JP7501919B2 - Cutting blade and method of manufacturing same - Google Patents

Description

The present invention relates to a cutting blade for performing cutting and grooving processes on resin, ceramics, glass, metal, and composite materials thereof, and a method for manufacturing the same.

Cutting blades for cutting and grooving resins, ceramics, glass, metals, and composite materials thereof are well known, as disclosed in, for example, Patent Document 1, Patent Document 2, and Patent Document 3. These well-known cutting blades are in the shape of a thin ring, and have multiple bottomed grooves on the outer periphery of both sides that do not penetrate the cutting blade in the thickness direction. These grooves facilitate the smooth supply of coolant to the cutting area and the discharge of cutting chips to the outside through the grooves, thereby reducing cutting resistance and maintaining sharpness.

However, the above-mentioned known cutting blades are electroformed products, and therefore flexible. During cutting, the cutting blade deforms or vibrates, causing bending during cutting, making it difficult to cut the workpiece in a straight line.
In addition, since the groove is formed to extend straight in the radial direction of the cutting blade, when cutting the workpiece, cutting chips accumulate in the groove and are difficult to remove, resulting in an increase in cutting resistance, which can lead to a decrease in sharpness and damage to the cutting blade.

JP 2013-154423 A JP 2013-244546 A JP 2014-221511 A

The technical objective of the present invention is to prevent deterioration of the cutting performance and damage to the cutting blade by increasing the rigidity of the cutting blade having grooves on both sides in the thickness direction, thereby eliminating bending during cutting, and by improving the discharge of cutting chips by the grooves, thereby reducing cutting resistance.

In order to solve the above problems, the present invention provides a cutting blade made of a sintered bond material with one or both of diamond abrasive grains and CBN abrasive grains dispersed therein. This cutting blade is in the shape of a thin ring, and is characterized in that a number of grooves, each of which has a depth shallower than 1/2 the thickness of the cutting blade, are formed on the outer periphery of both sides of the cutting blade in the thickness direction, and are inclined relative to a line segment in the radial direction of the cutting blade.

In the present invention, the groove has a groove tip portion that opens to the outer peripheral surface of the cutting blade and a closed groove rear end portion opposite the groove tip portion, and it is desirable that the direction in which the groove inclines with respect to the line segment is a direction gradually moving away from the line segment to the rear side in the rotational direction of the cutting blade from the groove tip side toward the groove rear end side.
In this case, the inner surface of the rear end portion of the recessed groove may be a concave curved surface.

In the present invention, the groove has a first side wall located on the front side in the rotation direction of the cutting blade and a second side wall located on the rear side in the rotation direction of the cutting blade, the length of the first side wall is longer than the length of the second side wall, and the first side wall and the second side wall may be convexly curved toward the rear side in the rotation direction of the cutting blade.
It is also preferable that the width of the groove is equal to the distance that the groove rises from the outer circumferential surface of the blade in the radial direction of the blade.

In the present invention, the multiple grooves on one side of the cutting blade and the multiple grooves on the other side are preferably arranged at equal intervals in the circumferential direction of the cutting blade, and the grooves on both sides are preferably arranged in staggered positions so that they do not overlap in the thickness direction of the cutting blade.

In addition, in the present invention, the cutting blade has an annular outer peripheral portion that includes the outer surface of the cutting blade, and an annular inner peripheral portion that is surrounded by the outer peripheral portion, and the outer peripheral portion and the inner peripheral portion are formed of different types of bonding materials, and the hardness and elastic modulus of the bonding material forming the inner peripheral portion may be greater than the hardness and elastic modulus of the bonding material forming the outer peripheral portion.

In the present invention, it is desirable that the radial width of the inner peripheral portion is greater than the radial width of the outer peripheral portion, and that the groove is formed so as to extend obliquely across the outer peripheral portion and reach the inner peripheral portion.

In the present invention, the bond material is made of one of the following: cemented carbide, cermet, and high-hardness intermetallic compound.

