SG190555A1 - Saw blade and method for multiple sawing of rare earth magnet - Google Patents
Saw blade and method for multiple sawing of rare earth magnet Download PDFInfo
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- SG190555A1 SG190555A1 SG2012087334A SG2012087334A SG190555A1 SG 190555 A1 SG190555 A1 SG 190555A1 SG 2012087334 A SG2012087334 A SG 2012087334A SG 2012087334 A SG2012087334 A SG 2012087334A SG 190555 A1 SG190555 A1 SG 190555A1
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- sawing
- cutting part
- particle size
- rare earth
- saw
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Links
- 229910052761 rare earth metal Inorganic materials 0.000 title claims abstract description 32
- 150000002910 rare earth metals Chemical class 0.000 title claims abstract description 31
- 238000000034 method Methods 0.000 title claims abstract description 11
- 238000005520 cutting process Methods 0.000 claims abstract description 61
- 239000000314 lubricant Substances 0.000 claims abstract description 25
- 239000000203 mixture Substances 0.000 claims abstract description 23
- 239000011230 binding agent Substances 0.000 claims abstract description 16
- 230000002093 peripheral effect Effects 0.000 claims abstract description 13
- 229920005989 resin Polymers 0.000 claims abstract description 13
- 239000011347 resin Substances 0.000 claims abstract description 13
- 235000012489 doughnuts Nutrition 0.000 claims abstract description 8
- 239000002245 particle Substances 0.000 claims description 31
- 239000011159 matrix material Substances 0.000 claims description 14
- 229910003460 diamond Inorganic materials 0.000 claims description 12
- 239000010432 diamond Substances 0.000 claims description 12
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 10
- 229910052799 carbon Inorganic materials 0.000 claims description 6
- 229910052582 BN Inorganic materials 0.000 claims description 5
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 5
- 229910052802 copper Inorganic materials 0.000 claims description 5
- QLOAVXSYZAJECW-UHFFFAOYSA-N methane;molecular fluorine Chemical compound C.FF QLOAVXSYZAJECW-UHFFFAOYSA-N 0.000 claims description 5
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 claims description 5
- 229910052982 molybdenum disulfide Inorganic materials 0.000 claims description 5
- 229910052759 nickel Inorganic materials 0.000 claims description 5
- ITRNXVSDJBHYNJ-UHFFFAOYSA-N tungsten disulfide Chemical compound S=[W]=S ITRNXVSDJBHYNJ-UHFFFAOYSA-N 0.000 claims description 5
- 229910052742 iron Inorganic materials 0.000 claims description 4
- 229920001187 thermosetting polymer Polymers 0.000 claims description 3
- -1 polytetrafluoroethylene Polymers 0.000 claims description 2
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 2
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 2
- 239000011162 core material Substances 0.000 description 27
- 238000000227 grinding Methods 0.000 description 15
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 12
- 125000006850 spacer group Chemical group 0.000 description 11
- 239000000463 material Substances 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 6
- 229910001172 neodymium magnet Inorganic materials 0.000 description 6
- 239000006061 abrasive grain Substances 0.000 description 5
- 229910045601 alloy Inorganic materials 0.000 description 5
- 239000000956 alloy Substances 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 5
- 239000002826 coolant Substances 0.000 description 5
- 238000003754 machining Methods 0.000 description 5
- 238000005245 sintering Methods 0.000 description 5
- 229910002804 graphite Inorganic materials 0.000 description 4
- 239000010439 graphite Substances 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
- 229910003481 amorphous carbon Inorganic materials 0.000 description 3
- 239000012530 fluid Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229920001568 phenolic resin Polymers 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 229920000877 Melamine resin Polymers 0.000 description 2
- 230000002411 adverse Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000009713 electroplating Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000011156 evaluation Methods 0.000 description 2
- 239000010419 fine particle Substances 0.000 description 2
- 238000005461 lubrication Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 235000006693 Cassia laevigata Nutrition 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 241000735631 Senna pendula Species 0.000 description 1
- 229910001315 Tool steel Inorganic materials 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 230000002596 correlated effect Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 229910052733 gallium Inorganic materials 0.000 description 1
- 229910052735 hafnium Inorganic materials 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 230000005415 magnetization Effects 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 229940124513 senna glycoside Drugs 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
- B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
- B26D1/12—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis
- B26D1/14—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a cutting member moving about an axis with a circular cutting member, e.g. disc cutter
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
