US20230219194A1 - Electrodeposition whetstone and manufacturing method - Google Patents
Electrodeposition whetstone and manufacturing method Download PDFInfo
- Publication number
- US20230219194A1 US20230219194A1 US18/187,325 US202318187325A US2023219194A1 US 20230219194 A1 US20230219194 A1 US 20230219194A1 US 202318187325 A US202318187325 A US 202318187325A US 2023219194 A1 US2023219194 A1 US 2023219194A1
- Authority
- US
- United States
- Prior art keywords
- abrasive grains
- plating layer
- plating
- grain size
- smaller
- 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
- 238000004070 electrodeposition Methods 0.000 title claims abstract description 74
- 238000004519 manufacturing process Methods 0.000 title claims description 12
- 239000006061 abrasive grain Substances 0.000 claims abstract description 215
- 238000007747 plating Methods 0.000 claims abstract description 160
- 229910003460 diamond Inorganic materials 0.000 claims description 10
- 239000010432 diamond Substances 0.000 claims description 10
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 10
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 10
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 8
- 229910052721 tungsten Inorganic materials 0.000 claims description 8
- 239000010937 tungsten Substances 0.000 claims description 8
- 229910044991 metal oxide Inorganic materials 0.000 claims description 6
- 150000004706 metal oxides Chemical class 0.000 claims description 6
- 238000007772 electroless plating Methods 0.000 claims description 5
- 238000009713 electroplating Methods 0.000 claims description 4
- -1 polytetrafluoroethylene Polymers 0.000 claims description 3
- 239000010410 layer Substances 0.000 description 84
- 239000011247 coating layer Substances 0.000 description 14
- 239000002245 particle Substances 0.000 description 13
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 12
- 239000000463 material Substances 0.000 description 12
- 230000004048 modification Effects 0.000 description 9
- 238000012986 modification Methods 0.000 description 9
- 229910052759 nickel Inorganic materials 0.000 description 6
- 238000005422 blasting Methods 0.000 description 5
- 230000002035 prolonged effect Effects 0.000 description 5
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 3
- 229910010271 silicon carbide Inorganic materials 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910018104 Ni-P Inorganic materials 0.000 description 2
- 229910021586 Nickel(II) chloride Inorganic materials 0.000 description 2
- 229910018536 Ni—P Inorganic materials 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 2
- 239000004327 boric acid Substances 0.000 description 2
- 239000004918 carbon fiber reinforced polymer Substances 0.000 description 2
- 239000003638 chemical reducing agent Substances 0.000 description 2
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 230000000873 masking effect Effects 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- QMMRZOWCJAIUJA-UHFFFAOYSA-L nickel dichloride Chemical compound Cl[Ni]Cl QMMRZOWCJAIUJA-UHFFFAOYSA-L 0.000 description 2
- 229910052755 nonmetal Inorganic materials 0.000 description 2
- 238000005240 physical vapour deposition Methods 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 229910052580 B4C Inorganic materials 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 238000003776 cleavage reaction Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- QLOAVXSYZAJECW-UHFFFAOYSA-N methane;molecular fluorine Chemical compound C.FF QLOAVXSYZAJECW-UHFFFAOYSA-N 0.000 description 1
- LNOPIUAQISRISI-UHFFFAOYSA-N n'-hydroxy-2-propan-2-ylsulfonylethanimidamide Chemical compound CC(C)S(=O)(=O)CC(N)=NO LNOPIUAQISRISI-UHFFFAOYSA-N 0.000 description 1
- 239000002113 nanodiamond Substances 0.000 description 1
- LGQLOGILCSXPEA-UHFFFAOYSA-L nickel sulfate Chemical compound [Ni+2].[O-]S([O-])(=O)=O LGQLOGILCSXPEA-UHFFFAOYSA-L 0.000 description 1
- KERTUBUCQCSNJU-UHFFFAOYSA-L nickel(2+);disulfamate Chemical compound [Ni+2].NS([O-])(=O)=O.NS([O-])(=O)=O KERTUBUCQCSNJU-UHFFFAOYSA-L 0.000 description 1
- 229910000363 nickel(II) sulfate Inorganic materials 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 230000007017 scission Effects 0.000 description 1
- 238000006748 scratching Methods 0.000 description 1
- 230000002393 scratching effect Effects 0.000 description 1
- 238000005201 scrubbing Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- IIACRCGMVDHOTQ-UHFFFAOYSA-M sulfamate Chemical compound NS([O-])(=O)=O IIACRCGMVDHOTQ-UHFFFAOYSA-M 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Images
Classifications
-
- 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
- B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
- B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
- B24D3/06—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
- B24D18/0018—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for by electrolytic deposition
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
- B24D18/0027—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for by impregnation
-
- 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
Definitions
- the present invention relates to an electrodeposition whetstone and a manufacturing method thereof.
- Jpn. Pat. Appln. KOKAI Publications No. 2011-245561, No. H2-145261, and H6-114739 disclose electrodeposition whetstones.
- abrasive grains with a larger average grain size and abrasive grains with a smaller average grain size are adhered by a plating layer.
- An abrasive grain layer containing the abrasive grains with a smaller average grain size is disposed on an outer side of an abrasive grain layer containing the abrasive grains with a larger average grain size.
- an electrodeposition whetstone includes a plating layer, first abrasive grains protruding from the plating layer, and second abrasive grains which are arranged between the first abrasive grains.
- the amount of protrusion of the second abrasive grains from the plating layer is smaller than the amount of protrusion of the first abrasive grains from the plating layer.
- a grain size of the second abrasive grains is smaller than a grain size of the first abrasive grains.
- FIG. 1 is a schematic view showing a cross section of an electrodeposition whetstone according to an embodiment.
- FIG. 2 is a schematic view showing steps of an exemplary manufacturing method according to the embodiment.
- FIG. 3 is a schematic view showing a cross section of an electrodeposition whetstone according to a modification example of the embodiment.
- FIG. 4 is a schematic view showing a cross section of an electrodeposition whetstone according to another modification example of the embodiment.
- FIG. 1 schematically shows a cross section of an electrodeposition whetstone according to this embodiment.
- the electrodeposition whetstone 1 includes a base 2 , a plating layer 3 , first abrasive grains 4 , and second abrasive grains 5 , which differ from the first abrasive grains 4 .
- the base 2 is a base component (base metal) of the electrodeposition whetstone 1 , which has conductivity.
- the base 2 is formed, for example, of a material that contains a metal such as aluminum, iron, or stainless steel, or an alloy thereof. The material of the base 2 is not limited as long as it has conductivity.
- the base 2 of the embodiment is shaped into a disk or substantially into a disk.
- a thickness direction (indicated by arrows D 1 and D 2 ) and an orthogonal direction intersecting (perpendicular or substantially perpendicular to) the thickness direction are defined.
- the direction from the base 2 toward the plating layer 3 (indicated by arrow D 1 ) is defined as outward, and the direction opposite to the outward direction (indicated by arrow D 2 ) is defined as inward.
- the shape of the base 2 can be suitably selected based on the use of the electrodeposition whetstone 1 , the type of a grinding workpiece, and the like.
- the plating layer 3 is arranged on the base 2 .
- the plating layer 3 includes the first abrasive grains 4 and the second abrasive grains 5 .
