EP3036063A1

EP3036063A1 - Form dressing roller

Info

Publication number: EP3036063A1
Application number: EP14755631.0A
Authority: EP
Inventors: Jörg Fuhlendorf; Detlef Lessow; Bert Rohde
Original assignee: Saint Gobain Diamantwerkzeuge GmbH and Co KG
Current assignee: Saint Gobain Diamantwerkzeuge GmbH and Co KG
Priority date: 2013-08-19
Filing date: 2014-08-18
Publication date: 2016-06-29
Anticipated expiration: 2034-08-18
Also published as: WO2015024892A1; ES2633012T3; US9956665B2; CN105473283B; US20160151881A1; HUE035386T2; EP3036063B1; DE102013108918A1; JP2016531010A; KR101837320B1; RS56108B1; JP6161820B2; KR20160031546A; CN105473283A

Abstract

The present invention relates to a form dressing roller 10 comprising: a base 1; a free-standing lining ring 2 containing diamond grains and/or small diamond rods, in a ceramic, metallic bond or a synthetic resin bond, for dressing diamond and CBN grinding disks and conventional disks having corundum or silicon carbide abrasives; clamping screws 4 for fastening the lining ring 2 between the base 1 and a fastening ring 6; and a receiving bore 5 in the center of the base 1, the lining ring 2 having at least three recesses 3.

Description

Form dressing roll

The present invention relates to a novel web controlled form roller and a process for its preparation and its use for dressing diamond and CBN grinding wheels in ceramic, bakelitischer, metallic or synthetic resin bond and conventional grinding wheels with abrasives of corundum or silicon carbide.

For the molding of profiles in workpiece surfaces grinding wheels are used, which have geometrically defined profiles on their grinding surface. These profiles must first be incorporated by dressing in a new disc and then reworked from time to time because of the occurring during grinding grinding wheel wear. Abrasive wheel wear can result in both impermissible profile deviations and inadequate grinding behavior, whereby the grinding forces, the temperature of the workpiece surface and / or the surface roughness get out of tolerance.

For shape-controlled dressing of conventional grinding wheels with abrasives made of corundum or silicon carbide diamond form dressing rolls have proven that carry a layer of diamonds on its circumferential surface. This diamond layer may consist of a diamond grain in a bond of electrodeposited nickel or of polycrystalline diamond aggregates, which at the circumferential surface of the

Formabrichtrolle be held by a galvanically or chemically deposited nickel precipitate or by a sintered metal applied in a sintering process.

Partly very small concave radii must be introduced into the rotating grinding wheel surface in order to realize on the workpiece very small corner radii, such as 0, 1 mm or 0.2 mm. These are Formabrichtrollen in their largest

The diameter is ground so that a convex radius with the corresponding diameter is created. The resulting from the dressing of these fine edges wear on the Formabrichtrolle is naturally high. If the wear exceeds the profile tolerance, the form dressing roller must be reground or replaced.

EP 0 1 16 668 B1 discloses a form dressing roller which solves the problem of wear on a diamond form dressing roller by a diamond coating which is multilayered perpendicular to the axis of rotation of the dressing roller and a diamond coating which is monolayered in the direction of the axis of rotation. The diamond coating forms a profile perpendicular to the axis of rotation, which generates itself at constant dressing conditions and thus a larger

Wear amount allows without the profile outside tolerance. With the known Formabrichtrolle fine profiles can be realized by the choice of a finer grain size. Dressing consists of profiling and sharpening the grinding wheel. The profiling is required to return the profile of the grinding wheel to the desired shape and tolerance. The sharpening takes place in order to also restore the grinding ability of the grinding wheel, ie to bring the grinding forces, the heat generation and the surface roughness generated on the workpiece back into the required limits.

