JP3035644B2 - Metal-coated abrasive, method for producing the same, and method for producing metal-bonded grindstone - Google Patents
Metal-coated abrasive, method for producing the same, and method for producing metal-bonded grindstoneInfo
- Publication number
- JP3035644B2 JP3035644B2 JP4312907A JP31290792A JP3035644B2 JP 3035644 B2 JP3035644 B2 JP 3035644B2 JP 4312907 A JP4312907 A JP 4312907A JP 31290792 A JP31290792 A JP 31290792A JP 3035644 B2 JP3035644 B2 JP 3035644B2
- Authority
- JP
- Japan
- Prior art keywords
- metal
- abrasive grains
- coated abrasive
- layer
- powder
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000002184 metal Substances 0.000 title claims description 140
- 229910052751 metal Inorganic materials 0.000 title claims description 140
- 238000004519 manufacturing process Methods 0.000 title claims description 41
- 239000006061 abrasive grain Substances 0.000 claims description 142
- 239000010410 layer Substances 0.000 claims description 48
- 239000000843 powder Substances 0.000 claims description 48
- 239000011247 coating layer Substances 0.000 claims description 47
- 238000000227 grinding Methods 0.000 claims description 31
- 239000002245 particle Substances 0.000 claims description 31
- 238000007747 plating Methods 0.000 claims description 30
- 239000011812 mixed powder Substances 0.000 claims description 28
- 239000011248 coating agent Substances 0.000 claims description 22
- 238000000576 coating method Methods 0.000 claims description 22
- 238000000034 method Methods 0.000 claims description 20
- 239000011230 binding agent Substances 0.000 claims description 18
- 238000005245 sintering Methods 0.000 claims description 13
- 239000011347 resin Substances 0.000 claims description 11
- 229920005989 resin Polymers 0.000 claims description 11
- 229910052718 tin Inorganic materials 0.000 claims description 10
- 239000000945 filler Substances 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 9
- 239000003638 chemical reducing agent Substances 0.000 claims description 8
- 229910052802 copper Inorganic materials 0.000 claims description 8
- 238000002156 mixing Methods 0.000 claims description 7
- 238000003825 pressing Methods 0.000 claims description 7
- 229910045601 alloy Inorganic materials 0.000 claims description 6
- 239000000956 alloy Substances 0.000 claims description 6
- 238000001746 injection moulding Methods 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 6
- 238000005096 rolling process Methods 0.000 claims description 6
- 150000002739 metals Chemical class 0.000 claims description 5
- 229910052709 silver Inorganic materials 0.000 claims description 5
- 239000002923 metal particle Substances 0.000 claims description 4
- 238000003466 welding Methods 0.000 claims description 4
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- 229910052804 chromium Inorganic materials 0.000 claims description 2
- 229910052737 gold Inorganic materials 0.000 claims description 2
- 229910052738 indium Inorganic materials 0.000 claims description 2
- 229910052742 iron Inorganic materials 0.000 claims description 2
- 229910052745 lead Inorganic materials 0.000 claims description 2
- 238000002844 melting Methods 0.000 claims description 2
- 230000008018 melting Effects 0.000 claims description 2
- 229910052759 nickel Inorganic materials 0.000 claims description 2
- 230000000052 comparative effect Effects 0.000 description 18
- 229910003460 diamond Inorganic materials 0.000 description 10
- 239000010432 diamond Substances 0.000 description 10
- 238000007772 electroless plating Methods 0.000 description 8
- 238000010894 electron beam technology Methods 0.000 description 6
- 230000001965 increasing effect Effects 0.000 description 6
- 239000010953 base metal Substances 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 5
- 230000006835 compression Effects 0.000 description 5
- 238000007906 compression Methods 0.000 description 5
- 238000000465 moulding Methods 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 238000009826 distribution Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000002474 experimental method Methods 0.000 description 4
- 238000007790 scraping Methods 0.000 description 4
- 239000004575 stone Substances 0.000 description 4
- 239000011521 glass Substances 0.000 description 3
- 230000003746 surface roughness Effects 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 2
- 239000003082 abrasive agent Substances 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000007731 hot pressing Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000007740 vapor deposition Methods 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000004453 electron probe microanalysis Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- -1 for example Substances 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 239000012255 powdered metal Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 230000002269 spontaneous effect Effects 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 238000010301 surface-oxidation reaction Methods 0.000 description 1
Landscapes
- Powder Metallurgy (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Description
【０００１】[0001]
【産業上の利用分野】本発明は、砥石の製造に使用され
る金属被覆砥粒、その製造方法、およびそれを用いたメ
タルボンド砥石の製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal-coated abrasive used for manufacturing a grinding wheel, a method for manufacturing the same, and a method for manufacturing a metal-bonded grinding wheel using the same.
【０００２】[0002]
【従来の技術】一般的なメタルボンド砥石は、通常、粉
末状の金属結合剤に砥粒を均一に混合し、この混合粉末
を台金とともに型込めした後、これらを圧粉成形および
焼結して製造されている。2. Description of the Related Art Generally, a general metal-bonded grindstone is prepared by uniformly mixing abrasive grains with a powdered metal binder, embedding the mixed powder with a base metal, compacting and sintering them. It is manufactured.
【０００３】[0003]
【発明が解決しようとする課題】ところで、上記のよう
なメタルボンド砥石の製造方法では、砥粒と結合剤を混
合し型込めする過程で個々の砥粒を均一に分散させるこ
とが難しく、焼結後の砥粒層の内部において砥粒の分布
密度に粗密が生じることは避けられない。このため、研
削面に露出した砥粒の配置に粗密が生じ、砥石の切れ味
に局部的なむらが生じて、研削性能が不安定になる欠点
があった。However, in the above-described method of manufacturing a metal-bonded grindstone, it is difficult to uniformly disperse the individual abrasive grains in the process of mixing and embedding the abrasive grains and the binder, and the burning is difficult. It is inevitable that the distribution density of the abrasive grains becomes uneven in the interior of the abrasive layer after the sintering. For this reason, there is a defect that the arrangement of the abrasive grains exposed on the grinding surface is uneven and the sharpness of the grinding wheel is locally uneven, and the grinding performance is unstable.
【０００４】なお、従来においても、砥粒表面に無電解
めっき法または蒸着法を用いて薄い金属被覆層を形成し
ておき、後は通常通りに金属結合剤と混合し、圧粉成形
および焼結してメタルボンド砥石を製造する場合があっ
た。このように金属被覆した砥粒を用いると、研削時に
発生する砥粒の熱が金属被覆層を通して発散するため、
砥粒の局部的な過熱が防止できる。また、金属被覆を介
在させると、結合相と砥粒の接合強度が増すため、結合
相による砥粒保持力が向上し、砥粒の脱落頻度が低下し
て寿命が延長できることも知られている。[0004] Conventionally, a thin metal coating layer is formed on the surface of an abrasive grain by electroless plating or vapor deposition, and then mixed with a metal binder as usual, followed by compacting and firing. In some cases, metal bond whetstones were manufactured by tying. When using the metal-coated abrasive grains, since the heat of the abrasive grains generated during grinding is radiated through the metal coating layer,
Local overheating of the abrasive grains can be prevented. It is also known that the presence of the metal coating increases the bonding strength between the binder phase and the abrasive grains, so that the abrasive phase holding power by the binder phase is improved, the frequency of the abrasive grains falling off is reduced, and the life can be extended. .
【０００５】ただし、上記従来の金属被覆砥粒は、結合
相と砥粒との接合性や砥粒の耐熱性を高める目的で被覆
層を形成したものであるから、その被覆層は厚さ約５μ
ｍ以下の薄いものだった。また、上記の金属被覆砥粒は
無電解めっき法あるいは蒸着法を用いて製造されるの
で、被覆層の形成速度は通常０．３μｍ／ｍｉｎ以下と
遅く、製造効率が悪かった。さらに、無電解めっき法の
場合には金属被覆層の材質が限定され、選択の自由度に
乏しい一方、蒸着法では砥粒の分散が悪く、均一な被覆
層形成は難しいという問題を有していた。[0005] However, since the above-mentioned conventional metal-coated abrasive grains are formed with a coating layer for the purpose of improving the bonding property between the binder phase and the abrasive grains and the heat resistance of the abrasive grains, the coating layer has a thickness of about 5μ
m or less. In addition, since the above-mentioned metal-coated abrasive grains are manufactured by using the electroless plating method or the vapor deposition method, the formation speed of the coating layer is usually as low as 0.3 μm / min or less, and the manufacturing efficiency is poor. Further, in the case of the electroless plating method, the material of the metal coating layer is limited, and the degree of freedom in selection is poor. Was.