- the plating layer 3 holds the first abrasive grains 4 and the second abrasive grains 5 .
- the plating layer 3 may be formed of a nickel-containing material.
- the thickness of the plating layer 3 is defined by the thickness extending from the outer surface (external surface) of the base 2 to the outer surface (external surface) of the plating layer 3 . For instance, the thickness of the plating layer 3 represents an average thickness of the plating layer 3 .
- the thickness of the plating layer 3 can be suitably determined based on the processing conditions such as the use of the electrodeposition whetstone 1 and the type of the grinding workpiece. As described later, the thickness of the plating layer 3 is determined in such a manner that at least part of the first abrasive grains 4 and at least part of the second abrasive grains 5 both protrude (are exposed) from the outer surface of the plating layer 3 .
- the thickness of the plating layer 3 may be 40% or larger and 80% or smaller of the average abrasive grain size of the abrasive grains 4 .
- the plating layer 3 includes a first plating layer 31 and a second plating layer 32 different from the first plating layer 31 .
- the first plating layer 31 is provided on the base 2
- the second plating layer 32 is provided on the first plating layer 31 .
- the second plating layer 32 is stacked on the first plating layer 31 .
- the first plating layer 31 and the second plating layer 32 may contain nickel.
- the second plating layer 32 may include particles having a friction coefficient lower than that of the second plating layer 32 . The average particle size of these particles can be measured using a commonly used method. For instance, a laser diffraction particle size distribution analyzer may be used for the measurement.
- such particles include at least one of polytetrafluoroethylene (PTFE), graphite fluoride, silicon carbide, boron carbide, and tungsten.
- the particles may also contain nanodiamond particles. Consequently, the friction coefficient of the second plating layer 32 is lowered, which makes the second plating layer 32 resistive to wearing by grinding chips. As a result, the wear resistance of the electrodeposition whetstone 1 is improved. In addition, clogging of the electrodeposition whetstone 1 , which tends to be caused by grinding chips, can be suppressed.
- the second plating layer 32 preferably contains PTFE of an average particle size of 0.1 ⁇ m or larger and 1 ⁇ m or smaller. With boron or tungsten contained in the second plating layer 32 , the hardness (Vickers hardness (Hv)) of the second plating layer 32 increases.
- the first abrasive grains 4 and the second abrasive grains 5 can be suitably selected depending on the grinding workpiece and the use of the electrodeposition whetstone 1 .
- the first abrasive grains 4 and the second abrasive grains 5 are at least one selected from silicon carbide-based abrasive grains, alumina-based abrasive grains, metal oxide abrasive grains, and superabrasive grains.
- the metal oxide abrasive grains may be zirconium oxide.
- the superabrasive grains may be diamond abrasive grains and cubic boron nitride (CBN) abrasive grains.
- Combinations of the first abrasive grains 4 and the second abrasive grains 5 may be: diamond abrasive grains and diamond abrasive grains; CBN abrasive grains and CBN abrasive grains; diamond abrasive grains and metal oxide abrasive grains; CBN abrasive grains and metal oxide abrasive grains; or CBN abrasive grains and diamond abrasive grains. It is preferable that the first abrasive grains 4 be CBN abrasive grains and the second abrasive grains 5 be diamond abrasive grains.
- the grain size of the second abrasive grains 5 is smaller than the grain size of the first abrasive grains 4 .
- the grain size of the first abrasive grains 4 (or second abrasive grains 5 ) indicates, for example, the average grain size of the first abrasive grains 4 (or second abrasive grains 5 ).
- the ratio of the grain size of the second abrasive grains to that of the first abrasive grains may stand at 0.4.
- the grain size of the first abrasive grains 4 may be 25 ⁇ m or larger and 300 ⁇ m or smaller.
- the grain size of the second abrasive grains 5 may be 10 ⁇ m or larger and 120 ⁇ m or smaller.
- the first abrasive grains 4 correspond to the grit size 600, and with the grain size of the first abrasive grains 4 being 300 ⁇ m, the first abrasive grains 4 correspond to the grit size 50.
- the grain size of the second abrasive grains 5 being 10 ⁇ m
- the second abrasive grains 5 correspond to the grit size 1500
- the second abrasive grains 5 being 120 ⁇ m
- the second abrasive grains 5 correspond to the grit size 120.
- the shape of the first abrasive grains 4 may be at least one selected from being blocky, semi-blocky, and irregular.
- the first abrasive grains 4 preferably have a semi-blocky shape. If the abrasive grains have a semi-blocky shape, a new cutting edge is created from a fracture in the cleavage plane existing in the crystal planes of the abrasive grains, thereby suppressing degradation in the grindability of the electrodeposition whetstone 1 .
- the second abrasive grains 5 preferably have a blocky shape.
- Both the first abrasive grains 4 and the second abrasive grains 5 protrude from the plating layer 3 . That is, at least part of the first abrasive grains 4 and at least part of the second abrasive grains 5 both protrude outwardly from the surface (outer surface) of the plating layer 3 .
- the amount of protrusion of the first abrasive grains 4 is larger than that of the second abrasive grains.
- the amount of protrusion denotes an average height of the abrasive grains protruding outwardly from the outer surface of the plating layer 3 . As illustrated in FIG.
- a tip (position) of each of the first abrasive grains 4 (or second abrasive grains 5 ) farthest away from the base 2 is a protruding end 41 of a first abrasive grain 4 (or protruding end 51 of a second abrasive grain 5 ).
- the protruding ends 41 of the first abrasive grains 4 are located farther away from the base 2 (i.e., the outer surface of the plating layer 3 ) than the protruding ends 51 of the second abrasive grains 5 are.
- a first virtual plane V 1 created by the protruding ends 41 and a second virtual plane V 2 created by the protruding ends 51 are defined. Since the amount of protrusion of the protruding ends 41 is larger than that of the protruding ends 51 , the first virtual plane V 1 is located on the outer side with respect to the second virtual plane V 2 . It is preferable that the average distance between the first virtual plane V 1 and the second virtual plane V 2 be equal to or shorter than a range R.
- the range R can be suitably set based at least on the grain size of the first abrasive grains 4 , the grain size of the second abrasive grains 5 , and the thickness of the plating layer 3 .
- the range R increase in accordance with an increase in the thickness of the plating layer 3 . It is preferable that the range R be defined as 6 ⁇ m or larger and 42 ⁇ m or smaller. In one example, if the first abrasive grains 4 are in a grit size of around 600, the range R is preferably around 6 ⁇ m. In another example, if the first abrasive grains 4 are in a grit size of around 50, the range R is preferably around 42 ⁇ m. As will be described later, with the electrodeposition whetstone 1 satisfying the range R, the life of the electrodeposition whetstone 1 can be prolonged.
- the first abrasive grains 4 are arranged in the plating layer 3 so as to be separated from each other in the orthogonal direction. That is, a gap is created in the orthogonal direction between the first abrasive grains 4 arranged in the orthogonal direction.
- the second abrasive grains 5 are arranged in the gaps created by the first abrasive grains 4 in the orthogonal direction.
- the second abrasive grains 5 are arranged in gaps created in the orthogonal direction by the first abrasive grains 4 adjacent to each other in the orthogonal direction.
- the size of the gap (interval) between the first abrasive grains 4 is preferably 20 ⁇ m or larger.