The cutting blade manufacturing method of the present invention includes a powder manufacturing step of manufacturing a powder for sintering by uniformly dispersing one or both of diamond abrasive grains and CBN abrasive grains in a powder of a bond material, a sintering step of filling the sintering powder into a ring-shaped sintering chamber of a sintering mold and sintering it to obtain a ring-shaped blade material whose outer diameter and thickness are larger than those of the cutting blade 1 and whose inner diameter is smaller than the inner diameter of the cutting blade 1, a size adjustment step of adjusting the outer diameter, inner diameter and thickness of the blade material so that they approach the target size of the outer diameter, inner diameter and thickness of the cutting blade, a groove forming step of forming multiple grooves by a chemical or mechanical method on the outer peripheral edge of both sides of the size-adjusted blade material, and a finishing step of matching the outer diameter, inner diameter and thickness of the blade material with the grooves formed to the target size.

Another method for manufacturing a cutting blade according to the present invention includes a powder manufacturing step of manufacturing a first sintering powder made of a bond material having a high hardness and elastic modulus and a second sintering powder made of a bond material having a low hardness and elastic modulus by uniformly dispersing one or both of diamond abrasive grains and CBN abrasive grains in powders of two types of bond materials having different hardness and elastic modulus, and a step of filling the second sintering powder in a ring-shaped sintering chamber on the outer periphery of the sintering chamber and filling the first sintering powder in a ring-shaped sintering chamber on the inner periphery of the second sintering powder, and sintering the resulting powders. The method includes a firing process for obtaining a ring-shaped blade material whose outer diameter and thickness are larger than those of the cutting blade 1 and whose inner diameter is smaller than the inner diameter of the cutting blade 1; a size adjustment process for adjusting the outer diameter, inner diameter and thickness of the blade material so that they approach target sizes set to the outer diameter, inner diameter and thickness of the cutting blade; a groove forming process for forming a plurality of grooves by a chemical or mechanical method on the outer peripheral edge portion on both sides of the size-adjusted blade material; and a finishing process for matching the outer diameter, inner diameter and thickness of the blade material with the grooves formed therein to the target sizes.

The cutting blade of the present invention has multiple grooves on both sides of the cutting blade that are inclined relative to the radial line of the cutting blade, which not only improves the discharge of cutting chips during cutting and improves lubricity during cutting to suppress the generation of frictional heat, but also reduces cutting resistance and prevents deterioration of sharpness and damage to the cutting blade. In addition, since the blade is formed from a sintered body, it has higher rigidity than electroformed products and is less likely to bend when cut.

FIG. 1 is a side view of a first embodiment of a cutting blade according to the present invention. FIG. 2 is an enlarged view of a main part of FIG. 1 . FIG. 3 is an enlarged cross-sectional view taken along line III-III in FIG. 2. FIG. 2 is a side view of the fired blade material prior to forming the cutting blade of the first embodiment. FIG. 5 is a cross-sectional view of the blade material of FIG. 4 . FIG. 4 is a side view of a second embodiment of a cutting blade according to the present invention. FIG. 7 is an enlarged view of a main portion of FIG. 6 . FIG. 13 is a side view of the fired blade material prior to forming the cutting blade of the second embodiment. 9 is a cross-sectional view of the blade material taken along line IX-IX in FIG. 8.

The embodiment of the cutting blade according to the present invention will be described in detail below with reference to the drawings. Figures 1 to 3 show a first embodiment of the cutting blade 1 according to the present invention. This cutting blade 1 is made of a sintered body obtained by sintering a bond material in which superabrasive grains are evenly dispersed, and is in the shape of a thin ring having a thickness of 0.1 mm or less. It has a mounting hole 2 in the center, and is attached to a cutting device by inserting the rotating shaft of the cutting device into this mounting hole 2, and is rotated in the direction of the arrow X to perform cutting and groove cutting on materials to be processed such as resin, ceramics, glass, metal, and composite materials thereof. The size of the cutting blade 1 shown in the figure is an outer diameter Φ1 of 54 mm, an inner diameter (diameter of mounting hole 2) Φ2 of 40 mm, and a thickness t of 0.05 mm. However, the cutting blade 1 of the present invention is not limited to such dimensions.

