JPH04210380A - Diamond grinding wheel and manufacture thereof - Google Patents
Diamond grinding wheel and manufacture thereofInfo
- Publication number
- JPH04210380A JPH04210380A JP27441490A JP27441490A JPH04210380A JP H04210380 A JPH04210380 A JP H04210380A JP 27441490 A JP27441490 A JP 27441490A JP 27441490 A JP27441490 A JP 27441490A JP H04210380 A JPH04210380 A JP H04210380A
- Authority
- JP
- Japan
- Prior art keywords
- metal
- abrasive grains
- diamond
- diamond abrasive
- coating
- 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.)
- Pending
Links
- 229910003460 diamond Inorganic materials 0.000 title claims abstract description 81
- 239000010432 diamond Substances 0.000 title claims abstract description 81
- 238000004519 manufacturing process Methods 0.000 title claims description 25
- 238000000227 grinding Methods 0.000 title abstract description 9
- 239000006061 abrasive grain Substances 0.000 claims abstract description 112
- 229910052751 metal Inorganic materials 0.000 claims abstract description 83
- 239000002184 metal Substances 0.000 claims abstract description 83
- 239000011230 binding agent Substances 0.000 claims abstract description 48
- 239000011248 coating agent Substances 0.000 claims abstract description 37
- 238000000576 coating method Methods 0.000 claims abstract description 37
- 239000000463 material Substances 0.000 claims abstract description 19
- 239000000843 powder Substances 0.000 claims abstract description 16
- 239000011812 mixed powder Substances 0.000 claims abstract description 13
- 239000007921 spray Substances 0.000 claims abstract description 12
- 238000000034 method Methods 0.000 claims description 38
- 229910045601 alloy Inorganic materials 0.000 claims description 27
- 239000000956 alloy Substances 0.000 claims description 27
- 239000007767 bonding agent Substances 0.000 claims description 8
- 230000000717 retained effect Effects 0.000 claims 2
- 239000010953 base metal Substances 0.000 abstract 2
- 230000002950 deficient Effects 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 54
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 47
- 238000007751 thermal spraying Methods 0.000 description 27
- 229910052697 platinum Inorganic materials 0.000 description 24
- 238000005507 spraying Methods 0.000 description 18
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 15
- 239000002245 particle Substances 0.000 description 12
- 239000011148 porous material Substances 0.000 description 8
- 229910052759 nickel Inorganic materials 0.000 description 7
- 238000005219 brazing Methods 0.000 description 5
- 230000006866 deterioration Effects 0.000 description 4
- 230000003647 oxidation Effects 0.000 description 4
- 238000007254 oxidation reaction Methods 0.000 description 4
- 238000007750 plasma spraying Methods 0.000 description 4
- 238000007747 plating Methods 0.000 description 4
- 229910052802 copper Inorganic materials 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000004381 surface treatment Methods 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000005422 blasting Methods 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000003685 thermal hair damage Effects 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
Landscapes
- Polishing Bodies And Polishing Tools (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
Description
【発明の詳細な説明】
［産業上の利用分野］
本発明は、超硬材料、セラミックス、半導体等の研削、
切断等に利用されるダイヤモンド砥石及びその製造方法
に関する。[Detailed Description of the Invention] [Industrial Application Field] The present invention is applicable to grinding of superhard materials, ceramics, semiconductors, etc.
This invention relates to a diamond grindstone used for cutting, etc., and a method for manufacturing the same.
［従来の技術］
現状のダイヤモンド砥石には、大別して、メタルボンド
砥石と電着砥石が使用されている。[Prior Art] Currently used diamond grindstones are broadly classified into metal bond grindstones and electroplated grindstones.
前者は、ダイヤモンド砥粒をＮｉ、Ｃｕ、Ｗ、Ｆｅ、Ａ
ｇ等の金属を主体とした結合剤粉末と共に焼き固めて成
形される焼結砥粒層を、白金にろう付は等の接合手段を
介して一体化したものであり、一方、後者は、合金上に
ダイヤモンド砥粒をＮｉ、Ｃｕ等の金属と共に直接電気
メツキして置着させたものである。The former uses diamond abrasive grains such as Ni, Cu, W, Fe, and A.
A sintered abrasive layer formed by sintering and compacting together with a binder powder mainly composed of metals such as G is integrated with platinum through bonding means such as brazing. Diamond abrasive grains and metals such as Ni and Cu are directly electroplated and deposited thereon.
しかし、メタルボンド砥石については、砥粒層に含まれ
る気孔が不足して目詰まりを発生しやすいという欠点が
あり、製造面でも、砥石の種類毎に成形金型を用意しな
ければならず、製造コスｌ−か高くつき生産性も低い。However, metal bonded whetstones have the disadvantage that they tend to become clogged due to the lack of pores in the abrasive grain layer, and in terms of manufacturing, a mold must be prepared for each type of whetstone. The manufacturing cost is high and the productivity is low.
一方、電着砥石の場合では、通常、砥粒層が一層しか形
成できないため寿命が短いという欠点がある。また、製
造面でも、メツキ槽等の大掛かりな付帯設備を必要とし
、やはり製造コストが高くつき製造作業にも長時間を要
する。On the other hand, in the case of an electrodeposited grindstone, usually only a single layer of abrasive grains can be formed, so the service life is short. In addition, in terms of manufacturing, large-scale incidental equipment such as a plating tank is required, which results in high manufacturing costs and a long manufacturing time.
そこで、既存のメタルポンド砥石や電着砥石に代わるタ
゛イヤモンド砥石の製造手段として、溶射を利用した方
法も提案されている。Therefore, a method using thermal spraying has been proposed as a means of manufacturing a diamond grindstone in place of the existing metal pound grindstone or electroplated grindstone.