- the second abrasive grains 5 serve as a bond coating of the plating layer 3 .
- This can improve the strength of the electrodeposition whetstone 1 , and can also increase the force of the plating layer 3 holding the abrasive grains.
- the abrasive grains are therefore prevented from coming off from the electrodeposition whetstone 1 .
- the plating layer 3 is prevented from being scratched by the grinding chips. The life of the electrodeposition whetstone 1 can thereby be prolonged.
- the grinding sharpness of the electrodeposition whetstone 1 is improved.
- the present inventors consider the explanation for this as follows.
- the grinding workpiece is shaved and deformed by the certain first abrasive grain 4 .
- the first abrasive grains 4 are separated from each other in the orthogonal direction, it is highly probable that another first abrasive grain 4 will grind the workpiece after the workpiece is elastically recovered. As a result, the grinding effects upon the grinding workpiece will be increased, and the friction upon the workpiece will be reduced.
- the grinding resistance acting upon the electrodeposition whetstone 1 from the contact surface between the electrodeposition whetstone 1 and the workpiece is lowered.
- effective grinding can be performed by the electrodeposition whetstone 1 , and the grinding sharpness of the electrodeposition whetstone 1 is improved.
- the grinding resistance reduced it is possible to prevent burrs from being produced in the workpiece by the electrodeposition whetstone 1 .
- the second abrasive grains 5 arranged as described earlier elongate the life of the electrodeposition whetstone 1 .
- the present inventors consider the explanation for this as follows. During grinding of the grinding workpiece with the first abrasive grains 4 , grinding chips are formed. Since the amount of protrusion of the second abrasive grains 5 from the plating layer 3 is smaller than the amount of protrusion of the first abrasive grains 4 from the plating layer 3 as described above, these grinding chips are broken by the second abrasive grains 5 into still smaller grinding chips. This reduces damage to the plating layer 3 that tends to be caused by the grinding chips.
- FIG. 2 shows the steps of an exemplary method of manufacturing the electrodeposition whetstone 1 according to the present embodiment.
- the base 2 used for the electrodeposition whetstone 1 is manufactured with a commonly known method.
- the surface (outer surface) of the base 2 may be treated with blasting, masking, or the like.
- the electrodeposition surface is treated by injecting particles onto the surface (electrodeposition surface) of the base 2 .
- alumina abrasive particles may be used in the blasting treatment.
- a waterproof tape may be used to cover the portions other than the electrodeposition surface.
- the first abrasive grains 4 are dispersed over the surface of the base 2 .
- the surface of the base 2 to which the first abrasive grains 4 are attached is plated with first plating (primary plating).
- the first plating may be electrolytic plating, examples of which include electrolytic nickel plating.
- the first abrasive grains 4 are secured to the surface of the base 2 .
- excessive first abrasive grains 4 may remain between the first abrasive grains 4 .
- the excessive first abrasive grains 4 need to be removed from the surface of the base 2 .
- suitable gaps (intervals) can be maintained between the first abrasive grains 4 in the orthogonal direction.
- Removal of the excessive first abrasive grains 4 may be conducted by hand scrubbing.
- the dispersion of the first abrasive grains 4 and the primary plating may be performed after the base 2 is cleaned following the blasting treatment. This will increase the adhesion between the primary plating and the base 2 .
- Further plating is performed upon the first abrasive grains suitably secured to the base 2 .
- the secondary plating may be performed in a manner similar to the primary plating. For instance, electrolytic nickel plating is performed.
- the previously mentioned first plating layer 31 is formed through the primary plating and secondary plating.
- the total thickness (average total thickness) obtained by adding the thickness of the primary plating and the thickness of the secondary plating can be suitably determined with reference to the grain size (average grain size) of the first abrasive grains.
- the average total thickness may be, for example, about 20% of the grain size of the first abrasive grains 4 , or about 30% of the grain size of the first abrasive grains 4 .
- the second abrasive grains 5 are dispersed so as to arrange the second abrasive grains 5 in the gaps created in the orthogonal direction between the first abrasive grains 4 .
- the second plating (tertiary plating) is performed upon the first plating layer 31 , the first abrasive grains 4 , and the second abrasive grains 5 .
- the second plating differs from the first plating.
- the second plating may be electroless plating, examples of which include electroless Ni—P plating.
- the previously mentioned second plating layer 32 is thereby formed.
- the thickness of the tertiary plating is preferably smaller than the thickness of the secondary plating.
- the thickness of the tertiary plating can be suitably determined with reference to the grain size of the first abrasive grains 4 and the grain size of the second abrasive grains 5 .
- the thickness may be 6 Tim or larger and 72 ⁇ m or smaller.
- the plating layer 3 is completed by the primary plating, secondary plating, and tertiary plating.
- heat treatment is conducted upon the electrodeposition whetstone 1 .
- a heat treatment a commonly used method can be suitably used. For instance, heat treatment at 350° C. may be performed.
- the electrodeposition whetstone 1 of the embodiment is completed, as illustrated in the bottom of FIG. 2 .
- the distance (average distance) between the first virtual plane V 1 and the second virtual plane V 2 can be determined within the range R.
- the plating solution for the tertiary plating may contain PTFE having an average particle size of 0.1 ⁇ m or larger and 1 ⁇ m or smaller in an amount of 5% by volume or more and 40% by volume or less with respect to the total volume of the plating solution.
- PTFE Ni—P—SiC dispersion plating, hard chromium plating, electroless Ni—P plating, electroless Ni—B plating, or electroless Ni—W—P plating may be performed.
- heat is applied to the second plating layer 32 after the tertiary plating so as to cure the second plating layer 32 . This improves the wear resistance of the electrodeposition whetstone 1 .
- the first abrasive grains 4 protrude from the plating layer 3 outwardly in the thickness direction.
- the second abrasive grains 5 are arranged between the first abrasive grains in the orthogonal direction.
- the amount of protrusion of the second abrasive grains 5 are a smaller than that of the first abrasive grains 4 from the plating layer 3 in the thickness direction, and the second abrasive grains 5 have a smaller grain size than that of the first abrasive grains 4 .
- the first abrasive grains 4 may contain at least one selected from the group consisting of diamond abrasive grains, CBN abrasive grains, and metal oxide abrasive grains.
- the second abrasive grains 5 may include at least one of diamond abrasive grains and CBN abrasive grains.
- the first abrasive grains 4 are secured to the base by the first plating, with gaps created between the first abrasive grains 4 in the orthogonal direction.
- a grain size of the second abrasive grains 5 being smaller than a grain size of the first abrasive grains 4 are arranged in these gaps in the orthogonal direction.
- the first abrasive grains 4 and the second abrasive grains 5 are secured by the second plating, which differs from the first plating, in such a manner that the amount of protrusion of the second abrasive grains 5 in the thickness direction is smaller than the amount of protrusion of the first abrasive grains 4 .
- the second plating which differs from the first plating
- a coating layer 33 may be formed in the electrodeposition whetstone 1 after the plating process is completed, as shown in FIG. 3 .
- the plating layer 3 of the electrodeposition whetstone 1 further includes the coating layer 33 .
- the thickness of the coating layer 33 is not limited as long as both the first abrasive grains 4 and the second abrasive grains 5 protrude from the coating layer 33 , as illustrated in FIG. 3 .