From EP 1312 446 B1 a form dressing roller with a coating of diamond grains for dressing diamond grinding wheels is known. The form dressing roller has a

closed pad ring on. It has been found that the known Formabrichtrolle permanently can not meet the increasing demands on the profile accuracy and the Wirkrautiefe on the dressed grinding wheel permanently.

A good profile accuracy of the grinding wheel is crucial for the result of the dressing process. Before dressing, a dressing contour is specified by a program. When dressing, it is then important to adhere to the specified profile in a given timeframe exactly.

Increased effective roughness of the grinding wheel after dressing is decisive for the result of the grinding process. The increased sawing depth at the grinding wheel due to the dressing leads to an improved grinding action of the grinding wheel.

The object of the present invention is to provide a web controlled Formabrichtrolle that produces a better profile accuracy and a higher Verschkrautiefe on the grinding wheel, the wear of the Formabrichtrolle is so low that even long profile trains can be dressed on a diamond grinding wheel with high profile accuracy.

Another object of the present invention is to provide an economical and environmentally friendly method of making the web-controlled form dressing roll.

The object is solved by the features of claims 1, 12 and 16. Preferred embodiments will become apparent from the dependent claims.

The object of the invention is preferably achieved by a form dressing roller with a carrier body, a freestanding pad ring with diamond grains in ceramic, metallic or synthetic resin bond for dressing diamond and CBN grinding wheels in ceramic, bakelitischer, metallic or synthetic resin bond and conventional grinding wheels with abrasives of corundum or silicon carbide with clamping screws that attach the pad ring between the carrier body and a mounting ring and a Receiving bore in the middle of the support body, wherein the lining ring has at least 3 recesses and the covering width of the lining ring preferably <

Diamond grain size and / or the bar width is.

The rotating form dressing roller according to the invention for the path-controlled dressing with a freestanding and interrupted hard material covering made of natural diamond,

Naturnadeldiamant, as well as synthetic diamonds in the form of CVD offers a long service life and leads to a Schleiffreudigen grinding wheel with an increased

Effective surface roughness. In CVD (Chemical Vapor Deposition), a few micrometers thick CVD diamond layer is deposited on the substrates in a vacuum chamber, for example

Carbide tools, deposited. Starting material is typically one

Gas mixture of methane and hydrogen, the former serves as a carbon source. The form dressing roller is suitable for dressing all bonded grinding wheels and grinding wheels as well as for all diamond or CBN grinding wheels and CBN grinding wheels. Analogous to diamond, cubic boron nitride (CBN) can also be produced from the hexagonal modification of boron nitride using high-pressure, high-temperature synthesis. CBN does not quite reach the hardness of diamond, but is resistant to oxygen at high temperatures, for example.

The form dressing roll according to the invention with large diamond grain sizes in one

free-standing diamond coating with interrupted cut offers a long service life and leads to a grinding grinding wheel with an increased weed depth. Due to the freestanding diamond coating, it is possible to machine a wide variety of complex profiles in one dressing cycle. Due to the interrupted cut, an increased weed depth and profile on the grinding wheel is produced. The form dressing roller according to the invention produces an improved and more uniform workpiece quality and profile, and thus a higher process reliability.

Web-controlled form dresser rolls with large hard material sizes and closed coating produce high degrees of overlap due to the coating widths, which leads to a low effect roughness and thus a more closed grinding wheel topography.

The recesses cause a pressure reduction between the Formabrichtrolle and the grinding wheel. The high pressure causes shape error and profile distortion at the

Grinding wheel. The recesses facilitate penetration of the single diamond grain of the pad of the form roller into the grinding wheel.

A preferred embodiment of the invention is a Formabrichtrolle having a lining ring of 3 to 12 recesses. The Abrichtung is an increased Weeping depth reached the grinding wheel. The increased effect roughness leads to an improved grinding action of the grinding wheel.

A particularly preferred embodiment of the invention is a Formabrichtrolle having a lining ring of 4 to 6 and most preferably 5 recesses. With the number of said recesses on the lining ring of the Formabrichtrolle is achieved by the Abrichtung an increased Wirkrautiefe on the grinding wheel.