【０００６】[0006]
【課題を解決するための手段】本発明は上記課題を解決
するためになされたもので、以下、その具体的な構成を
説明する。SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and a specific configuration thereof will be described below.
【０００７】始めに、本発明に係る金属被覆砥粒の製造
方法から説明する。この方法に使用する砥粒は、ダイヤ
モンドやＣＢＮ等の超砥粒、あるいはＳｉＣやＡｌ2Ｏ3
等の一般砥粒のいずれでもよい。砥粒の形状は、加圧攪
拌中の砥粒の転がり性を向上し、圧着被覆層の均一形成
を容易にするため、球状に近い方が好ましい。しかし極
端な鱗片状でない限り、不定形の砥粒を用いても圧着被
覆層は十分形成可能である。First, a method for producing metal-coated abrasive grains according to the present invention will be described. The abrasive grains used in this method are super-abrasive grains such as diamond and CBN, or SiC or Al 2 O 3
Any of general abrasives such as The shape of the abrasive grains is preferably closer to a sphere in order to improve the rolling properties of the abrasive grains during pressurized stirring and facilitate uniform formation of the pressure-bonded coating layer. However, as long as it is not an extremely scaly shape, the pressure-bonded coating layer can be sufficiently formed even by using irregular-shaped abrasive grains.
【０００８】砥粒の平均粒径は使用目的によっても異な
るが、製造上の理由から１０〜５００μｍ程度、特に２
０〜２００μｍが好ましい。１０μｍ未満では圧着被覆
層を形成する際に中心核となりにくく、５００μｍより
大では摩擦圧接作用による被覆が困難になる。The average grain size of the abrasive grains varies depending on the purpose of use, but is about 10 to 500 μm, particularly 2
0 to 200 μm is preferred. If it is less than 10 μm, it is difficult to form a central nucleus when forming a pressure-bonded coating layer, and if it is more than 500 μm, it becomes difficult to coat by friction welding.
【０００９】この方法ではまず、無電解めっき法等を用
いて、前記砥粒の表面に薄い金属めっき層を形成する。
この金属めっき層は圧着被覆層の形成（接合）を容易に
するためのもので、その材質としては、例えばＣｕ，Ｎ
ｉ，Ｃｏ，Ａｇ等が挙げられる。金属めっき層の厚さ
は、砥粒の平均粒径にもよるが０．１〜２０μｍ、特に
１〜５μｍ程度が望ましい。０．１μｍより薄いと圧着
被覆層の形成が困難になり、他方２０μｍより厚くする
と無電解めっきに要する時間が増すのみで生産性が低下
する。In this method, first, a thin metal plating layer is formed on the surface of the abrasive grains using an electroless plating method or the like.
This metal plating layer is for facilitating the formation (joining) of the pressure-bonding coating layer.
i, Co, Ag and the like. The thickness of the metal plating layer depends on the average particle size of the abrasive grains, but is preferably 0.1 to 20 μm, and particularly preferably about 1 to 5 μm. When the thickness is less than 0.1 μm, it becomes difficult to form the pressure-bonding coating layer. On the other hand, when the thickness is more than 20 μm, only the time required for electroless plating increases, and the productivity decreases.
【００１０】次に、こうして得られた金属めっき砥粒
を、少なくとも１種以上の相対的に軟質な金属粉末、お
よび少なくとも１種以上の相対的に硬質な金属の金属粉
末とともに混合し、図１に示すような装置を用いてこれ
らに加圧転動運動を加え、金属めっき層の上に所望の厚
さを有する圧着被覆層を摩擦圧接法によって形成する。Next, the metal-plated abrasive grains thus obtained are mixed with at least one or more relatively soft metal powders and at least one or more relatively hard metal powders. Then, a pressure rolling motion is applied to these by using an apparatus as shown in (1) to form a pressure-bonding coating layer having a desired thickness on the metal plating layer by a friction welding method.
【００１１】前記相対的に軟質な金属粉末の硬さはビッ
カース硬度で５０ｋｇ／ｍｍ2 以下が好ましく、かつ金
属めっき層を構成する金属よりも柔軟な材質であること
が好ましい。その方が、これら金属粉末粒子１３がめっ
き砥粒に固着しやすく、圧着被覆層１４の形成が容易に
行なえる。具体的な材質としては、Ａｌ，Ｓｎ，Ａｇ，
Ｉｎ，Ｐｂ，Ａｕ，Ｃｕまたはこれらの合金が挙げられ
る。混合粉末を構成する金属粉末が全てビッカース硬度
５０ｋｇ／ｍｍ2 以上であると、混合粉末の被覆が困難
になり、厚い被覆層の形成が難しくなる。一方、相対的
に硬質な金属としては、Ｎｉ，Ｃｏ，Ｆｅ，Ｃｒまたは
これらの合金が挙げられる。The relatively soft metal powder preferably has a Vickers hardness of 50 kg / mm 2 or less, and is preferably a material that is more flexible than the metal constituting the metal plating layer. This makes it easier for the metal powder particles 13 to adhere to the plating abrasive grains, and facilitates formation of the pressure-bonding coating layer 14. Specific materials include Al, Sn, Ag,
In, Pb, Au, Cu or their alloys are mentioned. If all of the metal powders constituting the mixed powder have a Vickers hardness of 50 kg / mm 2 or more, it becomes difficult to coat the mixed powder and to form a thick coating layer. On the other hand, relatively hard metals include Ni, Co, Fe, Cr and alloys thereof.
【００１２】圧着被覆層の材質について、例えば、Ｃｕ
とＳｎを用いた場合の１例を以下に記す。 金属めっき層： Ｃｕ 圧着被覆層： ＣｕとＳｎの混合物Regarding the material of the pressure-bonding coating layer, for example, Cu
An example in the case where Sn and Sn are used is described below. Metal plating layer: Cu Compression coating layer: Mixture of Cu and Sn
【００１３】図１に示す加圧転動装置の構成を簡単に説
明すると、図中符号１は軸線を水平に設置された円筒状
のドラムであり、軸線を中心として回転される。ドラム
１の内部には、軸線に沿って固定シャフト２が配置さ
れ、このシャフト２には下向きに加圧アーム３、および
その回転方向後方側の斜め下方に延びる掻き取りアーム
４がそれぞれ固定されている。ドラム１内にめっき砥粒
と金属粉体を添加した後、蓋（図示略）で塞ぐことによ
り、ドラム１内はほぼ密閉される。The structure of the pressure rolling device shown in FIG. 1 will be briefly described. In the figure, reference numeral 1 denotes a cylindrical drum whose axis is set horizontally, and is rotated about the axis. A fixed shaft 2 is disposed inside the drum 1 along an axis, and a pressure arm 3 and a scraping arm 4 extending diagonally downward on the rear side in the rotation direction are fixed to the shaft 2. I have. After the plating abrasive grains and the metal powder are added to the inside of the drum 1, the inside of the drum 1 is substantially sealed by closing with a lid (not shown).
【００１４】加圧アーム３の下端には、ドラム１の内面
と平行な円弧状をなす加圧板５が固定され、この加圧板
５とドラム１内面との間には、一定の間隙が形成されて
いる。一方、掻き取りアーム４の下端は刃先状に形成さ
れ、ドラム１内面に付着した粉体を掻き落とす構成とな
っている。At the lower end of the pressure arm 3, a pressure plate 5 having an arc shape parallel to the inner surface of the drum 1 is fixed, and a certain gap is formed between the pressure plate 5 and the inner surface of the drum 1. ing. On the other hand, the lower end of the scraping arm 4 is shaped like a blade, and is configured to scrape off powder adhered to the inner surface of the drum 1.
【００１５】圧着被覆を行なうには、まず、めっき砥粒
と金属混合粉体とを所定の割合でドラム１に入れる。図
２は、砥粒１０に金属めっき層１１を形成してなるめっ
き砥粒１２と、混合粉末１３とが混合された状態を示す
拡大図である。In order to perform pressure bonding, first, plating abrasive grains and a metal mixed powder are put into the drum 1 at a predetermined ratio. FIG. 2 is an enlarged view showing a state in which a plating abrasive grain 12 formed by forming a metal plating layer 11 on an abrasive grain 10 and a mixed powder 13 are mixed.
【００１６】使用する混合粉末１３の平均粒径は０．１
〜５０μｍとされ、かつめっき砥粒１２の平均粒径の１
〜２５％程度であることが望ましい。０．１μｍ未満あ
るいは１％未満では混合粉末１３の粒子数が大きくなり
すぎ、被覆と同時に混合粉末１３同士の凝集が起こり、
圧着被覆層１４の形成が困難である。逆に、５０μｍよ
り大あるいは２５％より大では、めっき砥粒１２が中心
核になりにくく、金属粉末粒子１３同士の圧着凝集が起
こり好ましくない。The average particle size of the mixed powder 13 used is 0.1
５０50 μm, and 1 of the average particle size of the plating abrasive grains 12.