The bond material is made of one of cemented carbide, cermet, or high-hardness intermetallic compounds, and the superabrasive grains (not shown) are made of one or both of diamond grains and CBN grains. Some of the abrasive grains dispersed in the bond material protrude slightly from the bond material on the outer peripheral surface 3 and both left and right side surfaces 4, 5 of the cutting blade 1, and these abrasive grains cut the workpiece. The grain size of the abrasive grains is about 4-60 μm, similar to the grain size of the abrasive grains used in known cutting blades 1.

On both the left and right side surfaces 4, 5 of the cutting blade 1, a plurality of bottomed grooves 6 with a depth d shallower than the thickness t of the cutting blade 1 are formed on the outer periphery at an angle to the radial line segment S of the cutting blade 1, at equal intervals in the circumferential direction of the cutting blade 1. In the embodiment shown in FIG. 1, 16 grooves 6 are formed on each of the left and right side surfaces 4, 5 of the cutting blade 1, and the grooves 6 on one side surface 4 and the grooves 6 on the other side surface 5 of the cutting blade 1 are arranged in staggered positions so that they do not overlap each other in the thickness direction of the cutting blade 1.

The depth d of the groove 6 is preferably smaller than half the thickness t of the cutting blade 1, and more preferably about 40% of the thickness t. Therefore, when the thickness t of the cutting blade 1 is 0.05 mm, the preferred depth d of the groove 6 is 0.02 mm.
In addition, the groove 6 is formed to a length that does not reach from the outer peripheral surface 3 of the cutting blade 1 to the mounting hole 2, and has a groove tip 8 that opens to the outer peripheral surface 3 of the cutting blade 1 and a closed groove rear end 9 opposite the groove tip 8, and the inner shape of the groove rear end 9 is a concave curved surface that curves toward the rear side of the groove 6.

The direction in which the groove 6 is inclined with respect to the line segment S is such that it gradually moves away from the line segment S toward the rear side in the rotational direction of the cutting blade 1 as it moves from the groove tip 8 side to the groove rear end 9 side, and the preferred inclination angle θ of the groove 6 at this time is 30-60 degrees, with the more preferred inclination angle θ being 60 degrees. Because the groove 6 is inclined in this manner, the groove tip 8 of the groove 6 opens in a slender shape in the circumferential direction on the outer circumferential surface 3 of the cutting blade 1, and the opening width a is greater than the width W of the groove 6. As a result, when cutting the workpiece, cutting chips can be smoothly and reliably taken in and discharged from the groove 6.

The groove 6 has a first side wall 6a on the front side in the rotation direction of the cutting blade 1 and a second side wall 6b on the rear side in the rotation direction, and the length of the first side wall 6a is longer than the length of the second side wall 6b. These first side wall 6a and second side wall 6b are not completely straight from the groove tip 8 side to the groove rear end 9 side of the groove 6, but are curved to form a slightly convex shape toward the rear side in the rotation direction of the cutting blade 1, and smoothly connect to the concave curved surface of the groove rear end 9.

The width W of the groove 6 and the distance (standing distance) T that the groove 6 rises from the outer peripheral surface 3 of the cutting blade 1 in the radial direction of the cutting blade 1 are equal to each other, and their preferable size is about 1-2 mm. When considering an imaginary tangent circle C that is tangent to the groove rear end 9 of all (16) grooves 6 formed on one side surface 4 of the cutting blade 1, the standing distance T can be said to be the difference between the radius R0 of this imaginary tangent circle C and the radius R of the cutting blade 1. This standing distance T is set to be greater than the cutting depth when cutting the workpiece with the cutting blade 1.