A preferred embodiment of the invention is a Formabrichtrolle, wherein the lining ring has a lining height of 10 mm to 20 mm and a usable document height of 4 mm to 6 mm. Due to the specified lining height of the lining ring is an improved

Profile accuracy achieved at the grinding wheel.

A preferred embodiment of the invention is a Formabrichtrolle, wherein the lining ring has a covering width of 0.4 mm to 2.0 mm and the covering width <

Diamond grain size and / or diamond stick size is. By the specified covering width of the lining ring a better profile accuracy and roundness of the workpieces is achieved.

A preferred embodiment of the invention is a Formabrichtrolle, wherein the width of the recesses is 1 mm to 10 mm. The recesses in the form dressing roll cause better penetration of the form dressing roll diamond into the grinding wheel bond during the dressing process and thus a reduction in dressing forces. With the indicated width of the recesses of the form dressing roller, a good result is achieved in reducing the dressing forces and in increasing the weed depth.

A preferred embodiment of the invention is a Formabrichtrolle, wherein the depth of the recesses corresponds to the exploitable depth of the covering. At the indicated depth of the recesses of the form roller, a good result is achieved in reducing the dressing forces and increasing the saw blade depth at the grinding wheel.

A preferred embodiment of the invention is a Formabrichtrolle, wherein the

The diameter of the form dressing roller is 80 mm to 250 mm. Form dressing rollers are very effective in increasing the profile accuracy and the life of the Formabrichtrolle at the indicated diameters.

A preferred embodiment of the invention is a Formabrichtrolle, wherein the

Diameter of the receiving bore is 8 mm to 120 mm. This area for the receiving bore has proven to be very effective for better running accuracy and easier installation of Formabrichtrolle. A preferred embodiment of the invention is a Formabrichtrolle, wherein the pad ring consists of at least one layer, wherein in each layer individual diamond grains or diamond rods are arranged in a narrow classified size in a plane perpendicular to the axis of rotation of the Formabrichtrolle according to a predetermined setting scheme. at

In the case of multi-layered form-dressing rolls, the diamond grains of one layer lie in the gaps between the diamond grains of the other layer and partially protrude into the other layer, so that the peripheral geometry of the form-dressing roll in FIG

Wear progress remains approximately constant. This embodiment of the invention, in particular the lining ring has proven to be very effective.

A further solution of the object of the invention is a method for producing the Formabrichtrolle invention, wherein

- diamond grains are placed according to a predetermined setting scheme on a substrate with adhesive layer to produce a layer,

- binding powder is added,

- The coating is cold-pressed and sintered to the coating and

- The recesses are cut out of the covering.

In the form dressing roll produced by the process according to the invention, the coating width is <the diamond grain size and / or the diamond stick width. The produced covering ring is ground with the diamond grains.

- diamond grains are placed according to a predetermined setting scheme on a substrate with an adhesive layer to produce a layer, wherein the recesses are formed in the lining,

- Bonding powder is added and

- The layer is cold pressed to the coating and sintered.

A preferred embodiment of the invention is a method for producing the Formabrichtrolle invention, wherein desired layers under

Relative displacement and / or rotation of the layers are piled up and the layer packet to the coating cold pressed and sintered. A preferred embodiment of the invention is a method for producing the Formabrichtrolle invention, wherein the produced Formabrichtrolle is then ground and finished.

The process according to the invention for the production of the form dressing roll can be summarized as follows:

- a two-part body is pre-rotated,

- a diamond lining ring is produced,

a diamond lining ring is mounted in the main body,

- The complete Diamond Dressing System (DDS) form dressing roll is finished, balanced, polished and engraved for profile and running accuracy.

With the form dressing roller according to the invention results in a freestanding diamond coating whose covering width <the diamond grain size and / or diamond strip width, the grain size is chosen so that at the edges of the Belagrings natural radii arise that generate themselves and the smallest predetermined concave radius at the Corresponding grinding wheel.