It is desirable to be about 25%. If it is less than 0.1 μm or less than 1%, the number of particles of the mixed powder 13 becomes too large, and the mixed powder 13 aggregates simultaneously with coating,
It is difficult to form the pressure-bonding coating layer 14. On the other hand, when it is larger than 50 μm or larger than 25%, the plating abrasive grains 12 are unlikely to become the central nucleus, and the metal powder particles 13 are undesirably aggregated by pressure bonding.
【００１７】めっき砥粒１２と混合粉末１３との混合比
は、形成すべき圧着被覆層１４の厚さに応じて決定され
るが、効率良く圧着被覆層１４を形成するには、粉末の
体積比で、以下の範囲に設定することが望ましい。 めっき砥粒量: 金属粉末量＝５０： １〜３：１ １回の圧接被覆では被覆厚さが足りない場合には、途中
で混合粉末１３を追加して圧着被覆を続行すればよい。The mixing ratio between the plating abrasive grains 12 and the mixed powder 13 is determined according to the thickness of the pressure-bonding coating layer 14 to be formed. It is desirable to set the ratio in the following range. Amount of plating abrasive: amount of metal powder = 50: 1 to 3: 1 When the coating thickness is not enough in one press-coating, mixed powder 13 may be added on the way to continue press-coating.
【００１８】上記の混合粉末をドラム１に入れて蓋をし
た後、ドラム１を回転させると、混合粉体が加圧板５と
ドラム１の隙間で加圧され、混合粉体に転動運動が加わ
りつつ互いに擦り合わされる。このような粉体同士の衝
突および摩擦によって各粒子１２，１３の界面に局所的
な発熱および衝撃力、延性力が生じ、金属めっき砥粒１
２の表面に混合粉末１３が団子状に固着する。さらにこ
れら団子状粒子の表面に、隣接する団子状粒子から力が
繰返し加わることにより、前記固着層が延びて偏平化
し、さらに金属めっき層１１に練り込まれて互いに結合
される。After the mixed powder is put into the drum 1 and covered, the drum 1 is rotated. When the mixed powder is pressed in the gap between the pressing plate 5 and the drum 1, the rolling motion is applied to the mixed powder. They rub against each other as they join. Due to the collision and friction between the powders, local heat generation, impact force and ductile force are generated at the interface between the particles 12 and 13, and the metal-plated abrasive grains 1
The mixed powder 13 adheres to the surface of No. 2 in a dumpling shape. Further, the force is repeatedly applied to the surface of the cluster-like particles from the adjacent cluster-like particles, so that the fixing layer is extended and flattened, further kneaded into the metal plating layer 11 and bonded to each other.
【００１９】ドラム１の内面に付着した粉体は掻き取り
アーム４で粉砕され、未付着の混合粉末１３は再び加圧
アーム３でめっき砥粒１２の表面に団子状に固着され
る。この作業を一定時間繰り返すことにより、混合粉末
１３は図３に示すようにめっき砥粒１２の表面に順次圧
着被覆されて被覆層が厚くなり、最終的にはほぼ全量圧
着被覆されて均一な被覆厚さを有する圧着被覆層１４と
なる。同時に、金属被覆砥粒１５の球形化が進み、流動
性が向上する。The powder adhering to the inner surface of the drum 1 is pulverized by the scraping arm 4, and the non-adhered mixed powder 13 is again fixed to the surface of the plating abrasive grains 12 by the pressing arm 3 in a dumpling manner. By repeating this operation for a certain period of time, the mixed powder 13 is successively press-coated on the surface of the plating abrasive grains 12 as shown in FIG. 3 to increase the thickness of the coating layer. It becomes the pressure-bonding coating layer 14 having a thickness. At the same time, the spheres of the metal-coated abrasive grains 15 are advanced, and the fluidity is improved.
【００２０】圧着被覆層を金属種を変えつつ階層的に形
成する必要があれば、ドラム１内に追加する混合粉末の
種類を変えつつ、前記圧着被覆を繰返せば良い。圧着被
覆層１４の厚さは、最終的に形成すべき砥石の結合相の
合金組成および集中度に基づいて決定すべきである。If it is necessary to form the pressure-bonding coating layer in a hierarchical manner while changing the type of metal, the above-mentioned pressure-bonding coating may be repeated while changing the type of the mixed powder added into the drum 1. The thickness of the compression coating layer 14 should be determined based on the alloy composition and concentration of the binder phase of the grinding wheel to be finally formed.
【００２１】上記構成からなる金属被覆砥粒の製造方法
では、砥粒１０に金属めっき層１１を形成する際に無電
解めっき法を使用するものの、その厚さは薄いため短時
間で済むうえ、混合粉を被覆するため、その上に厚い圧
着被覆層１４を短時間で形成することができる。したが
って、厚い被覆層(１１＋１４)が必要な場合にも、全体
としての製造時間を短縮することができ、生産性を高め
て量産を可能とし、製造コストの低減が図れる。In the method for producing metal-coated abrasive grains having the above-described structure, an electroless plating method is used when forming the metal plating layer 11 on the abrasive grains 10, but the thickness is small, so that it can be completed in a short time. Since the mixed powder is coated, a thick pressure-bonded coating layer 14 can be formed thereon in a short time. Therefore, even when a thick coating layer (11 + 14) is required, the overall manufacturing time can be shortened, productivity can be increased, mass production can be performed, and manufacturing costs can be reduced.
【００２２】また、この方法では、無電解めっき法が適
用できない金属種も圧着被覆層１４として砥粒１０の外
周に形成することができ、金属種の選択の自由度を高め
ることが可能であるうえ、金属被覆砥粒１５はほぼ球形
になるため流動性が良く、砥石製造時の取り扱いが容易
になる。また、砥粒が露出していないので、成形時にプ
レス型を痛めないうえ、流動性が良いから金型への自動
充填が可能等の利点もある。Further, according to this method, even a metal type to which the electroless plating method cannot be applied can be formed on the outer periphery of the abrasive grains 10 as the pressure-bonding coating layer 14, and the degree of freedom in selecting the metal type can be increased. In addition, since the metal-coated abrasive grains 15 have a substantially spherical shape, the fluidity thereof is good, and the handling at the time of manufacturing the grindstone becomes easy. In addition, since the abrasive grains are not exposed, there is an advantage that the press die is not damaged at the time of molding and the fluidity is good, so that the mold can be automatically filled.
【００２３】次に、上記金属被覆砥粒１５を用いたメタ
ルボンド砥石の第一の製造方法を説明する。この方法で
は、金属被覆砥粒１５を台金とともに型込めし、圧粉成
形および焼結を行う。すると、個々の圧着被覆層１４中
の低融点金属が溶融し、圧着被覆層１４間で拡散反応が
進み、図４に示すように各被覆層１４が相互に強固に結
合して結合相が形成され、金属被覆砥粒１５間の境界は
消失する。Next, a first method of manufacturing a metal-bonded grindstone using the metal-coated abrasive grains 15 will be described. In this method, the metal-coated abrasive grains 15 are molded together with the base metal, and compacting and sintering are performed. Then, the low-melting-point metal in each of the pressure-bonding coating layers 14 melts, a diffusion reaction proceeds between the pressure-bonding coating layers 14, and the coating layers 14 are firmly bonded to each other as shown in FIG. As a result, the boundary between the metal-coated abrasive grains 15 disappears.
【００２４】使用する台金および砥粒層の形状は、従来
実用化されているいかなる形状であってもよい。台金を
使用せず、砥石全体が砥粒層のみで構成されている砥石
も製造可能である。成形時のプレス条件や加熱条件は従
来と同様でよく、圧粉成形および焼結にはホットプレス
法等も含まれる。成形・焼結は大気中でも可能である
が、焼結性を高める点から、不活性あるいは還元性雰囲
気がより好ましい。The shapes of the base metal and the abrasive grain layer to be used may be any conventionally used shapes. A grindstone in which the whole grindstone is composed only of the abrasive grain layer without using a base metal can also be manufactured. Pressing conditions and heating conditions during molding may be the same as those in the related art, and the green compacting and sintering include a hot press method and the like. Although molding and sintering can be performed in the air, an inert or reducing atmosphere is more preferable from the viewpoint of enhancing sinterability.
