JP5042208B2 - Superabrasive tool and manufacturing method thereof - Google Patents

Description

  The present invention relates to a superabrasive tool that has a good sharpness and is less likely to burn on a workpiece. In particular, the present invention relates to a diamond rotary dresser having good sharpness and capable of high-precision dressing over a long period of time.

As an example of a conventional diamond rotary dresser, there is known a type in which diamond abrasive grains are fixed to a base metal by a bonding material and the surface shape of the diamond layer is formed in a cylindrical shape.
This type of diamond rotary dresser is generally used for dressing by traversing the surface of a grindstone. In actual dressing, the contact area between the diamond rotary dresser and the grindstone is small, the dressing resistance is low, and the dressing conditions can be changed over a wide range, so that the sharpness of the diamond rotary dresser hardly poses a problem.
(For example, see Patent Document 1)

As an example of another type of diamond rotary dresser, a diamond rotary dresser having a general shape is known. In the diamond rotary dresser having the overall shape, for example, when the grindstone axis and the diamond rotary dresser axis are arranged in parallel, the diamond rotary dresser is subjected to plunge dressing in which only the cut is made.
In the case of plunge dressing, the contact area between the diamond rotary dresser and the grindstone is large, so that the dressing resistance tends to be high. In order to perform smooth dressing, a good sharpness of the diamond rotary dresser is required. Furthermore, since the surface roughness of the diamond rotary dresser is directly transferred to the grindstone, the influence of the completion accuracy of the diamond rotary dresser on the dressing accuracy is extremely large.
(For example, see Patent Document 2)

As a method for improving the sharpness of the diamond rotary dresser, for example, the following methods (1) to (3) are often used.
(1) A method in which diamond abrasive grains are not fixed (diamond free zone) in a streak shape to reduce the number of working abrasive grains. This is one of the most effective ways to improve sharpness.
(2) Glass beads, ceramic beads, resin beads, etc. are mixed with diamond abrasive grains in a certain ratio in advance, and the mixture is fixed with a binder to lower the diamond concentration and reduce the number of working abrasive grains. Is the method.
(3) A method of providing a sharp cutting edge by forming a groove with a laser beam or the like at the protruding end of diamond abrasive grains of a diamond rotary dresser.
JP 59-47162 A Japanese Patent Publication No. 1-222115

However, the methods (1) to (3) described above are effective methods for improving sharpness, but have the following problems.
For (1), the diamond-free zone becomes a groove and becomes intermittent dressing, and vibrations are likely to occur during the dressing operation. The vibrations are transferred to the grindstone, and the surface roughness of the formed grindstone becomes rough. There was a problem. There is also a problem that noise during dressing is increased.
With regard to (2), the method of the invention invented to eliminate the above-mentioned disadvantage (1) can improve the sharpness of the entire diamond rotary dresser uniformly, and the total diamond rotary dresser can also be improved. Although it is an excellent method that can be applied, the mixing ratio of glass beads or the like must be changed each time depending on the specifications of the diamond rotary dresser, and thus there is a problem that a dedicated plating tank is required.
(3) is the most excellent method that can be processed after the diamond rotary dresser is completed, and that the sharpness can be arbitrarily controlled by the way of groove insertion. Moreover, it is possible to recover the sharpness by putting a groove in the diamond rotary dresser whose sharpness has been lowered by long-term use, and it has a feature that the application range is extremely wide. Although this is an extremely useful method, there is a problem that an expensive laser beam irradiation apparatus is required and the equipment is expensive. Further, since the shape of the diamond rotary dresser is almost the total shape, there is a problem that a laser beam irradiation program must be created each time.
The present invention is intended to solve these problems.

