JP2001212748A - Workpiece cutting device and workpiece cutting method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a workpiece cutting device and a workpiece cutting method capable of improving cutting accuracy and prolong the life of a cutting blade even in cutting of a comparatively thick workpiece. SOLUTION: The workpiece cutting device 10 includes a plurality of cutting blades 36 on each of which super abrasive grain 42 is scattered over the whole surface of a metal plating phase 40. A workpiece 56 formed of a rare earth alloy magnetic member is immersed in a coolant 52 inside a container 50. The cutting blade 36 is rotated at a high speed above 8000 rpm and moved from the vertical direction or from the normal direction of a contact between the cutting blade 36 and the workpiece 56 toward the workpiece 56 so as to cut the workpiece 56 immersed in the coolant 52. In cutting, the coolant 52 may be fed to a cutting part 60 from a hose 58. In cutting, the workpiece 56 is vibrated vertically to the face direction of the cutting blade 36 and the cutting direction. A groove 36b is formed in the tip of the cutting blade, and between the cutting blades, a spacer 38a having an annular stepped part 38b in each outer circumference of the main face is inserted desirably.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a work cutting device and a work cutting method, and more particularly to a work cutting device and a work cutting method using a cutting blade in which superabrasive grains are dispersed over the entire surface.

[0002]

2. Description of the Related Art Conventionally, a cutting blade having a small blade thickness formed by electroforming has been proposed as a cutting blade capable of reducing an amount of cutting and removing a work. This cutting blade is made of Ni, C, for example, as disclosed in Japanese Patent Publication No. 6-49275.
It is formed by dispersing superabrasive grains such as diamond and cBN in a metal plating phase made of o, and is mainly used for cutting a substrate of a magnetic head.

[0003]

In order to cut a hard and brittle work such as a rare earth magnet member having a large thickness with this cutting blade, the amount of protrusion of the cutting blade must be increased. However, since the rigidity of the cutting blade is weakened due to the small blade thickness, the cutting blade may be deformed at the time of cutting and the cutting accuracy may be deteriorated. Also, when cutting a work using such a cutting blade, the difference in blade thickness between the outer peripheral portion and the central portion of the cutting blade is small, so that the clearance important for supplying coolant to the cut portion of the work is small. Become. Therefore, when cutting a workpiece having a large cross-sectional area, particularly when a groove formed in the workpiece at the time of cutting becomes long, the coolant cannot be sufficiently supplied to the cutting portion, and the seizure of the cutting blade easily occurs, and the cutting blade is easily cut. There is a problem that the life of the device is shortened. Hence,
A main object of the present invention is to provide a work cutting apparatus and a work cutting method that can improve cutting accuracy even when cutting a work having a relatively large thickness. It is another object of the present invention to provide a work cutting device and a work cutting method that can extend the life of a cutting blade.

[0004]

According to one aspect of the present invention, there is provided a workpiece cutting apparatus for cutting a workpiece, wherein the workpiece is in contact with the workpiece at least during cutting. A cutting blade in which superabrasive grains are dispersed over the entire surface, first driving means for rotating the cutting blade, and at least the cutting blade and the work such that the relative movement direction of the cutting blade with respect to the work during cutting is vertical. A second drive unit for moving one of them is provided. Claim 2
Is a work cutting device for cutting a work, a cutting blade in which super-abrasive grains are dispersed at least over the entire surface in contact with the work during cutting, and a first blade for rotating the cutting blade. A driving unit, and a second driving unit that moves at least one of the cutting blade and the work such that a relative movement direction of the cutting blade with respect to the work at the time of cutting is a normal direction of a contact point between the cutting blade and the work. .

According to a third aspect of the present invention, there is provided a work cutting apparatus for cutting a work, wherein a housing means for housing a coolant for immersing the work, at least a portion which comes into contact with the work during cutting. Cutting blade in which superabrasive grains are dispersed over the entire surface, first driving means for rotating the cutting blade, and second driving for moving at least one of the cutting blade and the work to cut the work immersed in the coolant Means. According to a fourth aspect of the present invention, there is provided the workpiece cutting apparatus according to the third aspect, further comprising a coolant supply unit configured to supply a coolant to the workpiece.

A work cutting device according to a fifth aspect of the present invention is the work cutting device according to any one of the first to third aspects, further comprising a plurality of cutting blades and a spacer interposed between the cutting blades. It is characterized in that it has annular steps on the outer circumferences of both main surfaces. According to a sixth aspect of the present invention, there is provided a workpiece cutting apparatus according to any one of the first to third aspects, wherein the cutting blade is formed by dispersing superabrasive grains in a metal plating phase. .

According to a seventh aspect of the present invention, there is provided a workpiece cutting device according to any one of the first to third aspects, wherein the cutting blade has a groove at a tip thereof.
The work cutting device according to the eighth aspect is the first to third aspects.
Wherein the number of revolutions of the cutting blade is 8000 rpm or more.
According to the ninth aspect of the present invention, there is provided a workpiece cutting device.
The work cutting apparatus according to any one of the above, further comprising a vibrating means for vibrating the work in a surface direction of the cutting blade.

According to a tenth aspect of the present invention, in the workpiece cutting apparatus of the ninth aspect, the vibration direction of the workpiece is perpendicular to the direction of relative movement of the cutting blade with respect to the workpiece. . According to an eleventh aspect of the present invention, there is provided a workpiece cutting device according to any one of the first to third aspects, wherein the workpiece is a rare earth alloy magnet member. The method for cutting a workpiece according to claim 12, wherein the method for cutting a workpiece is a method for preparing a cutting blade in which superabrasive grains are dispersed over at least the entire surface of a portion that comes into contact with the workpiece during cutting. And a second step of rotating the cutting blade and moving at least one of the cutting blade and the work so that the relative movement direction of the cutting blade with respect to the work is vertical, and cutting the work with the cutting blade. .

