JP5230474B2 - Metal bond wheel - Google Patents
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- JP5230474B2 JP5230474B2 JP2009033182A JP2009033182A JP5230474B2 JP 5230474 B2 JP5230474 B2 JP 5230474B2 JP 2009033182 A JP2009033182 A JP 2009033182A JP 2009033182 A JP2009033182 A JP 2009033182A JP 5230474 B2 JP5230474 B2 JP 5230474B2
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- 239000002184 metal Substances 0.000 title claims description 114
- 229910052751 metal Inorganic materials 0.000 title claims description 114
- 239000002245 particle Substances 0.000 claims description 81
- 239000000314 lubricant Substances 0.000 claims description 69
- 239000007787 solid Substances 0.000 claims description 69
- 239000006061 abrasive grain Substances 0.000 claims description 54
- 229910045601 alloy Inorganic materials 0.000 claims description 17
- 239000000956 alloy Substances 0.000 claims description 17
- 229910052802 copper Inorganic materials 0.000 claims description 10
- 229910052718 tin Inorganic materials 0.000 claims description 10
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 150000002739 metals Chemical class 0.000 claims 1
- 238000007493 shaping process Methods 0.000 description 41
- 239000002923 metal particle Substances 0.000 description 36
- 229910001092 metal group alloy Inorganic materials 0.000 description 10
- 229910003460 diamond Inorganic materials 0.000 description 9
- 239000010432 diamond Substances 0.000 description 9
- 239000000463 material Substances 0.000 description 8
- 230000014759 maintenance of location Effects 0.000 description 6
- 239000000843 powder Substances 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 5
- 238000004453 electron probe microanalysis Methods 0.000 description 5
- 239000011347 resin Substances 0.000 description 5
- 229920005989 resin Polymers 0.000 description 5
- 239000010953 base metal Substances 0.000 description 4
- 239000008187 granular material Substances 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 230000002093 peripheral effect Effects 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 238000003754 machining Methods 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 229910017755 Cu-Sn Inorganic materials 0.000 description 2
- 229910017927 Cu—Sn Inorganic materials 0.000 description 2
- 229910020810 Sn-Co Inorganic materials 0.000 description 2
- 229910018757 Sn—Co Inorganic materials 0.000 description 2
- 229910018792 Sn—Co—Fe Inorganic materials 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 229910002804 graphite Inorganic materials 0.000 description 2
- 239000010439 graphite Substances 0.000 description 2
- 238000001000 micrograph Methods 0.000 description 2
- 229910052750 molybdenum Inorganic materials 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 229910052717 sulfur Inorganic materials 0.000 description 2
- 239000011800 void material Substances 0.000 description 2
- 229910000760 Hardened steel Inorganic materials 0.000 description 1
- 229910020938 Sn-Ni Inorganic materials 0.000 description 1
- 229910008937 Sn—Ni Inorganic materials 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 239000003575 carbonaceous material Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 230000008094 contradictory effect Effects 0.000 description 1
- 238000012937 correction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000000921 elemental analysis Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000005461 lubrication Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000000399 orthopedic effect Effects 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
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- Polishing Bodies And Polishing Tools (AREA)
Description
本発明は、整形を簡単に行うことが可能なメタルボンドホイールに関する。 The present invention relates to a metal bond wheel that can be easily shaped.
超硬金属、セラミック、焼き入れ鋼、ガラス等の加工を、ネジ研削、総型研削、溝研削、平面研削、円筒研削等で行うために、ダイヤモンド等の砥粒を結合剤で結合した砥粒層を有する研削ホイールが用いられている。このような用途の研削ホイールに使用する結合剤として、レジンボンドやビトリファイドボンドを使用した場合、これらのボンド材の形状維持性が低いため、硬質材料の研削を行った場合には砥粒が砥粒層から脱落しやすいという欠点がある。これに対し、メタルボンドを使用すると、レジンボンドやビトリファイドボンドと比較して、形状維持性が良いため砥粒保持力が強く、寿命が長いという利点がある。 Abrasive grains in which abrasive grains such as diamond are combined with a binder to process hard metal, ceramics, hardened steel, glass, etc. by thread grinding, general grinding, groove grinding, surface grinding, cylindrical grinding, etc. A grinding wheel having a layer is used. When resin bonds or vitrified bonds are used as binders for grinding wheels for such applications, the shape maintenance of these bond materials is low. There is a drawback that it is easy to fall off from the grain layer. On the other hand, when a metal bond is used, there is an advantage that the abrasive grain holding power is strong and the life is long because the shape maintainability is better than that of a resin bond or a vitrified bond.
一般に整形とは、所定の形状を形作ることである。使用中に研削ホイールの形状が崩れた場合にはＧＣ（グリーンカーボン）砥石などの整形砥石や鉄系材料を研削し、形状修正である整形を定期的に行う必要がある。この工程が潤滑に行われないと、研削ホイールの形状をもとに戻すことができず正常な研削ができない。このように整形の行いやすさ（以下、「整形性」と称す。）は、研削ホイールの性能に大きく影響する。 In general, shaping is to form a predetermined shape. When the shape of the grinding wheel breaks down during use, it is necessary to grind a shaping grindstone such as a GC (green carbon) grindstone or an iron-based material, and periodically perform shaping for shape correction. If this process is not performed for lubrication, the shape of the grinding wheel cannot be restored and normal grinding cannot be performed. The ease of shaping (hereinafter referred to as “formability”) greatly affects the performance of the grinding wheel.
