CN103313825B

CN103313825B - Cement carbide substrate outside cutting wheel and manufacture method thereof

Info

Publication number: CN103313825B
Application number: CN201180065608.7A
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: 2016-08-10
Anticipated expiration: 2031-11-28
Also published as: SG190924A1; US20130252521A1; TW201238715A; EP2647469A4; MY193551A; MY170393A; EP2647469A1; EP2647469B1; CN103313825A; KR20140005911A; MY193556A; TWI556913B; WO2012073855A1; PH12018500478B1; PH12018500478A1

Abstract

Disclosed cement carbide substrate outside cutting wheel includes the substrate of the annular thin discs form of hard alloy, and the blade in substrate outer rim.This blade comprises: the diamond of precoating magnetic material and/or cBN abrasive particle, by plating or electroless plating formed for abrasive particle being bonded together and being bonded in suprabasil metal or alloy bond material, penetrating into the resin between abrasive particle and between abrasive particle and substrate, described resin is the thermoplastic resin of the fusing point with the highest 350 DEG C or has the thermosetting resin of liquid thermosetting resin compositions acquisition of solidification temperature of the highest 350 DEG C by solidification.Also disclose the method for manufacturing described cement carbide substrate outside cutting wheel.

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 being applicable to cut rare-earth sintering magnet cut Cut wheel and its manufacture method.

Background technology

Cutting processing for rare earth permanent magnets block (or sintered magnet block), it is achieved that multiple Cutting technique, such as external diameter cutting, internal diameter cutting and saw blade cutting.Wherein, external diameter sword cutting Wheel uses the most extensive.External diameter sword cutting technique has many advantages, including cheap cutting tool, Dimensional accuracy that the relatively low cutting surplus relevant to hard alloy sword, cutting member are good and Relatively high process velocity.Due to these advantages and the mass production of improvement, external diameter sword cuts Technology is widely used in the cutting of rare-earth sintering magnet block.

It is disclosed in JP-A for cutting the external diameter sword cutting wheel of rare-earth sintering magnet In H09-174441, JP-A H10-175171, and JP-A H10-175172, these outsides are cut Cutting wheel and comprise cement carbide substrate, described substrate has diamond with phenolic resin, nickel plating etc. Or cBN abrasive particle is bonded in outer rim thereon.Substrate owing to being made up of hard alloy is strong at machinery Degree aspect is improved relative to alloy tool steel or the high-speed steel of prior art, it is achieved that Raising in machining accuracy, achieve by using thin sword to reduce on the productivity of the sheet that surplus is brought Raising and achieve the reduction of the processing cost that High-speed machining is brought.

Although in terms of cutting and processing characteristics, use the external diameter sword cutting wheel of cement carbide substrate Cut wheel than the external diameter sword of prior art to be improved, but, market constantly proposes to reduce into This requirement.Wish that there is a kind of high performance cutting can processed with high accuracy and high speed Wheel.

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

Applicant proposed one resin such as phenolic resin in the past and diamond abrasive grain was bonded in ring The technology of the outer rim of shape cement carbide substrate, and combine with the metal with suitable Young's modulus Diamond or cBN abrasive particle are bonded in the technology of the outer rim of Circular Hard Alloy substrate by material (JP-A2009-172751)。

Wheel is cut by two parts, substrate and blade group for cutting the outside of rare-earth sintering magnet block Become.Because accounting for the cutting most substrate of wheel to be made up of the hard alloy of high-modulus, cutting wheel exists Mechanical strength aspect is improved, and therefore cutting accuracy higher than prior art there is alloy work Cutting wheel at the bottom of tool steel and high-speed steel-base.Due to be combined with cement carbide substrate, there is suitable poplar The metallic bonding material of family name's modulus, improves the mechanical strength of whole cutting wheel, thus with existing Outside the resin mating-type as abrasive particle bond material with phenolic resin or polyimide resin of technology Sword cutting wheel is compared, it is thus achieved that the raising of three performances, the raising of machining accuracy, uses thin land The reduction of the processing cost that the raising of the material productivity come and high cutting speed are brought.

Cement carbide substrate outside cutting wheel can be by producing near the outer rim of cement carbide substrate Magnetisation field manufactures, and the action of a magnetic field is on the abrasive particle of precoating magnetic material, in order to magnetization abrasive particle On coating, thus based outer rim attracts abrasive particle, and carries out plating in this state, Thus abrasive particle is bonded in outer rim.This method reduce the manufacturing cost of outside cutting wheel.

The cement carbide substrate outside cutting wheel produced by said method is that one is with high-performance The outside cutting wheel of feature.But when using this outside cutting wheel, rare-earth sintering magnet block is cut into During magnetic sheet, sometimes because magnet block can be cut tiltedly, or on magnetic sheet cutting surfaces, leave cutting wheel Cutting vestige and make deteriorated dimensional accuracy.Specifically, when use, such as there is 80-200mm The cement carbide substrate outside of external diameter, the aperture of 30-80mm and 0.1-1.0mm thickness cut Cut wheel, and with at least 200mm³The time per unit processing volume of/min operates to carry out height During the cutting of speed, high load capacity, dimensional tolerance can be more than 50 μm.If deteriorated dimensional accuracy, then Need some remedial measures.Such as, magnetic sheet has to pass through such as the smooth grinding cutting table by polishing The additional step in face.Outside cutting wheel must use abrasive wheel to repair, or changes cutting condition.

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

It is an object of the invention to provide one to be cut into by rare-earth sintering magnet block there is high chi The cement carbide substrate outside cutting wheel of the sheet of very little precision, and one to manufacture this with low cost outer The method of sword cutting wheel.

The solution of problem

It is assumed that rare-earth sintered magnet block is cut oblique phenomenon is because outside cutting wheel There is the most lateral symmetry tooth shape shape, make cutting operation carry out in easy cut direction, and because When outside cutting wheel and being arranged on machining tool, there is warpage in outside cutting wheel.Also speculate, The phenomenon leaving cutting vestige on magnetic sheet is because ought be for above-mentioned reasons by magnet block Cut oblique outside cutting wheel on cutting operation path during unexpected change traffic direction, new cutting Cutting surfaces does not smoothly engage with the most cleaved cutting surfaces, defines step.

During cutting operation, there occurs the unexpected change of the traffic direction of outside cutting wheel, example As, when a part for the sword of outside cutting wheel deforms for a certain reason or peels off；When sword limit When edge changes suddenly its shape；When the feed speed taken turns due to cutting is higher than the grinding rate of sword, The internal stress caused in sword by this deformation becomes bigger than the external force putting on sword from workpiece, knot Really, when the power causing sword to deform is released and makes sword deform；It is cut the operation phase with when cutting groove Between the chip that formed the foreign body of external source fills up or smoothing and cause the fortune of outside cutting wheel When row is disturbed.In order to eliminate any cutting vestige that can be formed under these conditions, effectively The sword edge shape that changes the most suddenly it, and when during cutting operation any power be applied to sword On to change its traffic direction time, sword deforms before and after such degree makes change Cutting surfaces smoothly engages.

The outside that abrasive particle is bonded in substrate be formed blade by plating or electroless plating wherein is cut Cut generation voiding problem in wheel.Owing to abrasive particle has certain particle size, between abrasive particle and Between abrasive particle and substrate, the abrasive particle of bonding only part contact, and the space between them can not Filled by coating completely.As a result, even if after plating blade also leaving space.That is, blade Comprise the space connected with surface.

As long as the load being applied to during cutting operation on outside cutting wheel is low, even if having so Space exists, and hi-precision cutting is also possible, because blade is not subjected to be executed by during cutting The substantial deformation that the power added causes.But, under the highest load, carry out cutting make hard The place of alloy substrates deformation, sword edge can partly deform or come off.One prevents blade limit Edge deformation or the effective ways come off are the intensity by strengthening sword edge.As below will described in, Owing to blade should have enough elasticity to allow blade deformation to make it possible to smooth engagement cutting Surface, only strengthens the intensity of sword and carrys out resistance to deformation and can not solve this problem.

By the edging structure of mechanical performance needed for meeting high intensity, elasticity and blade is entered One step is looked into, and the inventors have discovered that by utilizing between abrasive particle and between abrasive particle and substrate Space, is obtained in that effective blade specifically by allowing resin penetrate into space.Resin penetrates into Thing is by heat of fusion plastic resin, formation of penetrating into and harden, or by by liquid thermosetting tree Oil/fat composition penetrates into and solidify to form.The outside comprising cement carbide substrate and such blade is cut It is effective for cutting wheel in the dimensional accuracy improving the magnetic sheet cut with it.Heat of fusion plastic resin, The technology penetrated into and harden or the technology penetrating into liquid thermosetting resin compositions and solidification are for system It is effective for making the outside cutting wheel being characterized with high cutting accuracy and low cost.The present invention is base Find in these and complete.

On the one hand, the present invention provides a kind of cement carbide substrate outside cutting wheel, and it includes tool There is the substrate of the annular thin discs form of the hard alloy of the Young's modulus of 450-700GPa and be somebody's turn to do Blade in substrate outer rim, this substrate have limit outer rim 80-200mm external diameter, The internal diameter of 30-80mm and the thickness of 0.1-1.0mm.