As a binding for a form dressing roll according to the invention, it is preferable to use a high tungsten content galvanic or sintered bond. The grit size is <1, 5 mm, and the usable height of the diamond coating in the feed direction is preferably between 5 mm and 10 mm.

Another object of the invention is that the form dressing roll is used to dress diamond and CBN grinding wheels in ceramic, bakelitic, metallic bonding or resin bonding, as well as conventional grinding wheels with corundum or silicon carbide abrasives.

The invention will be explained in more detail with reference to a drawing. 1 is a plan view of the front side of the form dressing roller; Fig. 2 is a plan view of the back of the Formabrichtrolle; 3 shows an enlarged detail Y of the covering with a recess according to FIG. 1 and FIG. 2;

4 shows a cross section through the Formabrichtrolle.

Fig. 5 is an enlarged detail Z of the cross section of Fig. 4; 6 shows a graphic representation of the effective roughness of the workpieces after dressing, when using a conventional form dressing roll DDS without recesses in comparison to a form dressing roll DDS cut according to the invention with recesses;

7 is a graph showing the surface roughness of the workpieces after

Dressing, when using a conventional form roller DDS without

Recesses in comparison with a form dressing roller DDS-cut according to the invention with recesses;

8 shows a graphic representation of the roundness of the workpieces after dressing, when using a conventional form dressing roller DDS without recesses in comparison with a form dressing roller DDS cut according to the invention with recesses;

1 shows a top view of the front side of a form dressing roll 10 for dressing diamond and CBN grinding wheels, not shown, in ceramic, bakelitic or synthetic resin bond and / or metallic bond as well as conventional grinding wheels with abrasives made of corundum or silicon carbide. The form dressing roller 10 is an example of a Diamond Dressing System (DDS). The Formabrichtrolle 10 allows the dressing of ceramic bonded diamond and boron nitride grinding wheels in high precision. The Formabrichtrolle 10 includes a set single-layer diamond backing 2, which is clamped in a two-piece steel base consisting of a support body 1 and a clamping ring 6. The pad 2 consists of individual diamond grains, which have approximately the same size. The diamond grains are exposed to rays passing through a common center of the form dressing roll 10. The diamonds are incorporated into a matrix which consists of a suitable binder, for example a galvanic or a sintered bond with a high tungsten content. The lining ring 2 shows in Fig. 1 five recesses 3. In Fig. 1, the receiving bore 5 and the clamping screws 4 are shown.

2 shows a plan view of the back of the Formabrichtrolle 10. Here are the inner edges 6A and outer edge 6B of the clamping ring 6 visible.

FIG. 3 shows an enlarged detail Y of the covering 2 with a recess 3 according to FIG. 1 and FIG. 2. The recess 3 has a width of 5 mm and a depth of 5 mm with a covering height of 5 mm. The recess 3 can be cut out or introduced during the molding process.

4 shows a cross section through the Formabrichtrolle 10 and Fig. 5 shows an enlarged section Z of the cross section of FIG. 4 in the region of the clamping ring 6 and the Belagrings 2. It is good to see that the carrier body 1 and the clamping ring. 6 With the clamping screws 4 are held together. Both the carrier body 1 and the clamping ring 6 are usually made of stainless steel. The clamping ring 6 is inserted with the inner edge 6 A in the carrier body 1 accurately. The lining ring 2 is placed on the carrier body 1. The lining ring 2 is clamped between the carrier body 1 and the clamping ring 6. The outer edge 6B of the clamping ring 6 is flush with the outer edge 6B of the carrier body 1. The usable height of the lining ring 2 is 5 mm.