- the thickness of the coating layer 33 may be, for example, 0.1 ⁇ m or larger and 0.5 ⁇ m or smaller.
- the coating layer 33 is formed through electroless plating using a nickel solution to which a reducing agent is added.
- the coating layer 33 is formed through electrolytic plating using a nickel solution to which a reducing agent is added.
- the plating bath may be a Watts bath or a sulfamate bath.
- the Watts bath contains, for example, nickel sulfate, nickel chloride, and boric acid as major components.
- the sulfamic acid bath contains, for example, nickel sulfamate and boric acid as major components.
- the coating layer 33 may include particles having a friction coefficient lower than that of the coating layer 33 .
- the aforementioned plating solution for the tertiary plating is used as a plating solution for the coating layer 33 .
- the life of the electrodeposition whetstone 1 can be further prolonged.
- the amount of protrusion of the first abrasive grains 4 is larger than the amount of protrusion of the second abrasive grains 5 in the electrodeposition whetstone 1 .
- the second plating layer may not always attain a sufficient thickness to secure the first abrasive grains 4 and the second abrasive grains 5 ; the second plating layer is therefore formed by plating that does not contain PTFE or tungsten. In this manner, the second plating layer can be formed up to a thickness sufficient to secure the second abrasive grains 5 . Thereafter, the coating layer 33 is formed. The coating layer 33 will be formed with plating that contains at least one of PTFE and tungsten.
- the electrodeposition whetstone 1 can still exhibit the same effects as the case where at least one of PTFE and tungsten is contained.
- a foundation layer 7 may be formed in the electrodeposition whetstone 1 , as shown in FIG. 4 .
- the electrodeposition whetstone 1 further includes a foundation layer 7 .
- the thickness of the foundation layer is not particularly limited. The thickness may be, for example, 0.1 ⁇ m or larger and 1 ⁇ m or smaller.
- the foundation layer 7 is formed of a material containing at least a ferrous material, aluminum, Alloy 42, or a non-metal material. Examples of the ferrous material include a stainless-steel material and a cast material. Examples of the non-metal material include a non-ferrous material and a resin material. Examples of the non-ferrous material include carbon fiber reinforced plastic (CFRP).
- the electrodeposition whetstone 1 includes the foundation layer 7 , plating suitable for the material of the foundation layer 7 is provided on the base 2 before the first abrasive grains 4 are dispersed on the base 2 .
- the base 2 is cleaned after the surface of the base 2 is subjected to the blasting or the like, and then the foundation layer 7 is formed on the base 2 .
- copper plating or nickel chloride plating may be adopted for the plating.
- the foundation plating may be formed by dry plating instead of wet plating, which uses a plating solution. As the dry plating, physical vapor deposition (PVD) or chemical vapor deposition (CVD) may be performed.
- PVD physical vapor deposition
- CVD chemical vapor deposition
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Ceramic Engineering (AREA)
- Inorganic Chemistry (AREA)
- Polishing Bodies And Polishing Tools (AREA)
Abstract
According to an embodiment, an electrodeposition whetstone includes a plating layer, first abrasive grains protruding from the plating layer, and second abrasive grains which are arranged between the first abrasive grains. The amount of protrusion of the second abrasive grains from the plating layer is smaller than the amount of protrusion of the first abrasive grains from the plating layer. A grain size of the second abrasive grains is smaller than a grain size of the first abrasive grains.
Description
- This application is a Continuation Application of PCT Application No. PCT/JP2021/027687, filed Jul. 27, 2021 and based upon and claiming the benefit of priority from prior Japanese Patent Application No. 2020-187129, filed Nov. 10, 2020, the entire contents of all of which are incorporated herein by reference.
- The present invention relates to an electrodeposition whetstone and a manufacturing method thereof.
- Jpn. Pat. Appln. KOKAI Publications No. 2011-245561, No. H2-145261, and H6-114739 disclose electrodeposition whetstones. In the electrodeposition whetstone of Jpn. Pat. Appln. KOKAI Publication No. 2011-245561, abrasive grains with a larger average grain size and abrasive grains with a smaller average grain size are adhered by a plating layer. An abrasive grain layer containing the abrasive grains with a smaller average grain size is disposed on an outer side of an abrasive grain layer containing the abrasive grains with a larger average grain size. In the electrodeposition whetstone of Jpn. Pat. Appln. KOKAI Publication No. H2-145261, the larger-diameter superabrasive grains and the smaller-diameter superabrasive grains are adhered to the base by a metal plating layer that is a uniformly dispersed single layer. In the electrodeposition whetstone of Jpn. Pat. Appln. KOKAI Publication No. H6-114739, larger-diameter superabrasive grains are supported by an electroless plating layer, and smaller-diameter superabrasive grains are uniformly dispersed in this electroless plating layer.
- According to an embodiment, an electrodeposition whetstone includes a plating layer, first abrasive grains protruding from the plating layer, and second abrasive grains which are arranged between the first abrasive grains. The amount of protrusion of the second abrasive grains from the plating layer is smaller than the amount of protrusion of the first abrasive grains from the plating layer. A grain size of the second abrasive grains is smaller than a grain size of the first abrasive grains.
-
FIG. 1 is a schematic view showing a cross section of an electrodeposition whetstone according to an embodiment. -
FIG. 2 is a schematic view showing steps of an exemplary manufacturing method according to the embodiment. -
FIG. 3 is a schematic view showing a cross section of an electrodeposition whetstone according to a modification example of the embodiment. -
FIG. 4 is a schematic view showing a cross section of an electrodeposition whetstone according to another modification example of the embodiment. - An embodiment of the present invention will be described with reference to the drawings.
