JP2020127978A - Electroplated tool manufacturing method - Google Patents

Abstract

To provide a method for manufacturing an electroplated tool in which abrasive grains are regularly arranged on a grindstone action surface.SOLUTION: This method includes: a step (S101) at which abrasive grains are located one by one in each open space of a mesh sheet bonded onto an adhesive tape; a step (S102) at which the mesh sheet is peeled from the adhesive tape; a step (S103) at which the adhesive tape is located in such a manner that a face thereof, to which the abrasive grains are adhered, is oriented to a surface of a base metal, and is pressed, thereby embedding the abrasive grains into the surface of the base metal; and a step (S105) at which electric plating is performed for the surface of the base metal.SELECTED DRAWING: Figure 3

Description

The present invention relates to a method for manufacturing an electrodeposition tool in which abrasive grains are electrodeposited and fixed on the surface of a base metal.

For the grinding of high hardness and small parts, which have been in increasing demand in recent years, electroplating tools in which electroplating is performed and only one layer of diamond abrasive grains is fixed on the surface of a base metal are often used. As a conventional electrodeposition tool, for example, in Patent Document 1, in order to make a smooth grinding surface by using a coarse-grained diamond wheel, the distance from the rotation center of the tool to the tip of the abrasive grain on the grindstone working surface is made uniform. A method of manufacturing an electro-deposited tool in which abrasive particles can be embedded is disclosed.

JP-A-6-39729

An electroplated tool in which only one layer of diamond abrasive is fixed on the surface of the tool base metal by electroplating has the best sharpness among existing tools. However, in the electrodeposition tool, normally, the distance from the center of rotation of the tool to the tip of the abrasive grains is not uniform, so that a smooth machined surface cannot be formed.

In the electrodeposition tool described in Patent Document 1, it is said that the distance from the center of rotation of the tool to the tip of the abrasive grains on the working surface of the grindstone can be made uniform, but mechanical vibration is added to the tool base metal to grind it. Even if the particles are dispersed, there is no guarantee that the abrasive particles are evenly distributed on the working surface of the grindstone. Therefore, the roughness of the grindstone in the width direction varies.

Therefore, it is an object of the present invention to provide a method for manufacturing an electrodeposition tool in which abrasive grains are regularly arranged on a grindstone working surface.

The method for producing the electrodeposition tool of the present invention is to dispose one abrasive grain in each open space of the mesh sheet attached on the adhesive tape, peel the mesh sheet from the adhesive tape, and remove the abrasive grains. The method includes arranging an adhesive tape with the adhered surface facing the surface of the base metal and pressing it to embed abrasive grains in the surface of the base metal, and performing electroplating on the surface of the base metal.

According to the method for manufacturing an electrodeposition tool of the present invention, when the mesh sheet is peeled from the adhesive tape by disposing the abrasive grains one by one in the open space of the mesh sheet attached on the adhesive tape, the adhesive tape Abrasive grains are regularly arranged on the top, and by arranging the surface of the adhesive tape on which the abrasive grains adhere to the surface of the base metal and pressing it, the abrasive grains are regularly arranged on the surface of the base metal, that is, the working surface of the grindstone. They are arranged and held on the base metal by electroplating.

Here, it is desirable that the electroplating is performed after pressing and after removing the pressure-sensitive adhesive adhering to the working surface of the grindstone. As a result, when the adhesive of the adhesive tape adheres to the whetstone working surface when the adhesive tape is peeled off, the adhered adhesive is removed and electroplating is performed to form a clean plating film. can do. If the adhesive remains, the adhesive becomes an insulator and cannot be electroplated. Therefore, after the pressing, the adhesive must be completely removed and then electroplated.

Further, in the method for producing an electrodeposition tool according to the present invention, it is desirable that after electroplating is applied to the thickness of one abrasive grain, the plating film is polished to expose a part of the abrasive grain on the surface. As a result, it is possible to completely cover the abrasive grains embedded in only one layer on the base metal with the plating film and remove the surface contact.