The superabrasive tool of the present invention is a superabrasive tool having a superabrasive layer in which superabrasive grains are bonded by a single layer, and the superabrasive layer is provided with grooves intersecting with each other. Super-abrasive grains are disposed on the edge portion formed by the working surface and the groove, and the super-abrasive grains inside the groove do not protrude from the groove surface.
The superabrasive tool of the present invention is provided with grooves intersecting each other in the superabrasive layer. That is, mesh grooves are provided in the superabrasive layer. Furthermore, since the superabrasive grains 5 are arranged on the edge portion formed by the working surface and the grooves of the superabrasive layer, an extremely good sharpness can be exhibited.
When the superabrasive tool of the present invention is applied to a diamond wheel or a CBN wheel, it is not clogged and exhibits an excellent sharpness stably over a long period of time. Highly efficient and highly efficient grinding is possible, contributing to mass production of various parts.
In particular, when the superabrasive tool of the present invention is applied to a diamond rotary dresser, the superabrasive grain 5 placed on the edge formed by the working surface of the superabrasive layer and the groove exhibits an excellent sharpness, so that the dressing resistance Is low. As a result, high-precision and high-efficiency dressing can be performed over a long period of time, and it can contribute to mass production of parts such as automobile parts and bearings at low cost.
Furthermore, since the superabrasive tool of the present invention is a mesh-like groove, the contact with the workpiece and the grindstone is smoothly performed compared to the stripe-like groove, and the generation of vibration and noise is reduced during grinding and dressing. Effect is obtained.
Further, in the superabrasive tool of the present invention, as shown in FIG. 3, the superabrasive grains (5a, 5b, 5c, 5d, 5e) inside the groove do not protrude from the groove surface, and are almost the same as the groove surface. It is arranged on a plane. As a result, the flow of the grinding fluid is extremely smooth, and chips and the like do not accumulate on the superabrasive layer and clogging does not occur. Therefore, it is possible to maintain a good sharpness for a long time.
Furthermore, the superabrasive tool of the present invention has superabrasive grains (5a, 5b, 5c, 5d, and 5e) disposed inside the groove, so that the groove is eroded by cutting powder and the like even when used for a long time. Therefore, there is very little change in the shape of the groove. Therefore, there is little influence on the shape accuracy of the superabrasive layer, and the shape accuracy of the superabrasive tool can be maintained with high accuracy for a long time.
For the above reasons, it is possible not only to maintain the shape accuracy of the superabrasive tool of the present invention for a long period of time, but also to maintain a good sharpness for a long period of time.

In the superabrasive tool of the present invention, it is preferable that a corner of the groove formed by the groove wall and the groove bottom is rounded.
As shown in FIG. 3, the corner portion formed by the groove wall portion and the groove bottom portion is rounded, so that the flow of the grinding fluid is smooth, and chips and grindstone debris are almost always deposited in the groove. Absent. The roundness is preferably a roundness having a radius as large as possible with the groove depth as a radius.

In the superabrasive tool of the present invention, the groove width Gw of the groove is 2 to 50 times the average grain size of the superabrasive grain, and the groove depth Gd of the groove is 0.1 times the average grain diameter of the superabrasive grain. To 5 times.
Since the groove width affects the area ratio of the working surface of the superabrasive layer, it is set so that the working area of the superabrasive grain is not significantly reduced and the life of the superabrasive tool is not shortened. The groove width is usually more preferably set to 2 to 30 times, and most preferably set to 2 to 20 times.
The groove depth is more preferably 0.2 to 5 times the average particle size of the superabrasive grains, and most preferably 0.2 to 3 times.
In the superabrasive tool of the present invention, the superabrasive layer is composed of a single superabrasive grain. Therefore, when the groove depth is set to about 1 times the average grain size of the superabrasive grains, the tool performance tends to be exhibited well. is there.

In the superabrasive tool of the present invention, the angle (α, β) between the groove and the axis of the superabrasive tool is preferably 5 ° to 60 °.
The angle formed by the groove with the axis of the superabrasive tool is more preferably 10 ° to 45 °, and most preferably 15 ° to 45 °.

In the superabrasive tool of the present invention, the average grain size of the superabrasive grains is preferably 10 to 2000 μm.
The average grain size of the superabrasive grains is appropriately determined based on the required surface roughness of the workpiece.
Here, the average particle diameter is a value measured at a position where the straight line traversing the superabrasive grain becomes longest when 100 arbitrary superabrasive grains are taken out and observed with a stereomicroscope or the like. The average particle size was defined as the average particle size.

The superabrasive tool of the present invention is preferably a diamond rotary dresser.
The present invention exhibits its performance more when applied to a diamond rotary dresser.

The superabrasive tool of the present invention is preferably a diamond rotary dresser having an overall shape.
The present invention is considered to exhibit its performance to the maximum when applied to a diamond rotary dresser having an overall shape. In particular, it is most preferably applied to a diamond rotary dresser having a shoulder portion, for example, in a shape that requires sharpness.

The present invention is a method for manufacturing a superabrasive tool using a reversal plating method, in which a conductive material is arranged in a mesh shape on the inner peripheral surface of a mother die, and fixed with a conductive adhesive, and the mother A process of forming superabrasive layers by embedding superabrasive grains in the inner peripheral surface of the mold and the surface of the conductive material by plating, a process of joining the superabrasive layers and the core metal, and removing the mother die And a step of exposing the superabrasive layer to a method for manufacturing a superabrasive tool.
A known method can be used for the inversion plating method.
A conductive material is arranged in a mesh shape on the inner periphery of the matrix and is fixed with a conductive adhesive. For example, aluminum, iron, copper, and alloys thereof can be used as the conductive material, but the conductive material is not limited to these materials.
For example, an aluminum alloy net can be used to arrange the nets. Or it can arrange | position in mesh shape using the wire or board | plate material made from an aluminum alloy. When using a plate material, it is preferable to round the corner portion on the center side with respect to the matrix of the plate material into an R shape. This is because roundness is formed at the corner of the bottom of the groove. In order to fix these to the inner periphery of the matrix, a known conductive adhesive can be used.
In order to embed the superabrasive grains in the inner periphery of the matrix by plating, it is preferable to use nickel plating. For plating, either electroplating or chemical plating can be used.
In order to join the superabrasive layer and the cored bar, a known low melting point alloy can be used.
After the matrix is removed by machining or the like to expose the superabrasive layer, when the conductive material is removed by machining or the like, a superabrasive layer in which a mesh-like groove is formed appears.
Then, the core bar is machined into the desired shape, and the superabrasive layer is truing and dressing to complete the superabrasive tool.