FIG. 1 schematically shows a cross section of an electrodeposition whetstone according to this embodiment. Theelectrodeposition whetstone 1 includes abase 2, aplating layer 3, firstabrasive grains 4, and secondabrasive grains 5, which differ from the firstabrasive grains 4. Thebase 2 is a base component (base metal) of theelectrodeposition whetstone 1, which has conductivity. Thebase 2 is formed, for example, of a material that contains a metal such as aluminum, iron, or stainless steel, or an alloy thereof. The material of thebase 2 is not limited as long as it has conductivity. It is assumed here that thebase 2 of the embodiment is shaped into a disk or substantially into a disk. In theelectrodeposition whetstone 1, a thickness direction (indicated by arrows D1 and D2) and an orthogonal direction intersecting (perpendicular or substantially perpendicular to) the thickness direction are defined. In the following description, the direction from thebase 2 toward the plating layer 3 (indicated by arrow D1) is defined as outward, and the direction opposite to the outward direction (indicated by arrow D2) is defined as inward. The shape of thebase 2 can be suitably selected based on the use of theelectrodeposition whetstone 1, the type of a grinding workpiece, and the like. - The plating
layer 3 is arranged on thebase 2. The platinglayer 3 includes the firstabrasive grains 4 and the secondabrasive grains 5. The platinglayer 3 holds the firstabrasive grains 4 and the secondabrasive grains 5. The platinglayer 3 may be formed of a nickel-containing material. The thickness of theplating layer 3 is defined by the thickness extending from the outer surface (external surface) of thebase 2 to the outer surface (external surface) of theplating layer 3. For instance, the thickness of theplating layer 3 represents an average thickness of theplating layer 3. The thickness of theplating layer 3 can be suitably determined based on the processing conditions such as the use of theelectrodeposition whetstone 1 and the type of the grinding workpiece. As described later, the thickness of theplating layer 3 is determined in such a manner that at least part of the firstabrasive grains 4 and at least part of the secondabrasive grains 5 both protrude (are exposed) from the outer surface of theplating layer 3. For instance, the thickness of theplating layer 3 may be 40% or larger and 80% or smaller of the average abrasive grain size of theabrasive grains 4. - The
plating layer 3 includes afirst plating layer 31 and asecond plating layer 32 different from thefirst plating layer 31. Thefirst plating layer 31 is provided on thebase 2, and thesecond plating layer 32 is provided on thefirst plating layer 31. In other words, thesecond plating layer 32 is stacked on thefirst plating layer 31. For instance, thefirst plating layer 31 and thesecond plating layer 32 may contain nickel. Thesecond plating layer 32 may include particles having a friction coefficient lower than that of thesecond plating layer 32. The average particle size of these particles can be measured using a commonly used method. For instance, a laser diffraction particle size distribution analyzer may be used for the measurement. In one example, such particles include at least one of polytetrafluoroethylene (PTFE), graphite fluoride, silicon carbide, boron carbide, and tungsten. The particles may also contain nanodiamond particles. Consequently, the friction coefficient of thesecond plating layer 32 is lowered, which makes thesecond plating layer 32 resistive to wearing by grinding chips. As a result, the wear resistance of theelectrodeposition whetstone 1 is improved. In addition, clogging of theelectrodeposition whetstone 1, which tends to be caused by grinding chips, can be suppressed. Thesecond plating layer 32 preferably contains PTFE of an average particle size of 0.1 μm or larger and 1 μm or smaller. With boron or tungsten contained in thesecond plating layer 32, the hardness (Vickers hardness (Hv)) of thesecond plating layer 32 increases. - The first
abrasive grains 4 and the secondabrasive grains 5 can be suitably selected depending on the grinding workpiece and the use of theelectrodeposition whetstone 1. For instance, the firstabrasive grains 4 and the secondabrasive grains 5 are at least one selected from silicon carbide-based abrasive grains, alumina-based abrasive grains, metal oxide abrasive grains, and superabrasive grains. The metal oxide abrasive grains may be zirconium oxide. The superabrasive grains may be diamond abrasive grains and cubic boron nitride (CBN) abrasive grains. Combinations of the firstabrasive grains 4 and the secondabrasive grains 5 may be: diamond abrasive grains and diamond abrasive grains; CBN abrasive grains and CBN abrasive grains; diamond abrasive grains and metal oxide abrasive grains; CBN abrasive grains and metal oxide abrasive grains; or CBN abrasive grains and diamond abrasive grains. It is preferable that the firstabrasive grains 4 be CBN abrasive grains and the secondabrasive grains 5 be diamond abrasive grains. - The grain size of the second
abrasive grains 5 is smaller than the grain size of the firstabrasive grains 4. The grain size of the first abrasive grains 4 (or second abrasive grains 5) indicates, for example, the average grain size of the first abrasive grains 4 (or second abrasive grains 5). The ratio of the grain size of the second abrasive grains to that of the first abrasive grains may stand at 0.4. The grain size of the firstabrasive grains 4 may be 25 μm or larger and 300 μm or smaller. The grain size of the secondabrasive grains 5 may be 10 μm or larger and 120 μm or smaller. In one example, with the grain size of the firstabrasive grains 4 being 25 μm, the firstabrasive grains 4 correspond to the grit size 600, and with the grain size of the firstabrasive grains 4 being 300 μm, the firstabrasive grains 4 correspond to the grit size 50. In another example, with the grain size of the secondabrasive grains 5 being 10 μm, the secondabrasive grains 5 correspond to the grit size 1500, and with the secondabrasive grains 5 being 120 μm, the secondabrasive grains 5 correspond to the grit size 120. The shape of the firstabrasive grains 4 may be at least one selected from being blocky, semi-blocky, and irregular. The firstabrasive grains 4 preferably have a semi-blocky shape. If the abrasive grains have a semi-blocky shape, a new cutting edge is created from a fracture in the cleavage plane existing in the crystal planes of the abrasive grains, thereby suppressing degradation in the grindability of theelectrodeposition whetstone 1. The secondabrasive grains 5 preferably have a blocky shape. - Both the first
abrasive grains 4 and the secondabrasive grains 5 protrude from theplating layer 3. That is, at least part of the firstabrasive grains 4 and at least part of the secondabrasive grains 5 both protrude outwardly from the surface (outer surface) of theplating layer 3. The amount of protrusion of the firstabrasive grains 4 is larger than that of the second abrasive grains. The amount of protrusion denotes an average height of the abrasive grains protruding outwardly from the outer surface of theplating layer 3. As illustrated inFIG. 1 , a tip (position) of each of the first abrasive grains 4 (or second abrasive grains 5) farthest away from thebase 2 is aprotruding end 41 of a first abrasive grain 4 (or protrudingend 51 of a second abrasive grain 5). The protruding ends 41 of the firstabrasive grains 4 are located farther away from the base 2 (i.e., the outer surface of the plating layer 3) than the protruding ends 51 of the secondabrasive grains 5 are. - In the
electrodeposition whetstone 1, a first virtual plane V1 created by the protruding ends 41 and a second virtual plane V2 created by the protruding ends 51 are defined. Since the amount of protrusion of the protruding ends 41 is larger than that of the protruding ends 51, the first virtual plane V1 is located on the outer side with respect to the second virtual plane V2. It is preferable that the average distance between the first virtual plane V1 and the second virtual plane V2 be equal to or shorter than a range R. The range R can be suitably set based at least on the grain size of the firstabrasive grains 4, the grain size of the secondabrasive grains 5, and the thickness of theplating layer 3. It is preferable that the range R increase in accordance with an increase in the thickness of theplating layer 3. It is preferable that the range R be defined as 6 μm or larger and 42 μm or smaller. In one example, if the firstabrasive grains 4 are in a grit size of around 600, the range R is preferably around 6 μm. In another example, if the firstabrasive grains 4 are in a grit size of around 50, the range R is preferably around 42 μm. As will be described later, with theelectrodeposition whetstone 1 satisfying the range R, the life of theelectrodeposition whetstone 1 can be prolonged. - The first