One abrasive grain is placed in each open space of the mesh sheet pasted on the adhesive tape, the mesh sheet is peeled off from the adhesive tape, and the surface with the abrasive grains is directed to the surface of the base metal. By arranging and pressing, the abrasive grains are embedded in the surface of the base metal, and the surface of the base metal is electroplated to obtain an electrodeposition tool in which the abrasive grains are regularly arranged on the working surface of the grindstone.

It is a figure which shows the outline|summary of the electrodeposition tool in embodiment of this invention, (A) is the front view which saw the electrodeposition tool from the grindstone action surface, (B) is the end surface of the ZZ line cutting part of (A). It is a figure. (A) An electrodeposition tool in which abrasive grains in a square arrangement in an embodiment of the present invention are obliquely arranged, and (B) abrasive grains are simply arranged in a square manner, and the tip of the abrasive grains on the working surface of the grindstone from the tool rotation center It is explanatory drawing which compared with the electrodeposition tool with which the same height was compared. It is a flowchart which shows the manufacturing method of the electrodeposition tool in embodiment of this invention. It is explanatory drawing of a mesh sheet preparation process, (A) is a longitudinal cross-sectional view, (B) is a top view. It is a microscope image of the mesh sheet produced by spraying the abrasive grain of mesh size #100 on the mesh sheet of mesh size #100. It is explanatory drawing of a mesh sheet peeling process, (A) is a longitudinal cross-sectional view and (B) is a top view. It is a microscope image of the adhesive tape to which the abrasive grain of mesh size #100 was regularly adhered. It is explanatory drawing which shows the process of embedding abrasive grains in a base metal. It is explanatory drawing which shows an adhesive removal process, Comprising: (A) is a longitudinal cross-sectional view which shows the state before adhesive removal, (B) is a longitudinal cross-sectional view which shows the state after adhesive removal. It is a microscope image of the base metal surface after removing an adhesive. It is explanatory drawing which shows a mode that a surface removal is performed by a machining center. It is explanatory drawing which shows a mode that the unevenness|corrugation of a plating film is planarized. It is explanatory drawing which shows a mode that dressing is performed by a rotoring dresser. It is explanatory drawing which shows a mode that an abrasive grain is exposed to a grindstone action surface by dressing. It is a microscope image showing the state of the working surface of the grindstone observed after embedding the abrasive grains in the base metal, after electroplating, and after wet lapping, in which the upper stage shows a 5× differential interference contrast microscope image, and the lower stage shows a laser scanning microscope. It is a figure which shows an image. It is explanatory drawing of a grinding experiment. (A) is a figure which shows the microscope image (comparative example) of the processed surface shape|molded using SD400, (B) is a figure which shows the microscope image (example) of the processed surface shape|molded using SD140P.

FIG. 1 is a diagram showing an outline of an electrodeposition tool according to an embodiment of the present invention, where (A) is a front view of the electrodeposition tool as seen from the working surface of a grindstone, and (B) is a line ZZ of (A). FIG.

As shown in FIG. 1(B), the electrodeposition tool 1 according to the embodiment of the present invention has abrasive grains 3 electrodeposited and fixed on the surface of a base metal 2 and the height of the tips of the abrasive grains 3 on the working surface of the grindstone. It is an electrodeposition grindstone with uniform (height from the tool rotation center to the tip of the abrasive grain 3). One abrasive grain 3 is arranged at each intersection 4A of the square mesh 4 shown in FIG. 1(A) (square arrangement). As shown in FIG. 1A, the square meshes 4 are arranged at an inclination angle θ with respect to the grinding direction. That is, the abrasive grains 3 are obliquely arranged at an inclination angle θ with respect to the grinding direction.

FIG. 2 shows (A) an electrodeposition tool in which square-arranged abrasive grains are obliquely arranged in the embodiment of the present invention, and (B) abrasive grains are simply square-arranged, and the grindstone working surface is located from the tool rotation center. It is explanatory drawing which compared with the electrodeposition tool which made the height to the abrasive grain tip uniform.