A work cutting method according to a thirteenth aspect is a work cutting method for cutting a work, comprising preparing a cutting blade in which superabrasive grains are dispersed at least over the entire surface of a portion that comes into contact with the work during cutting. A first step of rotating the cutting blade, and moving at least one of the cutting blade and the work such that a relative movement direction of the cutting blade with respect to the work is a normal direction of a contact point between the cutting blade and the work; The method includes a second step of cutting the work by the cutting blade. The method for cutting a workpiece according to claim 14, wherein the method for cutting a workpiece is a method for preparing a cutting blade in which superabrasive grains are dispersed at least over the entire surface of a portion that comes into contact with the workpiece during cutting. And a second step of rotating the cutting blade, moving at least one of the cutting blade and the work, and cutting the work with the cutting blade in a state of being immersed in the coolant.

According to a fifteenth aspect of the present invention, in the method of the fourteenth aspect, a coolant is further supplied to the workpiece in the second step. A work cutting method according to claim 16 is the work cutting method according to any one of claims 12 to 14, wherein in the first step, a plurality of cutting blades and spacers each having an annular step on the outer periphery of both main surfaces are provided. Is prepared,
A spacer is interposed between the cutting blades. A work cutting method according to a seventeenth aspect is the work cutting method according to any one of the twelfth to fourteenth aspects, wherein the cutting blade is formed by dispersing superabrasive grains in a metal plating phase. .

[0011] According to an eighteenth aspect of the present invention, there is provided a method for cutting a workpiece according to any one of the twelfth to fourteenth aspects, wherein the cutting blade has a groove at a tip thereof. According to a nineteenth aspect of the present invention, there is provided a workpiece cutting method.
15. The workpiece cutting method according to any one of 2 to 14, wherein the rotation speed of the cutting blade is 8000 rpm or more. According to a twentieth aspect of the present invention, in the method for cutting a workpiece according to any one of the twelfth to fourteenth aspects, in the second step, the workpiece is cut while vibrating the workpiece in a surface direction of the cutting blade. And

According to a twenty-first aspect of the present invention, there is provided a method for cutting a workpiece according to the twentieth aspect, wherein a vibration direction of the workpiece is perpendicular to a direction of relative movement of the cutting blade with respect to the workpiece. . The work cutting method according to claim 22 is the work cutting method according to any one of claims 12 to 14, wherein the work is a rare earth alloy magnet member.

[0013] In the work cutting device according to the first aspect, for example, the cutting blade is rotated to lower and cut into the work arranged at a predetermined position, thereby reducing the force for deforming the cutting blade. As a result, the load on the cutting blade is reduced. Further, if the cutting blade is rotated at a high speed, the dynamic rigidity of the cutting blade can be increased. Therefore, since the cutting blade is less likely to be deformed, the cutting is stable and the accuracy can be improved even when cutting a relatively thick work. The same applies to the workpiece cutting method according to the twelfth aspect. In the workpiece cutting device according to the second aspect, for example, the workpiece cutting device according to the first aspect is cut by rotating a cutting blade from a normal direction of a contact point with the workpiece to a workpiece disposed at a predetermined position. As with the apparatus, the cutting blade is less likely to be deformed, and the cutting accuracy can be improved even when cutting a relatively thick work. The same applies to the work cutting method according to the thirteenth aspect.

In the work cutting device according to the third aspect, the work immersed in the coolant is cut, so that the clearance between the work and the cutting blade, which is important for supplying the coolant to the cut portion of the work, is small. Even so, the coolant can be sufficiently supplied to the cutting section. As a result, seizure of the cutting blade can be prevented, and the life of the cutting blade can be extended. The same applies to the workpiece cutting method according to claim 14. When the cutting blade is rotated at a high speed, the coolant is removed from, for example, the surface of the work due to the co-rotating flow caused by the rotation of the cutting blade, so that the coolant may not be sufficiently supplied to the cutting portion. However, the work can be sufficiently immersed in the coolant by separately supplying the coolant to the work as in the work cutting device according to the fourth aspect, and the seizure of the cutting blade can be further prevented. The same applies to the workpiece cutting method according to claim 15.

In the case of a cutting blade in which superabrasive grains are dispersed over the entire surface, if the contact area between the cutting blade and the spacer increases, the number of abrasive grains in contact with the spacer increases, and the inclination of the cutting blade may increase. . However, by using the spacer having the annular step portion as in the work cutting device according to claim 5, the contact area between the superabrasive grains distributed on the side of the cutting blade and the spacer is reduced, and when the cutting blade is attached. The inclination of the cutting blade is reduced. The same applies to the work cutting method according to claim 16. In the work cutting apparatus according to the sixth aspect, by dispersing the superabrasive grains in the metal plating phase by, for example, electroforming, a desired cutting blade having a small blade thickness can be obtained, and the amount of grinding removal of the work can be reduced. The same applies to the workpiece cutting method according to claim 17.

In the work cutting device according to the present invention, by providing a groove at the tip of the cutting blade, the coolant is easily supplied to the cutting edge of the cutting blade, and the dimensional variation of the member obtained by cutting the work is reduced. . The same applies to the work cutting method according to claim 18. In the workpiece cutting device according to the eighth aspect, the dynamic rigidity of the cutting blade due to centrifugal force can be increased by rotating the cutting blade at a high speed of 8000 rpm or more. Therefore, the cutting blade does not flex during cutting, and the side surface of the cutting blade does not rub against the work. As a result, cutting accuracy can be maintained, seizure can be prevented, and the life of the cutting blade can be extended. The same applies to the work cutting method according to the nineteenth aspect.

In the work cutting apparatus according to the ninth aspect, at the time of cutting, the work is vibrated in the surface direction of the cutting blade so that the cutting blade can be periodically separated from the cutting part, and the coolant is supplied to the cutting part. Becomes even easier. Also,
The deformation of the cutting blade can be corrected, and the cutting accuracy can be improved. The same applies to the work cutting method according to claim 20. In the work cutting device according to claim 10,
By further making the vibration direction of the work perpendicular to the direction of relative movement of the cutting blade with respect to the work, the cutting load applied to the cutting blade can be further reduced, so that the deformation of the cutting blade is less likely to occur and the cutting accuracy can be improved. The same applies to the work cutting method according to claim 21. Claim 1
As described in 1, 22, the present invention is particularly effective when a hard, brittle, hard-to-cut rare earth alloy magnet member is used as a workpiece.

