EP0847455B1 - Fabrication de dresseurs au diamant - Google Patents

Fabrication de dresseurs au diamant Download PDF

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Publication number
EP0847455B1
EP0847455B1 EP96928616A EP96928616A EP0847455B1 EP 0847455 B1 EP0847455 B1 EP 0847455B1 EP 96928616 A EP96928616 A EP 96928616A EP 96928616 A EP96928616 A EP 96928616A EP 0847455 B1 EP0847455 B1 EP 0847455B1
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EP
European Patent Office
Prior art keywords
electrolyte
mould
current
nickel
diamonds
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP96928616A
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German (de)
English (en)
Other versions
EP0847455A1 (fr
Inventor
Peter David Morris
Stephen Leslie Noakes
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Consort Precision Diamond Co Ltd
Original Assignee
Consort Precision Diamond Co Ltd
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Publication date
Application filed by Consort Precision Diamond Co Ltd filed Critical Consort Precision Diamond Co Ltd
Publication of EP0847455A1 publication Critical patent/EP0847455A1/fr
Application granted granted Critical
Publication of EP0847455B1 publication Critical patent/EP0847455B1/fr
Anticipated expiration legal-status Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B24D18/0018—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for by electrolytic deposition
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D15/00—Electrolytic or electrophoretic production of coatings containing embedded materials, e.g. particles, whiskers, wires