【００２５】上記第１のメタルボンド砥石の製造方法に
よれば、図４に示すように砥粒１０同士の間隔が砥粒層
の全域に亙ってほぼ等しく、砥粒１０の分布密度が均一
なメタルボンド砥粒層が形成できる。したがって、砥粒
と結合剤粉末とを混合する従来の製造方法に比して、研
削面における砥粒１０の露出密度が均一になるため、研
削面の全域に亙って切れ味が一定になり、良好な被削材
面粗さが得られるとともに、研削むらや砥石の異常振動
が生じにくく、良好かつ安定した研削性能が得られる。According to the first method of manufacturing a metal-bonded grindstone, as shown in FIG. 4, the intervals between the abrasive grains 10 are substantially equal over the entire area of the abrasive grain layer, and the distribution density of the abrasive grains 10 is uniform. A metal bond abrasive grain layer can be formed. Therefore, compared with the conventional manufacturing method of mixing the abrasive grains and the binder powder, the exposure density of the abrasive grains 10 on the ground surface becomes uniform, so that the sharpness becomes constant over the entire area of the ground surface, Good work surface roughness can be obtained, and uneven grinding and abnormal vibration of the grindstone hardly occur, and good and stable grinding performance can be obtained.
【００２６】また、金属結合相１４による砥粒１０の保
持力が均一になるため、砥粒１０の無駄な脱落を防い
で、砥石寿命の延長が図れる。しかも上記の各効果は、
砥粒の集中度を高めた場合に一層顕著になるため、従来
では製造困難な高集中度のメタルボンド砥石が製造可能
である。さらにこの方法では、砥粒１０の外周に金属混
合粉末１３をそのまま被覆するため、異種の金属を多層
状に形成した場合に比して被覆状態の均一性にも優れ、
焼結性も高い。Further, since the holding force of the abrasive grains 10 by the metal bonding phase 14 becomes uniform, the abrasive grains 10 are prevented from being uselessly dropped, and the life of the grinding wheel can be extended. And each of the above effects,
Since it becomes more remarkable when the concentration of the abrasive grains is increased, it is possible to manufacture a metal bond grindstone with a high concentration, which is conventionally difficult to manufacture. Further, in this method, the outer periphery of the abrasive grains 10 is coated with the metal mixed powder 13 as it is, so that the uniformity of the coating state is excellent as compared with a case where different kinds of metals are formed in a multilayer shape,
High sinterability.
【００２７】なお、前記金属被覆砥粒の製造方法におい
て、各圧着被覆層１４の形成時に混合粉末１３に各種フ
ィラーを添加しておいてもよい。その場合には、成形後
の砥石にフィラー種に応じた機能を付与することが可能
である。In the above-described method for producing metal-coated abrasive grains, various fillers may be added to the mixed powder 13 at the time of forming each pressure-bonded coating layer 14. In that case, it is possible to impart a function according to the filler type to the formed grinding wheel.
【００２８】例えば、フィラーとしてカーボン粉を混合
粉末１３に混合し、圧着被覆層１４を形成すれば、最終
的に得られた砥石を研削に使用した際に、研削面に徐々
にカーボン粉が供給されるため、潤滑性や砥粒の自生発
刃作用を高めることができる。For example, if carbon powder is mixed with the mixed powder 13 as a filler to form the pressure-bonded coating layer 14, the carbon powder is gradually supplied to the ground surface when the finally obtained grindstone is used for grinding. Therefore, it is possible to enhance the lubricating property and the action of spontaneous cutting of the abrasive grains.
【００２９】また、圧着被覆層１４にＳｉＣやＡｌ2Ｏ3
等の硬質粒子をフィラーとして添加すると、砥粒層の内
部において個々の砥粒１０の周囲に重点的にフィラーを
均一配置することができるから、砥粒周囲の結合相の耐
摩耗性が高まり、砥粒保持力が向上して砥石寿命の延長
が図れる。Further, the pressure bonding coating layer 14 is made of SiC or Al 2 O 3
When hard particles such as are added as fillers, the fillers can be arranged uniformly around the individual abrasive grains 10 inside the abrasive grain layer, so that the wear resistance of the binder phase around the abrasive grains increases, The abrasive grain holding power is improved, and the life of the grinding wheel can be extended.
【００３０】また、金属粉末にＰ，Ｃ，Ｓ等の還元剤粉
末を添加してからめっき砥粒に圧着被覆し、還元剤を含
んだ金属被覆層を形成してもよい。こうすると、金属被
覆砥粒の焼結時に粒界面に生ずる表面酸化を還元して、
焼結性の向上が図れる。例えばＰを用いる場合には、混
合粉末１３に赤リン粉末を添加して圧着作業を行い、赤
リン粉末を圧着被覆層１４に取り込ませる。混合粉末１
３中の還元性物質の添加量は、焼結性の改善要求度、焼
結時におけるリン化物形成による金属層の硬さ向上との
関係で一概には特定できないが、一般には０．０１％〜
５％程度が好ましい。Further, a metal coating layer containing a reducing agent may be formed by adding a reducing agent powder such as P, C, S, etc. to the metal powder and then press-coating the plating abrasive grains. This reduces the surface oxidation that occurs at the grain interface during sintering of the metal-coated abrasive grains,
Sinterability can be improved. For example, when P is used, red phosphorus powder is added to the mixed powder 13 to perform compression bonding, and the red phosphorus powder is incorporated into the compression coating layer 14. Mixed powder 1
The amount of the reducing substance added in 3 cannot be specified unconditionally in relation to the required degree of improvement in sinterability and the improvement in hardness of the metal layer due to phosphide formation during sintering, but is generally 0.01%. ~
About 5% is preferable.
【００３１】また、圧着被覆層１４に還元剤粉末を添加
する代わりに、金属被覆砥粒１５の外周に還元性物質を
含有する還元性物質層を別途、圧着被覆してもよい。Instead of adding the reducing agent powder to the pressure-bonding coating layer 14, a reducing substance layer containing a reducing substance may be separately pressure-coated on the outer periphery of the metal-coated abrasive grains 15.
【００３２】本発明に係る第２のメタルボンド砥石の製
造方法としては、金属被覆砥粒をパラフィンワックス，
ポリビニルアルコール，アクリル樹脂等の樹脂結合剤と
混練した後、射出成形装置を用いてこの混練物を樹脂結
合剤の溶融温度以上に加熱し、射出成形してメタルボン
ド砥石を製造する方法も可能である。砥粒そのものを樹
脂結合剤に添加して射出成形することは、砥粒が射出成
形機のノズルを損傷するため不可能であるが、本発明の
金属被覆砥粒では、砥粒が厚い金属被覆層で覆われてい
るため、流動性が良好であるうえ、ノズルを損傷するお
それがなく、比較的少量の樹脂結合剤の添加で射出成形
が可能である。具体的な樹脂結合剤の添加量としては
０．５〜２０ｖｏｌ％程度が好適である。As a second method of manufacturing a metal-bonded grindstone according to the present invention, a metal-coated abrasive is made of paraffin wax,
After kneading with a resin binder such as polyvinyl alcohol and acrylic resin, the kneaded product is heated to a temperature equal to or higher than the melting temperature of the resin binder using an injection molding apparatus, and injection molding is performed to produce a metal bond grindstone. is there. Injection molding by adding the abrasive grains themselves to the resin binder is impossible because the abrasive grains damage the nozzle of the injection molding machine.However, with the metal-coated abrasive grains of the present invention, the abrasive grains have a thick metal coating. Since it is covered with the layer, the fluidity is good, and there is no risk of damaging the nozzle. Injection molding is possible by adding a relatively small amount of a resin binder. A specific amount of the resin binder to be added is preferably about 0.5 to 20 vol%.
【００３３】なお、本発明に係る金属被覆砥粒の製造方
法により得られた金属被覆砥粒１５の使用方法は、上記
２種の砥石製造方法に限定されない。例えば、金属被覆
砥粒１５を金属粉末，樹脂粉末，ガラス粉末等の各種結
合剤粉末と混合し、従来通りの方法でメタルボンド砥
石，レジンボンド砥石，ビトリファイドボンド砥石を成
形してもよい。この場合にも、砥粒層中における砥粒１
０の分散性および砥粒保持力を高める効果が得られる。
また、金属被覆砥粒をプレス成形する代わりに、押出し
成形することも可能である。The method of using the metal-coated abrasive grains 15 obtained by the method for producing metal-coated abrasive grains according to the present invention is not limited to the above-described two types of grinding stone manufacturing methods. For example, the metal-coated abrasive grains 15 may be mixed with various binder powders such as a metal powder, a resin powder, and a glass powder to form a metal bond grindstone, a resin bond grindstone, and a vitrified bond grindstone by a conventional method. Also in this case, the abrasive 1 in the abrasive layer
The effect of increasing the dispersibility of 0 and the abrasive grain holding power is obtained.