abrasive grains 4 are arranged in theplating layer 3 so as to be separated from each other in the orthogonal direction. That is, a gap is created in the orthogonal direction between the firstabrasive grains 4 arranged in the orthogonal direction. The secondabrasive grains 5 are arranged in the gaps created by the firstabrasive grains 4 in the orthogonal direction. For instance, the secondabrasive grains 5 are arranged in gaps created in the orthogonal direction by the firstabrasive grains 4 adjacent to each other in the orthogonal direction. The size of the gap (interval) between the firstabrasive grains 4 is preferably 20 μm or larger. In this case, the secondabrasive grains 5 serve as a bond coating of theplating layer 3. This can improve the strength of theelectrodeposition whetstone 1, and can also increase the force of theplating layer 3 holding the abrasive grains. The abrasive grains are therefore prevented from coming off from theelectrodeposition whetstone 1. In addition, theplating layer 3 is prevented from being scratched by the grinding chips. The life of theelectrodeposition whetstone 1 can thereby be prolonged. - With the first
abrasive grains 4 arranged as described above, the grinding sharpness of theelectrodeposition whetstone 1 is improved. The present inventors consider the explanation for this as follows. When a certain firstabrasive grain 4 grinds a grinding workpiece, the grinding workpiece is shaved and deformed by the certain firstabrasive grain 4. If the firstabrasive grains 4 are separated from each other in the orthogonal direction, it is highly probable that another firstabrasive grain 4 will grind the workpiece after the workpiece is elastically recovered. As a result, the grinding effects upon the grinding workpiece will be increased, and the friction upon the workpiece will be reduced. That is, the grinding resistance acting upon theelectrodeposition whetstone 1 from the contact surface between theelectrodeposition whetstone 1 and the workpiece is lowered. Thus, effective grinding can be performed by theelectrodeposition whetstone 1, and the grinding sharpness of theelectrodeposition whetstone 1 is improved. Furthermore, with the grinding resistance reduced, it is possible to prevent burrs from being produced in the workpiece by theelectrodeposition whetstone 1. - The second
abrasive grains 5 arranged as described earlier elongate the life of theelectrodeposition whetstone 1. The present inventors consider the explanation for this as follows. During grinding of the grinding workpiece with the firstabrasive grains 4, grinding chips are formed. Since the amount of protrusion of the secondabrasive grains 5 from theplating layer 3 is smaller than the amount of protrusion of the firstabrasive grains 4 from theplating layer 3 as described above, these grinding chips are broken by the secondabrasive grains 5 into still smaller grinding chips. This reduces damage to theplating layer 3 that tends to be caused by the grinding chips. Furthermore, with the grinding chips being small, clogging can be suppressed, which tends to be caused by grinding chips being stuck between abrasive grains. As a result, the scratching of theplating layer 3 of theelectrodeposition whetstone 1 can be suppressed, which can prolong the life of theelectrodeposition whetstone 1. - Next, the method of manufacturing the
electrodeposition whetstone 1 according to the present embodiment will be described.FIG. 2 shows the steps of an exemplary method of manufacturing theelectrodeposition whetstone 1 according to the present embodiment. Thebase 2 used for theelectrodeposition whetstone 1 is manufactured with a commonly known method. The surface (outer surface) of thebase 2 may be treated with blasting, masking, or the like. In a blasting treatment, the electrodeposition surface is treated by injecting particles onto the surface (electrodeposition surface) of thebase 2. For instance, alumina abrasive particles may be used in the blasting treatment. In a masking treatment, portions other than the electrodeposition surface are covered. For instance, a waterproof tape may be used to cover the portions other than the electrodeposition surface. The firstabrasive grains 4 are dispersed over the surface of thebase 2. Next, the surface of thebase 2 to which the firstabrasive grains 4 are attached is plated with first plating (primary plating). The first plating may be electrolytic plating, examples of which include electrolytic nickel plating. In this manner, the firstabrasive grains 4 are secured to the surface of thebase 2. Here, excessive firstabrasive grains 4 may remain between the firstabrasive grains 4. In this case, the excessive firstabrasive grains 4 need to be removed from the surface of thebase 2. As a result, suitable gaps (intervals) can be maintained between the firstabrasive grains 4 in the orthogonal direction. Removal of the excessive firstabrasive grains 4 may be conducted by hand scrubbing. The dispersion of the firstabrasive grains 4 and the primary plating may be performed after thebase 2 is cleaned following the blasting treatment. This will increase the adhesion between the primary plating and thebase 2. - Further plating (secondary plating) is performed upon the first abrasive grains suitably secured to the
base 2. The secondary plating may be performed in a manner similar to the primary plating. For instance, electrolytic nickel plating is performed. The previously mentionedfirst plating layer 31 is formed through the primary plating and secondary plating. As a result, the firstabrasive grains 4 are secured to the surface of thebase 2 by thefirst plating layer 31, as shown in the top ofFIG. 2 . The total thickness (average total thickness) obtained by adding the thickness of the primary plating and the thickness of the secondary plating can be suitably determined with reference to the grain size (average grain size) of the first abrasive grains. The average total thickness may be, for example, about 20% of the grain size of the firstabrasive grains 4, or about 30% of the grain size of the firstabrasive grains 4. - Next, as shown in the middle of
FIG. 2 , the secondabrasive grains 5 are dispersed so as to arrange the secondabrasive grains 5 in the gaps created in the orthogonal direction between the firstabrasive grains 4. The second plating (tertiary plating) is performed upon thefirst plating layer 31, the firstabrasive grains 4, and the secondabrasive grains 5. The second plating differs from the first plating. The second plating may be electroless plating, examples of which include electroless Ni—P plating. The previously mentionedsecond plating layer 32 is thereby formed. The thickness of the tertiary plating is preferably smaller than the thickness of the secondary plating. The thickness of the tertiary plating can be suitably determined with reference to the grain size of the firstabrasive grains 4 and the grain size of the secondabrasive grains 5. The thickness may be 6 Tim or larger and 72 μm or smaller. As described above, theplating layer 3 is completed by the primary plating, secondary plating, and tertiary plating. - After the completion of the
plating layer 3, heat treatment is conducted upon theelectrodeposition whetstone 1. As a heat treatment, a commonly used method can be suitably used. For instance, heat treatment at 350° C. may be performed. As a result, theelectrodeposition whetstone 1 of the embodiment is completed, as illustrated in the bottom ofFIG. 2 . With theelectrodeposition whetstone 1 formed as described above, the distance (average distance) between the first virtual plane V1 and the second virtual plane V2 can be determined within the range R. - If the
second plating layer 32 contains particles having a friction coefficient lower than that of thesecond plating layer 32, the plating solution for the tertiary plating may contain PTFE having an average particle size of 0.1 μm or larger and 1 μm or smaller in an amount of 5% by volume or more and 40% by volume or less with respect to the total volume of the plating solution. As the tertiary plating, Ni—P—SiC dispersion plating, hard chromium plating, electroless Ni—P plating, electroless Ni—B plating, or electroless Ni—W—P plating may be performed. In this case, heat is applied to thesecond plating layer 32 after the tertiary plating so as to cure thesecond plating layer 32. This improves the wear resistance of theelectrodeposition whetstone 1. - As described above, in the
electrodeposition whetstone 1 of the present embodiment, the firstabrasive grains 4 protrude from theplating layer 3 outwardly in the thickness direction. The secondabrasive grains 5 are arranged between the first abrasive grains in the orthogonal direction. The amount of protrusion of the secondabrasive grains 5 are a smaller than that of the firstabrasive grains 4 from theplating layer 3 in the thickness direction, and the secondabrasive grains 5 have a smaller grain size than that of the firstabrasive grains 4. This suppresses stacking of grinding chips between the abrasive grains, as discussed above, in theelectrodeposition whetstone 1 of the present embodiment, thereby prolonging the life of theelectrodeposition whetstone 1. - In the