- B24D5/12—Cut-off wheels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B27/00—Other grinding machines or devices
- B24B27/06—Grinders for cutting-off
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
- B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
- B24D3/346—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties utilised during polishing, or grinding operation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28D—WORKING STONE OR STONE-LIKE MATERIALS
- B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
- B28D1/22—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by cutting, e.g. incising
- B28D1/24—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by cutting, e.g. incising with cutting discs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28D—WORKING STONE OR STONE-LIKE MATERIALS
- B28D5/00—Fine working of gems, jewels, crystals, e.g. of semiconductor material; apparatus or devices therefor
- B28D5/02—Fine working of gems, jewels, crystals, e.g. of semiconductor material; apparatus or devices therefor by rotary tools, e.g. drills
- B28D5/022—Fine working of gems, jewels, crystals, e.g. of semiconductor material; apparatus or devices therefor by rotary tools, e.g. drills by cutting with discs or wheels
- B28D5/029—Fine working of gems, jewels, crystals, e.g. of semiconductor material; apparatus or devices therefor by rotary tools, e.g. drills by cutting with discs or wheels with a plurality of cutting blades
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Mining & Mineral Resources (AREA)
- Life Sciences & Earth Sciences (AREA)
- Forests & Forestry (AREA)
- Polishing Bodies And Polishing Tools (AREA)
- Processing Of Stones Or Stones Resemblance Materials (AREA)
- Sawing (AREA)
Abstract
Saw Blade and Method for Multiple Sawing of Rare Earth Magnet5A multiple blade assembly comprising a plurality of spaced apart saw blades mounted on a rotating shaft is used for sawing a rare earth magnet block into multiple pieces by rotating the plurality of saw blades. The saw blade10 comprises a core in the form of a thin doughnut disk and aperipheral cutting part on an outer peripheral rim of the core. The cutting part is made of a composition comprising an abrasive, a resin binder, and a lubricant.Fig. la
Description
Saw Blade and Method for Multiple Sawing of Rare Earth Magnet
This invention generally relates to a method for sawing a magnet block into multiple pieces. More particularly, it relates to a saw blade for use in sawing a rare earth magnet block into multiple pieces.
Systems for manufacturing commercial products of rare earth magnet include a single part system wherein a part of substantially the same shape as the product is produced at the stage of press molding, and a multiple part system wherein once a large block is molded, it is divided into a plurality of parts by machining. The single part system includes press molding, sintering or heat treating, and finishing steps. A molded part, a sintered or heat treated part, and a finished part (or product) are substantially identical in shape and size. Insofar as normal sintering is performed, a sintered part of near net shape is obtained, and the load of the finishing step is relatively low. However, when it is desired to manufacture parts of small size or parts having a reduced thickness in magnetization direction, the sequence of press molding and sintering is difficult to form sintered parts of normal shape, leading to a lowering of manufacturing yield, and at worst, such parts cannot be formed.
In contrast, the multiple part system eliminates the above-mentioned problems and allows press molding and sintering or heat treating steps to be performed with high productivity and versatility. It now becomes the mainstream
S1-
of rare earth magnet manufacture. In the multiple part system, a molded block and a sintered or heat treated block are substantially identical in shape and size, but the subsequent finishing step requires cutting or sawing. It is the key for manufacture of finished parts how to saw the block in the most efficient and least wasteful manner.
Tools for cutting rare earth magnet blocks include two types, a diamond grinding wheel inner-diameter (ID) blade having diamond grits bonded to an inner periphery of a thin doughnut-shaped disk, and a diamond grinding wheel outer-diameter (OD) blade having diamond grits bonded to an outer periphery of a thin disk as a core. Nowadays the sawing technology using OD blades becomes the mainstream, especially from the aspect of productivity. The sawing technology using ID blades is low in productivity because of a single blade cutting mode. In the case of OD blade, multiple cutting is possible. FIG. 1 illustrates an exemplary multiple blade assembly 1 comprising a plurality of saw blades 11 coaxially mounted on a rotating shaft (not shown) alternately with spacers 12, each blade 11 comprising a core 1llb in the form of a thin doughnut disk and a cutting part or abrasive grain layer lla on an outer peripheral rim of the core 11lb. This multiple blade assembly 1 is capable of multiple sawing, that is, cutting a block into a multiplicity of parts at a time.
For the manufacture of OD abrasive blades, diamond grains are generally bonded by three typical binding systems including resin bonding with resin binders, metal bonding with metal binders, and electroplating. These abrasive blades are often used in sawing of rare earth magnet blocks.
