JP2008030176A - Brush for brush plating, and method for manufacturing superabrasive tool using the brush - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a brush for brush plating usable for manufacturing a superabrasive tool. <P>SOLUTION: A plurality of insulating fibers 3 longer than a plurality of carbon fibers 2 are arranged on outer peripheries of the carbon fibers 2. The insulating fibers 3 are projected from the carbon fibers 2. It is desirable that straight fibers are used for both forms of the insulating fibers 3 and the carbon fibers 2. In this method for manufacturing the superabrasive tool 7, nickel plating using the brush 1 for brush plating is made to serve as a binder. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a brush for brush plating used in a brush plating method and a method for manufacturing a superabrasive tool using the brush.

A rotary dresser is known as one of superabrasive tools.
A rotary dresser is a dresser in which diamond is embedded and fixed on the outer peripheral surface of a roll so as to have a predetermined shape. While rotating this, it is pressed against a conventional grindstone or superabrasive grindstone, which is a workpiece, to transfer the shape of the dresser. For this reason, many rotary dressers have complicated shapes, and very strict dimensional accuracy is required.

A reversal method (also called “reversal plating method” or “electroforming method”) is known as one of the methods for producing a rotary dresser. In general, the inversion method includes the following steps (1) to (4).
(1) A step of manufacturing an inverted mold having a predetermined shape on the inner surface of the mold, and attaching abrasive grains to the inner surface using a plating method.
(2) A process in which overlay plating is further performed so that the abrasive grains are embedded by the plating metal.
(3) A step of setting a cored bar at the center of the inverted mold and pouring a filler such as a low melting point alloy between the abrasive layer and the cored bar.
(4) A step of performing centering using a reference surface provided in advance in the reversing mold, finishing the shaft hole and the end face, and then removing the outer reversing mold.
It should be noted here that, in the step (2), the plating thickness must be thick so that the abrasive grains are filled with the plating metal. If this is not done, the holding power of the abrasive grains and the rigidity of the plating layer are not maintained, and the abrasive grains fall off and the plating layer is deformed when using the superabrasive tool. Conventionally, in the step (2), an electrode and a reversal type as an object to be plated are immersed in a bath containing a plating solution, and positive and negative electric fields are respectively applied to embed the abrasive grains by plating.
(For example, see Patent Documents 1 and 2)

The following is known as the brush plating method.
For example, a brush-shaped electrode for brush plating used for partial plating or repair plating is known.
(For example, Patent Document 3)

As another brush plating method, a carbon fiber brush-like electrode is known.
(For example, Patent Document 4)

As another brush plating method, a rotating roller-shaped electrode is known.
(For example, Patent Document 5)
JP-A-2-256464 JP 2001-38630 A Japanese Utility Model Publication No. 5-66068 JP-A 63-297587 JP 2002-367634 A

In order to obtain the required plating thickness by the above method, plating for a long time is required. On the other hand, in order to shorten the plating time, it is conceivable to increase the current density and increase the plating speed. However, since the rotary dresser has a very complicated shape, if the current density is increased and the electrode is not the same shape as the workpiece having the complicated shape by cutting, etc., the plating thickness is uniform. As a result, there was a problem that a part where the sufficient plating thickness could not be obtained from the surface for holding the abrasive grains was generated. As a result, there is a problem that abrasive grains fall off when the rotary dresser is used. Further, it is uneconomical to cut the electrode.
The present invention has been made to solve these problems. That is, the present invention has been made to provide a brush for brush plating that can be used for manufacturing a superabrasive tool. Furthermore, the brush plating method is used to manufacture a high-precision rotary dresser with high accuracy and a long life in which abrasive grains do not fall off in a short period of time.

The present invention is a brush plating brush used in a brush plating method, wherein a plurality of insulating fibers longer than the carbon fibers are arranged on the outer periphery of the plurality of carbon fibers, and the insulating fibers protrude from the carbon fibers. It is a brush for brush plating characterized by these.
In the present invention, an elastic carbon fiber is used as the electrode, so that it can be deformed along the unevenness of the surface to be plated, and the carbon fiber comes into contact with the surface to be plated by the structure as described above. Nothing will happen.
Furthermore, according to the brush for brush plating of the present invention, since the distance between the carbon fiber as the electrode and the surface to be plated can be shortened, a very high current density can be obtained. Furthermore, a new plating solution is always supplied to the surface to be plated, and a plating component-deficient layer called a so-called diffusion double layer can be removed with insulating fibers, so that a stable high current density can be maintained.
For the above reasons, the brush plating brush of the present invention has a very high rate of forming a plating film. In particular, the time required to form a thick plating layer can be significantly shortened.

The form of the insulating fiber and the carbon fiber are both linear fibers.
When embedding abrasive grains by nickel plating using the brush for brush plating of the present invention, the abrasive grains are fixed on the surface to be plated, and large protrusions such as grater are formed. Even if the brush for brush plating of the present invention is scratched by the protrusion, the shape of the brush itself is broken or broken, and the fibers are removed by the scratch, and the removed fibers are not taken into the plating film. In particular, when high-speed plating is performed by brush plating, burrs are likely to be generated at the edge portion of the surface to be plated, and thus fibers are likely to fall off if straight fibers are not used.