［発明か解決しようとする課題］
この溶射を利用したダイヤモンド砥石の製法としては、
ダイヤモンド砥粒と結合剤粉末とを混合した混合粉を溶
射して、合金上に直接砥粒層を形成する方法や、予め合
金上にダイヤモンド砥粒を置着しておき、その上からダ
イヤモンド砥粒を埋め込むように結合剤を溶射する方法
などが提案されている。[Invention or problem to be solved] The method for manufacturing a diamond whetstone using thermal spraying is as follows:
There is a method in which a mixed powder of diamond abrasive grains and binder powder is thermally sprayed to form an abrasive grain layer directly on the alloy, or diamond abrasive grains are placed on the alloy in advance and the diamond abrasive layer is applied on top of the diamond abrasive grains. A method of thermally spraying a binder to embed the grains has been proposed.
しかしながら、従来の溶射技術を用いて形成した砥粒層
では、ダイヤモンド砥粒と結合剤の溶射皮膜とのなじみ
か悪く、両者の界面での接合不良やボイドに起因して砥
粒の保持力か不足し、砥石として実用性に欠ける嫌いか
あった。However, in the abrasive layer formed using conventional thermal spraying technology, the compatibility between the diamond abrasive grains and the thermally sprayed binder coating is poor, and the retention of the abrasive grains is affected due to poor bonding and voids at the interface between the two. There was a shortage of it, and it was considered impractical as a whetstone.
本発明は、このような技術背景の下に、既存のメタルボ
ンド砥石や電着砥石と実質的に代替可能な溶射技術を利
用した新規なダイヤモンド砥石を製造方法と共に提供す
るものである。In view of this technical background, the present invention provides a novel diamond grindstone using thermal spraying technology that can be substantially substituted for existing metal bond grindstones and electroplated grindstones, together with a manufacturing method.
［課題を解決するための手段］
本発明が新たに提唱するダイヤモンド砥石は、Ｎｉ、Ｃ
ｕ等の金属コーティングしたダイヤモンド砥粒を、好ま
しくは被覆剤と同一の金属結合剤の溶射皮膜に分散して
保持させた砥粒層を、白金と一体化してなるものである
。[Means for solving the problem] The diamond grindstone newly proposed by the present invention is made of Ni, C,
The abrasive grain layer is formed by integrating platinum and an abrasive grain layer in which diamond abrasive grains coated with a metal such as U are dispersed and held in a thermally sprayed coating of preferably the same metal binder as the coating material.
本発明に係る砥粒層の白金に対する一体化手段について
は、後述するように、砥粒層を構成する溶射皮膜を直接
合金に接合させて一体化することもできるし、或いは白
金と分離形成した砥粒層をろう付は等の接合手段を介し
て白金と一体化することもできる。Regarding the means for integrating the abrasive grain layer with platinum according to the present invention, as described later, the thermal spray coating constituting the abrasive grain layer can be directly joined and integrated with the alloy, or alternatively, it can be formed separately from the platinum. The abrasive grain layer can also be integrated with platinum through bonding means such as brazing.
本発明ては、この新規なダイヤモンド砥石の製造方法と
して、より詳しくは、金属コーティングしたダイヤモン
ド砥粒を金属結合剤の溶射皮膜に分散して保持させた砥
粒層の形成手段として、次に二つの方法を提案する。In the present invention, as a manufacturing method of this new diamond grinding wheel, more specifically, as a means for forming an abrasive grain layer in which metal-coated diamond abrasive grains are dispersed and held in a thermally sprayed coating of a metal binder, We propose two methods.
一つは、白金もしくは仮付基材の上に、金属コーティン
グしたダイヤモンド砥粒と金属結合剤粉末とを混合した
混合粉をプラズマ溶射して、金属コーティングしたダイ
ヤモンド砥粒を金属結合剤の溶射皮膜に分散して保持さ
せた砥粒層を形成する方法である（以下、略してＡ法と
もいう）。One is to plasma spray a mixed powder of metal-coated diamond abrasive grains and metal binder powder onto platinum or a temporary base material, and then apply a thermal spray coating of the metal-coated diamond abrasive grains to the metal binder powder. This is a method of forming a layer of abrasive grains in which the abrasive grains are dispersed and held (hereinafter also referred to as method A for short).
もう一つは、合金もしくは仮付基材の上に、金属コーテ
ィングしたダイヤモンド砥粒を分散させて置着した後、
金属結合剤の粉末もしくはワイヤをプラズマ溶射して、
金属コーティングしたダイヤモンド砥粒を金属結合剤の
溶射皮膜に分散して保持させた砥粒層を形成する方法で
ある（以下、略してＢ法ともいう）。The other method is to disperse and place metal-coated diamond abrasive grains on an alloy or temporary base material, and then
Plasma spray metal binder powder or wire,
This is a method of forming an abrasive layer in which metal-coated diamond abrasive grains are dispersed and held in a sprayed coating of a metal binder (hereinafter also referred to as method B for short).
但し、Ａ法、Ｂ法とも、砥粒層を合金上に直接溶射して
形成する場合には、予め白金の接合面を粗面化するブラ
スト等の下地処理を施しておく。However, in both methods A and B, if the abrasive grain layer is directly sprayed onto the alloy, a surface treatment such as blasting to roughen the platinum bonding surface is performed in advance.
こうすれば、溶射皮膜が白金の接合面と機械的に密着し
て、白金と、金属コーティングしたダイヤモンド砥粒を
金属結合剤の溶射皮膜に分散して保持させた砥粒層とが
一体強固に接合される。In this way, the thermal spray coating mechanically adheres to the bonding surface of the platinum, and the platinum and the abrasive grain layer, in which metal-coated diamond abrasive grains are dispersed and held in the thermal spray coating of the metal binder, become one solid body. Joined.