When sawing abrasive blades are used to machine a rare earth magnet block of certain size into a multiplicity of parts, the relationship of the cutting part (axial) width of _o-
the saw blade is crucially correlated to the material yield of the workpiece (magnet block). It is important to maximize a material yield and productivity by using a cutting part with a minimal width, machining at a high accuracy to minimize a machining allowance and reduce chips, and increasing the number of parts available.
In order to form a cutting part with a minimal width (or thinner cutting part) from the standpoint of material yield, the abrasive wheel core must be thin. In the case of
OD blade 11 shown in FIG. 1, its core 1llb is usually made of steel materials from the standpoints of material cost and mechanical strength. Of these steel materials, alloy tool steels classified as SK, SKS, SKD, SKT, and SKH according to the JIS standards are often used in commercial practice.
However, in an attempt to saw a hard material such as rare earth magnet by a thin OD blade, the prior art core of alloy tool steel is short in mechanical strength and becomes deformed or bowed during sawing operation, losing dimensional accuracy.
One solution to this problem is a cutoff wheel for use with rare earth magnet alloys comprising a core of cemented carbide to which high hardness abrasive grains such as diamond and CBN are bonded with a binding system such as resin bonding, metal bonding or electroplating, as described in JP-A H10-175172. Use of cemented carbide as the core material mitigates buckling deformation by stresses during machining, ensuring that rare earth magnet is sawed at a high accuracy. However, if a high frictional resistance is exerted between the cutting part and the magnet during sawing of the magnet, high accuracy machining is not expected. In particular, if substantial friction occurs between the side surface of the cutting part (not directly contributing to grinding operation) and the magnet, the grinding resistance _3-
is enhanced. Then, even if the cemented carbide core is used, chipping and/or bowing can occur, adversely affecting the machined state.
One solution to the above problem is to add a lubricant such as fatty acid to grinding fluid or coolant.
However, since the space between the saw blade and the workpiece or rare earth magnet is extremely narrow, it is difficult to effectively supply the coolant between the saw blade and the magnet.
Patent Document 1: JP-A H10-175172
An object of the invention is to provide a saw blade in the form of a resinoid wheel, which is used in multiple sawing of a rare earth magnet block into multiple pieces, which reduces the sawing resistance between the saw blade and the magnet block, and which ensures sawing at a high accuracy and high speed even if the saw blade is thinner than the conventional blades. Another object is to provide a method for sawing a rare earth magnet block into multiple pieces.
The invention pertains to a multiple blade assembly comprising a plurality of saw blades coaxially mounted on a rotating shaft at axially spaced apart positions. The multiple blade assembly is used for sawing a rare earth magnet block into multiple pieces by rotating the plurality of saw blades. The saw blade has a core in the form of a thin disk or thin doughnut disk and a peripheral cutting part on an outer peripheral rim of the core. The inventors have developed a saw blade in the form of a resinoid wheel having a cutting part made of a composition comprising a component or lubricant for reducing the friction between the cutting —g-
part and the magnet block during the sawing operation. When the magnet block is sawed by the saw blades, the sawing operation experiences a reduced cutting resistance, and achieves an equivalent yield and accuracy compared with the prior art even if thinner saw blades are used.
The invention generally pertains to a multiple blade assembly comprising a plurality of saw blades coaxially mounted on a rotating shaft at axially spaced apart positions, which is used for sawing a rare earth magnet block into multiple pieces by rotating the plurality of saw blades. In one aspect, the invention provides the saw blade comprising a core in the form of a thin disk or thin doughnut disk and a peripheral cutting part on an outer peripheral rim of the core, the cutting part being made of a composition comprising an abrasive, a resin binder, and a lubricant for reducing the friction between the cutting part and the magnet block during the sawing operation.
In a preferred embodiment, the lubricant is selected from the group consisting of boron nitride, carbon, molybdenum disulfide, tungsten disulfide, graphite fluoride, and polytetrafluoroethylene, and mixtures thereof. Also preferably, the lubricant is in particulate form having a particle size in the range of 1 to 200 um.
Typically, the cutting part is made of a composition comprising 10 to 40% by weight of diamond and/or CBN as the abrasive; 20 to 60% by weight of a matrix selected from the group consisting of SiC having a particle size of 1 to 100 um,
S10; having a particle size of 1 to 100 um, Al.0; having a particle size of 1 to 100 pum, WC having a particle size of 0.1 to 50 um, Fe, Ni and Cu having a particle size of 1 to 200 um, and mixtures thereof; 10 to 50% by weight of a thermosetting resin as the binder; and 1 to 50% by weight of the lubricant.