  According to the present invention, the sharpness is good and the accuracy of the superabrasive tool is maintained over a long period of time. In particular, the effect of the invention can be maximized by applying to a diamond rotary dresser.

  The best mode of the present invention will be described in detail in the Examples section.

A diamond rotary dresser was produced by the reversal plating method of Example 1 of the present invention as follows.
A thick cylindrical master is prepared, and a conductive adhesive is used to form a mesh of an aluminum alloy plate having a cross-sectional shape of 2 mm in width and 0.3 mm in thickness on the inner peripheral surface of the master. Stuck. The form of the mesh is such that the inner circumference of the matrix is divided into 36 equal parts at an angle of 30 degrees to the left and right with respect to the axis of the diamond rotary dresser (that is, α = β = 30 degrees in FIG. 2). . That is, a mesh was formed using 72 plate members.
Next, diamond abrasive grains having an average particle diameter of about 400 μm are temporarily fixed on the inner peripheral surface by a handset method using a conductive adhesive, and then the diamond abrasive grains are completely embedded by nickel plating to form a superabrasive layer. Formed.
Next, a core metal is put in, and the superabrasive layer and the core metal are joined with a low melting point alloy, the outer surface of the superabrasive layer is exposed by removing the matrix, and is embedded in the superabrasive layer in a mesh shape. The aluminum alloy plate was removed by machining.
Next, the core bar was machined into a desired shape, and then the superabrasive layer was truing-dressed to complete a diamond rotary dresser. The details of the completed diamond rotary dresser are as follows. The outer diameter is 80 mm, the groove width is 2 mm, the groove depth is 0.2 mm, the groove angle is α = β = 30 degrees, and the intersecting grooves divide the outer periphery of the dresser into 36 equal parts.
A conventional grindstone was dressed using the diamond rotary dresser of Example 1 to confirm the effect of the present invention. As a result, it was confirmed that the sharpness was good, the dressing resistance was low, the noise during dressing was small, and high-precision and high-efficiency dressing was possible. Furthermore, the dressing resistance was stable over a long period of time, and almost no decrease in shape accuracy was confirmed.

A diamond rotary dresser was produced by the reversal plating method of Example 2 of the present invention as follows.
A thick cylindrical master was prepared, and a copper plate having a cross section of 2 mm in width and 0.3 mm in thickness was fixed to the inner peripheral surface of the master using a conductive adhesive so as to form a mesh. . However, a rounding process with a radius of about 0.15 mm was performed on the side facing the center side with respect to the matrix of the copper plate material.
The form of the mesh is such that the inner circumference of the matrix is divided into 36 equal parts at an angle of 30 degrees to the left and right with respect to the axis of the diamond rotary dresser (that is, α = β = 30 degrees in FIG. 2). . That is, a mesh was formed using 72 plate members.
Next, diamond abrasive grains having an average particle diameter of about 400 μm are temporarily fixed on the inner peripheral surface by a handset method using a conductive adhesive, and then the diamond abrasive grains are completely embedded by nickel plating to form a superabrasive layer. Formed.
Next, a core metal is put in, and the superabrasive layer and the core metal are joined with a low melting point alloy, the outer surface of the superabrasive layer is exposed by removing the matrix, and is embedded in the superabrasive layer in a mesh shape. The aluminum alloy plate was removed by machining.
Next, the core bar was machined into a desired shape, and then the superabrasive layer was truing-dressed to complete a diamond rotary dresser. Details of the completed diamond rotary dresser are as follows: outer diameter 80 mm, groove width 2 mm, groove depth 0.2 mm, groove corner radius 0.15 mm, groove angle α = β = 30 degrees, intersecting grooves Divides the outer periphery of the dresser into 36 equal parts.
A conventional grindstone was dressed under the same conditions as in Example 1 using the diamond rotary dresser of Example 2, and the effect of the present invention was confirmed. As a result, it was confirmed that the sharpness was good, the dressing resistance was low, the noise during dressing was small, and high-precision and high-efficiency dressing was possible. Furthermore, the dressing resistance was stable over a long period of time, and almost no decrease in shape accuracy was confirmed.