[0018]

Embodiments of the present invention will be described below with reference to the drawings. Referring to FIG. 1, a work cutting device 10 according to one embodiment of the present invention is a kind of a so-called cantilever type outer peripheral cutting machine, and includes a bed 12.
A column 14 is erected on the bed 12. Column 14
Two rails 16 are formed on the front surface of each of the rails in parallel with the vertical direction (Z-axis direction). A slider 18 slidable in the vertical direction is mounted on the two rails 16. A slider supporting portion 20 having a vertical screw hole is provided on the back surface of the slider 18.
Is attached, and a screw 22 functioning as a cutting shaft is screwed into a screw hole of the slider support portion 20. The screw 22 is rotated by a lifting motor 24 disposed on the column 14. Therefore, the screw 22 is rotated by the control of the elevating motor 24, and the slider 1 is moved through the slider support 20.
8 can be moved up and down, and at the time of cutting, a cutting blade block 30 described later is sent in the direction of arrow A (downward). Also,
A support portion 26 is provided on the front surface of the slider 18, and the rotation shaft 28 is rotatably supported by the support portion 26.

A cutting blade block 30 is provided at one end of the rotating shaft 28.
The coupling 3 is attached to the other end of the rotating shaft 28.
2, a high-speed rotation motor 34 is connected. The high-speed rotation motor 34 is arranged on a base 35, and the rotation shaft 28 and the cutting blade block 30 are rotated by the high-speed rotation motor 34, for example, in the direction of arrow B. The rotation speed of the cutting blade block 30 is preferably 8000 rpm or more. The high-speed rotation motor 34 moves in the vertical direction along with the cutting blade block 30. With reference to FIG. 2, the cutting blade block 30 includes a plurality of cutting blades 36 and an annular spacer 38 interposed between the respective cutting blades 36.

As shown in FIGS. 3 (a) and 3 (b), the cutting blade 36 is of an all-blade type, for example, a metal plating phase 4 mainly made of Ni and Co by electroforming.
The super-abrasive grains 42 are dispersed throughout the area 0, and the blade thickness D (see FIG. 2) can be reduced. Such a cutting blade 3
By using 6, the dynamic rigidity of the cutting blade 36 when cutting a thick workpiece 56 (described later) at high speed can be secured. As the superabrasives 42, natural or synthetic diamond powder, cBN (cubic boron nitride)
Powder or diamond powder for natural or synthetic industry-cB
A mixture of N powder and the like are used. The volume ratio of superabrasive grains 42 is preferably 20% to 30%. If it is less than 20%, the cutting amount is extremely small with respect to the wear of the cutting blade 36, so the cutting efficiency is low. On the other hand, if it exceeds 30%, the superabrasive particles 42
Since the space between the cutting blades is small, the tip pocket is small, and sludge stays at the cutting edge of the cutting blade 36, and the cutting portion 60
The flow of the coolant 52 (described later) into and out of the (described later) is not smooth. Accordingly, the cutting load increases, and deformation and seizure of the cutting blade 36 occur, resulting in poor cutting accuracy. When the volume ratio of the superabrasive grains 42 is 20% to 30%, the supply of the coolant 52 and the discharge of the sludge are easy, and since the superabrasive grains 42 are easily degranulated, the cutting resistance is reduced and the cutting becomes smooth. The cutting efficiency and the cutting accuracy are improved.

The blade thickness D of the cutting blade 36 is 0.1 mm to 0.5.
mm, and in this case, it is possible to reduce the grinding removal amount (sharpening margin) of the work 56 and obtain many members 62 (described later) from the work 56. If the blade thickness D of the cutting blade 36 is less than 0.1 mm, the rigidity of the cutting blade 36 will be insufficient, and if it exceeds 0.5 mm, the amount of grinding removal of the work 56 will increase, causing problems. Also, the cutting blade 3
If 6 is warped by lapping using diamond-based abrasive grains, cutting accuracy can be further improved.
If the cutting blade 36 has a porous (porous) 43, the coolant 52 can be more easily supplied to the cutting blade 36 and the work 56.

Returning to FIG. 1, two rails 44 are laid on the base 12, a vibration table 46 is slidably mounted on the rails 44, and the vibration table 46 is
The work 56 can be vibrated. The vibration direction of the vibration table 46, that is, the work 56, is the surface direction of the cutting blade 36 as shown by the arrow C and is perpendicular to the cutting direction of the cutting blade 36 shown by the arrow A. Further, the vibration frequency of the work 56 is desirably 10 Hz or more. In this case, since the load applied to the cutting blade 36 is reduced, the deformation of the cutting blade 36 can be quickly corrected, and the cutting accuracy is improved.

A container 50 is disposed on the vibration table 46, and a coolant 52 is accommodated in the container 50 as shown in FIG. The coolant 52 contains water as a main component. The surface tension of the coolant 52 is 25 mN / m to 60 mN / m.
(25 dyn / cm to 60 dyn / cm) is preferred.
If the main component is water, the cooling effect will be high and the surface tension will be 2
5 mN / m to 60 mN / m (25 dyn / cm to 60 d
yn / cm), the permeability of the coolant 52 into the cutting portion 60 is good, and the cutting efficiency is good. As an additive contained in the coolant 52, a surfactant or a synthetic type synthetic lubricant, a rust inhibitor, a non-ferrous metal anticorrosive, a preservative, and an antifoaming agent can be used.

As the surfactant, as an anionic surfactant,
Fatty acid derivatives such as fatty acid soaps and naphthenic acid soaps, or sulfate ester types such as long-chain alcohol sulfates and sulfated oils of animal and vegetable oils, or sulfonic acid types such as petroleum sulfonic acid salts, and polyoxyethylene alkyls as nonionics Polyoxyethylenes such as phenyl ether and polyoxyethylene monofatty acid esters, polyhydric alcohols such as sorbitan monofatty acid esters, and alkylolamides such as fatty acid diethanolamide can be used. Specifically, J of chemical solution type
By adding P-0497N (manufactured by Castrol) to water at about 2% by weight, the surface tension and the coefficient of kinetic friction can be adjusted within a suitable range.