In another aspect, the invention provides a method for sawing a rare earth magnet block into multiple pieces, comprising the steps of providing a multiple blade assembly comprising a plurality of the above-defined saw blades coaxially mounted on a rotating shaft at axially spaced apart positions, and rotating the plurality of saw blades.
The saw blades in the form of a resinoid wheel are used in multiple sawing of a rare earth magnet block into multiple pieces. As compared with the prior art, the saw blade reduces the cutting resistance, improves the sawing accuracy, and ensures sawing at a high accuracy and high speed even if the saw blade is thinner than the conventional blades. The blade is of great worth in the industry.
FIG. 1 illustrates a multiple blade assembly in one embodiment of the invention, FIG. la being a perspective view and FIG. 1b being a cross-sectional view.
FIG. 2 is an enlarged cross-sectional view of a peripheral portion of the saw blade.
The term "axial" refers to the axis of a rotating shaft and "radial" refers to a circular blade in an assembly.
The width of the cutting part corresponds to an axial size in this sense.
A multiple blade assembly is constructed by coaxially mounting a plurality of saw blades on a rotating shaft at axially spaced apart positions (as shown in FIG. 1). The _6-
multiple blade assembly 1s operated by rotating the plurality of saw blades for thereby sawing a rare earth magnet block into a multiplicity of pieces at the same time. The saw blade 23 in the form of a resinoid wheel according to the invention is shown in FIG. 2 as comprising a core 21 in the form of a thin disk or thin doughnut disk and a peripheral cutting part 22 on an outer peripheral rim of the core 21.
The cutting part 22 is made of a composition comprising an abrasive 24, a resin binder, and a lubricant for reducing the friction between the cutting part and the workpiece (or magnet block) during the sawing operation.
Examples of the lubricant used herein include boron nitride, carbon (including graphite and amorphous carbon), molybdenum disulfide, tungsten disulfide, graphite fluoride, and polytetrafluorcethylene (PTFE), which may be used alone or in admixture of two or more. Although the conventional sawing operation is difficult to reduce the friction between the cutting part side surface and the workpiece by providing a coolant supply for lubrication, the inclusion of the lubricant within the cutting part is effective for reducing the friction between the cutting part side surface and the workpiece, thereby preventing the cutting edge from axial runout during the sawing operation. This allows the cutting part to transmit its grinding force only in a radial direction and ensures high-accuracy sawing operation even with the saw blade using a thin core with a low deflective strength.
If a smaller amount of the lubricant is used, the effect of reducing friction on the side surface is reduced.
A larger amount of the lubricant used has the problem that since the lubricant lacks the strength of a structural matrix, not only the strength of the cutting part of the blade is reduced, but also the frictional force of the grinding surface is reduced, resulting in a degraded grinding rate.
The lubricant should preferably be used in an amount of 1 to 50% by weight of the composition of which the cutting part is made. As to the preferred amount of each species (% by weight based on the composition), boron nitride is 1 to 40% by weight, carbon (including graphite and amorphous carbon) is 1 to 40% by weight, molybdenum disulfide is 1 to 40% by weight, tungsten disulfide is 5 to 50% by weight, graphite fluoride is 5 to 40% by weight, and PTFE is 5 to 40% by weight. More preferably, boron nitride is 5 to 30% by weight, carbon (including graphite and amorphous carbon) is 5 to 30% by weight, molybdenum disulfide is 5 to 30% by weight, tungsten disulfide is 10 to 40% by weight, graphite fluoride is 10 to 30% by weight, and PTFE is 10 to 30% by weight.
When a mixture of two or more lubricants is used, the total amount should preferably be in the range of 1 to 50% by weight, more preferably 5 to 40% by weight.
The lubricant is typically available in particulate form. Since the cutting part has a width of 0.2 to 2 mm, a particle size in excess of 0.2 mm (200 pum) is inadequate. Too fine particles have an increased volume, detracting from the strength of the cutting part. The lubricant preferably has a particle size of 1 to 200 um, more preferably 10 to 150 um.