また、Ａ法、Ｂ法とも、砥粒層を仮付基材上に溶射して
形成する場合は、砥粒層を形成した後、これを仮付基材
の表面から剥離し、この剥離した砥粒層を改めてろう付
は等の接合手段を介して白金と一体化することになる。In addition, in both methods A and B, when forming an abrasive grain layer by thermal spraying on a tack base material, after forming the abrasive grain layer, it is peeled off from the surface of the tack base material, and this peeled The abrasive grain layer is again integrated with platinum through a joining means such as brazing.
本発明で使用されるダイヤモンド砥粒は、金属結合剤の
粉末との混合粉で溶射する場合も、予め白金や仮付基材
の上に置着しておく場合も、必要な前処理として、表面
にＮｉやＣｕの金属コーティングを施したものが利用さ
れる。即ち、この金属コーティングしたダイヤモンド砥
粒を使用することで、溶射時における砥粒の高温酸化や
高温劣化が防止されると共に、表面の化学的濡れ性が改
善されて金属結合剤の溶射皮膜と良くなじみ、ダイヤモ
ンド砥粒を溶射特有の多孔質構造を呈する溶射皮膜によ
ってしっかりと保持させることかできる。従って、タ′
イヤモジ１〜砥粒と金属結合剤の粒径や、タ゛イヤモン
ド砥粒の表面にコーチインク゛される被覆金属のコーテ
ィング厚さについては、非常に重要となる。Whether the diamond abrasive grains used in the present invention are thermally sprayed as a mixed powder with metal binder powder or placed on platinum or a tack base material in advance, as a necessary pretreatment, A material whose surface is coated with a metal such as Ni or Cu is used. In other words, by using these metal-coated diamond abrasive grains, high-temperature oxidation and high-temperature deterioration of the abrasive grains during thermal spraying is prevented, and the chemical wettability of the surface is improved, making it compatible with the thermal spray coating of the metal binder. The diamond abrasive grains can be firmly held by the thermal spray coating, which has a porous structure unique to thermal spraying. Therefore, Ta′
The particle size of the abrasive grains and the metal binder and the coating thickness of the coated metal coated on the surface of the diamond abrasive grains are very important.
具体的には、ダイヤモンド砥粒径；８０〜５００μｍ、
結合剤粒子径；４０〜１００μｍ、コーティング（Ｎｊ
）厚さ；１５〜２５μｍが好ましい条件として挙げられ
る。コーティング厚さか１５μｍ以下であると、高温（
５０００〜６０００℃〉のプラズマ溶射雰囲気を飛行中
にコーティング層が希薄化され、ダイヤモンド砥粒が露
出して熱損傷を受は易い。しかし、２５μｍ以上になる
と、コスト高となると同時に、コーティングの効果も飽
和し、却って砥石としての品質の低下を来たす。Specifically, diamond abrasive grain size; 80 to 500 μm;
Binder particle size: 40 to 100 μm, coating (Nj
) Thickness: 15 to 25 μm is mentioned as a preferable condition. If the coating thickness is less than 15 μm, high temperature (
During flight in a plasma spray atmosphere of 5,000 to 6,000° C., the coating layer is diluted, and the diamond abrasive grains are exposed and susceptible to thermal damage. However, when the thickness is 25 μm or more, the cost increases and at the same time, the coating effect becomes saturated, resulting in a deterioration in the quality of the grindstone.
一方、金属コーティングしたダイヤモンド砥粒と共に、
或いは単独で溶射されて、ダイヤモンド砥粒を分散保持
する溶射皮膜を構成する金属結合剤ついては、好ましく
はダイヤモンド砥粒のコーティング金属と同一のメタル
ボンド剤が用いられる。そして、両者の混合粉を溶射す
る場合ては、金属コーティングしたダイヤモンド砥粒と
金属結合剤との混合割合についても重要となる。On the other hand, along with metal-coated diamond abrasive grains,
Alternatively, as for the metal bonding agent which is sprayed alone and constitutes the thermal sprayed coating that disperses and holds the diamond abrasive grains, preferably the same metal bonding agent as the coating metal of the diamond abrasive grains is used. When a mixed powder of both is thermally sprayed, the mixing ratio of the metal-coated diamond abrasive grains and the metal binder is also important.
第５図は、ニッケルコーティングダイヤモンド（６４％
ニッケルー３６％ダイヤモンド）を使用する後の実施例
の場合について、両者の混合状態が模式的に図示されて
いる。この場合、金属結合剤には、粒径１００μｍ程度
のものを、目標とする集中度Ｃに応して混ぜ合わせてい
る（例えは、Ｎ＝１８コ、集中度Ｃ；１００％、Ｎ＝１
．１０コ。Figure 5 shows nickel-coated diamond (64%
In the case of the latter example in which nickel-36% diamond) is used, a mixed state of both is schematically illustrated. In this case, metal binders with particle diameters of approximately 100 μm are mixed according to the target concentration C (for example, N = 18 particles, concentration C: 100%, N = 1
．． 10 pieces.
集中度Ｃ；２５％）
なお、溶射飛行中の砥粒と結合剤粒子の飛行速度を合わ
すため、できるだけ両者のｍａｓｓ ｂａｌａｎｃｅを
執る工夫、即ち粒子の質量を揃える工夫も重要であり、
こうすることにより、白金等の表面から砥粒のはね返り
を少なくし、燃焼防止にも改善効果を奏する。Concentration C: 25%) In order to match the flight speeds of the abrasive grains and binder particles during thermal spray flight, it is important to maintain a mass balance between the two as much as possible, that is, to make the mass of the particles the same.