As the synthetic type synthetic lubricant, synthetic solution type, synthetic emulsion type and synthetic soluble type can be used. Among them, the synthetic solution type is preferable, and specifically, Syntylo 9954 (Castrol) And # 8
80 (manufactured by Yushiro Chemical Industry Co., Ltd.). In any case, by adding about 2% by weight to water, the surface tension and the kinetic friction coefficient can be adjusted within a suitable range. Further, by containing a rust inhibitor, corrosion of the rare earth alloy can be prevented. Here, PH is 9 ~
It is preferably 11. As a rust inhibitor, carboxylate such as oleate and benzoate as an organic type,
Alternatively, amines such as triethanolamine, or phosphates, borates, molybdates, tungstates, or carbonates can be used as inorganics.

As the non-ferrous metal anticorrosive, for example, a nitrogen compound such as benzotriazole can be used, and as the preservative, a formaldehyde donor such as hexahydrotriazine can be used. As an antifoaming agent, a silicone emulsion can be used. By including an antifoaming agent, foaming of the coolant 52 is reduced, and the coolant 5
2 can improve the permeability, enhance the cooling effect, and prevent a temperature rise at the cutting edge. Therefore, abnormal temperature rise and abnormal wear at the cutting edge of the cutting blade 36 are less likely to occur.

A discharge port (not shown) for discharging the coolant 52 is provided on the bottom surface of the container 50. Container 50
A sticking plate 54 having a V-shaped cross section is disposed on the bottom surface of the, and a plurality of works 56 are fixed on the sticking plate 54 by an adhesive. In the container 50, the work 5
6 is immersed in the coolant 52. As the work 56, for example, a rare earth alloy magnet member made of a neodymium alloy or the like (US Pat. Nos. 4,770,723 and 4,792, U.S. Pat.
368) is used. A hose 58 of a coolant supply device (not shown) is disposed so as to face the inside of the container 52.
The coolant 52 is discharged to 6. At the time of cutting, the cutting blade 36 is rotated in the direction of arrow B, and the slider 18 is slid in the direction of arrow A, whereby the cutting blade 36 is relatively moved toward the work 56 at a constant speed. Then, the work 56 immersed in the coolant 52 is cut to a predetermined size by the cutting blade 36. At this time, the coolant 52 from the coolant supply device is supplied to the work 56 via the hose 58 as necessary.

According to such a work cutting device 10,
The following effects can be obtained. In general, it is ideal that the work cutting device is mounted so that the cutting blade is completely perpendicular to the rotation axis. In this case, the cutting reaction force is generated in the cutting blade surface, and the cutting blade is attached to the surface. No vertical deformation force is generated. However, in reality, as shown in FIG. 5, a cutting blade attachment error θ (θ = about 0.02 to 0.04 degrees) occurs. When the work 56 is cut by, for example, X-feed (by cutting the cutting blade 36 from the horizontal direction with respect to the work 56), the component f2 of the mounting error of the tangential component f1 of the cutting reaction force f and the mounting error f2.
(= F1 × sin θ) acts as a force for deforming the cutting blade 36, and the cutting blade 36 is deformed, resulting in poor cutting accuracy. The cutting blade 36 is formed by electroforming.
Is also symmetric in the thickness direction.

On the other hand, according to the work cutting device 10 for cutting the work 56 by the Z feed indicated by the arrow A (by moving the cutting blade 36 in the vertical direction), as shown in FIG. Even if there is an error θ, since the cutting reaction force F is substantially in the direction of the center of the rotating shaft 28,
The tangential component force F1 becomes smaller. Therefore, the component force F2 (= F1 × sin θ) for deforming the cutting blade 36 is necessarily smaller than that shown in FIG.
And the cutting blade 36 is less likely to be deformed. Further, in the work cutting device 10, as shown in FIG. 1, the work 56 is arranged in a V-shape and cut in a vertical direction (cutting direction), so that the work 56 does not shift due to the pressing force at the time of cutting. Therefore, cutting accuracy can be improved. Similarly, when the cutting blade 36 is formed by electroforming and the cutting blade 36 is not symmetrical in the thickness direction, the cutting accuracy is similarly improved.

As shown in FIG. 7, the stroke L1 of the cutting blade 36 from the start to the end of cutting by the work cutting device 10 is shorter than the stroke L2 in the case of X-feed as shown in FIG. We can see that we can do it.
When a plurality of works 56 are juxtaposed as shown in FIG. 1, the stroke can be further shortened as compared with the case of X feed, and the effect is remarkable. Further, the cutting blade 36 is set at 800
By rotating at a high speed of 0 rpm or more, the dynamic rigidity of the cutting blade 36 due to centrifugal force is increased, the deformation of the cutting blade 36 is less likely to occur, and the work 56 can be stably cut. Since the dynamic rigidity of the cutting blade 36 can be increased in this manner, even a relatively large cutting blade 36 having a protruding amount E (see FIG. 2) exceeding 25 mm can be used without any problem, and the protruding amount E can be reduced. A cutting blade 36 of about 30 mm can also be used.

Therefore, according to the work cutting apparatus 10, even when the work 56 having a relatively large thickness is cut, the amount of removal of the work 56 can be reduced and the cutting accuracy can be improved. In particular, the present invention is effective when cutting a thick workpiece which is a rare-earth alloy magnet member made of a hard, brittle, hard-to-cut neodymium alloy or the like. The higher the cutting speed, the higher the rigidity required for cutting. Therefore, rotating the cutting blade 36 at high speed is more effective as the cutting speed is higher. The above-described effects can also be obtained when the work 56 is cut from the normal direction of the contact point between the cutting blade 36 and the work 56.