In addition to the lubricant, the composition of which the cutting part is made contains abrasive grains, a resin binder, and a structural matrix. Preferred examples of the matrix include SiC having a particle size of 1 to 100 um,
S10; having a particle size of 1 to 100 um, Al.0; having a particle size of 1 to 100 um, WC having a particle size of 0.1 to 50 um, Fe, Ni and Cu having a particle size of 1 to 200 pm, which may be used alone or in admixture of two or more. The role of the matrix is to increase the strength of -g8-
the cutting part, prevent the cutting part from deforming in a direction perpendicular to the feed direction of the saw blade during the sawing operation, prevent the cutting edge from axial runout during the sawing operation, allows the saw blade to transmit its grinding force only in a radial direction, and ensures high-accuracy sawing operation even with the saw blade using a thin core with a low deflective strength. The matrix is available in particulate form. Too fine particles have an increased volume, failing to provide the cutting part with strength. If the particle size is large, only one particle is present per width of the cutting part, also leading to a reduced strength. Thus the matrix preferably has a particle size in the above range. More preferably, the particle size of SiC is 2 to 50 um, SiO; is 2 to 50 um, Al,0; is 2 to 50 um, WC is 1 to 30 um, and Fe, Ni and Cu is 10 to 150 um.
The matrix should preferably be used in an amount of to 60% by weight, more preferably 25 to 50% by weight of the composition. Outside the range, a smaller amount of the 20 matrix may be less effective whereas a larger amount may detract from the strength of the cutting part.
The abrasive grains may be any well-known abrasives, preferably diamond and CBN. The abrasive grains preferably have a particle size of 10 to 200 um, more preferably 50 to 200 pm. A particle size in excess of 200 um may exceed the width of the cutting part whereas a smaller particle size may interfere with grinding efficiency, sawing speed, and productivity. The abrasive should preferably be used in an amount of 20 to 60% by weight, more preferably 20 to 40% by weight of the composition. Outside the range, a smaller amount of the abrasive may lead to a lower grinding rate _g-
whereas a larger amount may detract from the strength of the cutting part.
The binder has a function of binding diamond or CBN, the lubricant and the matrix together to high strength so that a cutting part having a high stiffness despite thinness may be formed. Thermosetting resins are preferred as the binder. Inter alia, phenolic resins, formaldehyde resins and urea resins are more preferred. Phenol formaldehyde resins obtained by condensation of phenol and formaldehyde are most preferred since they have excellent heat resistance and water resistance and can tightly bind the abrasive and matrix.
Melamine resins prepared from melamine and formaldehyde are also favorable. The binder should preferably be used in an amount of 10 to 50% by weight of the composition. Outside the range, a smaller amount of the binder may be weak in binding the other components whereas a larger amount of the binder indicates smaller amounts of the other components, leading to shortage of strength, grinding rate and lubrication.
The core supporting the cutting part is preferably made of cemented carbide. Any of the cemented carbides described in Patent Document 1 may be used.
The workpiece which is intended herein to saw is a rare earth magnet block. The rare earth magnet as the workpiece is not particularly limited. Suitable rare earth magnets include sintered rare earth magnets of R-Fe-B systems wherein R is at least cone rare earth element inclusive of yttrium.
Suitable sintered rare earth magnets of R-Fe-B systems are those magnets containing, in weight percent, 5 to 40% of
R, 50 to 90% of Fe, and 0.2 to 8% of B, and optionally one or more additive elements selected from C, Al, Si, Ti, V, Cr, Mn,
Co, Ni, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Sn, Hf, Ta, and W, for the purpose of improving magnetic properties and corrosion resistance. The amounts of additive elements added are conventional, for example, up to 30 wt% of Co, and up to 8 wt% of the other elements. The additive elements, 1f added in extra amounts, rather adversely affect magnetic properties.
Suitable sintered rare earth magnets of R-Fe-B systems may be prepared, for example, by weighing source metal materials, melting, casting into an alloy ingot, finely dividing the alloy into particles with an average particle size of 1 to 20 pum, i.e., sintered R-Fe-B magnet powder, compacting the powder in a magnetic field, sintering the compact at 1,000 to 1,200°C for 0.5 to 5 hours, and heat treating at 400 to 1,000°C.
When the rare earth magnet block is sawed into a multiplicity of pieces by the multiple blade assembly of saw blades, any well-known procedures may be employed.
Examples and Comparative Examples are given below for further illustrating the invention although the invention is not limited thereto.
Example 1
OD blades were fabricated by providing a doughnut -shaped disk core of cemented carbide (consisting of
WC 90 wt%/Co 10 wt%) having an outer diameter 120 mm, inner diameter 40 mm, and thickness 0.3 mm, and heat pressing a composition to an outer peripheral rim of the core to form a resinoid grinding wheel section or cutting part. The composition contained 10 wt% of graphite having a particle size of 5 to 30 um as the lubricant, 40 wt% of #800 SiC (GC powder) as the matrix, 25 wt% of a phencl formaldehyde resin as the binder, and 25 wt% of synthetic diamond grains having an average particle size of 150 pum. Subsequent finish work completed OD blades (or sawing abrasive blades). The axial extension of the cutting part from the core was 0.05 mm on each side, that is, the cutting part had a width of 0.4 mm (in the thickness direction of the core). The radial extension or length of the cutting part is 2.5 mm, that is, the blade had an outer diameter of 125 mm.