レジンボンドやビトリファイドボンド使用した研削ホイールでは、ＧＣ砥石等を用いて簡単に整形を行うことができるのに対し、メタルボンドを使用した研削ホイール（以下、「メタルボンドホイール」と称す。）を整形するためには放電加工や、ＧＣ砥粒を多量に使用するため、コストと時間がかかり、整形を簡単に行うことができないという欠点がある。メタルボンドホイールの整形性の向上を目的とした技術が特許文献１〜３に記載されている。 Grinding wheels using resin bonds or vitrified bonds can be easily shaped using a GC grindstone, while grinding wheels using metal bonds (hereinafter referred to as "metal bond wheels") are shaped. In order to do so, since electric discharge machining and a large amount of GC abrasive grains are used, there are disadvantages that cost and time are required and shaping cannot be performed easily. Techniques aimed at improving the formability of the metal bond wheel are described in Patent Documents 1 to 3.
特許文献１に記載のメタルボンドホイールは、砥粒層中に多孔質ケイ酸カルシウム粒子を分散させた多孔質メタルボンドホイールであるが、多孔質体を含有しているため強度が低下し、欠けが発生しやすくなる。特許文献２に記載のメタルボンドホイールは、砥粒と、耐熱性があり且つ研削液に溶解する溶解性物質と、金属粉末とからなる混合充填物から、溶解性物質を溶解させることで砥粒層表面に多孔質部を形成したメタルボンドホイールであるが、多孔質体であるため欠けやすいことに加え、溶解性物質が溶解したときに砥粒の脱落が起こりやすい。特許文献３に記載のメタルボンドホイールは、ダイヤモンド砥粒を含有する多孔質のビトリファイド顆粒をメタルボンドやレジンボンドに内在させた超砥粒ホイールであるが、砥粒がビトリファイド顆粒の中にのみ存在し、これを覆うメタルボンドやレジンボンドには砥粒が存在しないため、砥粒の分散性が悪く、被削材の仕上げ面の加工精度にばらつきが生じる。また、ビトリファイド顆粒自体が欠けたり、ビトリファイド顆粒がボンドから脱落したりして欠けが発生しやすい。 The metal bond wheel described in Patent Document 1 is a porous metal bond wheel in which porous calcium silicate particles are dispersed in an abrasive grain layer. Is likely to occur. The metal bond wheel described in Patent Document 2 is an abrasive grain by dissolving a soluble substance from a mixed filler consisting of abrasive grains, a heat-resistant and soluble substance that dissolves in a grinding fluid, and a metal powder. Although it is a metal bond wheel in which a porous portion is formed on the surface of the layer, it is a porous body, and in addition to being easily chipped, the abrasive grains are likely to fall off when the soluble substance is dissolved. The metal bond wheel described in Patent Document 3 is a super abrasive wheel in which porous vitrified granules containing diamond abrasive grains are incorporated in metal bonds or resin bonds, but the abrasive grains exist only in vitrified granules. However, since there are no abrasive grains in the metal bond or resin bond covering this, the dispersibility of the abrasive grains is poor, and the processing accuracy of the finished surface of the work material varies. In addition, the vitrified granules themselves are chipped or the vitrified granules fall off from the bond, and chipping is likely to occur.
すなわち、良好な整形性と研削時における研削性能の両方を満足させるためには、使用されるメタルボンドは十分な砥粒保持力を有し、且つ、整形の際には摩耗が起こりやすい、という相反する条件を両立させることが必要となり、従来使用されてきたメタルボンドでは、この要求を満たすことができなかった。 In other words, in order to satisfy both good formability and grinding performance at the time of grinding, the metal bond used has sufficient abrasive grain holding power, and wear is likely to occur during shaping. It is necessary to make the contradictory conditions compatible with each other, and conventionally used metal bonds cannot satisfy this requirement.
本発明は、以上の問題点を解決するためになされたもので、整形性を良好に維持しつつ、研削時における適度な砥粒保持力を有するメタルボンドを使用したメタルボンドホイールを提供することを目的とする。 The present invention has been made to solve the above problems, and provides a metal bond wheel using a metal bond having an appropriate abrasive grain holding force during grinding while maintaining good formability. With the goal.
本発明のメタルボンドホイールは、砥粒と、粒子状の固体潤滑剤とをメタルボンドによって結合して形成された砥粒層を有するメタルボンドホイールにおいて、前記メタルボンドは、ＣｕとＳｎを含む合金からなる第１金属と、前記第１金属より高融点である金属あるいは合金からなる粒子状の第２金属から構成され、前記固体潤滑剤粒子は、前記メタルボンド内に分散し、その平均粒径が前記粒子状の第２金属よりも大きいことを特徴とする。 The metal bond wheel of the present invention is a metal bond wheel having an abrasive grain layer formed by bonding abrasive grains and particulate solid lubricant by metal bond, wherein the metal bond is an alloy containing Cu and Sn. And the solid lubricant particles are dispersed in the metal bond and have an average particle diameter thereof. The first metal is made of a metal or an alloy having a melting point higher than that of the first metal. Is larger than the particulate second metal.