Definitions

  • This invention concerns the production of diamond dressers.
  • Diamond dressers sometimes known as diamond profile rolls, are mainly used in the aero engine and motor engine manufacturing industries.
  • a diamond dresser is generally circular in shape with its periphery coated with diamonds to a predetermined configuration of high tolerance.
  • a diamond dresser is mounted on a grinding machine and rotated by means of an independent drive unit to dress the configuration of the dresser onto a rotating abrasive (grinding) wheel. The grinding wheel is then ready for use in forming and finishing components especially of aero- and motor engines.
  • Diamond dressers are generally made by first forming a graphite mould to high accuracy, the internal profile of the mould matching the desired external profile of the finished diamond dresser. Diamonds are then adhered onto the internal surface of the mould and the mould is placed in a bath of electrolyte. The mould forms the cathode and a basket of nickel pellets form the anode, so that nickel is deposited on the diamond layer by an electro-plating process. The electro-plating process is continued until a layer of nickel of sufficient depth has been deposited on the diamonds. A solid steel shaft is then fitted in the centre of the mould using a low melting alloy. When the mould has cooled, the end faces of the mould are machined in a lathe and the graphite mould broken away to leave the diamond dresser.
  • US Patent Specification No. 4737162 discloses a method of producing precision abrasive articles by electroforming for use in metal removal operations.
  • diamond particles are packed firm between the inner circumferential surface of a mould and a centrally located metallic grid.
  • Electrolyte for metal deposition selected from Ni, Cu, Fe, Sn and Ag, is then pumped from a reservoir into the space containing the abrasive diamond particles.
  • An electrical cathode connection is made to the mould and an anodic connection made to the anode.
  • Metallic deposition around the diamond particles occurs on the inner annular surface of the mould and continues until a matrix supporting the diamond particles is formed.
  • the mould with the matrix is then removed to receive the core material and the core is then machined to finished dimensions.
  • the method is carried out at temperatures up to 93.3°C and without any movement of the mould.
  • the electro-plating process is carried out slowly at a low current density.
  • the electro-plating process can take as long as 32 days. That length of time increases costs and causes considerable delays between receipt of and completion of an order for a diamond dresser.
  • each electro-plating process requires a large area of operation as each mould has to be in its own electrolyte bath and each bath requires a heating jacket to bring the electrolyte up to a suitable operating temperature.
  • An object of this invention is to provide an improved process and apparatus for producing diamond dressers.
  • a process for producing diamond dressers including the steps of forming a mould for the dresser having a desired internal profile, adhering diamonds to said profile, and electro-plating a metal, typically nickel, onto the diamonds, characterised in that the electro-plating process is carried out while a swirling motion is imparted to the electrolyte.
  • apparatus for producing diamond dressers comprising an electrolyte bath for receiving a mould of graphite having a desired internal profile coated with diamonds as cathode, a metal source, typically nickel, as anode and means for passing current between the anode and cathode, whereby metal is deposited on the diamonds, characterised by means for imparting a swirling motion to the electrolyte.
  • a swirling motion may be imparted to the electrolyte in any suitable way and preferably comprises pumping means.
  • the electrolyte is preferably pumped through a plate having angled passages for the electrolyte. These passages preferably have an entrance on one radius and an exit on another radius spaced axially from the one radius in order to impart the swirling motion to the electrolyte.
  • agitation of the electrolyte by imparting a swirling motion thereto in the mould eliminates air entrapment in the metal coating and hence reduces porosity. Furthermore, nodule formations on the metal coating may be reduced or ever eliminated because of the agitation. Further, it has been found that the invention can produce required nickel depths on the diamonds within a much shorter time period than hitherto. Typically a desirable depth of nickel may be achieved in under 7 days and even in about 3 1 / 2 days.
  • the electrolyte bath is preferably maintained at a temperature above 35°C. Lower temperatures tend to result in uneven nickel growth on the diamonds.
  • the electrolyte temperature is preferably in the range of 39 to 41°C.
  • the electrolyte for nickel plating is preferably nickel sulfamate ideally at a concentration in the range of 550 to 650 g/litre.
  • the electrolyte may contain hardener and other additives, typically boric acid, nickel chloride and wetting agent.
  • the electrolyte preferably has an acidic pH of above 3.5.
  • the diamonds may be adhered to the graphite mould in any suitable way.
  • a conductive adhesive is preferably used for this purpose, such as a silver based adhesive, especially a silver loaded epoxy adhesive.
  • the nickel used for the electro-plating process is preferably in the form of pellets. These are ideally contained in a basket in the electrolyte within the graphite mould.
  • the basket is preferably made of a conductive material that is not reactive with nickel
  • the preferred basket for use in the invention is made of titanium.
  • the electro-plating process is preferably commenced at low current, which may be dependent on the area to be plated. The larger the area to be plated, the higher is the current used.
  • the start current used will be in the region of 2 amps and will be raised incremently up to 12-14 amps. The start current may be maintained for 16-24 hours and the final current may be maintained for up to 48 hours.
  • This gradual raising of the current may be achieved manually ie with regular attendance at the apparatus to adjust manually the current up to the maximum current to be used. It is preferred, however, that such raising of the current be independently controlled, so that attendance at the apparatus can be kept to a minimum.
  • the raising of the current is pulsed, in other words, a constant current is preferably switched from one level to another in a predetermined, especially regular, manner. Raising of the current is preferably controlled by a microprocessor or computer.
  • pulsed electro-plating may have several advantages. These advantages include that the metal (nickel) deposited will be finer, purer and smoother. Secondly by raising the limiting current density, the rate of metal (nickel) deposition may be increased. Thirdly, there may be improved metal adhesion to the substrate. Fourthly, a better plating distribution may be achieved. Finally, with a programmable means for raising the current, the electro-plating process may be commenced at any time during the working day and left to reach its maximum operating current at any desired time day or night.
  • the mould can be removed from the electrolyte bath and finished in the usual way.
  • a diamond dresser is produced conventionally, in the following manner.
  • a graphite mould 10 is prepared having an internal profile 12 matching the desired outer profile of the diamond dresser to be made.
  • a coating 14 of diamonds is adhered to the profile 12 using a conductive adhesive.
  • the diamond coated mould 10 is placed in a bath of electrolyte 16 comprising an aqueous solution of nickel sulfamate.
  • a porous ceramic tube 18 within which is placed a titanium basket 20 containing nickel pellets 22.
  • the nickel pellets form the anode and the mould 10 the cathode of an electrolytic cell.
  • a constant current is applied across the anode and cathode for a sufficient period of time to deposit by electro-plating a layer of nickel 25 on the diamonds of a desired thickness.
  • the deposition period will be around 30-35 days.
  • the titanium basket of nickel pellets is replaced by a bianode, so that the basket can be flushed with water to remove debris.
  • the pH of the electrolyte is checked daily. Attempts to reduce the electro-plating time by increasing current density have proved unsuccessful.
  • the resultant nickel coating was uneven, modular and pitted. In mould recesses nickel plating was found to be thinner than elsewhere.
  • the mould After completion of the nickel plating, the mould is removed from the electrolyte bath, a steel shaft fixed in the centre of the mould using a low melting alloy and the graphite mould broken away. Finishing of end faces of the dresser on a lathe completes the production process.
  • FIG. 3 of the accompanying drawings shows how the principles of the apparatus of Figure 2 can be extended to enable more than one diamond dresser to be made at one time.
  • a bath 50 of nickel sulfamate electrolyte (as in Figure 2) contains a cylindrical plastics chamber 52 having a base 54 and a top 56.
  • the base 54 includes an inlet pipe 58 connected to a filter pump (not shown) leading to an entry flange 60 which encloses a multi-entry manifold 62.
  • a turbulence plate 64 Above the manifold. 62 is a turbulence plate 64 having angled passages 66 therethrough for delivering electrolyte pumped from the electrolyte bath.
  • the passages 66 are angled outward and upwards as well as into and out of the paper respectively in order to impart a swirling or turbulent motion to the electrolyte as it emerges into the chamber 52.
  • return pipes 68 for the electrolyte.
  • a graphite mould 70 Seated on the turbulence plate 64 is a graphite mould 70 which has three dresser forms 70A, B and C leaving a gap between each.
  • the internal profile of the mould is coated with diamonds 71 in the area of each dresser form. The diamonds being adhered using a silver loaded epoxy adhesive.
  • a porous ceramic tube 72 enclosing a titanium basket 74 containing nickel pellets 76 is fitted in the chamber 52 through its top 56 centrally of the mould 70.
  • the titanium basket and the graphite mould are connected to a d.c. current supply as anode and cathode respectively.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)
  • Disintegrating Or Milling (AREA)
  • Carbon And Carbon Compounds (AREA)
  • Grinding-Machine Dressing And Accessory Apparatuses (AREA)