As shown in FIG. 2(A), in the electrodeposition tool 1 in which the abrasive grains 3 arranged in a square are obliquely arranged, the width b of the striation is b=ω·cos θ/m, and if the inclination angle θ is increased, b Decreases. Therefore, the roughness in the grindstone width direction (direction orthogonal to the grinding direction) is approximately 0. Since the number of abrasive grains n on the same circumference is infinite, the roughness in the traverse direction ≈0.

On the other hand, as shown in FIG. 2B, in the electrodeposition tool in which the abrasive grains are simply arranged in a square manner and the height from the tool rotation center to the tip of the abrasive grains on the working surface of the grindstone is uniform, the width b of the scratches is It is ω/2, and the roughness in the width direction of the grindstone is uniform, but it is not good. Since the number of abrasive grains n on the same circumference is infinite, the roughness in the traverse direction is ≈0.

Next, a method of manufacturing the electrodeposition tool according to the embodiment of the present invention will be described with reference to the flowchart of FIG. FIG. 3 is a flow chart showing a method for manufacturing an electrodeposition tool according to an embodiment of the present invention.

(S101) Mesh Sheet Creation FIGS. 4A and 4B are explanatory views of the mesh sheet creation step, where FIG. 4A is a vertical sectional view and FIG. 4B is a plan view. As shown in FIG. 4, the adhesive tape 11 is attached to the back surface of the polyethylene mesh sheet 10, and the abrasive grains 3 are sprayed from the front side. As the abrasive grain 3, for example, a coarse diamond abrasive grain having a mesh size of #500 or less made by crushing blocky diamond particles is used. In this way, the mesh sheet 10 in which the abrasive grains 3 are arranged in each open space 10A is created. FIG. 5 is a microscope image of the mesh sheet 10 created by spraying the abrasive grains 3 of mesh size #100 on the mesh sheet 10 of mesh size #100.

(S102) Mesh Sheet Peeling FIGS. 6A and 6B are explanatory views of the mesh sheet peeling step, where FIG. 6A is a vertical sectional view and FIG. 6B is a plan view. When the mesh sheet 10 is peeled off from the adhesive tape 11 shown in FIG. 4, the adhesive tape 11 to which the abrasive grains 3 are regularly attached is prepared as shown in FIG. FIG. 7 is a microscope image of the adhesive tape 11 to which the abrasive grains 3 having a mesh size of #100 are regularly attached.

(S103) Embedding Abrasive Grains by Pressing FIG. 8 is an explanatory view showing a step of embedding abrasive grains in a base metal. As shown in FIG. 8, the adhesive tape 11 to which the abrasive grains 3 are attached is adhered to the surface of the cup-shaped base metal 12 and pressed with a pressing machine so that the tips of the abrasive grains 3 are aligned. Abrasive grains 3 are embedded in 12. The base metal 12 is a soft tool base metal such as brass and duralumin. For example, a brass base metal 12 is placed on a super hard metal mold 13, and the abrasive grains 3 are embedded in the base metal 12 by a 3t press. At this time, pressing is performed so that the heights of the tips of the abrasive grains 3 on the working surface of the grindstone are aligned. Since the adhesive 11A adhered by the adhesive tape 11 is removed later, the adhesive tape 11 should not be pressed completely flat.

(S104) Adhesive Removal FIG. 9 is an explanatory view showing an adhesive removing step, (A) is a vertical cross-sectional view showing a state before removing the adhesive, and (B) is a vertical section showing a state after removing the adhesive. It is a side view. After the pressing, the adhesive tape 11 is peeled off and the adhesive 11A attached to the working surface of the grindstone is removed. When the adhesive 11A is acrylic, it is immersed in toluene for removal. FIG. 10 is a microscope image of the surface of the base metal after removing the adhesive 11A.

(S105) Electroplating In order to increase the holding power of the abrasive grains 3 on the base metal 12, nickel is electroplated on the surface of the base metal 12. At this time, the plating film 14 (see FIG. 12) is formed by the thickness of one abrasive grain 3.

(S106) Exposure of Abrasive Grain Tip After plating, as shown in FIG. 11, the prepared electrodeposition tool 1A is attached to a vertical machining center, and centering is performed by using a runout preventing stop bolt to remove contact. For this purpose, as shown in FIG. 12, the plating film 14 is polished with water resistant paper or the like (not shown) to flatten the irregularities of the plating film 14 to partially expose the tips of the abrasive grains 3.