このような構成とすれば、砥粒と、粒子状の固体潤滑剤とを結合するメタルボンドにおいて、ＣｕとＳｎを含む合金からなる第１金属（以下、「第１金属合金」と称す）を介して、粒子状の第２金属（以下、「第２金属粒子」と称す）のそれぞれの粒子が接合することで砥粒を保持することができる。一方で、このようなメタルボンドでは、第２金属粒子同士の接合部分はそれぞれの粒子の接点近傍のみであるため、整形を行うと、第２金属粒子はその接合部分から容易に脱落する。また、第２金属粒子の周囲には第１金属合金が存在するため、第２金属粒子同士が凝集することを抑制することができる。 With such a configuration, the first metal made of an alloy containing Cu and Sn (hereinafter referred to as a “first metal alloy”) in the metal bond that bonds the abrasive grains and the particulate solid lubricant. Thus, the abrasive particles can be held by joining the respective particles of the particulate second metal (hereinafter referred to as “second metal particles”). On the other hand, in such a metal bond, the joint part between the second metal particles is only in the vicinity of the contact point of each particle. Therefore, when shaping is performed, the second metal particle easily falls off from the joint part. Moreover, since the 1st metal alloy exists around the 2nd metal particle, it can suppress that 2nd metal particle aggregates.
さらに粒子状の固体潤滑剤（以下、「固体潤滑剤粒子」と称す）はこのメタルボンド内に分散し、その平均粒径が第２金属粒子よりも大きいため、固体潤滑剤粒子の周囲を第２金属粒子が取り囲むように配置され、固体潤滑剤粒子の表面近傍に空隙が形成される。そのため、整形を行うと固体潤滑剤が適度に脱落することができ、さらに、固体潤滑剤の脱落痕がチップポケットとして機能することで、第２金属粒子の脱落効果が高まり、整形性が向上する。 Further, particulate solid lubricant (hereinafter referred to as “solid lubricant particles”) is dispersed in the metal bond, and the average particle size thereof is larger than that of the second metal particles. Two metal particles are arranged so as to surround, and a void is formed in the vicinity of the surface of the solid lubricant particles. Therefore, when the shaping is performed, the solid lubricant can be removed appropriately, and further, the falling mark of the solid lubricant functions as a chip pocket, so that the falling effect of the second metal particles is increased and the shaping property is improved. .
ここで、固体潤滑剤粒子の平均粒径が、第２金属粒子の平均粒径の２倍以上１５倍以下であることが望ましく、この数値範囲であると整形の際に固体潤滑剤粒子を好適に脱落させることができる。前記固体潤滑剤の平均粒径が、第２金属粒子の平均粒径の２倍未満であると、固体潤滑剤は脱落しにくいため、整形性が著しく低下する。一方、前記固体潤滑剤の平均粒径が、第２金属粒子の平均粒径の１５倍を超えると、固体潤滑剤は脱落しやすいが、研削時におけるメタルボンドの摩耗速度が大きすぎ、砥粒層の形状保持性が著しく低下する。 Here, it is desirable that the average particle diameter of the solid lubricant particles be 2 to 15 times the average particle diameter of the second metal particles, and if it is within this numerical range, the solid lubricant particles are suitable for shaping. Can be dropped. If the average particle size of the solid lubricant is less than twice the average particle size of the second metal particles, the solid lubricant is difficult to drop off, and the formability is significantly reduced. On the other hand, when the average particle size of the solid lubricant exceeds 15 times the average particle size of the second metal particles, the solid lubricant is likely to fall off, but the wear rate of the metal bond during grinding is too high, and the abrasive grains The shape retention of the layer is significantly reduced.
また、本発明において、前記粒子状の固体潤滑剤の含有量が、前記粒子状の第２金属の含有量の１５体積％以上３０体積％以下であることが望ましい。粒子状の固体潤滑剤の含有量が、第２金属の含有量の１５体積％未満であると、整形時に固体潤滑剤が脱落しても、その脱落痕の間隔が広すぎるため、第２金属粒子の脱落が促進されにくく整形性が悪くなる。また、固体潤滑剤の含有量が、第２金属の含有量の３０体積％を超えると、研削時における砥粒層の形状保持性が著しく低下するため好ましくない。 In the present invention, it is desirable that the content of the particulate solid lubricant is 15 volume% or more and 30 volume% or less of the content of the particulate second metal. If the content of the particulate solid lubricant is less than 15% by volume of the content of the second metal, even if the solid lubricant falls off during shaping, the interval between the dropout marks is too wide. Dropping of particles is difficult to promote and the formability deteriorates. Moreover, when the content of the solid lubricant exceeds 30% by volume of the content of the second metal, it is not preferable because the shape retention of the abrasive layer during grinding is significantly reduced.
本発明においては、固体潤滑剤は、ＭｏＳ2、ＷＳ2のいずれかであることが望ましい。固体潤滑剤として一般的によく用いられているグラファイトは、研削圧力が高い部分で潤滑性が劣るのに対し、ＭｏＳ2、ＷＳ2は潤滑性が高いため、特に研削圧力が高い場合において、砥材層の欠けが発生しづらい。 In the present invention, the solid lubricant is desirably either MoS 2 or WS 2 . Graphite, which is commonly used as a solid lubricant, is inferior in lubricity at a portion where the grinding pressure is high, whereas MoS 2 and WS 2 have high lubricity. Chipping of the material layer is difficult to occur.
本発明のメタルボンドホイールは、整形性を良好に維持しつつ、研削時における砥粒保持力を確保することができるため、従来のメタルボンドホイールのように放電加工等の時間を要する整形を必要とせず、ＧＣ砥石などの整形砥石を用いて研削盤上で容易に整形を行うことができる。 The metal bond wheel of the present invention can maintain the shapeability and maintain the abrasive grain holding force at the time of grinding, so that it requires time-consuming shaping such as electric discharge machining like the conventional metal bond wheel Instead, shaping can be easily performed on a grinding machine using a shaping grindstone such as a GC grindstone.