Using the OD blades, a sawing test was carried out on a workpiece which was a sintered Nd-Fe-B magnet block. 2 multiple blade assembly was constructed as shown in FIG. 1 by coaxially mounting 41 OD blades on a shaft at an axial spacing of 2.1 mm, with spacers interposed therebetween. The spacers each had an outer diameter 85 mm, inner diameter 40 mm, and thickness 2.1 mm. The multiple blade assembly was designed so that the magnet block was cut into magnet strips having a thickness of 2.0 mm.
Using the multiple blade assembly consisting of 41 OD blades and 40 spacers alternately mounted on the shaft, the sintered Nd-Fe-B magnet block was sawed. The sintered
Nd-Fe-B magnet block had a length 101 mm, width 30 mm and height 17 mm and had been polished on all six surfaces at an accuracy of +0.05 mm by a vertical double-disk polishing tool.
By the multiple blade assembly, the magnet block was longitudinally divided into a multiplicity of magnet strips of 2.0 mm thick. Specifically, one magnet block was cut into 40 magnet strips.
The sawing operation was carried out while supplying
L/min of a grinding fluid or coolant from the feed nozzle, rotating the OD blades at 7,000 rpm (circumferential speed of 30 46 m/sec), and feeding the multiple blade assembly at a speed of 20 mm/min.
After magnet strips were cut using the OD blades constructed as above, they were measured for thickness between the machined surfaces at the center by a micrometer.
The strips were rated "passed" if the measured thickness was within a cut size tolerance of 2.0+0.05 mm. If the measured thickness was outside the tolerance, the multiple blade assembly was tailored by adjusting the thickness of spacers, so that the measured thickness might fall within the tolerance. If the spacer adjustment was repeated more than two times for the same OD blades, these OD blades were judged as having lost stability and replaced by new OD blades.
Under these conditions, 1000 magnet blocks were sawed. The evaluation results of the sawed state are shown in Table 1.
Comparative Example 1
A sintered rare earth magnet block was sawed by the same procedure as in Example 1 except that the cutting part composition was changed. In this way, 1000 magnet blocks were sawed, and the sawed state was evaluated. The evaluation results are also shown in Table 1.
The composition of the cutting part in Comparative
Example 1 contained 45 wt% of #800 SiC (GC powder) as the matrix, 30 wt% of the phenol formaldehyde resin as the binder, and 25 wt% of synthetic diamond grains having an average particle size of 150 um.
Table 1
Number sawing of | sawing of | sawing of | sawing of | sawing of 200 400 600 800 1000 oo strips blocks blocks blocks blocks blocks
EEE EE core | oo Loo [ooo [oo] mrt] [oo [eo =] [2 [=o]
A: number of spacer adjustments
B: number of OD blade replacements
As seen from Table 1, the multiple sawing method of the invention maintains consistent dimensional accuracy for products over a long term despite the reduced blade thickness and is successful in reducing the number of spacer adjustments and the number of OD blade replacements. Then an increase in productivity is attained.
Examples 2 to 10 and Comparative Example 2
OD blades were fabricated by providing a doughnut -shaped disk core of cemented carbide (consisting of
WC 90 wt%/Co 10 wt%) having an outer diameter 95 mm, inner diameter 40 mm, and thickness 0.3 mm, and heat pressing a composition shown in Table 2 to an outer peripheral rim of the core to form a cutting part. The axial extension of the cutting part from the core was 0.025 mm on each side, that is, the cutting part had a width of 0.35 mm (in the thickness direction of the core). The radial extension or length of the cutting part is 2.5 mm, that is, the blade had an outer diameter of 100 mm.
Using the OD blades, a sawing test was carried out on a workpiece which was a sintered Nd-Fe-B magnet block. A multiple blade assembly was constructed as shown in FIG. 1 by coaxially mounting 38 OD blades on a shaft at an axial spacing of 1.05 mm, with spacers interposed therebetween.
The spacers each had an outer diameter 70 mm, inner diameter 40 mm, and thickness 1.05 mm. The multiple blade assembly was designed so that the magnet block was cut into magnet strips having a thickness of 1.0 mm.