electrodeposition whetstone 1 of the present embodiment, the firstabrasive grains 4 may contain at least one selected from the group consisting of diamond abrasive grains, CBN abrasive grains, and metal oxide abrasive grains. The secondabrasive grains 5 may include at least one of diamond abrasive grains and CBN abrasive grains. In this manner, the grinding chips can be reduced in size more efficiently in theelectrodeposition whetstone 1 of the embodiment, as a result of which the life of theelectrodeposition whetstone 1 can be further prolonged. - In the manufacturing method of the present embodiment, the first
abrasive grains 4 are secured to the base by the first plating, with gaps created between the firstabrasive grains 4 in the orthogonal direction. In the manufacturing method of the present embodiment, a grain size of the secondabrasive grains 5 being smaller than a grain size of the firstabrasive grains 4 are arranged in these gaps in the orthogonal direction. In the manufacturing method of the present embodiment, the firstabrasive grains 4 and the secondabrasive grains 5 are secured by the second plating, which differs from the first plating, in such a manner that the amount of protrusion of the secondabrasive grains 5 in the thickness direction is smaller than the amount of protrusion of the firstabrasive grains 4. As a result, anelectrodeposition whetstone 1 with a long life can be produced. - In a modification example, a
coating layer 33 may be formed in theelectrodeposition whetstone 1 after the plating process is completed, as shown inFIG. 3 . In this case, theplating layer 3 of theelectrodeposition whetstone 1 further includes thecoating layer 33. The thickness of thecoating layer 33 is not limited as long as both the firstabrasive grains 4 and the secondabrasive grains 5 protrude from thecoating layer 33, as illustrated inFIG. 3 . The thickness of thecoating layer 33 may be, for example, 0.1 μm or larger and 0.5 μm or smaller. In one example, thecoating layer 33 is formed through electroless plating using a nickel solution to which a reducing agent is added. In another example, thecoating layer 33 is formed through electrolytic plating using a nickel solution to which a reducing agent is added. In the electrolytic plating, the plating bath may be a Watts bath or a sulfamate bath. The Watts bath contains, for example, nickel sulfate, nickel chloride, and boric acid as major components. The sulfamic acid bath contains, for example, nickel sulfamate and boric acid as major components. - Similarly to the
second plating layer 32, thecoating layer 33 may include particles having a friction coefficient lower than that of thecoating layer 33. In this case, the aforementioned plating solution for the tertiary plating is used as a plating solution for thecoating layer 33. With thecoating layer 33 formed on theelectrodeposition whetstone 1 in this manner, the life of theelectrodeposition whetstone 1 can be further prolonged. In this case also, the amount of protrusion of the firstabrasive grains 4 is larger than the amount of protrusion of the secondabrasive grains 5 in theelectrodeposition whetstone 1. Thus, the same action and effects as those of the above embodiment can be achieved in this modification example. - In another example, if the second plating layer is formed by plating that contains at least one of PTFE and tungsten, the second plating layer may not always attain a sufficient thickness to secure the first
abrasive grains 4 and the secondabrasive grains 5; the second plating layer is therefore formed by plating that does not contain PTFE or tungsten. In this manner, the second plating layer can be formed up to a thickness sufficient to secure the secondabrasive grains 5. Thereafter, thecoating layer 33 is formed. Thecoating layer 33 will be formed with plating that contains at least one of PTFE and tungsten. With the second plating layer and thecoating layer 33 formed in this manner, even if the second plating layer cannot be formed to have a sufficient thickness, theelectrodeposition whetstone 1 can still exhibit the same effects as the case where at least one of PTFE and tungsten is contained. - In another modification example, a foundation layer 7 may be formed in the
electrodeposition whetstone 1, as shown inFIG. 4 . In this structure, theelectrodeposition whetstone 1 further includes a foundation layer 7. The thickness of the foundation layer is not particularly limited. The thickness may be, for example, 0.1 μm or larger and 1 μm or smaller. The foundation layer 7 is formed of a material containing at least a ferrous material, aluminum, Alloy 42, or a non-metal material. Examples of the ferrous material include a stainless-steel material and a cast material. Examples of the non-metal material include a non-ferrous material and a resin material. Examples of the non-ferrous material include carbon fiber reinforced plastic (CFRP). - If the
electrodeposition whetstone 1 includes the foundation layer 7, plating suitable for the material of the foundation layer 7 is provided on thebase 2 before the firstabrasive grains 4 are dispersed on thebase 2. In one example, thebase 2 is cleaned after the surface of thebase 2 is subjected to the blasting or the like, and then the foundation layer 7 is formed on thebase 2. In this case, copper plating or nickel chloride plating may be adopted for the plating. The foundation plating may be formed by dry plating instead of wet plating, which uses a plating solution. As the dry plating, physical vapor deposition (PVD) or chemical vapor deposition (CVD) may be performed. With the foundation layer 7 formed on theelectrodeposition whetstone 1 in this manner, the life of theelectrodeposition whetstone 1 can be further prolonged. In this case also, the amount of protrusion of the firstabrasive grains 4 is larger than the amount of protrusion of the secondabrasive grains 5 in theelectrodeposition whetstone 1. Thus, this modification example can achieve the same action and effects as those of the above embodiment. - Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
Claims (11)
1. An electrodeposition whetstone comprising:
a plating layer;
a base on which the plating layer is provided;
first abrasive grains protruding from the plating layer; and
second abrasive grains arranged between the first abrasive grains,
the amount of protrusion of the second abrasive grains from the plating layer being smaller than the amount of protrusion of the average grain size of the first abrasive grains from the plating layer, and
a grain size of the second abrasive grains being smaller than a grain size of the first abrasive grains,
wherein:
the plating layer includes a first plating layer provided on the base and a second plating layer provided on the first plating layer,
the electrodeposition whetstone includes:
a first virtual plane formed by a plurality of protruding ends of the first abrasive grains, and
a second virtual plane formed by a plurality of protruding ends of the second abrasive grains,
the first virtual plane is located outside with respect to the second virtual plane,
a distance between the first virtual plane and the second virtual plane is equal to or smaller than a range determined based at least on the average grain size of the first abrasive grains, the average grain size of the second abrasive grains, and a thickness of the plating layer, and
the range increases as a thickness of the first plating layer increases.
2. The electrodeposition whetstone according to claim 1 , wherein:
a grain size of the first abrasive grains is 25 μm or larger and 300 μm or smaller,
a grain size of the second abrasive grains is 10 μm or larger and 120 μm or smaller,
the thickness of the plating layer is 40% or larger and 80% or smaller of the average grain size of the first abrasive grains, and
the range is 6 μm or larger and 42 μm or smaller.
3. The electrodeposition whetstone according to claim 1 , wherein:
the first abrasive grains are separated from each other, and
the second abrasive grains are respectively arranged in a gap between the first abrasive grains.
4. The electrodeposition whetstone according to claim 3 , wherein a size of the gap between the first abrasive grains is 20 μm or larger.
5. The electrodeposition whetstone according to claim 1 , wherein:
lower ends of the first abrasive grains are at a boundary between the base and the first plating layer, and
lower ends of the second abrasive grains are at a boundary between the first plating layer and the second plating layer.
6. The electrodeposition whetstone according to claim 1 , wherein:
the first abrasive grains include at least one selected from a group consisting of diamond abrasive grains, CBN abrasive grains, and metal oxide abrasive grains, and
the second abrasive grains include at least either one of diamond abrasive grains and CBN abrasive grains.
7. The electrodeposition whetstone according to claim 1 , wherein the plating layer includes at least one selected from a group consisting of polytetrafluoroethylene and tungsten.