以下に、本発明に係る実施形態を、図面を参照しながら説明する。
図１はメタルボンドホイールに対する整形の説明図である。図１に示すメタルボンドホイール１においては、円盤状の台金２の外周側に、ダイヤモンド等の砥粒をメタルボンドで結合して形成された砥粒層３が設けられており、台金２の中心には取り付け穴４が設けられている。このメタルボンドホイール１に対して、例えばＧＣ砥石からなる整形砥石５を接触させ、メタルボンドホイール１を回転させることによって整形が行われる。
Embodiments according to the present invention will be described below with reference to the drawings.
FIG. 1 is an explanatory view of shaping for a metal bond wheel. In the metal bond wheel 1 shown in FIG. 1, an abrasive grain layer 3 formed by bonding abrasive grains such as diamond with metal bonds is provided on the outer peripheral side of a disk-shaped base metal 2. A mounting hole 4 is provided at the center of the. For example, shaping is performed by bringing a shaping grindstone 5 made of, for example, a GC grindstone into contact with the metal bond wheel 1 and rotating the metal bond wheel 1.
図２に従来のメタルボンドホイールの砥粒層の拡大図、図３に本発明の実施形態に係るメタルボンドホイールの砥粒層の拡大図を示す。
従来のメタルボンドホイール砥粒層３において、砥粒６と固体潤滑剤粒子７は合金状のメタルボンド８ａによって結合されている。メタルボンド８ａとしては例えば、Ｃｕ−Ｓｎ−Ｃｏ系合金、Ｃｕ−Ｓｎ−Ｃｏ−Ｆｅ系合金、Ｃｕ−Ｓｎ−Ｎｉ系合金などがある。この中でも砥粒保持力が高い、Ｃｕ−Ｓｎ−Ｃｏ系合金やＣｕ−Ｓｎ−Ｃｏ−Ｆｅ系合金が使用されることが多いが、これらの合金は硬度が高く摩耗性が低いため整形性が低い。
FIG. 2 is an enlarged view of the abrasive layer of the conventional metal bond wheel, and FIG. 3 is an enlarged view of the abrasive layer of the metal bond wheel according to the embodiment of the present invention.
In the conventional metal bond wheel abrasive grain layer 3, the abrasive grains 6 and the solid lubricant particles 7 are bonded by an alloy-like metal bond 8a. Examples of the metal bond 8a include a Cu—Sn—Co alloy, a Cu—Sn—Co—Fe alloy, and a Cu—Sn—Ni alloy. Of these, Cu-Sn-Co-based alloys and Cu-Sn-Co-Fe-based alloys with high abrasive grain retention are often used, but these alloys have high hardness and low wear properties, so that the formability is high. Low.
一方、図３に示すように本発明の実施形態に係るメタルボンドホイールの砥粒層３において、砥粒６及び固体潤滑剤粒子７は、第１金属合金９及び第２金属粒子１０から構成されるメタルボンド８ｂによって結合されている。このうち、第１金属合金９は第２金属より低融点で軟質であるＣｕとＳｎを含む合金（Ｃｕ−Ｓｎ系合金）であり、さらにＰ，Ａｇ，Ｆｅなどの成分を添加することもできる。 On the other hand, as shown in FIG. 3, in the abrasive grain layer 3 of the metal bond wheel according to the embodiment of the present invention, the abrasive grains 6 and the solid lubricant particles 7 are composed of the first metal alloy 9 and the second metal particles 10. Are bonded by a metal bond 8b. Among these, the first metal alloy 9 is an alloy (Cu—Sn alloy) containing Cu and Sn that has a lower melting point and softer than the second metal, and components such as P, Ag, and Fe can also be added. .
第２金属粒子１０は、耐熱性が高い金属種であるＣｏ，Ｆｅ，Ｎｉのいずれか、あるいはこれらを主成分とする合金からなる粒子である。なお、粒子の凝集や熱融合を抑制するためには、第２金属粒子１０としてはＣｏ、あるいはＣｏを主成分とする合金が好適に使用される。メタルボンド８ｂにおいて、第２金属粒子１０は、第１金属合金９を介してそれぞれの粒子の接点近傍で接合している。そのため、外部から強い力を加えると粒子間の接合部分が破壊され、第２金属粒子１０が脱落する。 The second metal particles 10 are particles made of one of Co, Fe, and Ni, which are metal species having high heat resistance, or an alloy containing these as a main component. In order to suppress particle aggregation and thermal fusion, the second metal particle 10 is preferably Co or an alloy containing Co as a main component. In the metal bond 8 b, the second metal particle 10 is bonded in the vicinity of the contact point of each particle via the first metal alloy 9. Therefore, when a strong force is applied from the outside, the joint portion between the particles is destroyed and the second metal particle 10 falls off.
なお、第２金属粒子１０の好適な平均粒径は０．５〜３．０μｍである。第２金属粒子１０の平均粒径が０．５μｍ未満であると、メタルボンド８ｂが緻密になり砥粒保持力が大きくなりすぎて整形性が低下し、平均粒径が３．０μｍを超えると、それぞれの第２金属粒子１０の接合力が小さくなりすぎて、砥粒層３の形状保持性が低下し、砥粒層３が崩壊しやすくなるため好ましくない。 In addition, the suitable average particle diameter of the 2nd metal particle 10 is 0.5-3.0 micrometers. When the average particle diameter of the second metal particles 10 is less than 0.5 μm, the metal bond 8b becomes dense, the abrasive grain holding power becomes too large, and the formability is lowered. When the average particle diameter exceeds 3.0 μm The bonding force of each second metal particle 10 becomes too small, so that the shape retention of the abrasive grain layer 3 is lowered and the abrasive grain layer 3 is liable to collapse, which is not preferable.