Further, instead of press-forming the metal-coated abrasive grains, it is also possible to carry out extrusion-forming.
【００３４】[0034]
【実施例】次に、本発明の実施例を挙げて効果を実証す
る。 （実施例１）ダイヤモンド粉末（粒径４０〜６０μｍ）
に無電解Ｃｕめっきを行ってダイヤモンド粉末と同じ総
重量のＣｕ被覆を形成し、Ｃｕめっきダイヤモンド砥粒
を作成した。図５は、このＣｕめっきダイヤモンド砥粒
を示す拡大写真である。EXAMPLES Next, the effects will be demonstrated with reference to examples of the present invention. (Example 1) Diamond powder (particle size: 40 to 60 µm)
Was subjected to electroless Cu plating to form a Cu coating having the same total weight as the diamond powder, thereby producing Cu-plated diamond abrasive grains. FIG. 5 is an enlarged photograph showing the Cu-plated diamond abrasive grains.
【００３５】このＣｕめっきダイヤモンド砥粒１５０ｇ
を図１に示す装置に投入し、さらに図６に示すＳｎ粉末
（平均粒径５μｍ）を３０ｇ、および図７に示すＣｕ粉
末２００ｇ（平均粒径５μｍ）を投入して混合した後、
蓋をして加圧アーム３とドラム１の距離０．２ｍｍ、ド
ラム１の回転数１０００ｒｐｍの条件で３０分間被覆処
理し、最終的に２８０ｇの金属被覆砥粒を得た。This Cu-plated diamond abrasive 150 g
Was charged into the apparatus shown in FIG. 1 and 30 g of the Sn powder (average particle size 5 μm) shown in FIG. 6 and 200 g of Cu powder (average particle size 5 μm) shown in FIG.
The lid was covered, and coating was performed for 30 minutes under the conditions of a distance of 0.2 mm between the pressure arm 3 and the drum 1 and a rotation speed of the drum 1 of 1000 rpm, to finally obtain 280 g of metal-coated abrasive grains.
【００３６】得られた金属被覆砥粒は球形化しており、
良好な流動性を示した。その組成比を湿式分析した結
果、重量比で ダイヤ：Ｃｕ：Ｓｎ＝１：８．７１：１．１２ であった。The obtained metal-coated abrasive grains are spherical,
It showed good fluidity. As a result of wet analysis of the composition ratio, the weight ratio was diamond: Cu: Sn = 1: 8.71: 1.12.
【００３７】このＣｕめっきダイヤモンド砥粒を用い
て、外径φ１４４ｍｍ、内径φ４０ｍｍ、厚さ７ｍｍの
低炭素鋼（ＳＳ４１）の外周に厚さ３ｍｍのメタルボン
ド砥粒層を形成し、実施例１のメタルボンド砥石を得
た。形成条件は次の通りである。台金を金型内にセット
した後、その外周に沿って金属被覆砥粒を充填し、常温
で５ｔｏｎ／ｃｍ2 の圧力をかけ５分間コールドプレス
した。次にホットプレスにより、圧力０．５ｔｏｎ／ｃ
ｍ2 、温度６００℃、窒素−水素混合気（１：１）雰囲
気下で１時間焼結し、実施例１の無気孔メタルボンド砥
石を作成した。Using this Cu-plated diamond abrasive, a 3-mm thick metal bond abrasive layer was formed on the outer periphery of low carbon steel (SS41) having an outer diameter of 144 mm, an inner diameter of 40 mm, and a thickness of 7 mm. A metal bond whetstone was obtained. The forming conditions are as follows. After the base metal was set in the mold, metal-coated abrasive grains were filled along the periphery thereof, and a pressure of 5 ton / cm 2 was applied at room temperature and cold pressed for 5 minutes. Next, by hot pressing, pressure 0.5 ton / c
Sintering was performed for 1 hour in an atmosphere of nitrogen-hydrogen gas mixture (1: 1) at m 2 , at a temperature of 600 ° C., to produce a non-porous metal-bonded grindstone of Example 1.
【００３８】（実施例２）前記金属被覆砥粒を用いて、
実施例１と同じ台金とともに金型内で２００ｋｇ／ｃｍ
2 の圧力で５分間コールドプレスした後、温度６００℃
の窒素−水素（１：１）雰囲気下で２４時間焼結（フリ
ーシンター）して、実施例２のメタルボンド砥石を作成
した。この実施例２の砥石の砥粒層気孔率は２３％であ
った。Example 2 Using the above metal-coated abrasive grains,
200 kg / cm in a mold with the same base as in Example 1.
After cold pressing at a pressure of 2 for 5 minutes, the temperature is 600 ° C.
Under a nitrogen-hydrogen (1: 1) atmosphere for 24 hours (free sintering) to produce a metal-bonded grindstone of Example 2. The porosity of the abrasive layer of the grindstone of Example 2 was 23%.
【００３９】（比較例１）前記と同じダイヤモンド粉
末、Ｓｎ粉およびＣｕ粉を、実施例１と同じ重量百分率
で充分混合した後、実施例１と同じ条件でコールドプレ
スおよびホットプレスを行い、実施例１と同形状、同組
成のメタルボンド砥石を作成した。(Comparative Example 1) After the same diamond powder, Sn powder and Cu powder as described above were thoroughly mixed at the same weight percentage as in Example 1, cold pressing and hot pressing were performed under the same conditions as in Example 1. A metal bond grindstone having the same shape and composition as in Example 1 was produced.
【００４０】（比較実験）前記のようにして得られた実
施例１，２および比較例１の各メタルボンド砥石にトル
ーイングおよびドレッシングを施した後、以下に示す研
削条件でガラス研削試験を行った。 研削試験条件 砥石形状：１Ａ１型 φ１５０ｍｍ×厚さ７ｍｍ 研削様式：平面研削 被削材 ：ガラス 試験機 ：岡本 ６３Ａ 周速度 ：１５００ｍ／mｉｎ テーブル送り：１０ｍ／mｉｎ 切込み速度 ：０．１ｍｍ／サイクル（０〜１００cc） ０．１５ｍｍ／サイクル（１００〜３００cc） 研削液 ：ＪＥ２２０(Comparative Experiment) Each of the metal bond grindstones of Examples 1 and 2 and Comparative Example 1 obtained as described above was subjected to truing and dressing, and then a glass grinding test was performed under the following grinding conditions. . Grinding test conditions Grinding stone shape: 1A1 type φ150mm x thickness 7mm Grinding style: Surface grinding Work material: Glass Testing machine: Okamoto 63A Circumferential speed: 1500m / min Table feed: 10m / min Cutting speed: 0.1mm / cycle (0 0.15mm / cycle (100-300cc) Grinding fluid: JE220
【００４１】その結果を表１に示す。実施例１の砥石で
は、摩耗による形状くずれが比較例１より小さかった。
実施例２の砥石では気孔が２３％存在するため、研削抵
抗が比較例１の６４％に抑えられた。また、実施例１，
２の砥石では表１に示すように研削後の被削材の面粗さ
が小さく、比較例１に比して良好な研削性能を示した。Table 1 shows the results. In the whetstone of Example 1, the shape deformation due to abrasion was smaller than that of Comparative Example 1.
Since the grindstone of Example 2 had 23% of the pores, the grinding resistance was suppressed to 64% of Comparative Example 1. Example 1,
As shown in Table 1, the grindstone No. 2 had a small surface roughness of the work material after grinding, and showed better grinding performance than Comparative Example 1.
【００４２】[0042]
【表１】 [Table 1]
【００４３】実施例１および比較例１の砥石表面につ
き、Ｘ線走査型マイクロアナライザーを使用して、反射
電子線像、Ｃｕ−Ｋα線像、Ｓｎ−Ｌα線像をそれぞれ
作成した。図８ないし図１０はそれぞれ実施例１の反射
電子線像、Ｃｕ−Ｋα線像、Ｓｎ−Ｌα線像であり、図
１１ないし図１３はそれぞれ比較例１の反射電子線像、
Ｃｕ−Ｋα線像、Ｓｎ−Ｌα線像である。Using the X-ray scanning microanalyzer, a backscattered electron beam image, a Cu-Kα ray image, and a Sn-Lα ray image were formed on the grindstone surfaces of Example 1 and Comparative Example 1. 8 to 10 are a backscattered electron beam image, a Cu-Kα line image, and a Sn-Lα line image of Example 1, respectively. FIGS. 11 to 13 are a backscattered electron beam image of Comparative Example 1, respectively.
It is a Cu-Kα ray image and a Sn-Lα ray image.