And the manufacturing method of the superabrasive tool which used the brush for brush plating of this invention and made nickel plating into a binder is provided.
The brush for brush plating of the present invention has a very high rate of forming a plating film. In particular, when applied to the manufacture of a superabrasive tool for forming a thick plating layer, the manufacturing period can be significantly shortened.
Furthermore, it is preferable to use a nickel sulfamate solution as a plating solution used in the brush plating method of the present invention. Nickel is affordable and easy to handle due to the established plating technology. Therefore, it is widely used in various fields and is one of the fields where the effect of the method of the present invention is great. When the present invention is used for nickel plating, a high plating rate is obtained, but the consumption of nickel ions in the plating solution is large. For this reason, a plating film can be efficiently formed by using a nickel sulfamate solution having a large amount of nickel ions in the plating solution.
Note that the nickel is preferably a nickel-based alloy containing 90% or more of nickel. This is because when nickel is used, a plating film can be efficiently formed and the abrasive grain holding power is excellent.

The superabrasive tool is a rotary dresser manufactured by a reversal plating method, and provides a method for manufacturing a superabrasive tool.
In particular, the present invention is most effective when applied to the production of a rotary dresser by reversal plating, which requires the formation of a thick plating layer, because the production period can be significantly shortened.
The structure of the plating layer formed by the brush plating brush of the present invention forms a layered structure composed of a number of thin layers by plating while rubbing the surface to be plated. Unlike the columnar structure formed by using the conventional plating method, this layered structure has a very strong corrosion resistance because it has a function of stopping the progress of corrosion for each layer. Therefore, the rotary dresser manufactured according to the present invention is less likely to be dissolved out in a severe corrosive environment and can be used stably.

  The superabrasive tool manufactured by the manufacturing method of the present invention has a very high added value because it can be manufactured in a short period of time as well as being highly accurate and not causing the abrasive grains to fall off. In particular, when applied to a rotary dresser, the remarkable effects of the present invention are exhibited.

  The best mode for carrying out the invention will be described in detail in the following examples. In the following embodiments, the same or corresponding parts are denoted by the same reference numerals, and the description thereof will not be repeated.

FIG. 1 is a schematic view showing a cross section of a brush plating brush according to the present invention.
The periphery of the bundle of the carbon fibers 2 was arranged so as to be surrounded by the insulating fibers 3, and the carbon fibers 2 were fixed by the holder 5 and the cover 4 at a position retracted by about 20 mm from the insulating fibers 3. The conductive cap 6 is used to connect lead wires for plating.
According to the brush for brush plating of Example 1, since the distance between the carbon fiber as the electrode and the surface to be plated can be shortened, a very high current density can be obtained. Furthermore, a new plating solution is always supplied to the surface to be plated, and a plating component-deficient layer called a so-called diffusion double layer can be removed with insulating fibers, so that a stable high current density can be maintained.
When a nickel plating film is formed on the surface of steel using the brush for brush plating of the present invention, the formation speed is extremely fast, and in particular, the time required to form a thick plating layer can be remarkably shortened. It was.

The manufacturing process of the second embodiment of the present invention shown in FIG. 2 will be described with reference to FIG.
First, in the step (a), a steel reversal mold 13 was prepared, and diamond 8 having an average particle diameter of 800 μm was temporarily fixed on the inner surface thereof by nickel plating 9 using a plating tank.
Further, in the step (b), diamond was embedded by nickel plating 10 while rubbing the secret plating surface with the brush plating brush 1 of Example 1. However, in FIG. 3B, those related to the plating apparatus such as lead wires are omitted.
Next, in the step (c), the base metal 12 was inserted, and the diamond layer and the base metal were bonded with the low melting point alloy 11.
Next, in step (d), the inversion mold 13 was removed. Next, the side surfaces, holes, and the like were finished by machining, and the nickel plating was further removed, and the diamond tip was projected to complete a diamond rotary dresser. The dimensions are an outer diameter of 160 mm and a width of 40 mm. It was confirmed that Example 2 can be manufactured in about half the time compared to the conventional plating method.
Next, for performance evaluation of Example 2, a dressing test was performed. The dressing test was performed by dressing a conventional whetstone using the plunge method. The dressing test conditions are: WA60K for the grinding wheel specifications, Φ220-5W, the circumferential speed ratio (Vr / Vs) of the peripheral speed (Vr) of the diamond rotary dresser and the peripheral speed (Vs) of the conventional grinding stone, and dressing. The direction was down dressing, and the cutting speed of the diamond rotary dresser per revolution of the conventional grindstone was 0.54 μm / rev. As a result of the test, there was no diamond dropout of the diamond rotary dresser. Moreover, it was confirmed that the dressing performance was equivalent to that produced by the conventional plating method.

Sectional drawing of the brush for brush plating of this invention is shown. Sectional drawing of Example 2 of this invention is shown. A part of manufacturing process of Example 2 of this invention is shown.

Explanation of symbols

1: Brush for brush plating 2: Carbon fiber 3: Insulating fiber 4: Cover 5: Holder 6: Cap 7: Rotary dresser 8: Diamond 9: Nickel plating 10: Nickel plating (building up)
11: Low melting point alloy 12: Base metal 13: Inversion type

Claims (4)

A brush for brush plating used in the brush plating method,
A plurality of insulating fibers longer than the carbon fibers are arranged on the outer periphery of the plurality of carbon fibers,
The brush for brush plating, wherein the insulating fiber protrudes from the carbon fiber.   The brush for brush plating according to claim 1, wherein the insulating fibers and the carbon fibers are both linear fibers.   A method for producing a superabrasive tool using nickel plating as a binder, wherein the brush for brush plating according to claim 1 is used.   The method of manufacturing a superabrasive tool according to claim 3, wherein the superabrasive tool is a rotary dresser manufactured by a reversal plating method.

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