8. A manufacturing method comprising:
securing a plurality of first abrasive grains to a base by a first plating layer, with gaps formed between the first abrasive grains, and forming a first virtual plane by a plurality of protruding ends of the first abrasive grains;
arranging second abrasive grains in the gaps, a grain size of the second abrasive grains being smaller than a grain size of the first abrasive grains; and
securing the first abrasive grains and the second abrasive grains by second plating different from the first plating layer in such a manner that the amount of protrusion of the second abrasive grains is smaller than the amount of protrusion of the first abrasive grains, forming a plating layer from the first plating layer and the second plating layer, and forming a second virtual plane by a plurality of protruding ends of the second abrasive grains,
wherein:
an average distance between the first virtual plane and the second virtual plane is equal to or smaller than a range determined based at least on an average grain size of the first abrasive grains, an average grain size of the second abrasive grains, and a thickness of the plating layer, and
the range increases as a thickness of the first plating layer increases.
9. The manufacturing method according to claim 8 , wherein:
the first plating layer is electrolytic plating, and
the second plating layer is electroless plating.
10. The manufacturing method according to claim 9 , further comprising:
separating the first abrasive grains from each other, and
arranging the second abrasive grains in the gaps between the first abrasive grains.
11. The manufacturing method according to claim 8 , wherein the second plating layer contains at least one selected from a group consisting of polytetrafluoroethylene and tungsten.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2020187129A JP7162910B2 (en) | 2020-11-10 | 2020-11-10 | Electroplated grindstone and manufacturing method |
JP2020-187129 | 2020-11-10 | ||
PCT/JP2021/027687 WO2022102173A1 (en) | 2020-11-10 | 2021-07-27 | Electrodeposition grinding wheel and method for producing same |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/JP2021/027687 Continuation WO2022102173A1 (en) | 2020-11-10 | 2021-07-27 | Electrodeposition grinding wheel and method for producing same |
Publications (1)
Publication Number | Publication Date |
---|---|
US20230219194A1 true US20230219194A1 (en) | 2023-07-13 |
Family
ID=81601028
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US18/187,325 Pending US20230219194A1 (en) | 2020-11-10 | 2023-03-21 | Electrodeposition whetstone and manufacturing method |
Country Status (5)
Country | Link |
---|---|
US (1) | US20230219194A1 (en) |
EP (1) | EP4245461A1 (en) |
JP (1) | JP7162910B2 (en) |
CN (1) | CN116615308A (en) |
WO (1) | WO2022102173A1 (en) |
Family Cites Families (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS63144965A (en) * | 1986-12-03 | 1988-06-17 | Kobe Steel Ltd | Grinding tool and its manufacture |
JPS63144963A (en) * | 1986-12-03 | 1988-06-17 | Kobe Steel Ltd | Manufacture of grinding tool |
JP2679178B2 (en) * | 1988-11-22 | 1997-11-19 | 三菱マテリアル株式会社 | Electroplated whetstone |
JPH0290057U (en) * | 1988-12-29 | 1990-07-17 | ||
JPH06114739A (en) * | 1992-10-09 | 1994-04-26 | Mitsubishi Materials Corp | Electrodeposition grinding wheel |
JPH10329029A (en) * | 1997-05-30 | 1998-12-15 | Osaka Diamond Ind Co Ltd | Electrodepositioning super grain grinding wheel |
JP3052896B2 (en) * | 1997-06-13 | 2000-06-19 | 日本電気株式会社 | Dress jig on polishing cloth surface and method of manufacturing the same |
JP2000153463A (en) | 1998-11-16 | 2000-06-06 | Asahi Diamond Industrial Co Ltd | Manufacture of electrodeposition tool |
JP3802884B2 (en) | 2003-04-09 | 2006-07-26 | 株式会社呉英製作所 | CMP conditioner |
JP2004358640A (en) | 2003-06-09 | 2004-12-24 | Goei Seisakusho:Kk | Method for manufacturing electroplated tool and electroplated tool |
JP2005022074A (en) | 2003-06-10 | 2005-01-27 | Nikon Corp | Grinding tool for grinding |
US8096859B2 (en) | 2008-12-18 | 2012-01-17 | Sunnen Products Company | Honing tool having enhanced wear resistance properties |
JP5567900B2 (en) | 2010-05-21 | 2014-08-06 | 日本碍子株式会社 | Electrodeposition whetstone and method for manufacturing the same |
-
2020
- 2020-11-10 JP JP2020187129A patent/JP7162910B2/en active Active
-
2021
- 2021-07-27 EP EP21891421.6A patent/EP4245461A1/en active Pending
- 2021-07-27 CN CN202180071478.1A patent/CN116615308A/en active Pending
- 2021-07-27 WO PCT/JP2021/027687 patent/WO2022102173A1/en active Application Filing
-
2023
- 2023-03-21 US US18/187,325 patent/US20230219194A1/en active Pending
Also Published As
Publication number | Publication date |
---|---|
EP4245461A1 (en) | 2023-09-20 |
JP2022076650A (en) | 2022-05-20 |
CN116615308A (en) | 2023-08-18 |
WO2022102173A1 (en) | 2022-05-19 |
JP7162910B2 (en) | 2022-10-31 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US9701043B2 (en) | Dicing blade | |
JPH06114739A (en) | Electrodeposition grinding wheel | |
US20110275288A1 (en) | Cmp pad dressers with hybridized conditioning and related methods | |
GB2263911A (en) | Abrasive tools | |
KR20100087297A (en) | Cmp pad conditioners with mosaic abrasive segments and associated methods | |
US20090203300A1 (en) | Carrier for holding an object to be polished | |
KR101720228B1 (en) | Cemented Carbide Base Outer Blade Cutting Wheel and Making Method | |
EP0179404A2 (en) | Grinding tool | |
US20090090066A1 (en) | Grinding tool and manufacturing method thereof | |
JP2522278B2 (en) | Electroformed thin blade grindstone | |
JP2008006526A (en) | Polishing carrier | |
US20230219194A1 (en) | Electrodeposition whetstone and manufacturing method | |
KR20150060915A (en) | Wire tool with abrasive grains | |
JP2004358640A (en) | Method for manufacturing electroplated tool and electroplated tool | |
JPH05131366A (en) | Diamond dressing gear for tool to hone gear or the like | |
CN103009273A (en) | Pyramid grinding plate | |
JPS6165776A (en) | Manufacture of grinder element for lubricated cutting processing | |
JP2001001266A (en) | Super abrasive grain cutting wheel | |
JPH10329029A (en) | Electrodepositioning super grain grinding wheel | |
RU2808089C2 (en) | Cutting tool with asymmetrical teeth containing cutting particles | |
JP3102715B2 (en) | Grinding wheel | |
US20210187696A1 (en) | Hybrid cmp conditioning head | |
JPH0215978A (en) | Grinding tool | |
JP2009078321A (en) | Electroplated tool and method of manufacturing the same | |
JP2002086360A (en) | Thin-blade grinding wheel produced by electroformation |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: TOKYO DIAMOND TOOLS MFG. CO., LTD., JAPAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:TSUDA, MASAAKI;KISHIMOTO, JUN;YAGI, TAKESHI;SIGNING DATES FROM 20230209 TO 20230217;REEL/FRAME:063048/0022 |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |