 0.3mm of external diameter with 125mm, 40mm, as substrate.

With adhesive tape this cement carbide substrate is covered, so that only will expose from the extend internally circumferential area on two surfaces of 1.5mm of outer rim.Water cleans with degreasing this substrate to be immersed in 40 ℃ the commercially available alkaline aqueous solution 10 minutes, immerses in 50 ℃, the aqueous solution of 30-80g/L sodium pyrophosphate, at 2-8A/dm ²Current density under carry out electrolysis.In deionized water, this substrate carried out ultrasonic cleaning and immerse in 50 ℃ the sulfamate watt nickel plating bath, at 5-20A/dm ²Current density under the plating priming coat.In case after Covering adhesive tapes peelled off, water cleaned substrate.

Side surface to the PPS resin disk of the thickness of external diameter with 130mm, 10mm is processed, and forms the groove of the degree of depth of internal diameter, the 1.5mm of external diameter with 123mm, 119mm.Equidistantly arrange 105 permanent magnet pieces that 1.8mm is long, 2mm is wide, 1.5mm is thick (N32Z, Br=1.14T that Shin-Etsu rare-earth magnet Co., Ltd produces) in the groove of this dish, the thickness direction of permanent magnet piece aligns with the depth direction of groove.Come securely the permanent magnet piece to be fixed in the groove with the epoxy resin filling groove, finish the holder of the magnet of packing into.Substrate is clipped between the holder of a pair of such formation anchor clamps, magnet one side of holder to the inside.In clamp position, permanent magnet is along the distance of substrate surface from the inside spaced apart 1.5mm of substrate outer rim.This permanent magnet produces magnetic field near the substrate outer rim, have at least intensity of 16kA/m (0.02T) according to analyzing this permanent-magnetic field in the space of extending the 10mm distance from the substrate outer rim.

In advance diamond abrasive grain is carried out the NiP plating to form the diamond abrasive grain through applying, it has 0.588 mass susceptibility χ g and 135 _μThe average particle size particle size of m.At the recess that is limited by holder and substrate, supply with the diamond abrasive grain of 0.4g through applying, thus abrasive particle by magnetic attraction to and be evenly distributed in whole substrate outer rim.The anchor clamps that attract to have abrasive particle on it are immersed in 50 ℃ the sulfamate watt nickel plating bath, at 5-20A/dm ²Current density under electroplate.Taking out anchor clamps and water cleans.The step 3 that repeats diamond abrasive grain, plating and the washing of magnetic attraction 0.4g through applying is inferior.

Liquid epoxy resin composition among the embodiment 1 is coated on the side surface of blade of outside cutting wheel, and kept 5 minutes.The outside cutting wheel is placed in 180 ℃ the baking oven and kept approximately 120 minutes.Turn off baking oven, allow wheel in baking oven, to cool down.

The tool using grinding machinery grinds the outside cutting wheel so that give prominence to the distance of cement carbide substrate 50 μ m at each abrasive grain layer.After the projection or thickness and external diameter of adjusting abrasive grain layer, the outside cutting wheel is repaired, produced cement carbide substrate outside cutting wheel, it has thickness is that 0.4mm, external diameter are abrasive grain layer or the blade of 129mm.

[embodiment 3]

With adhesive tape this cement carbide substrate is covered, so that only will expose from the extend internally circumferential area on two surfaces of 1.0mm of outer rim.Water cleans with degreasing this substrate to be immersed in 40 ℃ the commercially available alkaline aqueous solution 10 minutes, immerses in 50 ℃, the aqueous solution of 30-80g/L sodium pyrophosphate, at 2-8A/dm ²Current density under carry out electrolysis.In deionized water, this substrate carried out ultrasonic cleaning and immerse in 50 ℃ the sulfamate watt nickel plating bath, at 5-20A/dm ²Current density under the plating priming coat.In case after Covering adhesive tapes peelled off, water cleaned substrate.

Substrate is clipped between the holder of anchor clamps as in Example 1.In advance diamond abrasive grain is carried out the NiP plating forming the diamond abrasive grain through applying, it has 0.392 mass susceptibility χ g and the average particle size particle size of 130 μ m.At the recess that is limited by holder and substrate, supply with the diamond abrasive grain of 0.4g through applying, thus abrasive particle by magnetic attraction to and be evenly distributed in whole substrate outer rim.The anchor clamps that attract to have abrasive particle on it are immersed in 40 ℃ the cupric pyrophosphate plating bath, at 1-20A/dm ²Current density under electroplate.Taking out anchor clamps and water cleans.Unload the outside cutting wheel and carry out drying from anchor clamps.

Liquid epoxy resin composition among the embodiment 1 is coated on the side surface of blade of outside cutting wheel, and kept 5 minutes.The outside cutting wheel is placed in 180 ℃ the baking oven and kept approximately 120 minutes.Turn off baking oven, allow the outside cutting wheel in baking oven, to cool down.

The tool using grinding machinery grinds the outside cutting wheel so that give prominence to the distance of cement carbide substrate 50 μ m at each abrasive grain layer.After the projection or thickness and external diameter of adjusting abrasive grain layer, the outside cutting wheel is repaired, produced cement carbide substrate outside cutting wheel, it has thickness is that 0.4mm, external diameter are abrasive grain layer or the blade of 126mm.

[embodiment 4]

To be processed into by the carbide alloy that 95wt%WC and 5wt%Co form the annular thin discs of thickness of internal diameter, the 0.3mm of external diameter with 125mm, 40mm, as substrate.This substrate has the Young's modulus of 580GPa, the saturation magnetization of 40kA/m (0.05T).

Substrate is clipped between the holder of anchor clamps as in Example 1.In advance diamond abrasive grain is carried out the NiP plating forming the diamond abrasive grain through applying, it has 0.392 mass susceptibility χ g and the average particle size particle size of 130 μ m.At the recess that is limited by holder and substrate, supply with the diamond abrasive grain of 0.3g through applying, thus abrasive particle by magnetic attraction to and be evenly distributed in whole substrate outer rim.The anchor clamps that attract to have abrasive particle on it are immersed in 80 ℃ the electroless nickel phosphorus alloy plating bath and carry out electroless plating.Taking out anchor clamps and water cleans.Repeat twice of the diamond abrasive grain of magnetic attraction 0.3g through applying, electroless plating and water-washing step.Unload the outside cutting wheel and carry out drying from anchor clamps.

The propylene liguid acid resin composition that will comprise methyl methacrylate, metering system acid diesters, chlorosulfonated polyethylene and cumene hydroperoxide is coated on the side surface of blade of outside cutting wheel.The outside cutting wheel is placed in the baking oven, and baking oven moderately is evacuated, then 80 ℃ of heating 60 minutes.Turn off baking oven, allow the outside cutting wheel in the baking oven that keeps vacuum, to cool down.The acrylic resin that it should be noted that curing has 0.4 Poisson's ratio.

The tool using grinding machinery grinds the outside cutting wheel so that give prominence to the distance of cement carbide substrate 50 μ m at each abrasive grain layer.After the projection or thickness and external diameter of adjusting abrasive grain layer, the outside cutting wheel is repaired, produced cement carbide substrate outside cutting wheel, it has thickness is that 0.4mm, external diameter are abrasive grain layer or the blade of 127mm.

[Comparative Examples 1]

Substrate is clipped between the holder of anchor clamps as in Example 1.In advance diamond abrasive grain is carried out the NiP plating forming the diamond abrasive grain through applying, it has 0.392 mass susceptibility χ g and the average particle size particle size of 130 μ m.At the recess that is limited by holder and substrate, supply with the diamond abrasive grain of 0.4g through applying, thus abrasive particle by magnetic attraction to and be evenly distributed in whole substrate outer rim.The anchor clamps that attract to have abrasive particle on it are immersed in 50 ℃ the sulfamate watt nickel plating bath, at 5-20A/dm ²Current density under electroplate.Taking out anchor clamps and water cleans.Repeat diamond abrasive grain, plating and the water-washing step of magnetic attraction 0.4g through applying.

The holder that replaces anchor clamps with the PPS resin disk holder of the thickness of the external diameter with 123mm, 10mm.Substrate is clipped between the holder, so that the side surface of abrasive grain layer exposes.With the sulfamate watt nickel plating bath of 50 ℃ of anchor clamps immersions, at 5-20A/dm ²Current density under switch on, with at whole blade deposition coating.Taking out anchor clamps and water cleans.Unload substrate and dry, obtain the outside cutting wheel.

Table 1 has been reported the manufacturing finished product percentage of the cement carbide substrate outside cutting wheel of embodiment 1-4 and Comparative Examples 1.Plating finished product percentage is to calculate like this: preparation among each embodiment until 15 samples of the step by the plating bound abrasive grains when having Grain Falling Off or abrasive grain layer not to have defective, be not judged to be sample, and made good use of the number of sample divided by the number of plating sample.The processed finished products percentage is to calculate like this: the step after the good sample enforcement binding metal plating step until pre-shaping step has been judged to be sample when abrasive grain layer does not have defective, is made good use of the number of sample divided by the number of the good plating sample of beginning.Total finished product percentage is that plating finished product percentage multiply by the processed finished products percentage, and the finished product percentage that has meant sample is the outside cutting wheel of finishing with respect to the number of the initial substrate of using in the cutting wheel manufacturing.

Table 1

As can be seen from Table 1, good than Comparative Examples 1 of the yield rate of embodiment.Especially the processed finished products rate behind the plating is gratifying.This illustrates that manufacture method of the present invention also is improved on productivity ratio.

Using cement carbide substrate outside cutting wheel of the present invention, is magnetic sheet with rare-earth sintering magnet piece machine cuts.The cutting accuracy of magnetic sheet is plotted in the curve map of Fig. 6.

Cutting accuracy is to estimate by ten outside cutting wheels that embodiment 1-4 and Comparative Examples 1 are provided, two outside cutting wheels of each embodiment.Consist of many cutting wheels assembly by ten outside cutting wheel interval 1.5mm are arranged, the hole with in the rotating shaft basement fastens them together.By operating many cutting wheels assembly with the rotating speed of 4500rpm, the feed speed of 30mm/min, 40mm is wide, that 130mm is long, 20mm is high Nd-Fe-B rare-earth sintering magnet piece machine cuts becomes that 40mm is wide, 1.5mm long (=thick (t)), magnetic sheet that 20mm is high.Repeat cutting operation until the magnetic sheet sum of cutting reaches 1010.In them, be chosen in the magnetic sheet that cuts between the cutting wheel of a pair of identical embodiment and be used for checking.Each dimensional measurement circulation comprises the 1st to the 100th, altogether ten circulations of expression.The tenth day of lunar month sheet in each circulation is got makees sample (namely from the 1st to the 10th of the first circulation, from the 101st to the 110th of the second circulation, the rest may be inferred, and from the the most metacyclic the 1001st to the 1010th).For ten in each circulation, with the thickness (t) at center and four angles (totally five points) of the every a slice of miking.The difference of maximum and minimum of a value is cutting accuracy (μ m) in five measured values.Calculate the mean value of ten cutting accuracy.The mean value of each dimensional measurement circulation is plotted in the curve map of Fig. 6.

In Comparative Examples 1, (after the magnetic sheet of the 301st cutting) cutting accuracy variation after three dimensional measurement circulations.In embodiment 1-4, until the tenth circulation (until magnetic sheet of the 1010th cutting) cutting accuracy does not have variation yet.This shows that outside cutting wheel of the present invention is enough at useful life longevity.

Estimate elasticity or the pliability of outside cutting wheel, the result is plotted in the curve map of Fig. 7.Estimated the compression shear stress of outside cutting wheel in edge.Particularly, be the degree of R0.1 or C0.1 at least with the outside cutting wheel in edge's chamfering (rounding or bevelling).By cutting wheel being clipped between the thick round iron plate of 5mm, cutting wheel flatly is installed on the anchor clamps, so that only have blade to expose.So keep cutting wheel so that substrate can be in warpage under the pressurized.In the position from the outside interval 0.3mm of substrate outer rim, axial (or thickness direction of blade) at the rotating shaft of cutting wheel, linear velocity with 1mm/min is pressed edge pressing part with pressure head, and the length of the contact area of pressure head equals { projection of blade (mm) deducts 0.3mm }, and width is 10mm.With the stress of strength tester AG-1 (Shimadzu Mfg.Co., Ltd.) measurement for the displacement of pressure head.Continue to press until blade breaks.

As shown in Figure 7, in all embodiments, when movable press head when increasing, observe curve map and show linear zone, namely stress and movable press head are apart from proportional zone.Calculate the slope of curve (that is, stress/movable press head distance) in the range of linearity, the result is displayed in Table 2.