【００４４】写真から明らかなように、実施例１の砥石
ではＣｕ，Ｓｎがミクロ的に均一に分散しているのに対
し、比較例１の砥石では、図１３に顕著なように、数百
μｍの大きさのＳｎプール（Ｓｎ高濃度領域）が認めら
れ、組織は不均一であった。As is clear from the photograph, Cu and Sn were microscopically and uniformly dispersed in the grindstone of Example 1, whereas several hundreds were observed in the grindstone of Comparative Example 1, as is remarkable in FIG. A Sn pool (Sn high concentration region) having a size of μm was observed, and the tissue was heterogeneous.
【００４５】次に、本発明に係る金属被覆砥粒の製造方
法の効果を実証するため、以下のような実験を行った。
なおこの実験では、ダイヤモンド砥粒に圧着金属被覆層
を形成すると金属被覆砥粒を研磨して断面を観察できな
いため、ダイヤモンド砥粒に変えて、研磨の容易なＮｉ
粒子（５０μｍ）あるいはＣｕ粒子（７０μｍ）を疑似
砥粒として使用した。Next, in order to verify the effect of the method for producing metal-coated abrasive grains according to the present invention, the following experiment was conducted.
In this experiment, when a pressure-bonded metal coating layer was formed on diamond abrasive grains, the metal-coated abrasive grains could not be polished and the cross-section could not be observed.
Particles (50 μm) or Cu particles (70 μm) were used as pseudo abrasives.
【００４６】（実施例３）平均粒径５０μｍのＮｉ粒子
（疑似砥粒）、平均粒径５μｍの微細Ｃｕ粉、平均粒径
５μｍの微細Ｓｕ粉を図１の装置に投入し、軽く混合し
たのち、蓋をして加圧アーム３とドラム１の距離を１ｍ
ｍ、ドラム１の回転数を１０００ｒｐｍの条件で６０分
間摩擦圧接を行い、被覆層を形成した。微細Ｃｕ粉と微
細Ｓｎの混合割合は、重量比で１０：３とした。Example 3 Ni particles (pseudo-abrasive grains) having an average particle diameter of 50 μm, fine Cu powder having an average particle diameter of 5 μm, and fine Su powder having an average particle diameter of 5 μm were put into the apparatus shown in FIG. 1 and mixed gently. Then, close the lid and set the distance between the pressure arm 3 and the drum 1 to 1 m.
Then, friction welding was performed for 60 minutes under the conditions of the rotation speed of the drum 1 at 1000 rpm for 60 minutes to form a coating layer. The mixing ratio of the fine Cu powder and the fine Sn was 10: 3 by weight.
【００４７】（比較例２）前記Ｎｉ粒子（疑似砥粒）
に、第１層目として前記微細Ｓｎ粒子のみを圧着被覆
し、次いで第２層目として前記微細Ｃｕ粒子のみを圧着
被覆し、さらに第３層目として微細Ｓｎ粒子のみを圧着
被覆し、３層構造の被覆を形成した。微細Ｃｕ粉と微細
Ｓｎ粉の混合割合は実施例３と同様に重量比で１０：３
とした。(Comparative Example 2) The Ni particles (pseudo abrasive grains)
Then, only the fine Sn particles are pressure-coated as the first layer, then only the fine Cu particles are pressure-coated as the second layer, and only the fine Sn particles are pressure-coated as the third layer. A coating of the structure was formed. The mixing ratio of the fine Cu powder and the fine Sn powder was 10: 3 in weight ratio as in Example 3.
And
【００４８】実施例３および比較例２の金属被覆疑似砥
粒を、樹脂に埋込んで研磨し、その断面につき、Ｘ線走
査型マイクロアナライザーを使用して、反射電子線像、
Ｃｕ−Ｋα線像、Ｓｎ−Ｌα線像をそれぞれ作成した。
図１４ないし図１６はそれぞれ実施例３の反射電子線
像、Ｃｕ−Ｋα線像、Ｓｎ−Ｌα線像であり、図１７な
いし図１９はそれぞれ比較例２の反射電子線像、Ｃｕ−
Ｋα線像、Ｓｎ−Ｌα線像である。これらの結果より、
ＣｕおよびＳｎを混合被覆した実施例３の方が、Ｃｕお
よびＳｎを別個に積層被覆した比較例２に比べ、各金属
が均一に分散していることがわかる。The metal-coated pseudo-abrasive grains of Example 3 and Comparative Example 2 were buried in a resin and polished, and the cross-section thereof was subjected to reflection electron beam imaging using an X-ray scanning microanalyzer.
A Cu-Kα ray image and a Sn-Lα ray image were created.
14 to 16 are a backscattered electron beam image, a Cu-Kα line image, and a Sn-Lα line image of Example 3, respectively. FIGS. 17 to 19 are a backscattered electron beam image and Cu-
It is a Kα ray image and a Sn-Lα ray image. From these results,
It can be seen that the metal of Example 3 in which Cu and Sn were mixed and coated was more uniform than that of Comparative Example 2 in which Cu and Sn were separately coated.
【００４９】（実施例４）平均粒径７０μｍのＣｕ粒子
（疑似砥粒）に、Ｃｕ，Ａｇ，ＳｎおよびＣｏの混合粉
末を被覆した。これら被覆用金属粉はいずれもミクロン
オーダーの粒径を有し、それぞれの被覆重量の割合は、
Ｃｕ：Ａｇ：Ｓｎ：Ｃｏ＝４０：１０：３０：２０に設
定した。Example 4 Cu particles (pseudo abrasive grains) having an average particle size of 70 μm were coated with a mixed powder of Cu, Ag, Sn and Co. Each of these metal powders for coating has a particle size on the order of microns, and the proportion of each coating weight is
Cu: Ag: Sn: Co = 40: 10: 30: 20 was set.
【００５０】得られた金属被覆疑似砥粒を樹脂に埋込ん
で研磨し、断面のＥＰＭＡ分析を行なうことにより、各
被覆用金属の分布を測定した。結果を図２０〜図２４に
示す。相対的に軟質な金属であるＣｕ，Ｓｎ，Ａｇの存
在により、相対的な硬質粒子であるＣｏ粒子が均一分散
被覆されていることがわかる。本発明者らの実験では、
Ｃｏ単独での圧着被覆では非常に収率が悪く、被覆率の
コントロールが難しいことが分かっている。The obtained metal coating pseudo-abrasive grains were buried in a resin and polished, and the distribution of each coating metal was measured by conducting EPMA analysis of the cross section. The results are shown in FIGS. It can be seen that the presence of Cu, Sn, and Ag, which are relatively soft metals, allows Co particles, which are relatively hard particles, to be uniformly dispersed and coated. In our experiments,
It has been found that the press-coating of Co alone has a very low yield and it is difficult to control the coverage.
【００５１】図２５および図２６は、前記結果から判明
した本発明の金属被覆砥粒の製造方法による被覆状態を
示し、図２５は、相対的に軟質な金属粒子によって相対
的に硬質な金属が取り込まれた状態で被覆されている状
態を示す概念図、図２６は、延性のないセラミックス粒
子が、相対的に軟質な金属粒子によって取り込まれた状
態で被覆されている状態を示す概念図である。FIGS. 25 and 26 show the state of coating by the method for producing metal-coated abrasive grains of the present invention, which has been found from the above results. FIG. FIG. 26 is a conceptual diagram showing a state in which ceramic particles having no ductility are covered in a state in which they are taken in by relatively soft metal particles. .
【００５２】[0052]
【発明の効果】以上説明したように、本発明に係る金属
被覆砥粒の製造方法によれば、砥粒に薄い金属めっき層
を形成した後、その上に厚い圧着被覆層を短時間で形成
することができるため、厚い被覆層が必要な場合にも全
体としての製造時間を短縮することができ、生産性を高
めて量産が可能であり、製造コストの低減が図れる。As described above, according to the method for producing metal-coated abrasive grains according to the present invention, after a thin metal plating layer is formed on the abrasive grains, a thick pressure-bonded coating layer is formed thereon in a short time. Therefore, even when a thick coating layer is required, the overall manufacturing time can be shortened, productivity can be increased, mass production can be performed, and manufacturing cost can be reduced.
【００５３】また、この方法によれば、無電解めっき法
が適用できない金属種も圧着被覆層として容易に形成す
ることができ、金属種の選択の自由度を高めることが可
能である。さらに、得られる金属被覆砥粒は球状になる
ため、流動性が良く、砥石製造時の取り扱いが容易であ
る。また、相対的に軟質な展延性に優れる金属種が、相
対的に硬質な金属粒子を取り込んで砥粒外周に被覆され
るため、圧着被覆の困難な硬質金属粒子やフィラー粒子
も容易に被覆できる。Further, according to this method, even a metal type to which the electroless plating method cannot be applied can be easily formed as the pressure-bonding coating layer, and the degree of freedom in selecting the metal type can be increased. Furthermore, since the obtained metal-coated abrasive grains are spherical, they have good fluidity and are easy to handle during the manufacture of the grinding stone. In addition, since relatively soft metal species having excellent spreadability take in relatively hard metal particles and are coated on the periphery of the abrasive grains, hard metal particles and filler particles that are difficult to apply by pressure bonding can be easily coated. .