This blade includes diamond and/or the cBN abrasive particle of precoating magnetic material；By plating Or electroless plating formed for abrasive particle being bonded together and being bonded to suprabasil metal or conjunction Gold bond material；And penetrate into the resin between abrasive particle and between abrasive particle and substrate.Described resin It is the thermoplastic resin of the fusing point with the highest 350 DEG C or by solidification, there are the highest 350 DEG C The thermosetting resin that the liquid thermosetting resin compositions of solidification temperature obtains.

In a preferred embodiment, resin is selected from acrylic resin, epoxy resin, phenol In the modified resin of urea formaldehyde, polyamide, polyimide resin and aforementioned resin at least A kind of.Further preferably resin has the Poisson's ratio of 0.3-0.48.

In a preferred embodiment, substrate has at least 40kA/m(0.05T) saturated The intensity of magnetization.

In a preferred embodiment, abrasive particle has the average particle size particle size of 10-300 μm, Further preferably abrasive particle has the mass susceptibility χ g of at least 0.2.

On the other hand, the present invention provides a kind of side manufacturing cement carbide substrate outside cutting wheel Method, comprises the following steps:

There is provided by there is the Young's modulus of 450-700GPa, limiting the 80-200mm of outer rim External diameter, the internal diameter of 30-80mm, and the thin circle of annular of the hard alloy of the thickness of 0.1-1.0mm Sheet-form base,

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

Permanent magnet is placed near substrate outer rim so that the magnetic field produced by permanent magnet can Have an effect and coated abrasive particle magnetic force attracted and is maintained near substrate outer rim,

By metal or alloy plating or electroless plating to substrate outer rim be magnetically attracted and keep On coated abrasive particle, for abrasive particle being bonded together and being bonded to substrate, with by abrasive particle Fixedly secure and form blade in substrate outer rim, and

The thermoplastic resin allowing the fusing point with the highest 350 DEG C penetrates between abrasive particle and abrasive particle and base Any space at the end, or allow the liquid thermosetting tree of the solidification temperature with the highest 350 DEG C Oil/fat composition penetrates into any space between abrasive particle and between abrasive particle and substrate, and enters there Row solidification.

In a preferred embodiment, resin is selected from acrylic resin, epoxy resin, phenol At least the one of the modified resin of urea formaldehyde, polyamide, polyimide resin and aforementioned resin Kind.Further preferably penetrate into resin and there is the Poisson's ratio of 0.3-0.48.

In a preferred embodiment, abrasive particle has the average particle size particle size of 10-300 μm. Further preferably abrasive particle has the mass susceptibility χ g of at least 0.2.

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

Beneficial effects of the present invention

Use cement carbide substrate outside cutting wheel, rare earth magnet block is cut into magnetic sheet.Only adopt It is just high dimensional accuracy by magnetic sheet polish with cutting operation.Polish after any cutting operation Can omit.The rare earth magnetic sheet with high dimensional accuracy is obtained with low cost.

This method manufacturing outside cutting wheel is cost-effective.

The brief description of accompanying drawing

[Fig. 1] Fig. 1 schematically shows the outside cutting wheel in one embodiment of the invention, Fig. 1 (A) is plane graph, and Fig. 1 (B) is the profile along Fig. 1 (A) center line B-B, figure 1(C) be circle C(blade in Fig. 1 (B)) enlarged drawing.

[Fig. 2] Fig. 2 is the decomposition diagram of the exemplary clamp used in this method.

[Fig. 3] Fig. 3 is the outside amplification view of the holder clipping substrate in Fig. 2.

[Fig. 4] Fig. 4 (A) to 4(D) it is formed in the different embodiments of suprabasil blade Sectional view.

[Fig. 5] Fig. 5 is the microphotograph of the blade side surface of outside cutting wheel in embodiment 1.

[Fig. 6] Fig. 6 is to show cutting accuracy and use embodiment 1 to 4 and the outside of comparative example 1 The curve chart of the relation of the magnetic sheet number of cutting wheel cutting.

[Fig. 7] Fig. 7 is the outside cutting wheel showing stress with embodiment 1 to 4 and comparative example 1 The curve chart of the relation of blade deformation.

Embodiment explanation

With reference to Fig. 1, illustrate the cement carbide substrate in one embodiment of the invention Outside cutting wheel includes substrate 10 and blade 20, and substrate 10 is that the annular that hard alloy is made is thin Disk form, blade 20 is arranged in the outer rim of substrate 10.This blade 20 includes by plating Or the diamond that bonds with metal or metal alloy bond material of electroless plating and/or cBN abrasive particle.

Substrate 10 is annular thin discs (having the thin slice of the annular of centre bore 12) form, tool There are the restriction 80-200mm of outer rim, the external diameter of preferred 100-180mm, limit hole 12 30-80mm, the internal diameter of preferred 40-70mm, 0.1-1.0mm, the thickness of preferred 0.2-0.8mm Degree.

It is noted that as it is shown in figure 1, the disk of this substrate 10 has centre bore and excircle. Therefore term " radially " and " axially " use relative to disk center, and therefore thickness is axle To size, length (or height) is radial dimension.Term " internal " or " inwardly " and " outer similarly Portion " or " outwards " be relative to disk center or cutting wheel rotary shaft and use.

This substrate has the thickness in the range of 0.1 to 1.0mm and less than in the range of 200mm External diameter because the substrate of such size can manufacture accurately, and guarantee long-time with height Dimensional accuracy consistently cuts off processing workpiece, typically rare-earth sintering magnet block.Thickness is little Cause the probability of the obvious warpage unrelated with external diameter in 0.1mm, and make it difficult to high accuracy Manufacture substrate.Thickness shows to cut the increase of surplus more than 1.0mm.Existing in view of passing through Production and processing hard alloy technology manufacture size, external diameter is up to 200mm.Aperture It is arranged in the range of 30 to 80mm to adapt to cut off the axle of machining tool.

The example of the hard alloy of preparation substrate includes IVB, VB and the VIB in periodic chart The carbide powder of the metal in race, such as WC, TiC, MoC, NbC, TaC and Cr₃C₂ By viscous at Fe, Co, Ni, Mo, Cu, Pb, Sn or its metal alloy of sinter bonded Those hard alloys in knot agent substrate.In these hard alloys, preferably typical WC-Co, WC-Ti, C-Co and WC-TiC-TaC-Co system.They should have 450-700GPa Young's modulus.Further preferably those hard alloy with the electric conductivity being prone to plating or those energy Enough palladium catalysts etc. give the hard alloy of such electric conductivity.When giving firmly with palladium catalyst etc. During matter alloy conductive, known agent can be used, as the metallized metal of ABS resin Agent.

About the magnetic property of substrate, the biggest saturation magnetization is to attract to incite somebody to action by magnetic Abrasive particle is maintained at substrate.But, even if in the case of relatively low saturation magnetization, it is possible to logical Position and the magnetic field intensity of crossing control permanent magnet will coat the basad magnetic of abrasive particle of magnetic material Property attract.To this end, the substrate with the saturation magnetization of at least 40kA/m (0.05T) is order People's satisfaction.

By cutting the square sample of 5mm in the substrate with given thickness, and utilize Vibration sample gaussmeter (VSM) is at the magnetization curve (4 π I-H) of the temperature survey sample of 24-25 DEG C Determine the saturation magnetization of substrate.The upper limit of the magnetization value of first quartile is designated as Saturation magnetization.

Advantageously outer rim to substrate can carry out chamfering (bevelling or rounding), in order to increase Bond strength at the bottom of strong basis and between blade, blade is by with metallic bonding material bound abrasive grains It is formed in substrate.The chamfering of substrate outer rim is favourable, even if because when during grinding being Sword overmastication is exceeded the border between substrate and abrasive grain layer by purpose mistakenly that adjust sword thickness Time, metallic bonding material is left on boundary to prevent blade from being separated.The angle of chamfering and amount Can determine according to the average particle size particle size of the thickness of substrate and abrasive particle, because being suitable to chamfering Scope depends on the thickness of substrate.

Abrasive particle used herein is diamond particles and/or cBN granule.Abrasive particle should use magnetic Material is coated.According to the intended chi that should be used for determining the abrasive particle before coating magnetic material Very little and hardness.

For example, it is possible to be used alone diamond particles (to include natural diamond and commercial synthesis gold Hard rock) or cubic boron nitride (cBN) granule.Diamond particles and the mixture of cBN granule Also it is acceptable.According to workpiece, each type of abrasive particle can be selected from single crystal grain with many Brilliant granule, and may be used alone or in combination to adjust fragility.It addition, in order to Strengthen the bond strength to the magnetic material being subsequently coated with, sputter thickness about 1 μm at grain surface Metal such as Fe, Co or Cr be effective.