A diamond rotary dresser was produced by the reversal plating method of Example 3 of the present invention as follows.
A thick cylindrical mother mold was prepared, and an iron plate having a cross-sectional shape of 2 mm in width and 0.3 mm in thickness was fixed to the inner peripheral surface of the mother mold with a conductive adhesive so as to form a mesh. . However, a rounding process with a radius of about 0.15 mm was performed on the side facing the center side with respect to the matrix of the iron plate material.
The form of the mesh is such that the inner circumference of the matrix is divided into 36 equal parts at an angle of 30 degrees to the left and right with respect to the axis of the diamond rotary dresser (that is, α = β = 30 degrees in FIG. 2). . That is, a mesh was formed using 72 plate members.
Next, diamond abrasive grains having an average particle diameter of about 400 μm are temporarily fixed on the inner peripheral surface by a handset method using a conductive adhesive, and then the diamond abrasive grains are completely embedded by nickel plating to form a superabrasive layer. Formed.
Next, a core metal is put in, and the superabrasive layer and the core metal are joined with a low melting point alloy, the outer surface of the superabrasive layer is exposed by removing the matrix, and is embedded in the superabrasive layer in a mesh shape. The aluminum alloy plate was removed by machining.
Next, the core bar was machined into a desired shape, and then the superabrasive layer was truing-dressed to complete a diamond rotary dresser. Details of the completed diamond rotary dresser are as follows: outer diameter 80 mm, groove width 2 mm, groove depth 0.2 mm, groove corner radius 0.15 mm, groove angle α = β = 30 degrees, intersecting grooves Divides the outer periphery of the dresser into 36 equal parts.
Using the diamond rotary dresser of Example 3, a conventional grindstone was dressed under the same conditions as in Example 1 to confirm the effect of the present invention. As a result, it was confirmed that the sharpness was good, the dressing resistance was low, the noise during dressing was small, and high-precision and high-efficiency dressing was possible. Furthermore, the dressing resistance was stable over a long period of time, and almost no decrease in shape accuracy was confirmed.

It is a perspective view of the superabrasive tool of the present invention. It is an enlarged view of the superabrasive layer of the superabrasive tool of the present invention. It is sectional drawing of the groove | channel of the superabrasive tool of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Superabrasive tool 2 Superabrasive layer 3 Groove 4 Core metal 5 Superabrasive grain 5 '(5a-5e) Superabrasive grain 6 which groove part does not protrude 6 Binding material alpha, beta A groove serves as an axis of a superabrasive tool Angle Gd Groove depth Gw Groove width R Round corner radius of groove

Claims (8)

A superabrasive tool having a superabrasive layer in which only one superabrasive grain is bonded with a binder, and a conductive material is arranged in a mesh shape on the inner peripheral surface of the mother die and fixed with a conductive adhesive. The superabrasive grains are embedded in the inner peripheral surface of the matrix and the surface of the conductive material by reversal plating to form the superabrasive grain layer.
The superabrasive layer is provided with grooves corresponding to the mesh-like conductive material intersecting each other,
Superabrasive grains are arranged on the edge formed by the working surface of the superabrasive layer and the grooves,
The superabrasive tool in which the superabrasive grains inside the groove do not protrude from the groove surface.   The superabrasive tool according to claim 1, wherein a corner portion formed by the groove wall portion and the groove bottom portion is rounded in the groove. The groove width of the groove is 2 to 50 times the average particle diameter of the superabrasive grains,
The superabrasive tool according to claim 1 or 2, wherein the groove depth of the groove is 0.1 to 5 times the average grain size of the superabrasive grains.   4. The superabrasive tool according to claim 1, wherein an angle between the groove and the axis of the superabrasive tool is 5 ° to 60 °. 5.   5. The superabrasive tool according to claim 1, wherein the superabrasive has an average particle diameter of 1 to 2000 μm.   The superabrasive tool according to any one of claims 1 to 5, wherein the superabrasive tool is a diamond rotary dresser.   The superabrasive tool according to any one of claims 1 to 5, wherein the superabrasive tool is a diamond rotary dresser having an overall shape. It is a manufacturing method of the superabrasive tool according to any one of claims 1 to 7, by a reversal plating method,
A step of arranging a conductive substance on the inner peripheral surface of the matrix in a mesh shape and fixing with a conductive adhesive;
A step of embedding superabrasive grains in the inner peripheral surface of the matrix and the surface of the conductive material by plating to form a superabrasive layer;
Joining the superabrasive layer and the core metal;
A method for producing a superabrasive tool, comprising: removing a matrix and exposing a superabrasive layer.

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