By doing so, the rebound of abrasive grains from the surface of platinum or the like is reduced, and combustion prevention is also improved.
次に、金属結合剤等の溶射手段としては、Ａｒ等の不活
性ガスによるガスシールドを併用した高温プラズマ溶射
が用いられる。これは溶射材料に対するプラズマジェッ
トの大きな入熱により溶射皮膜の形成が高速で行えるこ
とと共に、プラズマカスにより溶射材料を噴射すること
で、燃焼雰囲気では酸化しやすいダイヤモンド砥粒や結
合剤溶滴の高温酸化や高温劣化を最少限に抑えることが
できるからである。Next, as a means for spraying the metal binder, high-temperature plasma spraying is used in combination with a gas shield using an inert gas such as Ar. This enables the formation of a thermal spray coating at high speed due to the large heat input of the plasma jet to the thermal spray material, and the high temperature of the diamond abrasive grains and binder droplets, which are easily oxidized in a combustion atmosphere, by injecting the thermal spray material with plasma scum. This is because oxidation and high-temperature deterioration can be minimized.
なお、ダイヤモンド砥粒や溶融結合剤粉末の酸化を防ぎ
、更に密着力等の改善を図る見地では、溶射雰囲気を大
気中から遮断したチャンバ内減圧溶射を利用することも
できる。Note that from the standpoint of preventing oxidation of the diamond abrasive grains and molten binder powder and further improving adhesion, etc., it is also possible to use vacuum thermal spraying in a chamber in which the thermal spraying atmosphere is isolated from the atmosphere.
本発明に係るダイヤモンド砥石には、この種既存のもの
と同様、必要に応じ補助砥粒として、タングステンカー
バイドやアルミナ等の超硬骨材のスケルトンを配合する
こともてきる。The diamond grindstone according to the present invention, like existing ones of this type, may contain a skeleton of cemented carbide aggregate such as tungsten carbide or alumina as auxiliary abrasive grains if necessary.
［発明の作用、効果］
本発明のダイヤモンド砥石にあっては、金属コーティン
グしたダイヤモンド砥粒を金属結合剤の溶射皮膜に分散
して保持させた砥粒層を形成する点に最大の特徴がある
。[Operations and Effects of the Invention] The most important feature of the diamond grinding wheel of the present invention is that it forms an abrasive layer in which metal-coated diamond abrasive grains are dispersed and held in a sprayed coating of a metal binder. .
即ち、ダイヤモンド砥粒を金属結合剤にダイレクトに混
入した混合粉を溶射する方法や、合金上に分散直着され
た無被覆のダイヤモンド砥粒の上に金属結合剤を溶射す
る既知の方法では、タ゛イヤモンド砥粒が高温酸化や劣
化を受けるだけでなく、ダイヤモンド砥粒と溶射皮膜と
のなじみか悪く、ダイヤモンド砥粒に研削加工等に耐え
る十分な保持力をもたせることができない。That is, in the known method of thermal spraying a mixed powder in which diamond abrasive grains are directly mixed into a metal binder, or in the known method of thermal spraying a metal binder on uncoated diamond abrasive grains that are directly dispersed on an alloy, Not only are the diamond abrasive grains subject to high-temperature oxidation and deterioration, but the compatibility between the diamond abrasive grains and the thermal spray coating is poor, and the diamond abrasive grains cannot have sufficient holding power to withstand grinding and the like.
これに対し、本発明の如く、タ゛イヤモンド砥粒に金属
コーティングを施したものを使用すれば、同質の金属結
合剤の溶射皮膜とのなじみが良く、両者の界面に大きな
接合強度か得られ、界面におけるボイドの発生も見られ
なくなる。このため、溶射技術を利用してダイヤモンド
砥石を製造する場合の最大のネックである、砥粒保持不
良の問題点を的確に解決することができる。On the other hand, if diamond abrasive grains are coated with metal as in the present invention, they are compatible with the thermally sprayed coating of the same metal binder, and a large bonding strength can be obtained at the interface between the two. The occurrence of voids is also no longer observed. Therefore, it is possible to accurately solve the problem of poor retention of abrasive grains, which is the biggest bottleneck in manufacturing diamond grindstones using thermal spraying technology.
なお、無被覆のダイヤモンド砥粒を金属結合剤粉末と直
接混合して溶射する方法による場合では、プラズマ雰囲
気飛行中において、密度、融点の異なる二種の粒子がア
ンバランスな単独飛行を生し、その結果、一方のみか過
剰な熱損傷や衝突飛散の不具合を生じ、白金到達の時点
ては到底均−な砥粒層を形成し得ない。また、仮に金属
コーチインク′したタ゛イヤモンド砥粒のみを溶射する
場合には、一種類の粒子として扱えるものの、形成され
た砥粒層は砥粒の集中度が高くなり過ぎた緻密質のもの
となり、砥粒の保持力が強くなり過ぎたりして、砥石と
しての品質バランス、コストバランスが保てない結果と
なる。In addition, when uncoated diamond abrasive grains are directly mixed with metal binder powder and sprayed, two types of particles with different densities and melting points fly alone in an unbalanced manner during flight in a plasma atmosphere. As a result, problems such as excessive heat damage and collision scattering occur on only one side, and it is impossible to form an even abrasive grain layer when the platinum reaches the platinum layer. In addition, if only diamond abrasive grains coated with metal coach ink are thermally sprayed, although they can be treated as one type of particle, the abrasive layer formed will be dense with too high a concentration of abrasive grains. The holding power of the abrasive grains becomes too strong, resulting in the quality balance and cost balance of the grindstone not being maintained.