When the work 56 is cut, the work 56
Is immersed in the coolant 52, so that even if the clearance between the workpiece 56 and the cutting blade 36 is small, the cutting portion 6
0 can be sufficiently supplied with the coolant 52. In addition, by rotating the cutting blade 36 at a high speed as described above, the dynamic rigidity of the cutting blade 36 increases, so that the cutting blade 36 does not bend during cutting, and the side surface of the cutting blade 36 does not rub against the work 56. Therefore, even when cutting a relatively thick work 56, seizure of the cutting blade 36 can be prevented, and the life of the cutting blade 36 can be extended. Further, by supplying the coolant 52 separately from the hose 58 to the cutting portion 60 of the work 56,
Can be sufficiently immersed in the coolant 52, and the seizure of the cutting blade 36 can be further prevented.

Since the difference in blade thickness between the outer peripheral portion and the central portion of the cutting blade 36 is small, the clearance between the cutting blade 36 and the cutting portion 60 of the work 56 is reduced as shown in FIG. However, by vibrating the vibration table 46, that is, the work 56, in the surface direction of the cutting blade 36 and perpendicularly to the cutting direction of the cutting blade 36 at the time of cutting, FIG.
As shown in (c), the cutting blade 36 can be periodically separated from the cutting portion 60 at the time of cutting, so that the supply of the coolant 52 to the cutting portion 60 becomes easy, and further, the discharge of sludge is promoted. You can also. In addition, deformation of the cutting blade 36 during cutting can be corrected. Further, since the cutting load applied to the cutting blade 36 can be reduced, the deformation of the cutting blade 36 hardly occurs. Therefore, cutting accuracy can be improved.
The effect of vibrating the work 56 is as follows.
This becomes more noticeable as the cutting speed is increased.

Next, each experimental example in which the work 56 is cut using the work cutting device 10 will be described. The following Experimental Examples 1 to 3 were performed under common experimental conditions shown in Table 1,
As shown in FIG. 11, the difference between the maximum value and the minimum value of the thickness of five points of the member 62 obtained by cutting the work 56 was calculated, and the dimensional variation was measured.

[0035]

[Table 1]

(Experimental Example 1) Z-feed cutting in which the cutting blade 36 is cut into the work 56 from the vertical direction and the work 56
And X feed cutting in which the cutting blade 36 is cut from the horizontal direction. At this time, both of the coolant 52
Is supplied to the work 56 by discharging from the hose 58, the rotation speed of the cutting blade is 8000 rpm, and the cutting speed is 2 mm / min for the Z feed and 5 mm for the X feed.
/ Min. The cutting process was performed twice for the Z feed, and the average value was obtained. 12 and FIG.
3 and FIG. 14, <left> refers to an inner member 62 obtained by cutting the left work 56 shown in FIG. 1, and <right> denotes an inner member obtained by cutting the right work 56. Member 62. The <Total> column shows the difference between the maximum value and the minimum value of a total of 10 points obtained from both inner members 62, and is defined as dimensional variation. FIG.
From the experimental results shown in (a) and (b), Z-feed cutting has smaller dimensional variation than X-feed cutting,
It can be seen that the cutting accuracy is good.

(Experimental Example 2) Next, the cutting blade rotation speed was 80
Z feed cutting was performed for each of 00 rpm and 3600 rpm. When the cutting blade rotation speed is 8000 rpm, the cutting speed is 1 mm / min, 2 mm / min,
mm / min and 6 mm / min, and when the cutting blade rotation speed is 3600 rpm, the cutting speed is 1 mm / min.
min, 2 mm / min, and 3 mm / min. In both cases, the work 56 was immersed in the coolant 52 in the container 50. FIG. 13A and FIG.
In 4 (a), n = 3 means that the cutting process is performed three times,
It shows that the average value was obtained. From the experimental results shown in FIGS. 13A and 13B, the cutting blade rotation speed was 3600 r.
It can be seen that the dimensional variation is smaller at 8000 rpm than at pm and the cutting accuracy is better. Also,
When the cutting blade rotation speed is 3600 rpm, the cutting speed is 3 mm
/ Min, the processing load applied to the abrasive grains due to the deflection of the cutting blade 36 becomes too large, and seizure occurs on the cutting blade 36. However, when the cutting blade rotation speed is 8000 rpm,
Seizure does not occur, and the life of the cutting blade 36 can be extended.
Therefore, by rotating the cutting blade 36 at high speed, the cutting accuracy can be improved and the life of the cutting blade 36 can be extended.
This effect is remarkable when the protrusion amount E is 25 mm or more.

(Experimental Example 3) Further, the work 56 was
In the case where the coolant 52 is immersed in the coolant 52 and the case where the coolant 52 is discharged from the hose 58 to the work 56,
Z feed cutting was performed. At this time, the cutting blade rotation speed was 8000 rpm. Also, the work 56 is placed in the container 5
When immersing in the coolant 52, the cutting speed is 1 mm / min, 2 mm / min, 4 mm / min,
6 mm / min.
2 is discharged, the cutting speed is 1 mm / min,
The cutting was performed at a rate of 3 mm / min. According to the experimental results shown in FIGS. 14A and 14B, in the case where the coolant 52 is supplied by discharge, when the cutting speed is 3 mm / min, the coolant 52 is less likely to be supplied to the cutting unit 60 by the entrainment flow. Seizure occurs on the cutting blade 36. On the other hand, when the work 56 is immersed in the coolant 52 in the container 50, no seizure occurs even if the cutting speed reaches 6 mm / min.
Therefore, when the work 56 is immersed in the coolant 52, seizure does not occur even when the cutting speed is increased, and the cutting can be performed well, and the life of the cutting blade 36 can be extended. Further, when the work 56 is immersed in the coolant 52, the dimensional variation is reduced and the cutting accuracy is better.

That is, the blade thickness D of the cutting blade 36 is 0.3 m
m, the clearance becomes small and the coolant 52
In order to supply the coolant 52 to the work 56 sufficiently, the coolant 52
It is effective to immerse the work 56 in the work. Further, according to the work cutting device 10, as can be seen from FIG. 15, the dimensional variation is smaller when the work 56 is vibrated (here, the vibration frequency is 20 Hz) than when the work 56 is not vibrated. It can be seen that the cutting accuracy is improved. The effect becomes more pronounced as the cutting speed increases.
Further, as shown in FIG. 16A, by applying vibration during cutting, the undulation (surface undulation) of the cut surface can be reduced, and the flatness is improved.

Here, the face undulation is obtained as follows. First, among the members 62 obtained by cutting the work 56, the surface height is measured by running a measuring device (not shown) in each of the directions of arrows H1 and H2 shown in FIG. 16B. Then, the difference between the maximum value and the minimum value in each of the directions of the arrows H1 and H2 is obtained, and the average value is obtained, which is defined as the surface undulation. In the workpiece cutting device 10, a spacer 38a as shown in FIGS. 17A and 17B may be used. The spacer 38 a is formed in a hollow disk shape, has annular step portions 38 b on the outer circumferences of both main surfaces thereof, and is inserted between the cutting blades 36. Here, the annular step portion 38
Experimental Example 4 regarding the presence or absence of b will be described.

(Experimental Example 4) When a spacer 38 having no annular step portion 38b as shown in FIG. 2 was used as a spacer, and as shown in FIGS. Z-feed cutting was performed in the case where the spacer 38a having the same was used. At this time, in both cases, the cutting blade 36 is a set of five, the protrusion amount E = 20 mm, the cutting speed is 2 mm / min, the cutting blade rotation speed is 8000 rpm, the target thickness is 2.0 mm, and the work 56 is the coolant 52 in the container 50. The coolant 52 was supplied to the workpiece 56 from the hose 58 at a discharge pressure of about 20 kPa (2 kgf / cm ² ). The dimensions of the spacer 38a are
Outer diameter 110.0 mm, inner diameter 60.0 mm, thickness T = 2.
0 mm, contact width W = 9.0 mm, and step G = 0.1 mm. Other conditions including the dimensions of the spacer 38 are shown in Table 1.
Was similar to Then, one work 56 arranged on the attachment plate having a flat surface is cut by a set of five cutting blades 36, and the obtained four inner members 62 (No. 1 to No. 6) are cut.
Using 4), the dimensional variation and the parallelism were measured.
The cutting process was performed three times, and the average value was obtained.

The parallelism is calculated as follows. Work 5
The thickness of the member 62 obtained by cutting 6 is measured at predetermined five locations shown in FIG. 11, and the difference between the maximum value and the minimum value is determined. This processing is performed for each of the cut-out members 62, and the average value of the difference between the maximum value and the minimum value obtained for each member 62 is set as the parallelism. The dimensional variation in Experimental Example 4 is the difference between the maximum value and the minimum value of a total of 20 points obtained from the four members 62 (No. 1 to No. 4).

From the experimental results shown in FIGS. 18 (a) and 18 (b), the dimensional variation and the parallelism were greater when using the spacer 38a having the annular step 38b than when using the spacer 38 without the annular step 38b. It can be seen that the degree is small and the cutting accuracy is good. This is because when the spacer is assembled to the cutting blade 36, the spacer 38a is
It is considered that the contact area with the superabrasive grains 42 existing on the side surface of the surface is small, interference of the superabrasive grains 42 is reduced, and the inclination of the cutting blade 36 is reduced. In addition, the spacer 38a having the annular step portion 38b has a smaller contact area with the cutting blade 36 than the spacer 38, and the assembling load is concentrated on the edge portion, so that the cutting blade 36 is more firmly fixed. Conceivable.

The contact width W of the annular step 38b is preferably about 1/3 of the difference P between the outer diameter and the inner diameter of the spacer 38a. In this case, the cutting blade 36 is securely held at the time of cutting, and the inclination of the cutting blade 36 can be reduced. Further, a cutting blade 36a as shown in FIG. 19A may be used as the cutting blade. The cutting blade 36a has a groove 3 at the tip of the cutting blade 36.
6b. The groove 36b has, for example, a width 1
16 mm are formed at equal intervals so as to divide the outer periphery of the cutting blade 36a into 16 parts at a depth of 2 mm. An experimental example 5 relating to the presence or absence of the groove 36b will be described.

(Experimental Example 5) The Z-feed was performed when the cutting blade 36 having no groove 36b was used as the cutting blade and when the cutting blade 36a having the groove 36b was used as shown in FIG. A cut was made. At this time, both use a spacer 38, and the cutting blades 36, 36a
Sheet set, protrusion amount E = 20 mm, work 56 is container 50
The coolant 52 was immersed in the coolant 52 and supplied to the workpiece 56 from the hose 58 at a discharge pressure of about 20 kPa (2 kgf / cm ² ). The other conditions were the same as the experimental conditions shown in Table 1. Then, the two works 56 arranged on the attaching plate 54 having a substantially V-shaped cross section are cut by the four cutting blades 36 or 36a, and the dimensional variation is reduced by using the obtained inner six members 62. It was measured.

In Experimental Example 5, the dimensional variation was determined as follows. First, a total of 30 of the obtained six members 62 was obtained.
The thickness of the point is measured, and the difference between the maximum value and the minimum value is determined. The process is performed for each cutting process, and the average value of the difference between the maximum value and the minimum value is obtained, and is set as the dimensional variation. In Experimental Example 5, the cutting process was performed three times, and an average value was obtained. For each case where the cutting blade rotation speed is 8000 rpm and 3600 rpm,
Cutting speed of 2mm / min, 4mm / min, 6mm
/ Min, and the cutting process was performed, and the dimensional variation was calculated for each case.

As can be seen from the experimental results shown in FIGS. 20A and 20B, when the cutting blade 36a having the groove 36b is used, the coolant 52 is used more than when the cutting blade 36 without the groove 36b is used. It is easy to supply to the cutting edge and dimensional variation is reduced. In particular, the cutting blade rotation speed is usually (360
0 rpm), the dimensional variation is reduced. In the work cutting device 10, the cutting blade 36 is used as a cutting blade.
a, when the spacer 38a is used as the spacer,
When the protrusion amount E is 20 mm or less, the dimensional variation is 0.1%.
mm or less. At this time, the warp of the cutting blade 36a was 30 μm or less. "Sledding" is shown in FIG.
Is obtained by adding the maximum value and the minimum value of the surface height in each of the directions of the arrows X and Y shown in FIG. For measurement of the warpage, for example, a stylus type shape measuring instrument is used.

As the coolant 52, a synthetic chemical type having excellent permeability is effective.
By providing the groove 36b as in 6a, the dimensional variation could be reduced. As shown in FIG. 21, in the workpiece cutting device 10, the coolant 52 is supplied from the bottom of the upper surface of the attaching plate 54 a using the attaching plate 54 a having a V-shaped cross section (upper surface) without using the container 50. You may do so. That is, the slope 64a of the attaching plate 54a
And 64b, respectively, on the placement plates 66a and 66b
Are mounted, and the work 56 is arranged on the arrangement plates 66a and 66b, respectively. Plate-like surrounding members 68 are respectively attached to both side surfaces of the attaching plate 54a so that the coolant 52 can be stored. A coolant supply path 70 is formed in the attachment plate 54a. The coolant 52 is supplied into the coolant supply path 70 from a hole 72 provided on the side surface of the attaching plate 54a, and the coolant 52 is directed upward from, for example, a plurality of hole-shaped supply ports 74 provided at the bottom of the upper surface of the attaching plate 54a. Discharged.

The coolant 52 is connected to the work 56 by the hose 58.
The coolant 52 can be sufficiently supplied to the cutting section 60 by supplying not only from above but also from below as described above. At this time, the amount of coolant discharged from the hose 58 is preferably 50 L / min to 200 L / min. The present invention is not limited to the case where the attaching plates 54 and 54a having a substantially V-shaped cross section as shown in FIGS. 22 (a) and 21 are used. As shown in FIG. 22B, an attaching plate 54 having an arc-shaped groove having a substantially same curvature as the outer periphery of the cutting blade 36.
b may be used. Further, as shown in FIG. 22C, four works 56a may be arranged in a line on the sticking plate 54c. Further, as shown in FIG. 22D, the work 56 arranged on the attaching plate 54d having a flat surface may be cut from the vertical direction. FIG.
As shown in (e), the cutting blade 36 is moved horizontally from the normal direction of the work 56 arranged in the vertical direction to
22 (f), the work 56 disposed in the vertical direction is moved in the horizontal direction, and the work 56 is cut by the cutting blade 36 from its normal direction. Is also good. Even in these cases, the load on the cutting blade 36 is reduced as shown in FIG.
Since the cutting blade 36 is hardly deformed, the cutting accuracy is improved. The present invention is not limited to the case where the cutting blade 36 is moved toward the work at the time of cutting, and the work may be moved toward the cutting blade 36. The same applies to the case where the cutting blade 36a is used.

The cutting blades 36 and 36a of the present invention
Not only electroformed type, but also resin type and Japanese Patent Publication No. 52-33
Any all-blade type cutter such as a metal type as shown in No. 356 may be used. Tokiko Sho 52-3
The cutter wheel included in the metal bond cutter described in No. 3356 is obtained as follows. First, by weight ratio, Sn: 1% to 18%, Ag: 1% to 20%, Fe,
Any one or several of Ni, Co, and Cr 5% to 45%
%, And a metal powder consisting of the balance Cu and abrasive grains such as natural and artificial diamonds are mixed so as to be homogeneous. The mixture is cold-pressed into a predetermined size and shape, and then sintered in a reducing atmosphere or a neutral atmosphere. The grain size of the diamond used in this case is $ 14
0 / 170-600 mesh (approximately 100μ-30μ), and the compounding amount differs depending on the applied model.
It is 5% to 30% by volume of the entire cutter wheel.
The cold forming pressure of the cutter wheel is 1 ton / c.
m ^{2 to 5} ton / cm ² , sintering temperature is 650 ° C to 900 ° C
It is.

Further, as disclosed in JP-A-8-109431 and JP-A-8-109432, diamond, cBN
A diamond sintered body alloy obtained by sintering a cemented carbide and the like may be used for the cutting blades 36 and 36a. Metal plating phase 4
As 0, if the rigidity that can withstand cutting is obtained,
Any element other than Ni and Co can be used. The super-abrasive grains 42 are used for cutting the workpiece 5 at least during cutting.
It is sufficient if it is dispersed over the entire surface in contact with 6. For example, it may be dispersed only at the protruding portion indicated by the protruding amount E in FIG.

[0052]

According to the present invention, the cutting blade, in which the superabrasive grains are dispersed at least over the entire surface in contact with the workpiece during cutting, is rotated at high speed, and the normal direction of the contact point between the cutting blade and the workpiece is achieved. By cutting the work from the direction, the amount of grinding removal of the work can be reduced and many members can be obtained.
The cutting accuracy can be improved. In addition, by cutting a work by immersing it in a coolant and cutting a hard and brittle work such as a rare earth magnet member having a large thickness, the cutting blade can be cut accurately without seizing of the cutting blade. it can.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an embodiment of the present invention.

FIG. 2 is a sectional view showing a main part of a cutting blade block.

3 (a) is a partially omitted side sectional view showing a cutting blade, and FIG. 3 (b) is a partially omitted front sectional view thereof.

FIG. 4 is an illustrative view showing a main part of the embodiment of FIG. 1;

FIG. 5 is an illustrative view showing a relationship of a processing reaction force applied to a cutting blade during X-feed cutting;

FIG. 6 is an illustrative view showing a relationship of a processing reaction force applied to a cutting blade during Z-feed cutting;

FIG. 7 is an illustrative view showing a cutting stroke at the time of Z-feed cutting;

FIG. 8 is an illustrative view showing a cutting stroke at the time of X-feed cutting;

FIG. 9 is an illustrative view showing a state where a cutting blade is cut into a work;

FIG. 10 is an illustrative view for explaining a clearance between the work and the cutting blade when the work is vibrated;

FIG. 11 is an illustrative view showing a position where a thickness of a member obtained by cutting is measured;

FIG. 12A is a table showing the results of Experimental Example 1, and FIG. 12B is a graph thereof.

13A is a table showing the results of Experimental Example 2, and FIG. 13B is a graph thereof.

14A is a table showing the results of Experimental Example 3, and FIG. 14B is a graph thereof.

FIG. 15 is a graph showing cutting accuracy during vibration cutting.

16 (a) is a graph showing surface waviness during vibration cutting, and FIG. 16 (b) is an illustrative view showing measurement points of surface waviness.

FIG. 17A is a front view showing a modified example of the spacer, and FIG. 17B is a sectional view thereof.

18A is a table showing the results of Experimental Example 4, and FIG. 18B is a graph thereof.

FIG. 19A is a front view showing a modification of the cutting blade, and FIG. 19B is an illustrative view for explaining a warp.

FIG. 20A is a table showing the results of Experimental Example 5, and FIG. 20B is a graph thereof.

FIG. 21 is an illustrative view showing one example of an attaching plate and a surrounding member;

FIG. 22 is an illustrative view showing a modified example of a mode of cutting a work;

[Explanation of symbols]

 REFERENCE SIGNS LIST 10 workpiece cutting device 24 elevating motor 28 rotating shaft 30 cutting blade block 34 high-speed rotating motor 36, 36 a cutting blade 36 b groove 38, 38 a spacer 38 b annular step 40 metal plating phase 42 superabrasive 46 vibration table 48 vibrating device 50 container 52 Coolant 54, 54a, 54b, 54c, 54d Adhering plate 56, 56a Work 58 Hose 60 Cutting part 68 Surrounding member

 ────────────────────────────────────────────────── ─── Continuing from the front page (72) Inventor Toshiaki Sasaki 2-15-17 Egawa, Shimamoto-cho, Mishima-gun, Osaka Prefecture F-term in Sumitomo Special Metals Co., Ltd. Yamazaki Works (reference) 3C058 AA03 AA09 AA18 AB01 AC04 BA04 CA04 CB01 CB10 DA10 3C063 AA02 AB03 BA02 BA24 BB02 BC02 BH03 BH20 CC12 EE01 EE31 FF18 FF23 FF30

Claims (22)

[Claims] 1. A work cutting apparatus for cutting a work, comprising: a cutting blade in which superabrasive grains are dispersed at least over an entire surface in contact with the work during cutting; a first drive for rotating the cutting blade A work cutting apparatus, comprising: means, and a second driving means for moving at least one of the cutting blade and the work such that a relative movement direction of the cutting blade with respect to the work at the time of cutting is vertical. 2. A work cutting apparatus for cutting a work, comprising: a cutting blade in which super-abrasive grains are dispersed at least over an entire surface in contact with the work during cutting; a first drive for rotating the cutting blade Means for moving at least one of the cutting blade and the work such that a relative movement direction of the cutting blade with respect to the work at the time of cutting is a normal direction of a contact point between the cutting blade and the work. A work cutting device including two driving means. 3. A work cutting device for cutting a work, comprising: a housing means containing a coolant for immersing the work, wherein superabrasive grains are dispersed at least over an entire surface in contact with the work during cutting. A cutting blade, a first driving unit for rotating the cutting blade, and a second driving unit for moving at least one of the cutting blade and the work to cut the work immersed in the coolant. Equipped with a workpiece cutting device. 4. The work cutting apparatus according to claim 3, further comprising a coolant supply unit that supplies the coolant to the work. 5. The method according to claim 1, further comprising a plurality of said cutting blades, and a spacer interposed between said cutting blades, wherein said spacer has an annular stepped portion on the outer periphery of both main surfaces thereof. The work cutting device according to the above. 6. The work cutting device according to claim 1, wherein the cutting blade is formed by dispersing the superabrasive grains in a metal plating phase. 7. The work cutting apparatus according to claim 1, wherein the cutting blade has a groove at a tip thereof. 8. The work cutting device according to claim 1, wherein the rotation speed of the cutting blade is 8000 rpm or more. 9. The work cutting apparatus according to claim 1, further comprising a vibration unit configured to vibrate the work in a surface direction of the cutting blade. 10. The work cutting apparatus according to claim 9, wherein a vibration direction of the work is perpendicular to a direction of relative movement of the cutting blade with respect to the work. 11. The work cutting device according to claim 1, wherein the work is a rare earth alloy magnet member. 12. A work cutting method for cutting a work, comprising: a first step of preparing a cutting blade in which superabrasive grains are dispersed at least over an entire surface of the work that comes into contact with the work during cutting; A second step of rotating the blade and moving at least one of the cutting blade and the work so that a relative movement direction of the cutting blade with respect to the work is a vertical direction, and cutting the work by the cutting blade; A work cutting method comprising: 13. A work cutting method for cutting a work, comprising: a first step of preparing a cutting blade in which superabrasive grains are dispersed over at least the entire surface of the work that comes into contact with the work during cutting;
Rotating the cutting blade and moving at least one of the cutting blade and the work such that a relative movement direction of the cutting blade with respect to the work is a normal direction of a contact point between the cutting blade and the work. And a second step of cutting the work by the cutting blade. 14. A work cutting method for cutting a work, comprising: a first step of preparing a cutting blade in which super-abrasive grains are dispersed over at least the entire surface of the work in contact with the work during cutting;
And a second step of rotating the cutting blade, moving at least one of the cutting blade and the work, and cutting the work with the cutting blade in a state where the work is immersed in a coolant. 15. The workpiece cutting method according to claim 14, wherein in the second step, the coolant is further supplied to the workpiece. 16. The method according to claim 12, wherein in the first step, a plurality of the cutting blades and spacers each having an annular step on the outer periphery of both main surfaces are prepared, and the spacer is interposed between the cutting blades. 15. The method for cutting a work according to any one of items 14 to 14. 17. The work cutting method according to claim 12, wherein the cutting blade is formed by dispersing the superabrasive grains in a metal plating phase. 18. The cutting blade has a groove at its tip,
The workpiece cutting method according to claim 12. 19. The rotation speed of the cutting blade is 8000 rpm
The work cutting method according to any one of claims 12 to 14, which is described above. 20. The work cutting method according to claim 12, wherein in the second step, the work is cut while vibrating the work in a surface direction of the cutting blade. 21. The method according to claim 20, wherein the direction of vibration of the work is perpendicular to the direction of relative movement of the cutting blade with respect to the work. 22. The method according to claim 12, wherein the work is a rare earth alloy magnet member.