Although particle size depends on that the thickness of substrate, preferably abrasive particle have the flat of 10-300 μm All particle sizes.If average particle size particle size is less than 10 μm, can stay less between abrasive particle Space so that occur during cutting operation as smoothing and problem filling up, and damage Lose cutting power.If average particle size particle size is more than 300 μm, can produce and such as be cut by it The magnetic sheet problem with rough surface.In view of cutting efficiency and life-span, can be used alone Or the abrasive particle of certain size in the range of this is used as the mixture of different size granule.

Use magnetic material coated grits in advance, the most coated abrasive particle can at short notice by Magnetic is attracted in the substrate of the hard alloy even with low saturation magnetization, and firm Admittedly be fixed in substrate to prevent from coming off during by the adhesion step of plating.Specifically, The most coated abrasive particle has the mass susceptibility χ g of at least 0.2, more preferably at least 0.39. Typically, magnetic material is at least one metal in Ni, Fe and Co, two kinds or The alloy of these metalloids more kinds of, or a kind of such metal or alloy with in P and Mn The alloy of at least one.Can such as sputter by any of technology, electroplate or nothing Electroplating is by such magnetic material coated grits, until coating layer thickness reaches abrasive grain diameter 0.5-100%, preferred 2-80%.

Owing to the susceptibility of coated abrasive particle depends on susceptibility and the magnetic of the magnetic material of coating Property material coating thickness, it should select magnetic material type, with obtain for certain size Captivation needed for abrasive particle.But, even if having the nothing electricity of low susceptibility because of high content of phosphorus The nickel phosphor coating of plating also can make susceptibility bring up to a certain degree by heat treatment.There is difference The multiple coating of the layer of susceptibility is also possible, it may for example comprise have low susceptibility layer and The coating of the layer with high susceptibility thereon.Therefore, the susceptibility of coated abrasive particle can To be adjusted according to special status.

As long as coated abrasive particle has the mass susceptibility χ g of at least 0.2, preferably at least 0.39, Coated abrasive particle just can be magnetized rapidly by the magnetic field produced near bed perimeter.Then grind Grain is arbitrary in the space 64 that the permanent magnet holder of the substrate shown in Fig. 3 and fixture is limited It is magnetically attracted on position generally equalizedly.If the mass susceptibility χ g of coated abrasive particle is little In 0.2, then the abrasive particle in that space will not be attracted completely.Under the most weak attraction, Some abrasive particles can come off during plating, it is impossible to forms abrasive grain layer (or blade) or defines many The abrasive grain layer in hole, thus there is low mechanical strength.

The mass susceptibility χ g of abrasive particle can determine by the following method, it is provided that has 8mm's External diameter, the internal diameter of 6mm, the plastic holding device of height of 5mm, by granule uniformly and thinly It is distributed in container, form one or two layer of granular layer, will particulate from reservoir device take out, measurement They are put back in container by the weight of grain, place the fusing point with about 50 DEG C on granular layer Paraffin, and add heat container in the baking oven of 60 DEG C.Once melted paraffin wax, will hold with lid Device is closed and cools down.Vibration sample gaussmeter (VSM) is utilized to survey in the temperature of 24-25 ° of C The initial magnetization curve (4 π I-H) of amount sample.Slope at initial magnetization curve flex point is given Differential magnetic susceptibility, except this differential magnetic susceptibility, to obtain the quality magnetization of abrasive particle with sample weight Rate χ g.It should be noted that and calibrate magnetic field with standard Ni sample, and abrasive grain density is by conduct Tapped Bulk Density (tap bulk density) is measured.

The coating thickness of magnetic material should fall into suitable scope, because coating thickness can affect The size in the space that blade produces during being formed.Preferably minimum coating thickness is 2.5 μm, at this The all abrasive particles of thickness can be coated by plating and substantially not have space to produce.Such as, for having The preferably abrasive particle of the average particle size particle size of maximum 300 μm of average grain size, is coated with Covering thickness can be at least the 0.5% of particle size, more preferably at least 0.8%.If magnetic material The coating of material has thickness in this range, and it provides for using outside in cutting operation The retentivity of Grain Falling Off can be reduced during cutting wheel.As long as selecting the magnetic material of suitable type Being used for coating, during coating step, abrasive particle will be attracted by magnetic field and be maintained at substrate Outer rim or its near and do not come off.

For having the average grain of 10 μm of the minima of preferred average grain size The abrasive particle of size, preferably at most coating thickness reach the 100% of abrasive particle average particle size particle size, because of Abrasive particle part for otherwise can not effectively play a role during cutting operation increases, and hinders mill Increasing from the part sharpened of grain, and working ability decline.

The metallic bonding material being bonded together by abrasive particle is coating metal or alloy.When forming sword During portion, it is necessary to permanent magnet is set near the outer rim of substrate to produce magnetic field.Such as, by two Individual or the more remanent magnetism (or residual magnetic flux density) with at least 0.3T permanent magnet is arranged On the side surface of the substrate being positioned at inside substrate outer rim, or be arranged on inside substrate outer rim and from The side surface interval of substrate is less than in the space of 20mm distance, thus is prolonging from substrate outer rim The magnetic field of at least 8kA/m is produced in the space of the distance stretching 10mm or less.The action of a magnetic field On the diamond being pre-coated with magnetic material and/or cBN abrasive particle, to produce magnetic attracting force. By this magnetic attracting force, abrasive particle is magnetically attracted and fixedly secures near substrate outer rim or its. In the case of abrasive particle fixedly secures, carry out the plating of metal or alloy or without electricity in substrate outer rim Plating, thus abrasive particle is bonded to substrate outer rim.

The fixture that this method uses includes that a pair holder, each holder include that external diameter is more than base The insulating cove of end external diameter, and arrange and fixedly secure on the lid inside substrate outer rim forever Magnet for a long time.Plating process is carried out while substrate is fixed between holder.

With reference to Fig. 2 and 3, it is shown that for an exemplary clamp of plating process.This fixture Including a pair holder 50,50, each clip includes insulating cove 52 and is arranged on lid Permanent magnet 54 on 52.Substrate 1 is sandwiched between holder 50 and 50.Permanent magnet 54 are preferably embedded in lid 52.Or, permanent magnet 54 is arranged on lid 52 thus is assembling Time permanent magnet 54 can dock with substrate 1.

The permanent magnet loaded in fixture should have enough magnetic force, in order at deposition metal knot Condensation material keeps being attracted to suprabasil abrasive particle during the plating process of bound abrasive grains.Although institute Magnetic force is needed to depend on the distance between substrate outer rim and magnet, and the magnetic being coated on abrasive particle The intensity of magnetization of material and susceptibility, preferable magnetic force can obtain from permanent magnet, and this is permanent Magnet has remanent magnetism and the coercivity of at least 0.2MA/m, preferably at least 0.6T of at least 0.3T Remanent magnetism and the remanent magnetism of the coercivity of at least 0.8MA/m, more preferably at least 1.0T and at least The coercivity of 1.0MA/m.

The remanent magnetism that permanent magnet has is the biggest, and the magnetic field gradient that it produces is the biggest.Therefore hope is worked as Permanent magnet during local attraction's abrasive particle with bigger residual induction is suitable.In this sense Saying, the permanent magnet that remanent magnetism at least 0.3T is preferably used prevents owing in plating process, plating is molten Vibration that the oscillating motion of the fixture of the stirring of liquid and clamping substrate produces and cause abrasive particle from substrate On separate.

When coercivity is bigger, even if when being exposed to high temperature plating solution, magnet also can will grind Grain length time magnetic more strongly attracts in substrate.The position of the magnet then used, shape Increase with the selection degree of freedom of size, facilitate the manufacture of fixture.There is higher coercivity Magnet meet magnets of required remanent magnetism selected from those.

Contact with the potential of plating solution in view of magnet, preferably permanent magnet coating is made magnetic Body can be more anticorrosive.Select coating material to make in plating solution in such a situa-tion to coat The replacement of the metal species in the dissolubility of material and plating solution minimizes.At one wherein In the embodiment that metallic bonding material is deposited from nickel plating bath, it is preferred for magnet Coating material is metal such as Cu, Sn or Ni or resin such as epoxy resin or acrylic acid tree Fat.

Load the shape of permanent magnet in fixture, size sum amount depends on cement carbide substrate Size and the position in desired magnetic field, direction and intensity.Such as, when hope, abrasive particle is equal Even when being bonded in substrate outer rim, the magnet ring corresponding with substrate external diameter can be set, or along Substrate outer rim is arranged the arc magnet block corresponding with substrate external diameter continuously and closely or has The cuboid magnet block of several millimeters of long side surfaces.In order to reduce the cost of magnet, can be by magnet block Spaced apart to reduce the quantity of magnet block.

Although dependent on the remanent magnetism of magnet block used, the space between magnet block still can be increased. Owing to magnet block is spaced apart, the abrasive particle being coated with magnetic material is divided into a group be attracted Grain and another group granule not being attracted.Then abrasive particle is by some of alternately bonded to substrate outer rim Region and be not glued to other region of substrate outer rim.Formed and be made up of spaced apart block Blade.

About the magnetic field produced near substrate outer rim, it is arranged on the two of clamping substrate by change The position of the permanent magnet on individual holder and the combination of the direction of magnetization can produce various magnetic field. The layout of magnet is determined so that from substrate outer rim by magnetic field analysis and experiment are repeated At least 8kA/m, preferably at least 40kA/m is produced in extending the space of 10mm or more small distance Magnetic field.When magnetic field intensity is less than 8kA/m, it has little magnetic force and attracts to be coated with magnetic The abrasive particle of property material, if carrying out plating in this state, in plating process, abrasive particle can move Open, formed as result and there is the most lacunose blade, or abrasive particle bonds with dendroid, leads Cause the size of blade more than desired value.Finishing subsequently can cause the separation of blade or spend longer Time.These all can improve the cost of manufacture.

Preferably, permanent magnet is placed on the part that is attracted from abrasive particle closer to place.One From the point of view of as, permanent magnet is placed on the basolateral surfaces inside substrate outer rim, or is being positioned at Inside substrate outer rim and extend not more than in the space of 20mm distance from basolateral surfaces, preferably It is being positioned at inside substrate outer rim and is extending not more than the space of 10mm distance from the side surface of substrate In.At least two has the permanent magnet of at least 0.3T remanent magnetism, and (the most each holder is at least One magnet) it is placed on the ad-hoc location in described space so that and magnet is wholly or partially It is positioned at described space, thus in the space extending not more than 10mm distance from substrate outer rim The magnetic field with at least 8kA/m intensity can be produced.Then, no matter substrate is high saturated by having The intensity of magnetization and the material such as alloy tool steel or high-speed steel of magnetic force may be caused to prepare, or By there is low saturation magnetization and being less likely to cause the material such as hard alloy of magnetic force to prepare, The magnetic field with suitable magnetic force can be produced near substrate outer rim.When in magnetic field, supply is coated with When being covered with the abrasive particle of magnetic material, coating is magnetized, and result abrasive particle is attracted and is maintained at substrate Outer rim or its near.

About magnet relative to the position of substrate outer rim, it is defined above if magnet is not placed on Space in, particularly when magnet is placed on the outside of substrate outer rim, although close to outside substrate Edge, such as, in the distance of the outside 0.5mm of substrate outer rim, then near substrate outer rim Magnetic field intensity is the highest, but there may be the region of a magnetic field gradients reverse.Then abrasive particle inclines To in showing the behavior floating up from substrate and coming off.If the position of magnet is in substrate outer rim Inner side, but from the substrate outer rim distance more than 20mm, then extending not from substrate outer rim Tend to that there is the intensity less than 8kA/m more than the magnetic field in the space of 10mm distance, there is magnetic Property attract the danger that diminishes of power of abrasive particle.In this case, magnetic field intensity can be by increasing Magnet size improves.But, the position that large-sized magnet not only attracted at abrasive particle is attached Closely, and region produces strengthened magnetic field around, and this is undesirable, because some Abrasive particle can attracted to the position that abrasive particle is not attracted.Large scale magnet is unrealistic, because The fixture loading magnet also becomes the biggest.

The shape of fixture (holder) meets the shape of substrate.The size of fixture (holder) Being such, when substrate is clipped between holder, the permanent magnet in holder can be in phase For on the desired position of substrate.The thickness of external diameter and 0.26mm for having 125mm Substrate and row's 2.5mm length, 2mm width, permanent magnet block thick for 1.5mm, such as, Use and there is the disk of the external diameter of at least 125mm and the thickness of about 20mm as holder.

Specifically, the external diameter of fixture or holder it is selected equal to or is more than { the external diameter of substrate + (height of abrasive grain layer) × 2 }, in order to guarantee height or the radially projecting amount (figure of abrasive grain layer H2 in 1(C)), and select the thickness of fixture or holder to provide enough strong Degree prevents owing to being moved in or out the suddenly change of the temperature that hot dip bath produces and sticking up of causing Bent.The thickness of the part that holder contacts with abrasive particle can be reduced to less than remainder, with Just the axially projecting amount (T3 in Fig. 1 (C)) of abrasive grain layer on substrate thickness direction is guaranteed. Thickness is sticked to this part equal to the masking tape of axially projecting amount so that thickness can be with it The thickness that remaining part is divided is equal.

Prepare the insulation material that the material of fixture or holder does not preferably have coating to deposit thereon Material, because in order to be deposited in substrate by metallic bonding material, have and be clipped between holder The whole fixture of substrate is dipped in hot dip bath.It is more desirable to this insulant and should have chemically-resistant Property, the thermostability of a maximum of about of 90 DEG C and if exposed to being moveable into and out the quickest of plating bath Thermal cycle time still there is the resistance to heat shocks that be enough to maintain size constancy.Also want to this insulant Should have be enough to prevent holder by internal stress (accumulation in molding and processing) generation warpage, Make to produce between holder and substrate the dimensional stability in space when immersing hot dip bath.Certainly, This insulant should be machinable, in order to can high accuracy free from flaw and breach ground any Position processing is for receiving the groove of permanent magnet.

Specifically, holder is by such as PPS, PEEK, POM, PAR, PSF and PES Engineering plastics and ceramic such as aluminium oxide standby.Holder is prepared by, and it is suitable to select Material, it is considered to mechanical strength determines thickness and other size, forms the material into as this size, The current electrode needed during with processing for receiving the groove of permanent magnet and for receiving and electroplating Recess.During use, assemble the holder being prepared for a pair substrate is sandwiched therebetween. When holder with for substrate power the electrode that can carry out electroplating be assembled together time, should Assembling process both provided power supply to also provide for machinery banding, and produced as overall compact package. It is, of course, preferable to coupled together as shown in Figure 2 by multiple fixtures, thus multiple substrate can be simultaneously Plating, because production process becomes more efficiently.

Specifically, as in figure 2 it is shown, pacified for plating the negative electrode 56 as substrate keeper Be contained in lid 52 is centrally recessed into part.By a pair holder 50 is combined with substrate 1, will The support shaft 58 of conduction inserts the hole of holder and substrate, and they bandings are come group together Clamps.In the assembled state, negative electrode 56 contacts with axle 58, it is allowed to from axle 58 to negative electrode 56 power supplies.In fig. 2, using separator 60 and end cap 62, two fixtures are with between suitably Every being arranged on axle 58, each fixture is made up of a pair holder 50,50.It is appreciated that figure In 2, the fixture of display is for electroplating.In the case of electroless plating, it is not necessary to negative electrode, can To replace with non-conductive keeper, and support shaft is also without being conduction.

Using fixture, plating is performed as follows.By permanent load in holder 50,50 Clamp substrate 1 between magnet and assemble fixture.In this state, as it is shown on figure 3, by folder Outer peripheral portion 52a, 52a(of the lid 52,52 of gripping member 50,50 extend outwardly beyond substrate) Space 64 is defined with the outer rim of substrate 1.Weigh with scale and proper amount of be pre-coated with magnetic material Material abrasive particle and be fed in space 64, in space 64, abrasive particle is attracted magnetically and protects Hold.

The amount keeping abrasive particle in space depend on the external diameter of substrate and thickness, the size of abrasive particle, Desired height and width with blade to be formed.Holding abrasive particle is further preferably repeated several times and enters The process of row plating so that the amount phase of per unit volume abrasive particle on any position of substrate outer rim Deng, and plating technique (tenaciously) bound abrasive grains securely can be passed through.

Form blade by this way.Preferably, blade comprises 10-80 volume %, more excellent Select the abrasive particle of the volume fraction of 30-75 volume %.Volume fraction less than 10 volume % means The less abrasive particle contributing to cutting, causes resistance in cutting operation process to increase.More than 80 The volume fraction of volume % means that cut edge deflection reduces during cutting operation, is cutting Cut surface leave cutting vestige and make dimensional accuracy and cutting sheet degraded appearance.Owing to these are former Cause, cutting speed must slow down.The most preferably by changing the magnetic material painting on abrasive particle The thickness of layer changes particle size, thus adjusts the volume fraction of abrasive particle for application-specific.

As shown in Fig. 1 (C), blade 20 is made up of a pair leg lock 22a, 22b and main body 20, Clamping the outer rim of substrate 10 between leg lock 22a, 22b in the axial direction, main body 20 outward radial prolongs Stretch the outside (edge) beyond substrate 10.It should be noted that and so divide to describe It is convenient, because lower limb and main body are integrally formed blade.The thickness of blade 20 is more than the thickness of substrate 10 Degree.In order to form the blade of this design, structure space 64 the most as shown in Figure 3.

More specifically, the leg lock of the blade 20 for the outer rim of clamping substrate 10 in-between 22a, 22b, each length H1 preferably with 0.1-10mm, more preferably 0.5-5mm.Often Individual lower limb 22a, 22b preferably have at least 5 μm (=0.005mm), more preferably 5-2000 μm, The thickness T3 of even more preferably 10-1000 μm.The gross thickness of lower limb 22a, 22b is preferably at least 0.01mm, more preferably 0.01-4mm, even more preferably 0.02-2mm.The total thickness of blade 20 Spend thicker than substrate 10.If length H1 of leg lock 22a, 22b is less than 0.1mm, they Prevent cement carbide substrate outer rim from occurring on breach and crack the most effective, but strengthen substrate Aspect effect is little, and sometimes can not prevent the deformation that substrate causes by Cutting Drag.If it is long Degree H1 obtains under sacrifice expense more than 10mm, the enhancing of substrate.If leg lock Thickness T3 is less than 5 μm, and the thinnest lower limb can not strengthen the mechanical strength of substrate or effectively arrange Go out metal fragment.

Such as Fig. 4 (A)-4(D) shown in, leg lock 22a, 22b can be by metallic bonding material 24 and abrasive particle 26 form (Fig. 4 (A)), metallic bonding material 24 form (Fig. 4 (B)), Or include the covering being made up of metallic bonding material 24 bottom on the substrate 10 and tied by metal Condensation material 24 and the superimposed layer (Fig. 4 (C)) of abrasive particle 26 composition.It is noted that pass through Metallic bonding material is deposited so that as shown in Figure 4 (D) shows around whole in the structure of Fig. 4 (C) Outer surface, the intensity of blade can improve further.

At Fig. 4 (B)-4(D) in the embodiment that shows, leg lock is interior with what substrate 10 contacted Sidepiece is only formed by metallic bonding material 24.To this end, substrate is occluded so that only want The part of the substrate forming leg lock above is to expose, and enters in the base part not being occluded Row plating.Then substrate is arranged on fixture, with abrasive particle 26 packing space 64, and enters Row plating.After plating abrasive particle, with the lid 52,52 of Fig. 2, substrate 10 can be covered, should Lid 52 has less external diameter and the part of plating is come out, and again carries out plating, formed by The layer of metallic bonding material 24 composition is as the outermost layer of blade, as shown in Figure 4 (D) shows.

Referring again to Fig. 1 (C), extend radially outwards the blade 20 of outer rim beyond substrate 10 Main body there is length H2, although can change along with the size of abrasive particle to be bonded, this is long Degree is preferably 0.1-10mm, more preferably 0.3-8mm.If length H2 of this main body is less than 0.1mm, due to the impact in cutting operation and abrasion, blade can consume at short notice, This shows that the life-span of cutting wheel is short.If length H2 of main body can become more than 10mm, blade Obtain easily deformable, although the thickness (T2 in Fig. 1 (C)) of blade is depended in deformation, this Cause the magnetic sheet cut out to have wavy cutting surfaces, therefore make dimensional accuracy be deteriorated.Blade Main body be generally made up of abrasive particle 26, metallic bonding material 24 and resinoid bond.

Metallic bonding material is the metal or alloy by coating deposition.Metal used herein is tied Condensation material is at least one metal in Ni, Fe, Co, Cu and Sn, by least two The alloy of kind of above-mentioned metal composition, or by least one above-mentioned metal or alloy and phosphorus (P) and The alloy of one or both compositions in manganese (Mn).This metal or alloy passes through coating deposition, Make to be formed between abrasive particle and between abrasive particle and substrate interconnection.

It is generally divided into two kinds, galvanoplastic and without electricity by the method for coating deposition metallic bonding material Plating.In the practice of the invention, galvanoplastic are easily controlled and remain in metallic bonding material Internal stress and production cost low, electroless plating (or chemical plating) method guarantees relatively uniform The deposition of metallic bonding material, if plating solution infiltration.Two kinds of methods can be alone or in combination Use so that blade can comprise the space of the OK range that will be described later.

The stress in plated film can be controlled by suitable mode.Such as, in single metal-plated In copper or nickel plating, typically nickel sulfamic acid plating, can be by suitable scope Electric current density during interior selection active component or the concentration of nickel sulfamic acid, plating, plating bath Temperature, and add organic additive such as adjacent benzenesulfonimide (o-benzenesulfonimide) or Para toluene sulfonamide (p-toluenesulfonamide) or element such as Zn, S or Mn control Stress.In addition, alloy plated such as Ni-Fe alloy, Ni-Mn alloy, Ni-P alloy, In Ni-Co alloy or Ni-Sn alloy, can by select in the range of suitably Fe in alloy, The content of Mn, P, Co or Sn, the temperature of plating bath and other parameter carry out proof stress.Closing In the case of gold plating, certainly adding organic additive is effective to proof stress.

Single metal or alloy can be deposited by any one in the known plating bath of selection, and adopt Plating is carried out with the conventional plating condition of this plating bath.

The preferably example of electroplating bath includes sulfamate watt (Watts) nickel electroplating bath, its bag Nickel sulfamic acid containing 250-600g/L, the nickel sulfate of 50-200g/L, the Nickel dichloride. of 5-70g/L, The boric acid of 20-40g/L and appropriate adjacent benzenesulfonimide；With Copper pyrophosphate. electroplating bath, it comprises The Copper pyrophosphate. of 30-150g/L, the potassium pyrophosphate of 100-450g/L, the 25% of 1-20mL/L Ammonia and the potassium nitrate of 5-20g/L.Typical electroless plating bath is nickel-phosphorus alloy electroless plating bath, It comprises the nickel sulfate of 10-50g/L, the sodium hypophosphite of 10-50g/L, the sodium acetate of 10-30g/L, The sodium citrate of 5-30g/L and appropriate thiourea.

By plating, abrasive particle is bonded together and is bonded to the outer rim of substrate, accurately Formed and there is the blade of the size close to net shape, wherein abrasive particle can be diamond abrasive grain, CBN abrasive particle or diamond and the mixture of cBN abrasive particle.

The blade so formed comprises space between abrasive particle and between abrasive particle and substrate.According to this Invention, penetrates into the thermoplastic resin of the fusing point with the highest 350 DEG C in this space and hard at this Change, or the liquid thermosetting resin compositions of the solidification temperature with the highest 350 DEG C is penetrated into Solidify in this space and at this.Therefore, the feature of blade of outside cutting wheel is, from surface to Internal whole blade, between abrasive particle and between abrasive particle and substrate, existence has the highest 350 DEG C Fusing point thermoplastic resin or from the liquid thermosetting of the solidification temperature with the highest 350 DEG C The thermosetting resin of resin combination.

Suitably penetrate into resin and include thermoplastic resin and thermosetting resin, typically asphalt mixtures modified by epoxy resin Fat, acrylic resin, phenolic resin, polyamide resin, polyimide resin and aforementioned resin Modified resin, they may be used alone or in combination.

This thermoplastic resin or thermosetting resin can penetrate into blade, such as, by thermoplastic resin It is processed into and there is 0.1-2.0mm, the line of diameter of preferred 0.8-1.5mm, granule or thin film ring, This thin film ring has the shape and size identical with blade, and thickness is 0.05-1.5mm, by this line, Granule or ring are placed on blade, heat this blade extremely on heater such as heating plate or in baking oven Higher than the temperature of fusing point, this temperature is kept to allow melted resin penetrate into blade, afterwards Slow cooling To room temperature.Can be by resin and organic solvent, firming agent etc. be mixed to form liquid thermosetting Resin combination, casts in said composition blade, allows said composition penetrate into blade, in solidification Temperature or the temperature heating higher than solidification temperature, thus solidify, be slowly cooled to room temperature afterwards Thermosetting resin is made to penetrate into.Or between outside is cut wheel being placed near blade and have In the female die of gap, fill this half module, by upper half with the resin or resin combination claiming weight Mould coordinates with female die, heats the mould after this cooperation, allow on mould while applying certain pressure Resin or resin combination penetrate into blade and penetrate into.Cool down mould afterwards, then discharge pressure And cutting wheel is taken out from mould.Then the cooling step of heating steps should be slowly to avoid appointing What overstrain.

When using the resin with relatively good wettability, can be stainless by substrate is clipped in Between the metal parts of steel, ferrum or copper, it is energized to metal parts, makes metal parts produce heat, Thus add hot substrate and blade, and by the blade of heating and melted resin or liquid resin composition Thing contact is penetrated into.

In the blade obtained, abrasive particle, the magnetic material covered on abrasive particle, metal combine material The resin in material and infiltration space is properly dispersed.

The resin penetrating into blade should preferably have following physical property.Fusing point is preferably no greater than 350℃.In the case of thermoplastic resin, fusing point is not higher than 350 DEG C, preferably no greater than 300 DEG C, Purpose is to prevent cement carbide substrate deformation from making dimensional accuracy be deteriorated or changing mechanical strength, and Prevent blade deformation or due between cement carbide substrate and blade the marked difference of thermal expansion and produce Raw strain.In the case of thermosetting resins, fusion temperature is more preferably at least 10 DEG C, because this Compositions of thermosetting resin can be met there is enough mobility at room temperature penetrate into.

Resin preferably has elasticity, is expressed as 0.3-0.48 with Poisson's ratio, more preferably 0.33-0.44. The resin with the Poisson's ratio less than 0.3 lacks pliability and is difficult to smoothly engage cutting table Face.The resin with the Poisson's ratio more than 0.48 does not reaches mark in other physical property such as hardness Standard, has sword edge and the danger of notable deformation occurs.Poisson's ratio can use 15 × 15 × 15mm Infiltration resin samples measured by impulse ultrasound method.

The hardness of resin can not be the highest, and hardness is the highest can hinder when abrasive particle mill during cutting operation Damage, when destroying or come off abrasive particle from sharpening, (new abrasive particle occurs, contributes to showing of cutting operation As), and the hardness of resin is less than for bound abrasive grains and the magnetic material being coated on abrasive particle The hardness of metallic bonding material.Even if further preferably when being exposed in the course of processing processing used Time in liquid or coolant, resin should not occur change or the corrosion of intensity.

If it is required, by the grinding of the abrasive wheel that uses aluminium oxide, carborundum or diamond or The blade being within it infiltrated with resin is adjusted to desired size by electro-discharge machining.In this, Although dependent on the thickness of blade, but the edge of blade can be with chamfering (bevelling or rounding) To the degree of at least C0.1 or R0.1, because such chamfer machining is to reducing on cutting surfaces Cutting vestige or to alleviate the fragmentation of final magnetic sheet be effective.

The outside cutting wheel of the application of the invention, can cut various workpiece.Typical workpiece Including R-Co rare-earth sintering magnet and R-Fe-B rare-earth sintering magnet, wherein R is to include Y At least one of rare earth element.These magnets are prepared as follows.

R-Co rare-earth sintering magnet includes RCo₅And R₂Co₁₇System.Wherein, R₂Co₁₇Magnet Composition (weight %) comprise 20-28%R, 5-30%Fe, 3-10%Cu, 1-5%Zr Co with surplus.They are prepared as follows, and weigh source material by this composition, are melted, casting Make melt, and alloy fine powder is broken to the average particle size particle size of 1-20 μm, produce R₂Co₁₇ Magnet powder.Then sinter 0.5-5 hour by powder compaction and at 1100-1250 ° of C in magnetic field. By sintered body less than solution treatment 0.5-5 hour at a temperature of sintering temperature 0-50 DEG C, and Keep a period of time to carry out burin-in process at 700-950 DEG C, then cool down.

The composition (weight %) of R-Fe-B rare-earth sintering magnet comprises 5-40%R, 50-90%Fe And 0.2-8%B.In order to improve magnetic characteristic and corrosion resistance, the unit added can be added thereto to Element, additional elements 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 for Co For the highest 30 weight %, it is the highest 8 weight % for other element.This magnet is prepared as follows, Weigh source material by this composition, melted, cast melt, and alloy fine powder is broken to 1-20 μm Average particle size particle size, produce R-Fe-B magnet powder.Then by powder pressure in magnetic field Tightly and at 1000-1200 DEG C sinter 0.5-5 hour, then keep a period of time at 400-1000 DEG C Carry out burin-in process, then cool down.

The outside cutting wheel using the present invention does not leaves cutting trace at cutting surfaces with high dimensional accuracy Rare earth magnet block is cut into magnetic sheet by slash.Particularly when the edge of blade, there is particular range Compression shear stress time this is real.Such as, this outside cutting wheel includes blade, this sword Portion have the thickness of 0.1-1.0mm, the external diameter of 80-200mm, by edge chamfer (rounding Or bevelling) it is the degree of at least R0.1 or C0.1.Thick by cutting wheel being clipped in 5mm Round iron plate between, this cutting wheel is horizontally mounted on fixture so that only blade is sudden and violent Dew.Cutting wheel is so kept to make the substrate will not be in warpage under pressurized.Outside from substrate outer rim The position of spaced apart 0.3mm, at axial (or the thickness direction of blade) of the rotary shaft of cutting wheel On press edge pressing part with the linear velocity of 1mm/min with pressure head, the length etc. of the contact area of pressure head In { the radially projecting amount (mm) of blade deducts 0.3mm}, and width is 10mm.Measure pressure The stress of head displacement.Continue pressing until blade ruptures.Increasing along with movable press head distance Add, can confirm that curve chart shows that linear region i.e. stress is proportional to the displacement of pressure head Region.Calculate the slope of curve in the region that stress is proportional to deflection.If this slope In the range of 100-10000N/mm, cutting wheel is not staying at cutting surfaces with high dimensional accuracy It is exactly effective that rare earth magnet block is cut into magnetic sheet aspect by cutting vestige ground.

Embodiment

The most by way of illustration and nonrestrictive mode provides embodiment and comparative example.

[embodiment 1]

The hard alloy being made up of 90wt%WC and 10wt%Co is processed into there is 125mm External diameter, the internal diameter of 40mm, 0.3mm the annular thin discs of thickness as substrate.This base The end, 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 extend internally 1.0mm from outer rim Two surfaces circumferential area expose.This substrate is immersed in the commercial available alkaline aqueous solution of 40 DEG C Within 10 minutes, with defat, clean with water, immerse 50 DEG C, in the aqueous solution of 30-80g/L sodium pyrophosphate, With 2-8A/dm²Electric current density be electrolysed.In deionized water this substrate is carried out ultrasonic clearly Wash and immerse in the sulfamate watt nickel plating bath of 50 DEG C, at 5-20A/dm²Electric current close The lower plating priming coat of degree.After once being peelled off by Covering adhesive tapes, clean substrate with water.

Polyphenylene sulfide (PPS) resin disk to the thickness with the external diameter of 130mm, 10mm A side surface be processed, formed there is the external diameter of 123mm, the internal diameter of 119mm, 1.5mm The groove of the degree of depth.75 2.5mm length, 2mm width it is equally spaced in the groove of this dish, Thick for 1.5mm permanent magnet block (N39UH that Shin-Etsu rare-earth magnet company limited produces, Br=1.25T), the thickness direction of permanent magnet block aligns with the depth direction of groove.Use asphalt mixtures modified by epoxy resin Fat filling slot to be fixed in groove by permanent magnet block securely, completes to load the holder of magnet. Substrate is clipped between the holder of a pair such composition fixture, the magnet one side of holder To inner side.In clamp position, permanent magnet is inwardly spaced from substrate outer rim along substrate surface The distance of 1mm.This permanent magnet produces magnetic field near substrate outer rim, according to analyzing this magnetic field In the space extending 10mm distance from substrate outer rim, there is the strong of at least 8kA/m (0.01T) Degree.

In advance diamond abrasive grain is carried out NiP plating to form coated diamond abrasive grain, its There is mass susceptibility χ g and the average particle size particle size of 135 μm of 0.588.By holder and The recess of base bound, the diamond abrasive grain that supply 0.4g is coated, thus abrasive particle is by magnetic Gravitational attraction to and be evenly distributed in whole substrate outer rim.The fixture of abrasive particle is had to soak by attracting on it Enter in the sulfamate watt nickel plating bath of 50 DEG C, at 5-20A/dm²Electric current density under carry out Plating.Take out fixture and clean with water.Repeat magnetic force attract the coated diamond abrasive grain of 0.4g, Plating and the step of washing.

PPS resin disk holder generation with the thickness with the external diameter of 123mm, 10mm Holder for fixture.Substrate is clipped between holder so that the side surface of abrasive grain layer exposes. Fixture is immersed the sulfamate watt nickel plating bath of 50 DEG C, at 5-20A/dm²Electric current density Lower energising, with at whole blade deposited plating layer.Take out fixture and clean with water, unloading base afterwards The end, is also dried, it is thus achieved that outside cutting wheel.

As Primary resins, bisphenol A diglycidyl ether and dicyandiamide are formed component be dissolved in In machine solution, thus obtained liquid epoxy resin composition is coated in the sword of outside cutting wheel On the side surface in portion, and keep 3 minutes.This outside cutting wheel is placed on the baking oven of 180 DEG C Middle holding about 120 minutes.Turn off baking oven, it is allowed to outside cutting wheel cools down in an oven. It should be noted that the epoxy resin of solidification has the Poisson's ratio of 0.34.Fig. 5 is blade side table The microphotograph in face.

Tool grinding machinery is used to be ground by outside cutting wheel to highlight at each abrasive grain layer The distance (T3) of cement carbide substrate 50 μm.Adjusting the projection of abrasive grain layer or thickness and outer Behind footpath, outside cutting wheel is repaired, create cement carbide substrate outside cutting wheel, its Have thickness (T2) be 0.4mm, external diameter be abrasive grain layer or the blade of 127mm.

[embodiment 2]

The hard alloy being made up of 90wt%WC and 10wt%Co is processed into there is 125mm External diameter, the internal diameter of 40mm, the annular thin discs of thickness of 0.3mm, as substrate.

With adhesive tape, this cement carbide substrate is covered so that only will extend internally 1.5mm from outer rim Two surfaces circumferential area expose.This substrate is immersed in the commercial available alkaline aqueous solution of 40 DEG C Within 10 minutes, with defat, clean with water, immerse 50 DEG C, in the aqueous solution of 30-80g/L sodium pyrophosphate, At 2-8A/dm²Electric current density under be electrolysed.In deionized water this substrate is carried out ultrasonic Clean and immerse in the sulfamate watt nickel plating bath of 50 DEG C, at 5-20A/dm²Electric current Plating priming coat under density.After once being peelled off by Covering adhesive tapes, clean substrate with water.

A side surface to the PPS resin dish of the thickness with the external diameter of 130mm, 10mm It is processed, is formed and there is the external diameter of 123mm, the internal diameter of 119mm, the degree of depth of 1.5mm Groove.105 1.8mm length, 2mm width, 1.5mm it is equally spaced in the groove of this dish The thick permanent magnet block (N32Z, Br=1.14 that Shin-Etsu rare-earth magnet company limited produces T), the thickness direction of permanent magnet block aligns with the depth direction of groove.Fill with epoxy resin Groove to be fixed in groove by permanent magnet block securely, completes to load the holder of magnet.By base The end, is clipped between the holder of a pair such composition fixture, and the magnet one side of holder is inside Side.In clamp position, permanent magnet along substrate surface from substrate outer rim 1.5mm spaced inward Distance.This permanent magnet produces magnetic field near substrate outer rim, according to analyzing this permanent-magnetic field In the space extending 10mm distance from substrate outer rim, there is the strong of at least 16kA/m (0.02T) Degree.

In advance diamond abrasive grain is carried out NiP plating to form coated diamond abrasive grain, its There is the mass susceptibility χ g and 135 of 0.588_μThe average particle size particle size of m.By holder and The recess of base bound, the diamond abrasive grain that supply 0.4g is coated, thus abrasive particle is by magnetic Gravitational attraction to and be evenly distributed in whole substrate outer rim.The fixture of abrasive particle is had to soak by attracting on it Enter in the sulfamate watt nickel plating bath of 50 DEG C, at 5-20A/dm²Electric current density under carry out Plating.Take out fixture and clean with water.Repeat magnetic force attract the coated diamond abrasive grain of 0.4g, The step 3 time of plating and washing.

Liquid epoxy resin composition in embodiment 1 is coated to the blade of outside cutting wheel On side surface, and keep 5 minutes.Outside cutting wheel is placed in the baking oven of 180 DEG C and keeps About 120 minutes.Turn off baking oven, it is allowed to wheel cools down in an oven.

Tool grinding machinery is used to make at each abrasive grain layer prominent hard by outside cutting wheel grinding The distance of matter alloy substrates 50 μm.After adjusting the projection of abrasive grain layer or thickness and external diameter, right Outside cutting wheel is repaired, and creates cement carbide substrate outside cutting wheel, and it has thickness For abrasive grain layer or blade that 0.4mm, external diameter are 129mm.

[embodiment 3]

With adhesive tape, this cement carbide substrate is covered so that only will extend internally 1.0mm from outer rim Two surfaces circumferential area expose.This substrate is immersed in the commercial available alkaline aqueous solution of 40 DEG C Within 10 minutes, with defat, clean with water, immerse 50 DEG C, in the aqueous solution of 30-80g/L sodium pyrophosphate, At 2-8A/dm²Electric current density under be electrolysed.In deionized water this substrate is carried out ultrasonic Clean and immerse in the sulfamate watt nickel plating bath of 50 DEG C, at 5-20A/dm²Electric current Plating priming coat under density.After once being peelled off by Covering adhesive tapes, clean substrate with water.

As in Example 1 substrate is clipped between the holder of fixture.In advance to diamond Abrasive particle carries out NiP plating to form coated diamond abrasive grain, and it has the quality of 0.392 Susceptibility χ g and the average particle size particle size of 130 μm.Recessed by holder and base bound Part, the diamond abrasive grain that supply 0.4g is coated, thus abrasive particle is magnetically attracted and uniform Be distributed in whole substrate outer rim.The pyrophosphoric acid that the fixture having abrasive particle will be attracted on it to immerse 40 DEG C In electroless copper bath, at 1-20A/dm²Electric current density under electroplate.Taking-up fixture is the most clear with water Wash.From fixture, unload outside cutting wheel and be dried.

Liquid epoxy resin composition in embodiment 1 is coated to the blade of outside cutting wheel On side surface, and keep 5 minutes.Outside cutting wheel is placed in the baking oven of 180 DEG C and keeps About 120 minutes.Turn off baking oven, it is allowed to outside cutting wheel cools down in an oven.

Tool grinding machinery is used to make at each abrasive grain layer prominent hard by outside cutting wheel grinding The distance of matter alloy substrates 50 μm.After adjusting the projection of abrasive grain layer or thickness and external diameter, right Outside cutting wheel is repaired, and creates cement carbide substrate outside cutting wheel, and it has thickness For abrasive grain layer or blade that 0.4mm, external diameter are 126mm.

[embodiment 4]

The hard alloy being made up of 95wt%WC and 5wt%Co is processed into there is 125mm External diameter, the internal diameter of 40mm, the annular thin discs of thickness of 0.3mm, as substrate.Should Substrate has the Young's modulus of 580GPa, the saturation magnetization of 40kA/m (0.05T).

With adhesive tape, this cement carbide substrate is covered so that only will extend internally 1.0mm from outer rim Two surfaces circumferential area expose.This substrate is immersed the commercially available alkaline aqueous solution of 40 DEG C In 10 minutes with defat, clean with water, immerse 50 DEG C, 30-80g/L sodium pyrophosphate water-soluble In liquid, at 2-8A/dm²Electric current density under be electrolysed.In deionized water this substrate is entered Row ultrasonic cleaning and immerse the sulfamate watt nickel plating bath of 50 DEG C, at 5-20A/dm² Electric current density under plating priming coat.After once being peelled off by Covering adhesive tapes, clean substrate with water.

As in Example 1 substrate is clipped between the holder of fixture.In advance to diamond Abrasive particle carries out NiP plating to form coated diamond abrasive grain, and it has the quality of 0.392 Susceptibility χ g and the average particle size particle size of 130 μm.Recessed by holder and base bound Part, the diamond abrasive grain that supply 0.3g is coated, thus abrasive particle is magnetically attracted and uniform Be distributed in whole substrate outer rim.The electroless nickel that the fixture having abrasive particle will be attracted on it to immerse 80 DEG C Phosphorus alloy plating bath carries out electroless plating.Take out fixture and clean with water.Repeat magnetic force and attract 0.3g Coated diamond abrasive grain, electroless plating and water-washing step twice.Outside is unloaded from fixture Cutting is taken turns and is dried.

Methyl methacrylate, metering system acid diesters, chlorosulfonated polyethylene and hydrogen mistake will be comprised The propylene liguid acid resin compositions of cumene oxidation is coated in the side surface of the blade of outside cutting wheel On.Outside cutting wheel be placed in baking oven, baking oven is moderately evacuated, then at 80 DEG C Heat 60 minutes.Turn off baking oven, it is allowed under outside cutting wheel cools down in the baking oven keeping vacuum Come.It should be noted that the acrylic resin of solidification has the Poisson's ratio of 0.4.

Tool grinding machinery is used to make at each abrasive grain layer prominent hard by outside cutting wheel grinding The distance of matter alloy substrates 50 μm.After adjusting the projection of abrasive grain layer or thickness and external diameter, right Outside cutting wheel is repaired, and creates cement carbide substrate outside cutting wheel, and it has thickness For abrasive grain layer or blade that 0.4mm, external diameter are 127mm.

[comparative example 1]

As in Example 1 substrate is clipped between the holder of fixture.In advance to diamond Abrasive particle carries out NiP plating to form coated diamond abrasive grain, and it has the quality of 0.392 Susceptibility χ g and the average particle size particle size of 130 μm.Recessed by holder and base bound Part, the diamond abrasive grain that supply 0.4g is coated, thus abrasive particle is magnetically attracted and uniform Be distributed in whole substrate outer rim.The amino sulphur that the fixture having abrasive particle will be attracted on it to immerse 50 DEG C In hydrochlorate watt nickel plating bath, at 5-20A/dm²Electric current density under electroplate.Take out fixture And clean with water.Repeat magnetic force to attract the coated diamond abrasive grain of 0.4g, electroplate and wash step Suddenly.

PPS resin disk holder generation with the thickness with the external diameter of 123mm, 10mm Holder for fixture.Substrate is clipped between holder so that the side surface of abrasive grain layer exposes. Fixture is immersed the sulfamate watt nickel plating bath of 50 DEG C, at 5-20A/dm²Electric current density Lower energising, with at whole blade deposited plating layer.Take out fixture and clean with water.Unload substrate also It is dried, it is thus achieved that outside cutting wheel.

Table 1 reports the cement carbide substrate outside cutting wheel of embodiment 1-4 and comparative example 1 Manufacture finished product percentage rate.Plating finished product percentage rate is to be calculated such that in each embodiment preparation Until by 15 samples of the step of plating adhesion abrasive particle, when there is no Grain Falling Off or abrasive grain layer There is no during defect to judge sample preferably, and make good use of the number number divided by plating sample of sample.Processing Finished product percentage rate is to be calculated such that the step after good sample is implemented binding metal coating step Until pre-shaping step, judging sample preferably when abrasive grain layer does not has defect, the number making good use of sample removes The number of the good plating sample to start.Total finished product percentage rate is that plating finished product percentage rate is multiplied by processing Finished product percentage rate, it is intended that the finished product percentage rate of good sample is to use relative in cutting wheel manufacture The outside the completed cutting wheel of the number of starting substrates.

Table 1

As it can be seen from table 1 good than comparative example 1 of the yield rate of embodiment.Especially plating After processed finished products rate be gratifying.The manufacture method of this explanation present invention is in productivity ratio Also it is improved.

Use the cement carbide substrate outside cutting wheel of the present invention, by rare-earth sintering magnet block machinery It is cut into magnetic sheet.The cutting accuracy of magnetic sheet is plotted in the curve chart of Fig. 6.

Cutting accuracy is by providing ten outside cutting wheels of embodiment 1-4 and comparative example 1 Evaluate, two outside cutting wheels of each embodiment.By by ten outside cutting wheel intervals 1.5mm arranges to constitute and cuts wheel assembly more, by the hole in rotary shaft basement, they are tight Gu together.By cutting with the operation of the feed speed of the rotating speed of 4500rpm, 30mm/min more Cut wheel assembly, by 40mm width, 130mm length, Nd-Fe-B rare earth high for 20mm sintering magnetic Body block is mechanically cut into 40mm width, 1.5mm length (=thick (t)), magnetic sheet high for 20mm. Repeat cutting operation until the magnetic sheet sum of cutting reaches 1010.In them, select at a pair Between the cutting wheel of identical embodiment, the magnetic sheet of cutting is used for checking.Each dimensional measurement circulation bag Include the 1st to the 100th, represent ten circulations altogether.The tenth day of lunar month sheet in each circulation is taken Make sample (i.e. from the 1st to the 10th of the first circulation, from the 101st of the second circulation the To the 110th, the rest may be inferred, and from the most metacyclic 1001st to the 1010th). For ten in each circulation, the center the most a piece of with miking and four angles (totally five Individual point) thickness (t).In five measured values, the difference of maximum and minima is cutting accuracy (μm).Calculate the meansigma methods of the cutting accuracy of ten.The meansigma methods of each dimensional measurement circulation It is plotted in the curve chart of Fig. 6.

In comparative example 1, (the magnetic from the 301st cutting after three dimensional measurement circulations After sheet) cutting accuracy variation.In embodiment 1-4, until the tenth circulation (until the The magnetic sheets of 1010 cuttings) cutting accuracy is not the most deteriorated.The outside cutting of this display present invention Wheel is enough on useful life longevity.

Evaluating elasticity or the pliability of outside cutting wheel, result is plotted in the curve chart of Fig. 7. Have rated the outside cutting wheel compression shear stress in edge.Specifically, by outside cutting wheel In the degree that edge's chamfering (rounding or bevelling) is at least R0.1 or C0.1.Pass through Cutting wheel is clipped between the thick round iron plate of 5mm, cutting wheel is horizontally mounted at fixture On so that only blade exposes.Cutting wheel is so kept to make the substrate will not be in warpage under pressurized. In the position being outwards spaced 0.3mm from substrate outer rim, cutting wheel rotary shaft axial (or The thickness direction of blade), press edge pressing part with the linear velocity of 1mm/min with pressure head, pressure head The length of contact area is equal to { projection (mm) of blade deducts 0.3mm }, and width is 10mm. With strength tester AG-1 (Shimadzu Mfg.Co., Ltd.) measure for pressure head movement away from From stress.Continue pressing until blade ruptures.

As it is shown in fig. 7, in all embodiments, when movable press head distance increases, it was observed that Curve chart show linear region, i.e. stress to movable press head apart from proportional region.Calculate The slope of curve (that is, stress/movable press head distance) in the range of linearity, result shows in table 2 Show.

Table 2

In above-mentioned cutting test, use all magnetic sheets of the outside cutting wheel cutting of embodiment All there is the cutting surfaces of good appearance.Magnetic in the outside cutting wheel cutting using comparative example 1 In the case of sheet, some samples (cut magnetic from the 301st after three dimensional measurement circulations After sheet), cutting surfaces has cutting vestige or step.This shows, as long as relatively It is oblique that stress in movable press head distance and the elasticity as cutting wheel or flexible sign are given Rate is the highest, i.e. blade has a certain degree of pliability, for high dimensional accuracy, For magnet block machine cuts is become magnetic sheet with not cutting vestige by cutting surfaces, outside cuts Wheel is exactly effective.

This shows, when using the outside cutting wheel of the present invention by workpiece, typically rare earth sinters When magnet block machine cuts is sheet, the sheet of cutting has high accuracy and need not the essence after cutting Processing.The sheet with high dimensional accuracy can be obtained.

Claims

1. a cement carbide substrate outside cutting wheel, including the Young with 450-700GPa Blade in the substrate of the annular thin discs form of the hard alloy of modulus and substrate outer rim, should Substrate have restriction the external diameter of 80-200mm of outer rim, the internal diameter of 30-80mm and The thickness of 0.1-1.0mm,

Described blade includes:

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

By plating or electroless plating formed for abrasive particle being bonded together and being bonded in substrate On metal or alloy bond material, and

Penetrate into the resin between abrasive particle and between abrasive particle and substrate, described resin be have the highest The thermoplastic resin of the fusing point of 350 DEG C or be there is the solidification temperature of the highest 350 DEG C by solidification The thermosetting resin that liquid thermosetting resin compositions obtains,

Described blade has 100～10000N/mm obtained by following measuring method at edge In the range of the stress slope proportional to deflection,

Measuring method:

By outside cutting wheel in edge's rounding or journey that bevelling is at least R0.1 or C0.1 Degree；By cutting wheel is clipped between the thick round iron plate of 5mm, cutting wheel is flatly pacified It is contained on fixture so that only blade exposes；So keep cutting wheel that substrate will not be subject to Pressure warpage；In the position being outwards spaced 0.3mm from substrate outer rim, in the rotary shaft of cutting wheel Axially or the thickness direction of blade, press edge pressing part with the linear velocity of 1mm/min with pressure head, The length of the contact area of pressure head deducts 0.3mm equal to the projection of described blade, and width is 10mm, the protruding unit of wherein said blade is mm；Measure the displacement for pressure head Stress；Continue pressing until blade ruptures；When movable press head distance increases, it was observed that should Power to movable press head apart from proportional region；Calculate the slope of curve in the range of linearity, i.e. should Power/movable press head distance.

2. the cement carbide substrate outside cutting wheel described in claim 1, wherein resin is to be selected from Acrylic resin, epoxy resin, phenolic resin, polyamide, polyimide resin and front State at least one in the modified resin of resin.

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

4. the cement carbide substrate outside cutting wheel described in claim 1 or 2, wherein said base The end, has the saturation magnetization of at least 40kA/m.

5. the cement carbide substrate outside cutting wheel described in claim 1 or 2, wherein said mill Grain has the average particle size particle size of 10-300 μm.

6. the cement carbide substrate outside cutting wheel described in claim 1 or 2, wherein said mill Grain has the mass susceptibility χ g of at least 0.2.

7. the method manufacturing cement carbide substrate outside cutting wheel, described cement carbide substrate Outside cutting wheel has blade, and described blade is had at edge and to be obtained by following measuring method The stress slope proportional to deflection in the range of 100～10000N/mm, the method include with Lower step:

There is provided outside the 80-200mm with the Young's modulus of 450-700GPa, restriction outer rim The annular thin discs of footpath, the internal diameter of 30-80mm, and the hard alloy of the thickness of 0.1-1.0mm The substrate of form,

Permanent magnet is placed near substrate outer rim so that the magnetic field produced by permanent magnet can Have an effect to attract coated abrasive particle magnetic force and be maintained near substrate outer rim,

By metal or alloy plating or electroless plating to substrate outer rim be magnetically attracted and keep On coated abrasive particle, for abrasive particle being bonded together and being bonded to substrate, with by abrasive particle It is securely fixed in substrate outer rim thus forms blade, and

The thermoplastic resin allowing the fusing point with the highest 350 DEG C penetrates between abrasive particle and abrasive particle and base Any space at the end, or allow the liquid thermosetting of the solidification temperature with the highest 350 DEG C Any space between resin combination infiltration abrasive particle and between abrasive particle and substrate, and there Solidification,

Measuring method:

8. the method described in claim 7, wherein resin is selected from acrylic resin, asphalt mixtures modified by epoxy resin In the modified resin of fat, phenolic resin, polyamide, polyimide resin and aforementioned resin At least one.

9. the method described in claim 7 or 8, the resin wherein penetrated into has 0.3-0.48's Poisson's ratio.

10. the method described in claim 7 or 8, wherein said substrate has at least 40kA/m Saturation magnetization.

Method described in 11. claim 7 or 8, wherein said abrasive particle has 10-300 μm Average particle size particle size.

Method described in 12. claim 7 or 8, wherein said abrasive particle has the matter of at least 0.2 Amount susceptibility χ g.

Method described in 13. claim 7 or 8, wherein permanent magnet is prolonging from substrate outer rim The magnetic field of at least 8kA/m is produced in stretching the space of 10mm or more small distance.