The cutting blade 1 of the first embodiment (outer diameter 54 mm, inner diameter 40 mm, thickness 0.05 mm, depth of groove 6 0.02 mm) can be manufactured by the following process (first manufacturing method).

First, the powder for sintering is produced by evenly dispersing either diamond abrasive grains or CBN abrasive grains or both in a powder of a bond material made of either a cemented carbide, a cermet, or a high-hardness intermetallic compound (powder production process).

Next, the powder for firing is filled into the inside of a ring-shaped firing chamber of a firing mold and fired to form a ring-shaped blade material 1A (see FIG. 4) whose outer diameter and thickness are slightly larger than those of the cutting blade 1 and whose inner diameter is slightly smaller than that of the cutting blade 1 (firing step). As shown in FIGS. 4 and 5, the size of this blade material 1A is, for example, an outer diameter Φ1 of 58.5 mm, an inner diameter Φ2 of 39.5 mm, and a thickness t of 0.3 mm.

Then, the blade material 1A is subjected to mechanical processing such as grinding and cutting to adjust the size of the blade material 1A, i.e., the outer diameter, inner diameter, and thickness, so that the size of the cutting blade 1 is set as the target size (size adjustment process). After size adjustment, the size of the blade material 1A is, for example, an outer diameter Φ1 of 54.5 mm, an inner diameter Φ2 of 39.5 mm, and a thickness t of about 0.1 mm.

Next, multiple grooves 6 (see FIG. 1) are formed on the outer periphery of both side surfaces 4, 5 of the blade material 1A that has been adjusted to size by a chemical method such as etching, or a mechanical method such as laser processing or blasting (groove forming process). At this time, if necessary, the parts where the grooves 6 are not to be formed can be covered with a mask, so that only the parts where the grooves 6 are to be formed can be processed.

Then, the cutting blade 1 can be obtained by performing a finishing process in which the outer diameter Φ1, inner diameter Φ2 and thickness t of the blade material 1A in which the groove 6 is formed are finished to the target size by polishing, cutting, etc.
In this finishing process, the thickness t of the blade material 1A is reduced from 0.1 mm to 0.05 mm, so in order to make the final depth d of the groove 6 0.02 mm, it is necessary to set the depth of the groove 6 formed in the groove forming process to approximately 0.045 mm.

The cutting blade 1 is attached to the cutting device by inserting the rotating shaft of the cutting device into the mounting hole 2, and is used to perform cutting and grooving on materials to be processed, such as resin, ceramics, glass, metal, and composite materials thereof.

At this time, since a groove 6 inclined toward the rear in the rotation direction of the cutting blade 1 is formed on both sides 4 and 5 of the cutting blade 1, the supplied coolant flows quickly through the groove 6 along the inclination of the groove 6 after flowing into the groove 6, and is efficiently supplied to the cutting part. At the same time, the cutting chips generated by cutting are smoothly taken into the groove 6, and then move along with the coolant through the groove 6 toward the groove rear end 9 side, and are smoothly and quickly discharged from the groove rear end 9 side to the outside. As a result, not only is the lubricity during cutting improved and the generation of frictional heat suppressed, but the cutting resistance is also reduced due to the smooth and quick discharge of the cutting chips, and deterioration of the cutting blade 1 and damage, etc. are prevented. In addition, since the blade is formed of a sintered body, it has higher rigidity than electrocast products and is less likely to bend when cut.

According to a cutting experiment conducted by the present inventors, when three types of cutting blades (those of the first embodiment) having a groove 6 width W and a rising height T of 2 mm and a groove 6 inclination angle θ of 30 degrees, 45 degrees, and 60 degrees were used to cut a phenolic resin plate having a thickness of 1.5 mm at a blade rotation speed of 40,000 rpm and a processing speed of 100 mm/sec, it was confirmed that the cutting blade of the present invention having an inclined groove 6 has a better ability to discharge cutting chips than the general cutting blade having a non-inclined groove, and in particular, the greater the inclination angle of the groove 6 , the better the ability to discharge cutting chips, and the better the angle is when the groove 6 is 60 degrees.