Examples

FIG. 6 shows a graphic representation of the apparent roughness of a ceramic CBN

(cubic crystalline boron nitride) grinding wheel after dressing. During the grinding process, the production of concentricity accuracy, the geometric shape and the optimum depth of rotation of the grinding wheel are important factors. Shown is the Wirkrautiefe R _ts [μηι] a dressed grinding wheel. These were a grinding wheel with a

Forming roll (DDS CUT) according to the invention and a second grinding wheel with a conventional Formabrichtrolle (DDS) dressed. It could be shown that with the form dressing roller according to the invention, a saw groove depth on the grinding wheel of 3.5 μm was achieved. With the conventional Formabrichtrolle a Wrkrautiefe was achieved at the dressed grinding wheel of only 1, 8 μηι. The Wirkrautiefe, the dressed with the Formabrichtrolle invention grinding wheel is higher than with the normal dressing roller. This suggests a more abrasive grinding topography. This result was surprising and unexpected.

Fig. 7 is a graph showing the surface roughness of a grinding wheel after dressing. In the grinding process, restoring the desired surface roughness of the workpieces plays an important role. Shown is the

Surface roughness Ra [μηι] ground workpieces. For this purpose, grinding wheels with a form dressing roller according to the invention (DDS CUT) and with a conventional

Form dressing roll (DDS) dressed. It could be shown: By dressing with the form dressing roller DDS CUT according to the invention a slightly higher surface roughness of 0.23 μηι was achieved in the workpieces than in the conventional Formabrichtrolle DDS of 0.22 μηι.

With the form-dressing roller DDS CUT according to the invention, a somewhat lower surface roughness of 0.25 μm was achieved with 400 workpieces than with the conventional one

Form dressing roller DDS of 0.32 μηι achieved. The surface roughness was somewhat higher with the conventional form dressing roll DDS, but with the conventional one

Form dressing roller could be ground only 400 workpieces with specified surface roughness. Therefore, with the conventional form roller DDS could only one Dressing cycle of 400 workpieces can be achieved.

With the form dressing roller DDS CUT according to the invention, a surface roughness of 0.26 was achieved for 600 workpieces and 0.25 μm for 800 workpieces. The

Surface roughness was almost constant over the 800 workpieces. The performance was doubled with the form dressing roller (DDS CUT) according to the invention. It was achieved a much better constant in the surface roughness of the ground workpieces. This result was surprising and unexpected.

Fig. 8 is a graph showing the roundness of the workpieces after dressing the grinding wheel. Roundness is a measure of the accuracy with which an ideal round shape (circular shape) is achieved. It results in a better roundness profile, therefore less form deviations arise. During the grinding process the optimal roundness of the workpieces plays an important role. Shown is the roundness in [μηι] of the pieces of work. For this purpose, grinding wheels were dressed with a form dressing roller (DDS CUT) according to the invention and with a conventional form dressing roller (DDS). It could be shown:

With the form dressing roller DDS CUT according to the invention was in the ground

Workpieces a lower roundness of 1, 2 μηι than in the conventional

Form dressing roller DDS of 2.8 μηι achieved.

With the form dressing roll DDS CUT according to the invention, a lower roundness of 1.3 μm was achieved with 400 workpieces than with the conventional form dressing roll DDS of 2.7 μm. The roundness errors were higher with the conventional form dressing roll. With the conventional form dressing roller DDS, only 400 workpieces could be ground to the required accuracy. With the form dressing roller DDS CUT according to the invention a roundness of 1, 3 μηι was achieved at 600 workpieces and at 800 workpieces of 1, 2 μηι. The roundness was almost constant over the 800 ground workpieces. The performance was doubled with the form dressing roller (DDS CUT) according to the invention. It was achieved a much better constant in the roundness of the ground workpieces. The results of the roundnesses show that with the invention

Form dressing roller (DDS CUT) over the entire dressing cycle constant roundness values can be achieved. The trued with the conventional form dressing roller DDS

Grinding wheels had to be dressed again after 400 workpieces because the surface roughness and the roundness were outside the workpiece tolerance.