そして、金属コーティングしたダイヤモンド砥粒を、溶
射ガンから噴射される金属結合剤の溶滴か堆積して形成
される溶射皮膜に分散保持させたものであると、ダイヤ
モンド砥粒を保持する結合剤の溶射皮膜には、飛着溶滴
が潰れて網目状に結合し、その内部に多数の気孔を含む
溶射特有の多孔質組織が形成される。しかも、溶射皮膜
中の気孔の大きさや分布状態は、結合剤粉末の粒度、溶
射入熱量、溶射距離等の溶射条件を選ぶことにより自在
に調整できる利点かある。When the metal-coated diamond abrasive grains are dispersed and held in a thermal spray coating formed by depositing droplets of a metal bonding agent sprayed from a thermal spray gun, the bonding agent that holds the diamond abrasive particles is In the thermal sprayed coating, the flying droplets are crushed and combined into a network, forming a porous structure unique to thermal spraying that contains many pores inside. Moreover, the size and distribution of pores in the thermal sprayed coating can be freely adjusted by selecting thermal spraying conditions such as the particle size of the binder powder, thermal spraying heat input, and thermal spraying distance.
このため、既存のメタルポンド砥石に比較すると、ダイ
ヤモンド砥粒の保持力に低下を来たすことなく、結合剤
の溶射皮膜中に適度な気孔を生成することかできて、切
り屑の排出性に優れ、目詰まりが発生しにくい研削性能
を有したものが得られ、また、既存の電着砥石と比較ず
れば、溶射により白金や仮付基材の形状通りの砥粒層か
形成できる利点に加えて、電着砥石では不可能なダイヤ
モンド砥粒の多層盛りが実現できる。Therefore, compared to existing metal pound grinding wheels, it is possible to generate appropriate pores in the thermally sprayed binder coating without reducing the holding power of diamond abrasive grains, and it has excellent chip evacuation properties. In addition, compared to existing electroplated grindstones, it has the advantage of being able to form an abrasive layer that matches the shape of the platinum or tack base material by thermal spraying. This makes it possible to create multiple layers of diamond abrasive grains, which is impossible with electroplated grindstones.
なお、Ａ法、Ｂ法いずれの製法による場合て゛も、砥石
の製造に必要な器具として溶射機を用意すれば足り、金
型、焼結炉、メツキ槽等の従来の大掛かりな製造設備は
一切不要となる。また、砥石製造時間も、溶射による白
金等への膜付作業により、短時間のうちに完遂できる。In addition, regardless of whether method A or method B is used, it is sufficient to prepare a thermal spraying machine as the equipment necessary for manufacturing the whetstone, and conventional large-scale manufacturing equipment such as molds, sintering furnaces, plating tanks, etc. are not required at all. becomes. Furthermore, the manufacturing time for the whetstone can be completed in a short time by applying a film to platinum or the like by thermal spraying.
［実施例］ 以下、実施例を挙げて更に具体的に説明する。[Example] Hereinafter, a more specific explanation will be given with reference to Examples.
失施１
第１図〜第４図は、前記Ａ法に従って白金に直接砥粒層
を形成する製造プロセスと、この方法によって製造され
るタイヤモント砥石（砥粒層）の詳細が示される。Loss of application 1 Figures 1 to 4 show details of the manufacturing process of directly forming an abrasive layer on platinum according to method A, and of the Tiremont grindstone (abrasive layer) manufactured by this method.
この方法では、砥粒層を一体化する合金１（例えば鋼板
）の接合面］ａには、予めブラスト等の下地処理を施し
て粗面化しておく。In this method, the bonding surface [a] of the alloy 1 (for example, a steel plate) that integrates the abrasive grain layer is roughened by performing a surface treatment such as blasting in advance.
合金１には、第１図のように、接合面（溶射面）１ａの
近接対向位置にプラズマ溶射機のトーチ２か配置される
。プラズマ溶射機は、溶射材料を収容するホッパー３を
具備し、ホッパー３内には、第２図に拡大して示すよう
に、金属コーティング４ａを施したダイヤモンド粒子４
と、金属結合剤の粉末５とを均一に混合した混合粉６が
収容されている。As shown in FIG. 1, a torch 2 of a plasma spraying machine is placed on the alloy 1 at a position close to and facing the joint surface (sprayed surface) 1a. The plasma spraying machine is equipped with a hopper 3 that stores a thermal spraying material, and inside the hopper 3 are diamond particles 4 coated with a metal coating 4a, as shown in an enlarged view in FIG.
A mixed powder 6, which is a uniform mixture of powder and metal binder powder 5, is housed therein.
本実施例の場合、混合粉６の成分と混合比は、次の通り
である。In the case of this example, the components and mixing ratio of the mixed powder 6 are as follows.
ダイヤモンド砥粒
粒径：２００〜３００μｍ
総重量；４０（ｇ）
金属コーティング；無電解ニッケルメッキ被覆厚さ；２
０μｍ
総重量ニア３（ｇ＞
金属結合剤；ニッケル（２００＃）
粒径：１１００ＬＬ
総重量：１３６０ ＜ｇ）
混合粉総重量； １４７３ （ｇ）
なお、この場合、砥粒、結合剤の混合状態は、第５図に
示す通りであり、Ｎ＝１１０コに設定して集中度Ｃ；２
５％で実施した。Diamond abrasive grain size: 200-300 μm Total weight: 40 (g) Metal coating: Electroless nickel plating coating thickness: 2
0μm Total weight near 3 (g> Metallic binder; Nickel (200#) Particle size: 1100LL Total weight: 1360 <g) Total mixed powder weight; 1473 (g) In this case, the mixed state of abrasive grains and binder is as shown in Fig. 5, setting N = 110 and concentration degree C; 2.