6 to 9 show a second embodiment of the cutting blade according to the present invention. The cutting blade 10 of the second embodiment differs from the cutting blade 1 of the first embodiment in that the cutting blade 1 of the first embodiment is entirely made of one type of bond material, which is either cemented carbide, cermet, or high-hardness intermetallic compound, whereas the cutting blade 10 of the second embodiment uses two types of bond materials with different hardness and elastic modulus, and the ring-shaped outer peripheral portion 11 including the outer peripheral surface 3 is made of a soft bond material with a low hardness and elastic modulus, and the ring-shaped inner peripheral portion 12 surrounded by the outer peripheral portion 11 is made of a hard bond material with a hardness and elastic modulus higher than those of the soft bond material.

The dimensions of the cutting blade 10 in this second embodiment are an outer diameter Φ1 of 54 mm, an inner diameter Φ2 of 40 mm, a thickness t of 0.05 mm, and a diameter Φ3 of the inner periphery 12 of 53.4 mm. Therefore, the radial width of the outer periphery 11 is 0.3 mm.

The configuration and operation of the cutting blade 10 of the second embodiment is substantially the same as the configuration of the cutting blade 1 of the first embodiment, except that it has the outer circumferential portion 11 and the inner circumferential portion 12. Therefore, the same reference numerals as in the first embodiment are used to designate the main identical components of the two, and detailed explanations of their configurations and operations will be omitted.

The inner circumference 12 of the cutting blade 10, which makes up the majority of the blade, is made of a hard bond material with high hardness and elasticity. Because of its high rigidity, the blade is less likely to bend when cutting the workpiece, and can cut the workpiece straight. This improves the processing quality and increases the durability of the cutting blade 10.

Next, a second manufacturing method for manufacturing the cutting blade 10 will be described. This second manufacturing method is basically the same as the first manufacturing method for manufacturing the cutting blade 1 of the first embodiment, but differs from the first manufacturing method in the first powder manufacturing process and the second firing process.

That is, in the powder production process of the second production method, powders of two types of bond materials with different hardness and elastic modulus are used, and one or both of diamond abrasive grains and CBN abrasive grains are evenly dispersed in the powders of the two types of bond materials to produce a first sintering powder made of a bond material with high hardness and elastic modulus, and a second sintering powder made of a bond material with low hardness and elastic modulus.

In the next firing step, the second firing powder is filled in a ring shape on the outer periphery of the annular firing chamber of the firing mold, and the first firing powder is filled in a ring shape on the inner periphery of the firing chamber, and firing is performed in that state.

As a result, as shown in Figures 8 and 9 , a ring-shaped blade material 10A is formed having an outer peripheral portion 11 and an inner peripheral portion 12, an outer diameter and thickness larger than the outer diameter and thickness of the cutting blade 1, and an inner diameter smaller than the inner diameter of the cutting blade 1.
The blade material 10A is then subjected to a size adjustment process, a groove forming process, and a finishing process in this order to obtain the cutting blade 10 as shown in FIG .

1, 10 Cutting blade 1A, 10A Blade material 3 Outer circumferential surface 4, 5 Side surface 6 Groove 6a First side wall 6b Second side wall 8 Groove tip 9 Groove rear end X Rotation direction Φ1 Outer diameter Φ2 Inner diameter t Thickness d Depth w Width S Line segment T Standing distance

Claims (10)