This result was surprising and unexpected. Reference sign:

10 form dressing roller

1 carrier body

2 rubber ring / rubber / diamond sintered surface

3 recesses

4 clamping screws

5 receiving hole

6 clamping ring

6A Inner edge of the clamping ring

6B outer edge of the clamping ring

Y enlargement according to FIG. 1 and FIG. 2 / enlarged detail Y

Z magnification according to FIG. 4 / enlarged detail Z

Claims

claims

1. Form dressing roller (10) with

a carrier body (1),

a freestanding covering ring (2) containing diamond grains and / or diamond rods in ceramic, metallic or synthetic resin bond for dressing grinding wheels,

Clamping screws (4) which clamp the lining ring (2) between the carrier body (1) and a clamping ring (6) and

a receiving bore (5) in the middle of the carrier body (1),

wherein the pad ring (2) has at least 3 recesses (3).

2. Formabrichtrolle (10) according to claim 1, wherein the lining ring (2) 3 to 12

Having recesses (3).

3. Formabrichtrolle (10) according to claim 1 or 2, wherein the pad ring (2) 4 to 6,

Having recesses (3).

4. Formabrichtrolle (10) according to any one of claims 1 to 3, wherein the lining ring (2) has a lining height of 10 mm to 20 mm and a usable lining height of 4 mm to 6 mm.

5. Formabrichtrolle (10) according to any one of claims 1 to 4, wherein the lining ring (2) has a covering width of 0.4 mm to 2.0 mm and wherein the covering width <the diamond grain size and / or diamond rod size.

6. Formabrichtrolle (10) according to one of claims 1 to 5, wherein the width of the

Recesses (3) is 1 mm to 10 mm.

7. Formabrichtrolle (10) according to one of claims 1 to 6, wherein the depth of

Recesses (3) corresponds to the exploitable pad height.

8. Form Abrichtrolle (10) according to any one of claims 1 to 7, wherein the diameter of the Formabrichtrolle (10) is 80 mm to 250 mm.

9. Formabrichtrolle (10) according to any one of claims 1 to 8, wherein the diameter of the receiving bore (5) is 8 mm to 120 mm.

10. Form Abrichtrolle (10) according to any one of claims 1 to 9, wherein the lining ring (2) consists of at least one layer, wherein in each layer individual diamond grains in close classified size in a plane perpendicular to the axis of rotation of the Formabrichtrolle (10) according to a predetermined setting scheme and with more than single-layered form-dressing rollers, the diamond grains of one layer lie in gaps between the diamond grains of the other layer and partially protrude into the other layer, so that the Umflächengeometrie the dressing roll (10) remains approximately constant in wear progress.

1 1. A method for producing the Formabrichtrolle (10) according to one of claims 1 to 10, wherein

Diamond grains are placed according to a predetermined setting scheme on a substrate with adhesive layer to produce a layer,

Binding powder is added,

the layer to the coating (2) is cold pressed and sintered and

the recesses (3) are cut out of the covering (2).

12. A method for producing the Formabrichtrolle (10) according to any one of claims 1 to 10, wherein

Diamond grains according to a predetermined setting scheme on a base with

Adhesive layer are set to produce a layer, wherein the

Recesses (2) are formed in the lining (3),

Binding powder is added and

the layer to the coating (3) is cold pressed and sintered.

13. The method of claim 11 or 12, wherein desired layers below

Relative displacement and / or rotation of the layers are stacked and the layer packet to the coating (3) cold pressed and sintered.

14. A method for producing a Formabrichtrolle (10) according to any one of claims 1 1 to 13, wherein the produced Formabrichtrolle (10) is then ground and finished. Use of the form dressing roller (10) according to any one of claims 1 to 10 for dressing diamond and CBN grinding wheels in ceramic, bakelitischer, metallic bond or resin bond and grinding wheels with abrasives made of corundum or silicon carbide.