【００５４】さらに、金属粉末に含まれる相対的に軟質
な金属種が、金属めっき層を構成する金属種よりも柔軟
である場合には、混合粉末がめっき砥粒に固着しやす
く、圧着被覆層の形成が容易に行なえる。Further, when the relatively soft metal species contained in the metal powder is more flexible than the metal species constituting the metal plating layer, the mixed powder easily adheres to the plating abrasive grains, and the pressure coating layer Can be easily formed.
【００５５】一方、本発明に係る金属被覆砥粒およびそ
れを用いたメタルボンド砥石の製造方法によれば、得ら
れた砥石における砥粒同士の間隔が砥粒層の全域に亙っ
てほぼ等しく、砥粒の分布密度が均一になるため、砥粒
と結合剤粉末を混合する従来の製造方法に比して、研削
面における砥粒の露出密度が均一化できる。これによ
り、研削面の全域で切れ味が一定になるから、良好な仕
上げ面粗さが得られるとともに、研削むらや砥石の異常
振動が生じにくく、良好かつ安定した研削性能が得られ
る。また、金属結合相による砥粒保持力が均一になるた
め、砥粒の無駄な脱落を防いで、砥石寿命の延長が図れ
るという利点も有する。On the other hand, according to the metal-coated abrasive grains of the present invention and the method of manufacturing a metal-bonded grinding wheel using the same, the intervals between the abrasive grains in the obtained grindstone are substantially equal over the entire area of the abrasive grain layer. Since the distribution density of the abrasive grains becomes uniform, the exposure density of the abrasive grains on the ground surface can be made uniform as compared with the conventional manufacturing method in which the abrasive grains and the binder powder are mixed. As a result, the sharpness is constant over the entire area of the ground surface, so that a good finished surface roughness can be obtained, and uneven grinding and abnormal vibration of the whetstone are less likely to occur, and good and stable grinding performance can be obtained. In addition, since the holding power of the abrasive grains by the metal bonding phase becomes uniform, there is an advantage that the abrasive grains can be prevented from falling off wastefully and the life of the grinding stone can be extended.
【００５６】また、砥粒の外周に複数の金属粉末を用い
て均一な分散圧着被覆層を形成しているため、各金属種
同士の単位体積当たりの接触面積が広く、焼結時にはこ
れら金属種が効果的に反応しあい、均一な合金組織が形
成できる。さらに、変形可能な金属被覆層を砥粒表面に
有するため成形性が良好であるうえ、加圧成形条件や焼
結条件の調整により、気孔率の高い砥粒層から気孔の全
くない砥粒層まで容易に製作可能である。Further, since a uniform dispersed pressure bonding coating layer is formed using a plurality of metal powders on the outer periphery of the abrasive grains, the contact area per unit volume of each metal type is wide, and these metal types are sintered during sintering. React effectively and a uniform alloy structure can be formed. Furthermore, since the surface of the abrasive grains has a deformable metal coating layer, the formability is good. In addition, by adjusting the pressure forming conditions and sintering conditions, the abrasive layer having a high porosity can be changed to an abrasive layer having no pores. It can be easily manufactured.
【００５７】一方、金属被覆砥粒の外周に還元性物質層
を設けた場合には、圧粉および焼結時に被覆層が相互に
融着しやすくなり、焼結性が向上する。On the other hand, when the reducing substance layer is provided on the outer periphery of the metal-coated abrasive grains, the coating layers are easily fused to each other at the time of compacting and sintering, and the sinterability is improved.
【００５８】さらに、金属混合粉末にフィラーを添加し
た場合には、砥粒層の内部で個々の砥粒の周囲にフィラ
ーを均一に分散配置することができ、成形後の砥石にそ
れに基づく機能を効果的に付与することが可能である。Further, when a filler is added to the metal mixed powder, the filler can be uniformly dispersed around the individual abrasive grains inside the abrasive grain layer, and the function based on the grinding wheel after molding can be obtained. It can be provided effectively.
【図１】本発明の金属被覆砥粒の製造方法に使用される
装置の説明図である。FIG. 1 is an explanatory view of an apparatus used for a method for producing metal-coated abrasive grains of the present invention.
【図２】圧着被覆前の金属めっき砥粒と金属粉末の混合
状態を示す拡大図である。FIG. 2 is an enlarged view showing a mixed state of metal plating abrasive grains and metal powder before pressure coating.
【図３】圧着被覆により得られた金属被覆砥粒の拡大図
である。FIG. 3 is an enlarged view of metal-coated abrasive grains obtained by pressure coating.
【図４】金属被覆砥粒を成形して得られた砥粒層の組織
図である。FIG. 4 is a structural diagram of an abrasive layer obtained by molding metal-coated abrasive grains.
【図５】本発明の実施例で得られた銅めっき砥粒の拡大
写真である。FIG. 5 is an enlarged photograph of a copper-plated abrasive grain obtained in an example of the present invention.
【図６】実施例で使用したＳｎ粉末を示す拡大写真であ
る。FIG. 6 is an enlarged photograph showing Sn powder used in Examples.
【図７】実施例で使用したＣｕ粉末を示す拡大写真であ
る。FIG. 7 is an enlarged photograph showing Cu powder used in Examples.
【図８】実施例１の砥粒層表面の反射電子像を示す写真
である。FIG. 8 is a photograph showing a backscattered electron image of the surface of the abrasive grain layer of Example 1.
【図９】実施例１の砥粒層表面のＸ線（Ｃｕ−Ｋα線）
像を示す写真である。FIG. 9 is an X-ray (Cu-Kα ray) on the surface of the abrasive grain layer in Example 1.
It is a photograph showing an image.
【図１０】実施例１の砥粒層表面のＸ線（Ｓｎ−Ｌα
線）像を示す写真である。FIG. 10 shows an X-ray (Sn-Lα) of the surface of the abrasive grain layer of Example 1.
(Line) is a photograph showing an image.
【図１１】比較例１の砥粒層表面の反射電子像を示す写
真である。FIG. 11 is a photograph showing a backscattered electron image of the surface of the abrasive grain layer of Comparative Example 1.
【図１２】比較例１の砥粒層表面のＸ線（Ｃｕ−Ｋα
線）像を示す写真である。FIG. 12 shows an X-ray (Cu-Kα) of the surface of the abrasive layer of Comparative Example 1.
(Line) is a photograph showing an image.
【図１３】比較例１の砥粒層表面のＸ線（Ｓｎ−Ｌα
線）像を示す写真である。FIG. 13 shows an X-ray (Sn-Lα) of the surface of the abrasive layer of Comparative Example 1.
(Line) is a photograph showing an image.
【図１４】実施例３の砥粒断面の反射電子像を示す写真
である。FIG. 14 is a photograph showing a backscattered electron image of an abrasive grain cross section of Example 3.
【図１５】実施例３の砥粒断面のＸ線（Ｃｕ−Ｋα線）
像を示す写真である。FIG. 15 is an X-ray (Cu-Kα ray) of an abrasive grain cross section of Example 3.
It is a photograph showing an image.
【図１６】実施例３の砥粒断面のＸ線（Ｓｎ−Ｌα線）
像を示す写真である。FIG. 16 is an X-ray (Sn-Lα ray) of the abrasive grain cross section of Example 3.
It is a photograph showing an image.
【図１７】比較例２の砥粒断面の反射電子像を示す写真
である。17 is a photograph showing a backscattered electron image of a cross section of an abrasive grain of Comparative Example 2. FIG.
【図１８】比較例２の砥粒断面のＸ線（Ｃｕ−Ｋα線）
像を示す写真である。FIG. 18 is an X-ray (Cu-Kα ray) of a cross section of an abrasive grain of Comparative Example 2.
It is a photograph showing an image.
【図１９】比較例２の砥粒断面のＸ線（Ｓｎ−Ｌα線）
像を示す写真である。FIG. 19 is an X-ray (Sn-Lα line) of a cross section of an abrasive grain of Comparative Example 2.
It is a photograph showing an image.
【図２０】実施例４の砥粒断面の反射電子像を示す写真
である。FIG. 20 is a photograph showing a backscattered electron image of a cross section of an abrasive grain of Example 4.