It was carried out at 5%.
この混合粉６かトーチ２がら噴き出されるプラズマジェ
ット７に乗って合金１上に溶射される。This mixed powder 6 rides on a plasma jet 7 ejected from the torch 2 and is thermally sprayed onto the alloy 1.
なお、溶射作業中はトーチ２を図示矢印の如く往復移動
させて、接合面１ａに均一に皮膜を形成する。During the thermal spraying operation, the torch 2 is moved back and forth as shown by the arrow in the figure to uniformly form a coating on the joint surface 1a.
第３図は、溶射完了後の状態を示し、合金１の上には、
混合溶射されたＮｉコーティングダイヤモンド砥粒４が
、金属結合剤（Ｎｉ）の溶射皮膜８に分散して保持され
た砥粒層９が所望の厚みで形成される。この砥粒層９は
溶射皮膜８が合金１の接合面１ａと機械的に密着して接
合され、合金１と強固に一体化されている。Figure 3 shows the state after thermal spraying is completed, and on Alloy 1 there are
An abrasive layer 9 in which Ni-coated diamond abrasive grains 4 that have been mixed and thermally sprayed are dispersed and held in a thermally sprayed coating 8 of a metal binder (Ni) is formed to a desired thickness. In this abrasive layer 9, the thermal spray coating 8 is mechanically closely bonded to the joint surface 1a of the alloy 1, so that the abrasive layer 9 is firmly integrated with the alloy 1.
第４図は、砥粒層９の断面構造を模式的に図示したもの
で、集中度２５％で所々に分散されるダイヤモンド砥粒
４と、金属結合剤の多孔質な溶射皮膜８とかタ′イヤモ
ンド砥粒表面のＮｉコーティング４ａを介して濡れ性よ
く接合され、溶射皮膜８に強固に保持されている。一方
、Ｎｉ溶射金属で形成された溶射皮膜８は、適度に気孔
１０か内在されて、砥粒層９全体としては、砥粒４、ボ
ンド材８及び気孔］−〇の三要素が適度にミックスされ
た砥石構造か実現される。FIG. 4 schematically shows the cross-sectional structure of the abrasive grain layer 9, which includes diamond abrasive grains 4 dispersed here and there at a concentration of 25%, and a porous sprayed coating 8 of a metal binder. It is bonded with good wettability via the Ni coating 4a on the surface of the diamond abrasive grain, and is firmly held by the thermal spray coating 8. On the other hand, the sprayed coating 8 formed of Ni sprayed metal contains a moderate amount of pores 10, and the abrasive grain layer 9 as a whole contains a moderate mix of the three elements: abrasive grains 4, bond material 8, and pores ]-0. A new grinding wheel structure is realized.
この方法では、合金１は平板状のものに限らず曲面を有
するものであってもよく、その表面に倣って合金１の形
状通りに砥粒層９を一体化させることができる。In this method, the alloy 1 is not limited to a flat plate, but may have a curved surface, and the abrasive layer 9 can be integrated in the shape of the alloy 1 by following the surface.
なお、上記Ａ法に従うダイヤモンド砥石の製造方法では
、白金に代えて、まず平滑な仮付基材の上に砥粒層を溶
射形成し、しかる後、砥粒層を剥離して、別途用意され
る合金上にろう付は等の接合手段を介して一体化させる
プロセスを採ることもできる。In addition, in the method for manufacturing a diamond whetstone according to method A above, instead of platinum, an abrasive grain layer is first thermally sprayed onto a smooth temporary base material, and then the abrasive grain layer is peeled off to form a separately prepared abrasive grain layer. It is also possible to adopt a process of integrating the metal alloy through a bonding means such as brazing.
夾旌盟旦
第６図〜第８図は、前記Ｂ法に従って白金に直接砥粒層
を形成する製造プロセスと、この方法（こよって製造さ
れるダイヤモンド砥石（砥粒層）の詳細か示される。Figures 6 to 8 show details of the manufacturing process of directly forming an abrasive layer on platinum according to method B, and of the diamond grinding wheel (abrasive layer) manufactured by this method. .
この方法では、前記実施例Ａと同様、砥粒層を一体化す
る合金１の接合面１−ａを、予めプラスト等の下地処理
を施して粗面化しておく。そし、て、下地処理した合金
１の接合面１ａには、第６図のように、接着剤やメツキ
層を介して予め金属コーティング４ａを施したダイヤモ
ンド砥粒４を分散して置着しておく。In this method, as in Example A, the bonding surface 1-a of the alloy 1 that integrates the abrasive grain layer is roughened in advance by subjecting it to a surface treatment such as plasting. Then, as shown in FIG. 6, diamond abrasive grains 4, which have been previously coated with a metal coating 4a via an adhesive or plating layer, are dispersed and placed on the joint surface 1a of the base-treated alloy 1. put.
かくして、金属コーティングしたタイヤモンｌ〜砥粒４
を分散置着した合金１の接合面１ａには、近接対向位置
に配したプラズマ溶射機のトーチ２から、金属結合剤が
単独でプラズマ溶射される。Thus, metal-coated tire mon l ~ abrasive grain 4
The metal bonding agent is plasma-sprayed alone onto the bonding surface 1a of the alloy 1, on which the metal bonding agent is dispersedly deposited, from the torch 2 of a plasma spraying machine disposed in close opposing positions.