砥粒層３において、固体潤滑剤粒子７は、第２金属粒子１０より大径の粒子であり、メタルボンド８ｂ内に適度に分散している。そのため、固体潤滑剤粒子７の周囲には、第１金属合金９を介して接合した第２金属粒子１０が取り囲むように配置している。このように固体潤滑剤粒子７の周囲に第２金属粒子１０が配置されると、固体潤滑剤粒子７の表面近傍に適度に空隙が形成される。この空隙はそれ自身がチップポケットとしての機能を有すると共に、固体潤滑剤粒子７が砥粒層３から脱落することを容易にする作用がある。 In the abrasive layer 3, the solid lubricant particles 7 are larger in diameter than the second metal particles 10 and are appropriately dispersed in the metal bond 8b. Therefore, it arrange | positions so that the 2nd metal particle 10 joined via the 1st metal alloy 9 may surround the circumference | surroundings of the solid lubricant particle 7. FIG. When the second metal particles 10 are thus arranged around the solid lubricant particles 7, moderate gaps are formed in the vicinity of the surface of the solid lubricant particles 7. This void itself has a function as a chip pocket, and also has an effect of facilitating the solid lubricant particles 7 falling off from the abrasive grain layer 3.
ここで、固体潤滑剤粒子７の平均粒径は、第２金属粒子１０の平均粒径の２倍以上１５倍以下、特に２倍以上６倍以下が好適である。固体潤滑剤粒子７の平均粒径がこの範囲であれば、適度な脱落性と砥粒層の形成保持性を両立することができる。固体潤滑剤粒子７の平均粒径が第２金属粒子１０の平均粒径の２倍未満であると、固体潤滑剤粒子７の保持力が大きすぎて固体潤滑剤粒子７の脱落が起こりづらく、１５倍以上であると逆に固体潤滑剤粒子７の保持力が小さすぎて砥粒層３が簡単に崩壊してしまうため好ましくない。なお、前記固体潤滑剤の含有量が、第２金属の含有量の１５体積％以上３０体積％以下とすると前記固体潤滑剤粒子７の脱落が起こりやすく、整形性が特に向上する。 Here, the average particle size of the solid lubricant particles 7 is preferably 2 to 15 times, more preferably 2 to 6 times the average particle size of the second metal particles 10. If the average particle diameter of the solid lubricant particles 7 is within this range, it is possible to achieve both appropriate drop-off property and formation retention of the abrasive layer. If the average particle size of the solid lubricant particles 7 is less than twice the average particle size of the second metal particles 10, the retention force of the solid lubricant particles 7 is too large, and the solid lubricant particles 7 are unlikely to fall off. On the contrary, if it is 15 times or more, the holding force of the solid lubricant particles 7 is too small, and the abrasive layer 3 easily collapses, which is not preferable. In addition, when the content of the solid lubricant is 15% by volume or more and 30% by volume or less of the content of the second metal, the solid lubricant particles 7 are likely to fall off, and the formability is particularly improved.
なお、固体潤滑剤としては従来のグラファイトなどの炭素系材料も使用できるが、特に研削圧力が高い加工に使用されるメタルボンドホイールの場合、研削圧力が高い状態においても潤滑性がよいＭｏＳ2、ＷＳ2が好適に使用される。 As a solid lubricant, conventional carbon-based materials such as graphite can also be used. However, in the case of a metal bond wheel used for processing with particularly high grinding pressure, MoS 2 having good lubricity even under high grinding pressure, WS 2 is preferably used.
本発明の実施形態に係るメタルボンドホイールの砥粒層構造を実現する方法として、以下の製造方法が挙げられる。メタルボンドを構成する第１金属の原材料となるＣｕ及びＳｎを含む粉末を３０〜４５重量％、第２金属粒子の原材料となるＣｏ等の金属粉末を含む粉末を５０〜７０重量％、ＭｏＳ2などの固体潤滑剤の粉末を５〜２０重量％として混合し、この混合物に適量の砥粒を加えて撹拌し、必要量を型に投入してプレス機にて圧力と温度を加える。なお、好適なプレス圧は３０〜５００ｋｇ／ｃｍ2の範囲である。次に、焼結機に圧粉体を入れ、第１金属の原材料が合金化する温度まで温度上昇させ、この温度を一定時間維持した後冷却する。なお、温度が上がり過ぎると、金属粉末の表面だけでなくその内部まで反応してしまい、第２金属粒子が接点近傍だけでなく面で接合するようになるため好ましくない。なお、第１金属が合金化し、且つ、第２金属粒子が接点近傍で接合するために好適な焼成温度は５００〜７００℃であり、特に５５０℃〜６５０℃が望ましい。 The following manufacturing method is mentioned as a method of implement | achieving the abrasive grain structure of the metal bond wheel which concerns on embodiment of this invention. 30 to 45% by weight of a powder containing Cu and Sn as raw materials of the first metal constituting the metal bond, 50 to 70% by weight of a powder containing metal powder such as Co as a raw material of the second metal particles, MoS 2 A solid lubricant powder such as 5 to 20% by weight is mixed, an appropriate amount of abrasive grains is added to the mixture and stirred, and the required amount is put into a mold and pressure and temperature are applied with a press. A suitable pressing pressure is in the range of 30 to 500 kg / cm 2 . Next, the green compact is put into a sintering machine, the temperature is raised to a temperature at which the raw material of the first metal is alloyed, and this temperature is maintained for a certain time and then cooled. If the temperature rises too much, it reacts not only on the surface of the metal powder but also inside thereof, so that the second metal particles are joined not only in the vicinity of the contact but also on the surface. Note that a suitable firing temperature is 500 to 700 ° C., particularly 550 ° C. to 650 ° C., in order that the first metal is alloyed and the second metal particles are joined in the vicinity of the contact.