A cutting blade made of a sintered body of a bond material in which one or both of diamond abrasive grains and CBN abrasive grains are dispersed,
The cutting blade is in the shape of a thin plate ring, and a plurality of grooves, each having a depth less than half the thickness of the cutting blade, are formed on the outer peripheral edge of both sides in the thickness direction of the cutting blade so as to be inclined with respect to a line segment in the radial direction of the cutting blade ,
The cutting blade is characterized in that the groove has a groove tip portion that opens to the outer peripheral surface of the cutting blade and a closed groove rear end portion opposite the groove tip portion, and the direction in which the groove inclines with respect to the line segment is a direction gradually moving away from the line segment to the rear side in the direction of rotation of the cutting blade from the groove tip side toward the groove rear end side . 2. The cutting blade according to claim 1 , wherein the inner surface of the rear end of the groove is a concave curved surface. The cutting blade according to claim 1 or claim 2, characterized in that the groove has a first side wall located on the front side in the rotation direction of the cutting blade and a second side wall located on the rear side in the rotation direction of the cutting blade, the length of the first side wall is longer than the length of the second side wall, and the first side wall and the second side wall are convexly curved toward the rear side in the rotation direction of the cutting blade. 4. A cutting blade according to claim 1 , wherein the width of said groove is equal to the distance that said groove rises from the outer circumferential surface of the blade in the radial direction of the blade. A cutting blade as described in any one of claims 1 to 4, characterized in that the multiple grooves on one side surface of the cutting blade and the multiple grooves on the other side surface are each arranged at equal intervals in the circumferential direction of the cutting blade, and are arranged in alternating positions so that the grooves on both sides do not overlap in the thickness direction of the cutting blade. The cutting blade according to any one of claims 1 to 5, characterized in that the cutting blade has an annular outer peripheral portion including the outer surface of the cutting blade and an annular inner peripheral portion surrounded by the outer peripheral portion, the outer peripheral portion and the inner peripheral portion being formed of different types of bonding materials, and the hardness and elastic modulus of the bonding material forming the inner peripheral portion are greater than the hardness and elastic modulus of the bonding material forming the outer peripheral portion . 7. The cutting blade according to claim 6, wherein the radial width of the inner peripheral portion is greater than the radial width of the outer peripheral portion, and the groove is formed so as to cross the outer peripheral portion obliquely and reach the inner peripheral portion. 8. The cutting blade according to claim 1, wherein the bond material is made of any one of a cemented carbide, a cermet, and a high-hardness intermetallic compound. a powder production step for producing a powder for sintering by uniformly dispersing diamond abrasive grains and/or CBN abrasive grains in a powder of a bond material;
a firing step of filling the firing powder into a ring-shaped firing chamber of a firing mold and firing the powder to obtain a ring-shaped blade material having an outer diameter and thickness larger than those of a cutting blade and an inner diameter smaller than the inner diameter of the cutting blade;
a size adjusting step of adjusting the outer diameter, inner diameter and thickness of the blade material so as to approach the target sizes of the outer diameter, inner diameter and thickness of the cutting blade;
a groove forming step of forming a plurality of grooves on the outer peripheral edge of both sides of the sized blade material by a chemical or mechanical method;
a finishing process for matching the outer diameter, inner diameter and thickness of the blade material having the groove formed therein to the target size;
A method for manufacturing a cutting blade comprising the steps of: a powder production process for producing a first sintering powder made of a bond material having a high hardness and elastic modulus and a second sintering powder made of a bond material having a low hardness and elastic modulus by uniformly dispersing one or both of diamond abrasive grains and CBN abrasive grains in powders of two types of bond materials having different hardness and elastic modulus;
a firing step of filling the second powder for firing in a ring-shaped firing chamber of a firing mold in a ring shape on the outer periphery of the firing chamber and filling the first powder for firing in a ring shape on the inner periphery of the second powder for firing, and firing the resulting ring-shaped blade material having an outer diameter and thickness larger than those of the cutting blade and an inner diameter smaller than the inner diameter of the cutting blade;
a size adjusting step of adjusting the outer diameter, inner diameter and thickness of the blade material so as to approach the target sizes of the outer diameter, inner diameter and thickness of the cutting blade;
a groove forming step of forming a plurality of grooves on the outer peripheral edge of both sides of the sized blade material by a chemical or mechanical method;
a finishing process for matching the outer diameter, inner diameter and thickness of the blade material having the groove formed therein to the target size;
A method for manufacturing a cutting blade comprising the steps of:

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