この際、溶射材料には前記実施例Ａと同じく結合剤粉末
を供給することもできるか、結合剤単独溶射の場合は、
Ｃｕ心線のような金属ワイヤ１１をトーチ２の火口に送
給する方式を採用した方がより簡便となる。At this time, it is possible to supply a binder powder to the thermal spray material as in Example A, or in the case of thermal spraying with a binder alone,
It is easier to adopt a method in which a metal wire 11 such as a Cu core wire is fed to the mouthpiece of the torch 2.
この状態で、溶射機の１−一層２から金属結合剤の溶滴
を噴射して、金属コーティングしたタ゛イヤモント砥粒
４を適度な深さに埋め込んで金属結合剤の溶射皮膜８を
膜付けすると、第７図に示すように、合金１の上には、
金属コーティングされたダイヤモンド砥粒４を金属結合
剤の溶射皮Ｍ８に分散して保持させた砥粒層９が形成さ
れる。そして、この場合も砥粒層９は、溶射皮膜８か合
金１の接合面１ａと機械的に密着して、合金１と強固に
一体化される。In this state, droplets of metal binder are sprayed from layer 1 to layer 2 of the thermal spraying machine, the metal-coated tire abrasive grains 4 are embedded to an appropriate depth, and a thermal spray coating 8 of metal binder is applied. , as shown in FIG. 7, on top of Alloy 1,
An abrasive layer 9 is formed in which metal-coated diamond abrasive grains 4 are dispersed and held in a sprayed coating M8 of a metal binder. In this case as well, the abrasive grain layer 9 is mechanically in close contact with the thermal spray coating 8 or the bonding surface 1a of the alloy 1, and is firmly integrated with the alloy 1.
第８図は、砥粒層９の断面構造を模式的に図示したもの
で、所々に分散するダイヤモンド砥粒４が、表面の金属
コーティング４ａを介して金属結合剤の溶射皮膜８と良
く密着され、かつ溶射皮膜８には適度に気孔１０が内在
されている。FIG. 8 schematically shows the cross-sectional structure of the abrasive grain layer 9, in which the diamond abrasive grains 4 dispersed here and there are well adhered to the sprayed coating 8 of the metal binder through the metal coating 4a on the surface. , and the thermal spray coating 8 contains a suitable amount of pores 10.
この方法では、実施例Ａの場合と同様に、合金１は平板
状のものに限らず曲面を有するものであってもよく、そ
の表面に倣って合金１の形状通りに砥粒層９を一体化さ
せることができる。また、図示例では、ダイヤモンド砥
粒４を一層にのみ配列する場合を示したが、この方法で
あれば、砥粒付けと溶射工程とを繰り返すことて、ダイ
ヤモンド砥粒４を多層に配列した砥粒層を形成すること
も容易に実現できる。In this method, as in the case of Example A, the alloy 1 is not limited to a flat plate, but may have a curved surface, and the abrasive grain layer 9 is integrated in the shape of the alloy 1 following the surface. can be made into In addition, although the illustrated example shows the case where the diamond abrasive grains 4 are arranged in only one layer, if this method is used, the abrasive grains 4 can be arranged in multiple layers by repeating the abrasive grain application and thermal spraying process. Formation of a grain layer can also be easily realized.
なお、上記Ｂ法に従うダイヤモンド砥石の製造方法では
、前記実施例Ａの場合と同様に、平滑な仮付基材の上に
形成した砥粒層を剥離して、別途用意される合金上に接
合して一体化させることもできる。その際、砥粒層を裏
返して白金に接合すると、白金に面する砥粒層の接合面
に、タ゛イヤモンド砥粒を完全に埋め込んだ金属結合剤
の溶射皮膜のみが現われて、白金に対するろう付けの接
合強度が高められると同時に、予め仮付基村上に下つら
を揃えて置着されたダイヤモンド砥粒が反転されて、今
度は上つらを揃えた状態で露出されることになるなめ、
実質的に砥粒層の有効厚さが増し、使用寿命が延長され
る効果が得られる。In addition, in the method for manufacturing a diamond whetstone according to method B described above, as in the case of Example A, the abrasive grain layer formed on the smooth temporary base material is peeled off and bonded onto a separately prepared alloy. They can also be integrated. At that time, when the abrasive grain layer is turned over and bonded to the platinum, only a thermally sprayed coating of the metal bonding agent completely embedded with the diamond abrasive grains appears on the bonding surface of the abrasive grain layer facing the platinum, and the brazing to the platinum is completed. At the same time as the bonding strength is increased, the diamond abrasive grains that were previously placed on the tack base plate with the lower edges aligned are reversed and are now exposed with the upper edges aligned.
The effect is that the effective thickness of the abrasive grain layer is substantially increased and the service life is extended.