本発明の実施形態に係るメタルボンドホイールに対する整形の状況を、図４に基づいて説明する。
整形前において、メタルボンドホイール１の砥粒層３の切刃となる砥粒６は、第１金属合金９と第２金属粒子１０と固体潤滑剤粒子７からなるメタルボンド８ｂによって固定されており、表面近傍の砥粒６はほとんど露出していない（図４（ａ））。メタルボンドホイール１を回転させ、整形砥石５の砥粒１１を砥粒層３に接触させると、砥粒層３の表面の第２金属粒子１０が脱落する（図４（ｂ））。これは上述したように第２金属粒子１０は軟質金属である第１金属合金９によって被覆され、接点近傍のみで接合しており、それぞれの粒子の接合力はそれほど強くないためである。
The shaping state of the metal bond wheel according to the embodiment of the present invention will be described with reference to FIG.
Before shaping, the abrasive grains 6 serving as the cutting edges of the abrasive grain layer 3 of the metal bond wheel 1 are fixed by metal bonds 8b made of the first metal alloy 9, the second metal particles 10, and the solid lubricant particles 7. The abrasive grains 6 near the surface are hardly exposed (FIG. 4A). When the metal bond wheel 1 is rotated and the abrasive grains 11 of the shaping grindstone 5 are brought into contact with the abrasive grain layer 3, the second metal particles 10 on the surface of the abrasive grain layer 3 fall off (FIG. 4B). This is because, as described above, the second metal particles 10 are covered with the first metal alloy 9 which is a soft metal and bonded only in the vicinity of the contact, and the bonding force of each particle is not so strong.
表面近傍の第２金属粒子１０の脱落が進行すると、第２金属粒子１０に取り囲まれることでメタルボンド８ｂ中に保持されていた固体潤滑剤粒子７が周辺の第２金属粒子１０と共に脱落し、比較的大きな脱落痕が形成される（図４（ｃ））。このような脱落痕が多数形成されると、メタルボンド８ｂの砥粒保持力が低下し、表面近傍の砥粒６が脱落し（図４（ｄ））する。また、このような脱落痕は第２金属粒子１０などの排出のためのチップポケットとしても機能し、結果として砥粒層３の整形性が向上する。このような工程を繰り返すことで、メタルボンドホイールの砥粒層形状が修正できる。（図４（ｅ））。 As the second metal particles 10 in the vicinity of the surface drop off, the solid lubricant particles 7 held in the metal bond 8b are dropped together with the surrounding second metal particles 10 by being surrounded by the second metal particles 10, A relatively large drop mark is formed (FIG. 4C). When many such dropping marks are formed, the abrasive grain holding power of the metal bond 8b is reduced, and the abrasive grains 6 in the vicinity of the surface fall off (FIG. 4D). Further, such a drop mark also functions as a chip pocket for discharging the second metal particles 10 and the like, and as a result, the shapeability of the abrasive layer 3 is improved. By repeating such steps, the abrasive layer shape of the metal bond wheel can be corrected. (FIG. 4 (e)).
以下に、具体的な実施例を示す。 Specific examples are shown below.
使用したメタルボンドホイールの詳細は以下の通りである。
台金寸法：１５０Ｄ×６Ｕ×５０．８Ｈ×３Ｘ
台金材質：Ｆｅ
砥粒：ダイヤモンド、＃６００（平均粒径：３０μｍ）
第１金属合金：Ｃｕ−Ｓｎ系合金
：メタルボンド中の体積比率：他成分の残り
第２金属粒子：Ｃｏ（平均粒径：１．４μｍ）
：メタルボンド中の体積比率：５０〜６５体積％
固体潤滑剤粒子：ＭｏＳ2（平均粒径：０．８〜２２．５μｍ）
：メタルボンド中の体積比率：１０〜４０体積％
焼結条件：５５０℃、５分
圧力：５０ｋｇ／ｃｍ2
The details of the metal bond wheel used are as follows.
Base metal dimensions: 150D x 6U x 50.8H x 3X
Base metal material: Fe
Abrasive grain: Diamond, # 600 (average particle diameter: 30 μm)
First metal alloy: Cu-Sn alloy
: Volume ratio in metal bond: remaining of other components Second metal particle: Co (average particle size: 1.4 μm)
: Volume ratio in metal bond: 50 to 65% by volume
Solid lubricant particles: MoS 2 (average particle size: 0.8-22.5 μm)
: Volume ratio in metal bond: 10 to 40% by volume
Sintering conditions: 550 ° C., 5 minutes Pressure: 50 kg / cm 2
整形試験条件及び研削試験条件は以下の通りである。
（整形試験条件）
整形砥石：ＧＣ６００Ｖ
研削盤：平面研削盤
砥石周速：３６０ｍ/ｍｉｎ以下
ホイール周速：３６０ｍ/ｍｉｎ
（研削試験条件）
加工方式：トラバース研削
砥石周速：１８００ｍ/ｍｉｎ
被研削材：超硬材
切込み：６μｍ／ｐａｓｓ
送り速度：１０ｍ／ｍｉｎ
The shaping test conditions and the grinding test conditions are as follows.