Finally, as shown in FIG. 13, a rotoring dresser GV3000V having a mesh size of #3000 is used for the electrodeposition tool 1A from which the surface contact has been removed, and the abrasive grains 3 have a particle size d as shown in FIG. The dressing for exposing to the working surface of the grindstone is carried out for about 1/5 of the above. As a result, the abrasive grains 3 are partially embedded in the surface of the base metal 12, and the electrodeposition tool 1A having the plating layer 14A in which a part of the abrasive grains 3 is exposed on the surface of the base metal 12 is completed.

FIG. 15 is a microscope image showing a working surface of a grindstone observed after embedding abrasive grains in a base metal, after electroplating, and after wet lapping. The upper stage is a 5× differential interference contrast microscope image, and the lower stage is a laser scanning microscope. The image is shown.

In order to confirm the usefulness of the electrodeposition tool of the present invention, a commercially available resin bond diamond wheel (SD400B) having a particle size of 37.5 μm (mesh size #400) as a comparative example and abrasive grains 3 as an example were used. A grinding experiment was performed using an electrodeposition tool 1A (SD140P) having a particle size of 107.1 μm (mesh size #140). As shown in FIG. 16, first, grinding was performed using SD400B (comparative example), and then grinding was performed using SD140P (example). Grinding was performed at 1500 rpm, 100 mm/min, and 2 μm incision.

FIG. 17A shows a microscope image (comparative example) of a machined surface formed by using SD400, and FIG. 17B shows a microscope image (example) of a machined surface formed by using SD140P. As shown in FIG. 17, despite using the electrodeposition tool 1A having a mesh size of #140 (SD140P (example)), a commercially available resin bond diamond wheel having a mesh size of #400 (SD400B (comparative example)). A smooth processed surface (0.3 μm Rz) is obtained as compared with the processed surface (2.5 μm Rz) when using.

That is, in the electrodeposition tool of the present invention, since it is possible to reduce the width of the scratches by the abrasive grains obliquely arranged in the grinding direction, it is possible to make the roughness in the grinding stone width direction uniform, the mesh Even if coarse particles of size #500 or less are used, it is possible to make a smooth ground surface. Further, by setting the inclination angle θ to, for example, 80° or more, it is possible to use the coarse particles having a mesh size of #500 or less and the roughness in the grindstone width direction to be 10 nm Rz or less.

INDUSTRIAL APPLICABILITY The electrodeposition tool of the present invention is useful for grinding high hardness/small parts, and in particular, the roughness in the width direction of the grindstone is made uniform, and a smooth machined surface is formed by coarse particles having a mesh size of #500 or less. It is suitable as a possible electrodeposition tool.

1,1A Electrodeposition tool 2 Base metal 3 Abrasive grains 4 Mesh 4A Intersection 10 Mesh sheet 10A Open space 11 Adhesive tape 11A Adhesive 12 Base metal 13 Mold 14 Plating film 14A Plating layer

Claims (4)

Arranging one abrasive grain in each open space of the mesh sheet attached on the adhesive tape,
Peeling the mesh sheet from the adhesive tape,
Placing the adhesive tape with the surface to which the abrasive particles are attached facing the surface of the base metal, and embedding the abrasive particles in the surface of the base metal by pressing,
A method for manufacturing an electrodeposition tool, which comprises subjecting the surface of the base metal to electroplating. The method for manufacturing an electrodeposition tool according to claim 1, wherein the electroplating is performed after the pressing and after removing an adhesive agent adhering to the working surface of the grindstone. The electrodeposition according to claim 1 or 2, wherein after the electroplating is performed by a thickness of one of the abrasive grains, the plating film is polished to expose a part of the abrasive grains on the surface. Tool manufacturing method. 4. The electrodeposition tool according to any one of claims 1 to 3, wherein the abrasive grains are arranged in each open space of the mesh sheet by spraying the abrasive grains onto the mesh sheet. Manufacturing method.