【図２１】実施例４の砥粒断面のＸ線（Ｃｕ−Ｋα線）
像を示す写真である。FIG. 21 is an X-ray (Cu-Kα ray) of an abrasive grain cross section in Example 4.
It is a photograph showing an image.
【図２２】実施例４の砥粒断面のＸ線（Ｓｎ−Ｌα線）
像を示す写真である。FIG. 22 is an X-ray (Sn-Lα ray) of a cross section of an abrasive grain of Example 4.
It is a photograph showing an image.
【図２３】実施例４の砥粒断面のＸ線（Ａｇ−Ｌα線）
像を示す写真である。FIG. 23 is an X-ray (Ag-Lα ray) of an abrasive grain cross section of Example 4.
It is a photograph showing an image.
【図２４】実施例４の砥粒断面のＸ線（Ｃｏ−Ｌα線）
像を示す写真である。24 is an X-ray (Co-Lα ray) of a cross section of an abrasive grain of Example 4. FIG.
It is a photograph showing an image.
【図２５】本発明の金属被覆砥粒の製造方法による被覆
状態を示す概念図である。FIG. 25 is a conceptual diagram showing a coated state by the method for producing metal-coated abrasive grains of the present invention.
【図２６】本発明の金属被覆砥粒の製造方法による被覆
状態を示す概念図である。FIG. 26 is a conceptual diagram showing a coated state according to the method for producing metal-coated abrasive grains of the present invention.
１ ドラム ２ 固定シャフト ３ 加圧アーム ４ 掻き取りアーム ５ 加圧板 １０ 砥粒 １１ 金属めっき層 １２ めっき砥粒 １３ 混合粉末 １４ 圧着被覆層 １５ 金属被覆砥粒 DESCRIPTION OF SYMBOLS 1 Drum 2 Fixed shaft 3 Pressure arm 4 Scraping arm 5 Pressure plate 10 Abrasive grain 11 Metal plating layer 12 Plating abrasive grain 13 Mixed powder 14 Compression coating layer 15 Metal coating abrasive
───────────────────────────────────────────────────── フロントページの続き (72)発明者 飯塚 弘明 埼玉県大宮市北袋町１丁目297番地 三 菱マテリアル株式会社 中央研究所内 (72)発明者 長田 正信 福島県いわき市泉町黒須野字江越246− １ 三菱マテリアル株式会社 いわき製 作所内 (56)参考文献 特開 平４−354801（ＪＰ，Ａ) (58)調査した分野(Int.Cl.7，ＤＢ名) C23C 24/06 B22F 1/02 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Hiroaki Iizuka 1-297 Kitabukurocho, Omiya City, Saitama Prefecture, Central Research Laboratory, Mitsui Materials Co., Ltd. 1 Mitsubishi Materials Corporation Iwaki Works (56) References JP-A-4-354801 (JP, A) (58) Fields investigated (Int. Cl. 7 , DB name) C23C 24/06 B22F 1/02
Claims (9)
し圧着被覆してなる厚さ５μｍ以上の被覆層を設け、前
記被覆層は、少なくとも１種以上の相対的に軟質な金属
の粉末と、少なくとも１種以上の相対的に硬質な金属の
粉末とを混合して圧着被覆したもので、前記相対的に軟
質な金属が母相を形成し、この母相中に、相対的に硬質
な金属粒子が分散配置され、 前記相対的に軟質な金属は、Ａｌ，Ｓｎ，Ａｇ，Ｉｎ，
Ｐｂ，Ａｕ，Ｃｕまたはこれらの合金である一方、前記
相対的に硬質な金属は、Ｎｉ，Ｃｏ，Ｆe，Ｃrまたはこ
れらの合金であることを特徴とする金属被覆砥粒。 1. A coating layer having a thickness of 5 μm or more formed by mixing two or more kinds of metal powders and applying pressure coating on the outer periphery of the abrasive grains.
The coating layer comprises at least one relatively soft metal.
Of at least one kind of relatively hard metal
Powder and mixed by pressure bonding.
Metal forms a parent phase, in which a relatively hard metal
Metal particles are dispersed and arranged, and the relatively soft metal is Al, Sn, Ag, In,
Pb, Au, Cu or an alloy thereof,
Relatively hard metals are Ni, Co, Fe, Cr or
Metal-coated abrasive grains characterized by these alloys.
ることを特徴とする請求項１記載の金属被覆砥粒。Wherein said covering layer is a metal-coated abrasive grains according to claim 1, wherein the filler is dispersed.
ら金属めっき砥粒を、これらより平均粒径が小さい複数
種の金属粉末と混合して加圧転動運動を加え、機械的な
摩擦圧接作用により、前記金属めっき層上に金属混合粉
末を圧着させて被覆層を形成することを特徴とする金属
被覆砥粒の製造方法。3. A metal plating layer is formed on the surface of the abrasive grains, and these metal plated abrasive grains are mixed with a plurality of types of metal powders having an average particle size smaller than these, and subjected to a press rolling motion to provide a mechanical rolling. A method for producing metal-coated abrasive grains, comprising: forming a coating layer by pressing a metal mixed powder onto the metal plating layer by a frictional welding operation.
対的に軟質な金属の粉末と、少なくとも１種以上の相対
的に硬質な金属の粉末とを混合したものであり、前記相
対的に軟質な金属は、いずれも前記金属めっき層を構成
する金属よりも軟質な材質であることを特徴とする請求
項３記載の金属被覆砥粒の製造方法。4. The metal powder is a mixture of at least one kind of relatively soft metal powder and at least one kind of relatively hard metal powder. The method for producing metal-coated abrasive grains according to claim 3, wherein each of the soft metals is a material softer than a metal forming the metal plating layer.
ビッカース硬度で５０ｋｇ／ｍｍ2以下であることを特
徴とする請求項４記載の金属被覆砥粒の製造方法。5. The hardness of the relatively soft metal powder is:
The method for producing metal-coated abrasive grains according to claim 4 , wherein the Vickers hardness is 50 kg / mm 2 or less.
属粉末に還元性物質を添加して圧着被覆することを特徴
とする請求項３，４または５記載の金属被覆砥粒の製造
方法。6. The method for producing metal-coated abrasive grains according to claim 3 , wherein a reducing substance is added to said metal powder to form said metal-coated abrasive layer when said metal-coated abrasive layer is formed.
を、圧粉成形および焼結することにより、メタルボンド
砥粒層を形成することを特徴とするメタルボンド砥石の
製造方法。7. A method for producing a metal-bonded grinding wheel, comprising forming a metal-bonded abrasive layer by compacting and sintering the metal-coated abrasive according to claim 1 or 2 .
を、押出し成形することにより、メタルボンド砥粒層を
形成することを特徴とするメタルボンド砥石の製造方
法。8. A method for producing a metal-bonded grindstone, comprising forming a metal-bonded abrasive layer by extruding the metal-coated abrasive according to claim 1 or 2 .
を、樹脂結合剤と混練した後、この混練物を樹脂結合剤
の溶融温度以上に加熱し、射出成形することを特徴とす
るメタルボンド砥石の製造方法。9. The method according to claim 1, wherein the metal-coated abrasive grains according to claim 1 or 2 are kneaded with a resin binder, and the kneaded material is heated to a temperature equal to or higher than the melting temperature of the resin binder to perform injection molding. Manufacturing method of metal bond whetstone.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP4312907A JP3035644B2 (en) | 1992-10-28 | 1992-10-28 | Metal-coated abrasive, method for producing the same, and method for producing metal-bonded grindstone |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP4312907A JP3035644B2 (en) | 1992-10-28 | 1992-10-28 | Metal-coated abrasive, method for producing the same, and method for producing metal-bonded grindstone |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH06136561A JPH06136561A (en) | 1994-05-17 |
| JP3035644B2 true JP3035644B2 (en) | 2000-04-24 |
Family
ID=18034896
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP4312907A Expired - Lifetime JP3035644B2 (en) | 1992-10-28 | 1992-10-28 | Metal-coated abrasive, method for producing the same, and method for producing metal-bonded grindstone |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3035644B2 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR101573957B1 (en) * | 2008-02-14 | 2015-12-02 | 엘리먼트 씩스 리미티드 | Method for manufacturing encapsulated superhard material |
| US9555387B2 (en) | 2008-02-14 | 2017-01-31 | Element Six Limited | Method for manufacturing encapsulated superhard material |
| CN110125389A (en) * | 2019-05-31 | 2019-08-16 | 天津大学 | A kind of preparation method of copper-graphite alkene collaboration reinforced aluminum matrix composites |
-
1992
- 1992-10-28 JP JP4312907A patent/JP3035644B2/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| JPH06136561A (en) | 1994-05-17 |
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