(Shaping test conditions)
Orthopedic whetstone: GC600V
Grinding machine: Surface grinder Wheel peripheral speed: 360 m / min or less Wheel peripheral speed: 360 m / min
(Grinding test conditions)
Processing method: Traverse grinding Wheel peripheral speed: 1800m / min
Material to be ground: Carbide material Cutting depth: 6μm / pass
Feeding speed: 10m / min
ＳＥＭ／ＥＰＭＡ分析装置（（株）島津製作所製、ＥＰＭＡ−Ｃ１）を使用して、実施例におけるメタルボンドホイールの砥粒層部分についての電子顕微鏡観察及びＥＰＭＡによる元素分析を行った。ＥＰＭＡ分析においては、ダイヤモンド砥粒を構成する炭素、第１金属を構成するＣｕ及びＳｎ、第２金属を構成するＣｏ、固体潤滑剤を構成するＭｏ及びＳについての元素分布状態を評価した。図５は本発明の代表的な実施例におけるメタルボンドホイールの砥材層表面の電子顕微鏡像である。なお、図５において、ＥＰＭＡ分析により炭素が検出された領域を、ダイヤモンド砥粒として点線で示している。 Using an SEM / EPMA analyzer (manufactured by Shimadzu Corporation, EPMA-C1), the abrasive layer portion of the metal bond wheel in the examples was observed with an electron microscope and subjected to elemental analysis by EPMA. In the EPMA analysis, element distribution states of carbon constituting diamond abrasive grains, Cu and Sn constituting the first metal, Co constituting the second metal, Mo and S constituting the solid lubricant were evaluated. FIG. 5 is an electron microscope image of the surface of the abrasive layer of the metal bond wheel in a typical example of the present invention. In FIG. 5, a region where carbon is detected by EPMA analysis is indicated by a dotted line as diamond abrasive grains.
図５からダイヤモンド砥粒が砥粒層に適度に分散されていることがわかる。ＥＰＭＡ分析によるとＣｕ，Ｓｎはこのダイヤモンド砥粒が検出された部分以外からは同程度のシグナル強度で一様に検出された。一方、Ｃｏは、Ｃｕ，Ｓｎと同様にダイヤモンド砥粒が検出された部分以外から一様に検出されたが、Ｃｕ，Ｓｎの場合と異なり、その分布形状は島状であり、粒子であることが確認された。また、Ｍｏ，Ｓも粒子状でありその周囲にはＣｏが検出された。 FIG. 5 shows that the diamond abrasive grains are moderately dispersed in the abrasive grain layer. According to the EPMA analysis, Cu and Sn were uniformly detected with the same signal intensity except for the portion where the diamond abrasive grains were detected. On the other hand, Co was detected uniformly from the portion other than the portion where diamond abrasive grains were detected, like Cu and Sn, but unlike Cu and Sn, its distribution shape is island-like and particles. Was confirmed. Mo and S were also in the form of particles, and Co was detected around them.
次に固体潤滑剤の含有量を変化させて整形性を評価した結果を表１に示す。なお、使用した固体潤滑剤の平均粒径３μｍである。ここで、研削比とは、研削による被削材の削除量を砥石の磨耗量で割った値として定義されるものであり、固体潤滑材の含有量が２０体積％のときの研削比を１００、整形時間を１００とした指数で表示している。 Next, Table 1 shows the result of evaluating the formability by changing the content of the solid lubricant. The solid lubricant used had an average particle size of 3 μm. Here, the grinding ratio is defined as a value obtained by dividing the removal amount of the work material by grinding by the wear amount of the grindstone, and the grinding ratio when the solid lubricant content is 20% by volume is 100. The index is expressed as an index with the shaping time as 100.
固体潤滑剤の含有量が、Ｃｏの含有量の１５体積％まで、整形砥石に実施例のメタルボンドホイールを接触させても整形を良好に行うことができなかった。これは固体潤滑剤の含有量が少なすぎて、整形時に固体潤滑剤が脱落しても、十分な量のチップポケットが形成されないためと考えられる。なお、整形時間は固体潤滑剤の含有量が増えるほど短くなっていき、固体潤滑剤の含有量１５体積％から特に整形時間が短縮し、特に２０体積％になると容易に整形を行うことができた。整形性の指標である研削比も固体潤滑剤の含有量１５体積％から向上し、１５〜３０体積％の範囲で整形後のメタルボンドホイールを使用すると好適に研削を行うことができた。その一方、固体潤滑剤の含有量が、Ｃｏの含有量の３０体積％を超えると、整形時間はさらに短くなったが、研削比が大きく低下した。これは固体潤滑剤が多すぎて、メタルボンドの結合力が著しく低下し、砥粒層自体の摩耗が大きくなったためと考えられる。 Even when the solid lubricant content was 15 vol% of the Co content, even if the metal bond wheel of the example was brought into contact with the shaping grindstone, shaping could not be performed satisfactorily. This is presumably because the content of the solid lubricant is too small and a sufficient amount of chip pockets are not formed even if the solid lubricant falls off during shaping. The shaping time becomes shorter as the solid lubricant content increases, and the shaping time is particularly shortened from the solid lubricant content of 15% by volume. It was. The grinding ratio, which is an index of shaping, was also improved from the solid lubricant content of 15% by volume, and when the shaped metal bond wheel was used in the range of 15 to 30% by volume, grinding could be suitably performed. On the other hand, when the solid lubricant content exceeded 30% by volume of Co, the shaping time was further shortened, but the grinding ratio was greatly reduced. This is presumably because there was too much solid lubricant, the bond strength of the metal bond was significantly reduced, and the wear of the abrasive layer itself was increased.