第１図〜第４図は、本発明の第１の砥石製造方法（Ａ法
）による実施例を示す。第１図は白金に対する溶射工程
の概要を示す概略正面図、第２図は混合粉の拡大図、第
３図は製造砥石の断面図、第４図は砥粒層の拡大断面図
である。第５図は金属コーティングしたダイヤモンド砥
粒と金属結合剤（Ｎｉ）との混合状態を示す説明図であ
る。
第６図〜第８図は、本発明の第２の砥石製造方法（Ｂ法
）による実施例を示す。第６図は白金に対する溶射工程
の概要を示す概略正面図、第７図は製造砥石の断面図、
第８図は砥粒層の拡大断面図である。
１・・・合金 １ａ・・・接合面２・・・
トーチ（溶射機） ３・・・ホッパー４・・・ダイヤモ
ンド砥粒 ４ａ・・・コーティング５・・・金属結合剤
粉末 ６・・・混合粉７・・・プラズマジェット ８
・・・溶射皮膜９・・・砥粒層 １０・・・気
孔１１・・・金属結合剤ワイヤ
特許出願人 日本アルミニウム工業株式会社特許出願人
三和研磨工業株式会社
戸
代理人弁理士 西 谷 英雄Ｈ”’、７：−”ｈ。1 to 4 show an example according to the first grindstone manufacturing method (method A) of the present invention. FIG. 1 is a schematic front view showing an overview of the thermal spraying process for platinum, FIG. 2 is an enlarged view of the mixed powder, FIG. 3 is a cross-sectional view of the manufacturing grindstone, and FIG. 4 is an enlarged cross-sectional view of the abrasive grain layer. FIG. 5 is an explanatory diagram showing a mixed state of metal-coated diamond abrasive grains and a metal binder (Ni). 6 to 8 show examples of the second grindstone manufacturing method (method B) of the present invention. Figure 6 is a schematic front view showing the outline of the thermal spraying process for platinum, Figure 7 is a cross-sectional view of the manufacturing grindstone,
FIG. 8 is an enlarged sectional view of the abrasive grain layer. 1...Alloy 1a...Joint surface 2...
Torch (spraying machine) 3...Hopper 4...Diamond abrasive grains 4a...Coating 5...Metal binder powder 6...Mixed powder 7...Plasma jet 8
...Thermal spray coating 9...Abrasive grain layer 10...Pores 11...Metal binder wire Patent applicant: Nippon Aluminum Industry Co., Ltd. Patent applicant: Sanwa Polishing Industry Co., Ltd. Patent attorney: Hideo Nishitani H"', 7:-"h.
Claims (3)
合剤の溶射皮膜に分散して保持させた砥粒層を、合金と
一体化したことを特徴とするダイヤモンド砥石。(1) A diamond whetstone characterized in that an abrasive grain layer in which metal-coated diamond abrasive grains are dispersed and held in a sprayed coating of a metal binder is integrated with an alloy.
したダイヤモンド砥粒と金属結合剤粉末とを混合した混
合粉をプラズマ溶射して、金属コーティングしたダイヤ
モンド砥粒を金属結合剤の溶射皮膜に分散して保持させ
た砥粒層を形成することを特徴とするダイヤモンド砥石
の製造方法。(2) Plasma spray a mixed powder of metal-coated diamond abrasive grains and metal binder powder onto the alloy or tack base material, and apply the metal-coated diamond abrasive grains to a sprayed coating of metal binder. A method for producing a diamond whetstone, characterized by forming a layer of dispersed and retained abrasive grains.
したダイヤモンド砥粒を分散させて置着した後、金属結
合剤の粉末もしくはワイヤをプラズマ溶射して、金属コ
ーティングしたダイヤモンド砥粒を金属結合剤の溶射皮
膜に分散して保持させた砥粒層を形成することを特徴と
するダイヤモンド砥石の製造方法。(3) After dispersing and placing metal-coated diamond abrasive grains on the alloy or temporary base material, plasma spray metal bonding agent powder or wire to metal-bond the metal-coated diamond abrasive grains. A method for manufacturing a diamond whetstone, which comprises forming a layer of abrasive grains dispersed and retained in a sprayed coating of a diamond abrasive.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP27441490A JPH04210380A (en) | 1990-10-13 | 1990-10-13 | Diamond grinding wheel and manufacture thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP27441490A JPH04210380A (en) | 1990-10-13 | 1990-10-13 | Diamond grinding wheel and manufacture thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH04210380A true JPH04210380A (en) | 1992-07-31 |
Family
ID=17541342
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP27441490A Pending JPH04210380A (en) | 1990-10-13 | 1990-10-13 | Diamond grinding wheel and manufacture thereof |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH04210380A (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR100676054B1 (en) * | 2004-12-20 | 2007-01-29 | 재단법인 포항산업과학연구원 | Manufacturing method for metal bonded diamond wheel |
| WO2007060984A1 (en) * | 2005-11-28 | 2007-05-31 | A.L.M.T. Corp. | Resin-bonded superabrasive wheel and process for producing the same |
| JP2020040138A (en) * | 2018-09-07 | 2020-03-19 | 石川県 | Tool with abrasive grain, manufacturing method of tool with abrasive grain and abrasive grain sticking method |
| JPWO2021161728A1 (en) * | 2020-02-13 | 2021-08-19 |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS58202780A (en) * | 1982-05-20 | 1983-11-26 | Nippon Kogaku Kk <Nikon> | Grindstone manufacturing method by frame spray coating |
-
1990
- 1990-10-13 JP JP27441490A patent/JPH04210380A/en active Pending
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS58202780A (en) * | 1982-05-20 | 1983-11-26 | Nippon Kogaku Kk <Nikon> | Grindstone manufacturing method by frame spray coating |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR100676054B1 (en) * | 2004-12-20 | 2007-01-29 | 재단법인 포항산업과학연구원 | Manufacturing method for metal bonded diamond wheel |
| WO2007060984A1 (en) * | 2005-11-28 | 2007-05-31 | A.L.M.T. Corp. | Resin-bonded superabrasive wheel and process for producing the same |
| JP2020040138A (en) * | 2018-09-07 | 2020-03-19 | 石川県 | Tool with abrasive grain, manufacturing method of tool with abrasive grain and abrasive grain sticking method |
| JPWO2021161728A1 (en) * | 2020-02-13 | 2021-08-19 | ||
| WO2021161728A1 (en) * | 2020-02-13 | 2021-08-19 | 日産自動車株式会社 | Sliding mechanism |
| US11624338B2 (en) | 2020-02-13 | 2023-04-11 | Nissan Motor Co., Ltd. | Sliding mechanism |
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