Table 2

In above-mentioned cutting test, all magnetic sheets of the outside cutting wheel cutting of use embodiment all have the cutting surfaces of good appearance.In the situation of the magnetic sheet that the outside cutting wheel that uses Comparative Examples 1 cuts, some samples are (after the 301st cutting magnetic sheet) after three dimensional measurements circulations, at cutting surfaces cutting vestige or step is arranged.This shows, as long as not too high with respect to the stress of movable press head distance and the slope that provides as elasticity or the flexible sign of cutting wheel, namely, blade has pliability to a certain degree, for with high dimensional accuracy, do not cut vestige ground at cutting surfaces the magnet block machine cuts become magnetic sheet, the outside cutting wheel is exactly effective.

This shows, when using outside cutting wheel of the present invention with workpiece, typically be rare-earth sintering magnet piece machine cuts when being sheet, the sheet of cutting have high accuracy and do not need to cut after fine finishining.Can obtain to have the sheet of high dimensional accuracy.

Claims

1. cement carbide substrate outside cutting wheel, comprise the substrate of annular thin discs form of carbide alloy of the Young's modulus with 450-700GPa and the blade on the substrate outer rim, this substrate has external diameter, the internal diameter of 30-80mm and the thickness of 0.1-1.0mm of the 80-200mm that limits outer rim

Described blade comprises:

The diamond of precoating magnetic material and/or cBN abrasive particle,

By electroplating or electroless plating forms is used for abrasive particle is bonded together and is bonded in suprabasil metal or alloy bond material, and

Infiltrate between the abrasive particle and the resin between abrasive particle and the substrate, described resin is the thermosetting resin that has the thermoplastic resin of the highest 350 ℃ fusing point or have the liquid thermosetting resin combination acquisition of the highest 350 ℃ solidification temperature by curing.

2. the cement carbide substrate outside cutting wheel of claim 1, wherein resin is to be selected from least a in the modified resin of acrylic resin, epoxy resin, phenolic resins, polyamide, polyimide resin and aforementioned resin.

3. claim 1 or 2 cement carbide substrate outside cutting wheel, wherein resin has the Poisson's ratio of 0.3-0.48.

4. each described cement carbide substrate outside cutting wheel of claim 1-3, wherein said substrate has at least saturation magnetization of 40kA/m (0.05T).

5. each described cement carbide substrate outside cutting wheel of claim 1-4, wherein said abrasive particle has the average particle size particle size of 10-300 μ m.

6. each described cement carbide substrate outside cutting wheel of claim 1-5, wherein said abrasive particle has at least 0.2 mass susceptibility χ g.

7. method of making cement carbide substrate outside cutting wheel may further comprise the steps:

Young's modulus with 450-700GPa, the external diameter that limits the 80-200mm of outer rim, the internal diameter of 30-80mm are provided, and the substrate of the annular thin discs form of the carbide alloy of the thickness of 0.1-1.0mm,

Metal or alloy electroplated or electroless plating to the substrate outer rim with by on magnetic attraction and the abrasive particle through applying that keeps, be used for abrasive particle is bonded together and is bonded to substrate, thereby form blade abrasive particle is securely fixed in the substrate outer rim, and

Allow the thermoplastic resin with the highest 350 ℃ fusing point infiltrate between the abrasive particle and any space between abrasive particle and the substrate, perhaps allow the liquid thermosetting resin combination with the highest 350 ℃ solidification temperature infiltrate between the abrasive particle and any space between abrasive particle and the substrate, and solidify there.

8. the method for claim 7, wherein resin is to be selected from least a in the modified resin of acrylic resin, epoxy resin, phenolic resins, polyamide, polyimide resin and aforementioned resin.

9. claim 7 or 8 method, the resin that wherein infiltrates has the Poisson's ratio of 0.3-0.48.

10. each described method of claim 7-9, wherein said substrate has at least saturation magnetization of 40kA/m (0.05T).

11. each described method of claim 7-10, wherein said abrasive particle has the average particle size particle size of 10-300 μ m.

12. each described method of claim 7-11, wherein said abrasive particle have at least 0.2 mass susceptibility χ g.

13. each described method of claim 7-12, wherein permanent magnet is extending 10mm or is more producing at least magnetic field of 8kA/m in the space of small distance from the substrate outer rim.