固体潤滑剤の含有量はすべて２０体積％に固定し、固体潤滑剤の平均粒径を変化させて整形を行った結果を表２に示す。なお、上記の通り、Ｃｏ粒子の平均粒径は１．４μｍである。また、表２においては、固体潤滑剤の平均粒径が３μｍ、すなわち、固体潤滑剤とＣｏ粒子の粒径比（以下、単に「粒径比」と称す。）が２．１のときの研削比、整形時間を１００とした指数で表示している。 Table 2 shows the results of shaping by fixing the solid lubricant content to 20% by volume and changing the average particle size of the solid lubricant. As described above, the average particle size of the Co particles is 1.4 μm. In Table 2, grinding is performed when the average particle size of the solid lubricant is 3 μm, that is, the particle size ratio between the solid lubricant and the Co particles (hereinafter simply referred to as “particle size ratio”) is 2.1. The ratio and the shaping time are indicated by an index of 100.
固体潤滑剤の平均粒径が１．５μｍ（粒径比：１．１）までは、整形砥石に実施例のメタルボンドホイールを接触させてもメタルボンドがほとんど摩耗せず、整形を行うことができなかったが、固体潤滑剤の大きさがＣｏ粒子と同程度であると、固体潤滑剤粒子の脱落が起こりづらく、メタルボンドの摩耗が進行しづらいためと考えられる。固体潤滑剤粒子の平均粒径２．３μｍ（粒径比：１．６）になるとメタルボンドの摩耗が確認され、整形を行うことができた。さらに固体潤滑剤粒子の平均粒径３μｍ（粒径比：２．１）になると、整形時間が短縮される。固体潤滑剤粒子の平均粒径２１μｍ（粒径比：１５）を超えると、著しく固体潤滑剤粒子が脱落しやすくなり、整形時間は短くなったが、研削比も大きく低下した。 Until the average particle size of the solid lubricant is 1.5 μm (particle size ratio: 1.1), even if the metal bond wheel of the example is brought into contact with the shaping grindstone, the metal bond is hardly worn and shaping can be performed. Although it was not possible, it is considered that when the size of the solid lubricant is the same as that of the Co particles, it is difficult for the solid lubricant particles to fall off and the metal bond wear does not proceed easily. When the average particle size of the solid lubricant particles was 2.3 μm (particle size ratio: 1.6), metal bond wear was confirmed and shaping could be performed. Furthermore, when the average particle size of the solid lubricant particles is 3 μm (particle size ratio: 2.1), the shaping time is shortened. When the average particle size of the solid lubricant particles exceeded 21 μm (particle size ratio: 15), the solid lubricant particles were remarkably easy to drop off and the shaping time was shortened, but the grinding ratio was also greatly reduced.
本発明のメタルボンドホイールは研削時に適度な砥粒保持力を確保しつつ、ＧＣ砥石など一般的な整形砥石を使用して整形を行うことができるので、常に切味が高い研削ホイールとして、高精度金型加工などの用途に好適に使用することができる。 Since the metal bond wheel of the present invention can be shaped using a general shaping whetstone such as a GC grindstone while securing an appropriate abrasive grain holding force during grinding, It can be suitably used for applications such as precision die machining.
１ メタルボンドホイール
２ 台金
３ 砥粒層
４ 取り付け穴
５ 整形砥石
６，１１ 砥粒
７ 固体潤滑剤粒子
８ａ，８ｂ メタルボンド
９ 第１金属合金
１０ 第２金属粒子
DESCRIPTION OF SYMBOLS 1 Metal bond wheel 2 Base metal 3 Abrasive grain layer 4 Mounting hole 5 Shaping grindstone 6,11 Abrasive grain 7 Solid lubricant particle 8a, 8b Metal bond 9 1st metal alloy 10 2nd metal particle
Claims (4)
前記メタルボンドは、ＣｕとＳｎを含む合金からなる第１金属と、前記第１金属より高融点である金属あるいは合金からなる粒子状の第２金属から構成され、
前記粒子状の第２金属のそれぞれは、前記ＣｕとＳｎを含む合金からなる第１金属を介して接合し、
前記粒子状の固体潤滑剤は、前記メタルボンド内に分散し、その平均粒径が前記粒子状の第２金属よりも大きく、かつ、 前記粒子状の固体潤滑剤の含有量が、前記粒子状の第２金属の含有量の１５体積％以上３０体積％以下であることを特徴とするメタルボンドホイール。 In a metal bond wheel having an abrasive grain layer formed by bonding abrasive grains and particulate solid lubricant by metal bond,
The metal bond is composed of a first metal made of an alloy containing Cu and Sn, and a particulate second metal made of a metal or alloy having a higher melting point than the first metal,
Each of the particulate second metals is bonded via the first metal made of an alloy containing Cu and Sn,
The particulate solid lubricant is dispersed in the metal bond, an average particle diameter of much larger than the said particulate second metal, and the content of the particulate solid lubricant, the particles A metal bond wheel, wherein the content of the second metal is 15 volume% or more and 30 volume% or less .
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