Claims (30)

  1. Procédé de fabrication d'outils de dressage diamantés comportant les étapes consistant à former un moule (10) pour l'outil de dressage, ayant le profil interne (12) voulu, faire adhérer des diamants (14) audit profil, placer le moule dans l'électrolyte, et plaquer par galvanoplastie un métal sur les diamants, caractérisé par le fait que l'opération de placage par galvanoplastie est effectuée pendant qu'un mouvement tourbillonnaire est imparti à l'électrolyte.
  2. Procédé selon la revendication 1, caractérisé par le fait que l'électrolyte est pompé à travers le moule.
  3. Procédé selon les revendications 1 ou 2, caractérisé par le fait que l'électrolyte est pompé à travers une plaque (24) ayant des passages (26) formant un angle pour l'électrolyte.
  4. Procédé selon la revendication 3, caractérisé par le fait que les passages ont une entrée sur un rayon et une sortie sur un autre rayon, espacé axialement du premier rayon.
  5. Procédé selon une quelconque des revendications 1 à 4, caractérisé par le fait que l'électrolyte est maintenu à une température supérieure à 35 °C.
  6. Procédé selon la revendication 5, caractérisé par le fait que la température de l'électrolyte est maintenue dans la gamme de 39 à 41 °C.
  7. Procédé selon une quelconque des revendications 1 à 6, caractérisé par le fait que le métal est du nickel.
  8. Procédé selon la revendication 7, caractérisé par le fait que l'électrolyte est du sulfamate de nickel en solution aqueuse.
  9. Procédé selon la revendication 8, caractérisé par le fait que la concentration de l'électrolyte est dans la gamme de 550 à 650 g/litre.
  10. Procédé selon la revendication 8 ou 9, caractérisé par le fait que l'électrolyte a un pH acide au-dessus de 3,5.
  11. Procédé selon une quelconque des revendications 1 à 10, caractérisé par le fait que les diamants adhèrent au profil au moyen d'un adhésif conducteur.
  12. Procédé selon la revendication 11, caractérisé par le fait que l'adhésif est un adhésif à base d'argent.
  13. Procédé selon la revendication 12, caractérisé par le fait que l'adhésif est un adhésif epoxy à charge d'argent.
  14. Procédé selon une quelconque des revendications 7 à 13, caractérisé par le fait que le nickel est sous la forme de grains.
  15. Procédé selon une quelconque des revendications 1 à 14, caractérisé par le fait que le placage par galvanoplastie est commencé à un courant bas qui est augmenté graduellement.
  16. Procédé selon la revendication 15, caractérisé par le fait que le placage par galvanoplastie est commencé à un courant dans la zone des 2 Ampères.
  17. Procédé selon la revendication 15 ou 16, caractérisé par le fait que le courant est augmenté jusqu'à 12 à 14 Ampères.
  18. Procédé selon les revendications 15, 16 ou 17, caractérisé par le fait que le courant de départ est maintenu pendant 16 à 24 heures.
  19. Procédé selon une quelconque des revendications 1 à 18, caractérisé par le fait que le courant final est maintenu pendant une période de temps jusqu'à 48 heures.
  20. Procédé selon une quelconque des revendications 15 à 19, caractérisé par le fait que l'augmentation de courant est pulsée.
  21. Appareil de fabrication d'outils de dressage diamantés comportant un bain d'électrolyte pour recevoir un moule de graphite (70) ayant le profil interne voulu recouvert de diamants (71) en tant que cathode, une source de métal (76) en tant qu'anode et des moyens pour faire passer un courant électrique entre l'anode et la cathode grâce à quoi le métal est déposé sur les diamants, caractérisé par le fait qu'il comporte des moyens pour impartir un mouvement tourbillonnaire à l'électrolyte.
  22. Appareil selon la revendication 21, caractérisé par le fait que les moyens conçus pour impartir un mouvement tourbilionnaire à l'électrolyte comportent des moyens de pompage.
  23. Appareil selon la revendication 22, caractérisé par le fait qu'il comporte une plaque (64) au travers de laquelle l'électrolyte est pompé, la plaque ayant des passages (66) formant un angle à travers elle.
  24. Appareil selon la revendication 23, caractérisé par le fait que les passages de la plaque comportent une entrée sur un rayon et une sortie sur un autre rayon, espacé axialement du premier rayon.
  25. Appareil selon une quelconque des revendications 21 à 24, caractérisé par le fait qu'il comporte des moyens pour chauffer l'électrolyte.
  26. Appareil selon une quelconque des revendications 21 à 25, caractérisé par le fait que le métal est contenu dans un panier dans l'électrolyte à l'intérieur du moule de graphite.
  27. Appareil selon la revendication 26, caractérisé par le fait que le panier est fait en un matériau conducteur qui ne réagit pas avec le nickel.
  28. Appareil selon la revendication 26 ou 27, caractérisé par le fait que le panier est fait de titane.
  29. Appareil selon une quelconque des revendications 21 à 28, caractérisé par le fait qu'il comporte des moyens pour modifier le courant appliqué.
  30. Appareil selon la revendication 29, caractérisé par le fait qu'il comporte des moyens pour modifier le courant appliqué de façon pulsée.
EP96928616A 1995-09-01 1996-08-30 Fabrication de dresseurs au diamant Expired - Lifetime EP0847455B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
GB9517854 1995-09-01
GBGB9517854.7A GB9517854D0 (en) 1995-09-01 1995-09-01 Production of diamond dressers
PCT/GB1996/002132 WO1997009469A1 (fr) 1995-09-01 1996-08-30 Fabrication de dresseurs au diamant

Publications (2)

Publication Number Publication Date
EP0847455A1 EP0847455A1 (fr) 1998-06-17
EP0847455B1 true EP0847455B1 (fr) 1999-05-06

Family

ID=10780049

Family Applications (1)

Application Number Title Priority Date Filing Date
EP96928616A Expired - Lifetime EP0847455B1 (fr) 1995-09-01 1996-08-30 Fabrication de dresseurs au diamant

Country Status (6)

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EP (1) EP0847455B1 (fr)
AT (1) ATE179767T1 (fr)
AU (1) AU6833596A (fr)
DE (1) DE69602373T2 (fr)
GB (1) GB9517854D0 (fr)
WO (1) WO1997009469A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102009007992A1 (de) * 2009-02-07 2010-08-19 Ab Skf Beschichtungsanordnung

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004094111A1 (fr) * 2003-04-24 2004-11-04 Empa Eidgenössische Materialprüfungs- Und Forschungsanstalt Procede pour realiser un outil abrasif
CN104440605B (zh) * 2014-11-11 2017-08-25 富耐克超硬材料股份有限公司 一种多角形超硬复合磨料、采用该磨料制备磨具的方法
CN112757178A (zh) * 2021-01-14 2021-05-07 沈阳恒鹏商务服务有限公司 一种金刚石滚轮的上砂方法及金刚石滚轮

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4737162A (en) * 1986-08-12 1988-04-12 Alfred Grazen Method of producing electro-formed abrasive tools

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102009007992A1 (de) * 2009-02-07 2010-08-19 Ab Skf Beschichtungsanordnung

Also Published As

Publication number Publication date
WO1997009469A1 (fr) 1997-03-13
EP0847455A1 (fr) 1998-06-17
ATE179767T1 (de) 1999-05-15
DE69602373T2 (de) 2000-01-13
AU6833596A (en) 1997-03-27
DE69602373D1 (de) 1999-06-10
GB9517854D0 (en) 1995-11-01

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