The multiple blade assembly consisting of 38 OD blades and 37 spacers alternately mounted on the shaft was set relative to the sintered Nd-Fe-B magnet block such that the lowermost end of the blades was 2 mm below the bottom surface of the magnet block. The sintered Nd-Fe-B magnet block had a length 50 mm, width 30 mm and height 12 mm and had been polished on all six surfaces at an accuracy of +0.05 mm by a vertical double-disk pclishing tool. By the multiple blade assembly, the magnet block was longitudinally divided into a multiplicity of magnet strips of 1.0 mm thick. Specifically, one magnet block was cut into 37 magnet strips.
The sawing operation was carried out while supplying 30 L/min of a grinding fluid or coolant from the feed nozzle, rotating the OD blades at 7,000 rpm (circumferential speed of 37 m/sec), and feeding the multiple blade assembly at a speed of 20 mm/min.
Using each of the OD blades of Examples 2 to 10 and
Comparative Example 2, 1000 magnet blocks were sawed. The magnet strips were measured for thickness between the machined surfaces at the center by a micrometer. Provided that the cut size tolerance was 1.040.075 mm, a process capability index (Cpk) of measured thickness was computed.
The results are shown in Table 2.
Table 2 (wt%)
Ce] ew LI TILT cee | TTL [ oe mw | | TT 1 [rome cm ow | | 0] TTT] is] pm senna wo |] | 1] | Jw] fmm amr |] TT 11 moron snror ow] | | Jw] | |] ere vr ow | | | 1 J] me TT pn oe | ol | | oo] ow el Jl [
Jew TT TTT ee TTT =
DEE EE oom LL Jel TTP LT] sow [J] Jefe] [OT] [=]
or
Jormmric srs se] Jo] [=] | [a] [50 # [ono CTE 2 — 1 7 —
As seen from Table 2, the saw blades comprising the lubricant ensures high-accuracy sawing operation even when they are as thin as 0.35 mm.
The number of cut strips is increased.
Claims (5)
1. In connection with a multiple blade assembly comprising a plurality of saw blades coaxially mounted on a rotating shaft at axially spaced apart positions, which is used for sawing a rare earth magnet block into multiple pieces by rotating the plurality of saw blades, the saw blade comprising a core in the form of a thin disk or thin doughnut disk and a peripheral cutting part on an outer peripheral rim of the core, the cutting part being made of a composition comprising an abrasive, a resin binder, and a lubricant for reducing the friction between the cutting part and the magnet block during the sawing operation.
5 2. The saw blade of claim 1 wherein the lubricant is selected from the group consisting of boron nitride, carbon, molybdenum disulfide, tungsten disulfide, graphite fluoride, and polytetrafluoroethylene, and mixtures thereof.
3. The saw blade of claim 1 or 2 wherein the lubricant is in particulate form having a particle size in the range of 1 to 200 pm.
4. The saw blade of any one of claims 1 to 3 wherein the cutting part is made of a composition comprising 10 to 40% by weight of diamond and/or CBN as the abrasive, 20 to 60% by weight of a matrix selected from the group consisting of SiC having a particle size of 1 to 100 um, S10; having a particle size of 1 to 100 um, Al,0; having a particle size of 1 to 100 um, WC having a particle size of
0.1 to 50 um, Fe, Ni and Cu having a particle size of 1 to 200 wm, and mixtures thereof,
10 to 50% by weight of a thermosetting resin as the binder, and 1 to 50% by weight of the lubricant.
5. A method for sawing a rare earth magnet block into multiple pieces, comprising the steps of providing a multiple blade assembly comprising a plurality of saw blades coaxially mounted on a rotating shaft at axially spaced apart positions, each saw blade being as set forth in any one of claims 1 to 4, and rotating the plurality of saw blades.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2011259157 | 2011-11-28 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| SG190555A1 true SG190555A1 (en) | 2013-06-28 |
Family
ID=47257626
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| SG2012087334A SG190555A1 (en) | 2011-11-28 | 2012-11-28 | Saw blade and method for multiple sawing of rare earth magnet |
Country Status (8)
| Country | Link |
|---|---|
| US (1) | US20130137343A1 (en) |
| EP (1) | EP2596929B1 (en) |
| JP (1) | JP5900298B2 (en) |
| KR (1) | KR20130059295A (en) |
| CN (1) | CN103170922A (en) |
| MY (1) | MY174975A (en) |
| SG (1) | SG190555A1 (en) |
| TW (1) | TW201341110A (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| USD791205S1 (en) | 2015-04-06 | 2017-07-04 | Zenith Cutter, Inc. | Serrated male slot knife |
| USD791206S1 (en) | 2015-07-31 | 2017-07-04 | Zenith Cutter, Inc. | Serrated male slot knife |
| JP6896327B2 (en) * | 2017-03-09 | 2021-06-30 | 株式会社ディスコ | Cutting blade, mount flange |
| CN108000611A (en) * | 2017-12-29 | 2018-05-08 | 中铁十六局集团第三工程有限公司 | A kind of railway track plate expansion joint environmental protection cutting and elimination saw |
| USD918280S1 (en) * | 2019-02-18 | 2021-05-04 | Cathlyn J Huttner | Double cutting die |
| CN109702255A (en) * | 2019-02-26 | 2019-05-03 | 临沂市新天力机械有限公司 | A kind of milling side device for edging and trimming saw |
| JP7298100B2 (en) * | 2019-08-29 | 2023-06-27 | 株式会社ノリタケカンパニーリミテド | Multi-layer whetstone for gear grinding |
| KR102420875B1 (en) * | 2022-03-25 | 2022-07-14 | 최태성 | Manufacturing Method of Circular Knife for Cutting Cigarette |
Family Cites Families (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6288575A (en) * | 1985-10-14 | 1987-04-23 | Mitsubishi Metal Corp | Grinding wheel |
| JPS63283866A (en) * | 1987-02-27 | 1988-11-21 | Toshiba Tungaloy Co Ltd | Superabrasive grain cutting grindstone |
| US5313742A (en) * | 1991-01-11 | 1994-05-24 | Norton Company | Highly rigid composite shaped abrasive cutting wheel |
| JPH10175172A (en) * | 1996-12-16 | 1998-06-30 | Shin Etsu Chem Co Ltd | Multi diamond grinding wheel for cutting rare earth magnet |
| US6517427B1 (en) * | 1998-02-23 | 2003-02-11 | Shin-Etsu Chemical Co., Ltd. | Abrasive-bladed multiple cutting wheel assembly |
| US6595094B1 (en) * | 1999-01-29 | 2003-07-22 | Sumitomo Special Metals Co., Ltd. | Working cutting apparatus and method for cutting work |
| US6386948B1 (en) * | 1999-06-01 | 2002-05-14 | Sumitomo Special Metals Co., Ltd. | Magnet member cutting method and magnet member cutting |
| US6463920B1 (en) * | 1999-11-22 | 2002-10-15 | Sumitomo Special Metals Co., Ltd. | Work cutting apparatus and work cutting method |
| JP4961647B2 (en) * | 2001-09-06 | 2012-06-27 | 日立金属株式会社 | Rare earth alloy cutting method and rare earth magnet manufacturing method |
| JP4351424B2 (en) * | 2002-07-18 | 2009-10-28 | 旭ダイヤモンド工業株式会社 | Super abrasive cutting wheel |
| US8568203B2 (en) * | 2008-11-05 | 2013-10-29 | Shin-Etsu Chemical Co., Ltd. | Method and apparatus for multiple cutoff machining of rare earth magnet block, cutting fluid feed nozzle, and magnet block securing jig |
| KR101659078B1 (en) * | 2009-09-02 | 2016-09-22 | 쓰리엠 이노베이티브 프로퍼티즈 캄파니 | Composition for cutting wheel and cutting wheel by using the same |
| MY157471A (en) * | 2010-01-06 | 2016-06-15 | Shinetsu Chemical Co | Rare earth magnet holding jig, cutting machine and cutting method |
-
2012
- 2012-11-23 MY MYPI2012005070A patent/MY174975A/en unknown
- 2012-11-26 TW TW101144219A patent/TW201341110A/en unknown
- 2012-11-26 JP JP2012257024A patent/JP5900298B2/en active Active
- 2012-11-27 EP EP12194492.0A patent/EP2596929B1/en active Active
- 2012-11-27 KR KR1020120135244A patent/KR20130059295A/en not_active Application Discontinuation
- 2012-11-28 CN CN2012105992413A patent/CN103170922A/en active Pending
- 2012-11-28 US US13/687,039 patent/US20130137343A1/en not_active Abandoned
- 2012-11-28 SG SG2012087334A patent/SG190555A1/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| TW201341110A (en) | 2013-10-16 |
| JP2013136143A (en) | 2013-07-11 |
| JP5900298B2 (en) | 2016-04-06 |
| CN103170922A (en) | 2013-06-26 |
| KR20130059295A (en) | 2013-06-05 |
| US20130137343A1 (en) | 2013-05-30 |
| EP2596929A1 (en) | 2013-05-29 |
| MY174975A (en) | 2020-05-30 |
| EP2596929B1 (en) | 2017-02-22 |
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