US3375181A - Method of forming an abrasive surface including grinding and chemically dressing - Google Patents

Method of forming an abrasive surface including grinding and chemically dressing Download PDF

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Publication number
US3375181A
US3375181A US369048A US36904864A US3375181A US 3375181 A US3375181 A US 3375181A US 369048 A US369048 A US 369048A US 36904864 A US36904864 A US 36904864A US 3375181 A US3375181 A US 3375181A
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main component
surface portion
particles
metal
softer
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US369048A
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Koech Gunther
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/60—After-treatment
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F1/00—Etching metallic material by chemical means
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25F—PROCESSES FOR THE ELECTROLYTIC REMOVAL OF MATERIALS FROM OBJECTS; APPARATUS THEREFOR
    • C25F3/00—Electrolytic etching or polishing
    • C25F3/02—Etching

Definitions

  • the present invention contemplates a method of producing coarse, rough operating surface portions on metal bodies, such as tools, friction wheels, belt pulleys, clutch discs and the like, having at least at said operating surface portion a surface zone of heterogeneous micro-crystalline structure including a softer main component forming the major proportion of the surface portion, and having distributed through and embedded in the softer main component, a plurality of harder crystalline particles forming the minor proportion of the surface portion, comprising the steps of shaping eg by cutting or grinding the operating surface portion, to its desired configuration, and selectively removing the upper layer of the softer main component only, so as to form a surface the major proportion of which consists of the softer main component and the minor proportion of which consists of the harder microcrystalline particles sharpened by said grinding and projecting outwardly from the softer main component to the exact operating surface and forming only a minor fraction of the operating surface portion, whereby due to the outwardly projecting harder particles a rough operating surface portion is formed.
  • the surface portion of the metal body which is to be treated is of heterogeneous composititin namely such that the major part of the surface portion consists of a relatively soft material and that harder particles or crystals are embedded therein.
  • the uppermost layer of the major part of the surface portion i.e., the softer material, is then selectively removed by chemical or electrolytic action so that the tips of the embedded harder particles which are less susceptible to chemical or electrolytic attack will become exposed and will give to the surface portion the desired degree of roughness.
  • the softer material which is partially removeddfiring the process as described above will form the major portion of the surface of the surface area of the projectinghard particles of the treated surface will constitute only a minor portion of the total treated surface area.
  • the rough, coarse surface portions are produced on metal bodies which have at least in the operating surface portion a surface zone of heterogeneous crystalline or microcrystalline structure which includes a less hard main component forming the major part of the surface portion and a considerably harder minor portion consisting of particles preferably chemically bonded to the main component.
  • the surface portion of the metal body may be machined, e.g. by grinding, to its desired geometrical shape and thereafter the uppermost layer of the less hard main component is removed by chemical or electrochemical etching. Thereby it will be accomplished that the upper portions of the very hard particles will then project outwardly from the less hard main part of the surface and these projecting very hard generally microcrystalloid surface particles will give to the operating' surface portion the desired degree of roughness. It may be noted again that the outwardly projecting harder particles constitute only a minor fraction of the total surface area.
  • the present method may be applied to producing a great variety of metal bodies shaped to a high degree of accuracy irrespective of the specific geometrical shape involved, such as spherical cups of all sizes, roller bodies, nozzle bores of smaller diameter, spherical bearing surfaces and the like.
  • the metal bodies are finished or finally machined or smoothed with tools produced according to the present invention and thereafter the softer component of the surface portion is removed chemically or preferably electrolytically.
  • This method may also be used for producing on metal parts or workpieces any desired coarse or rough surface portion having a microcrystalline structure which is suitable for positive engagement with a surface portion of another metal body for the purpose of increasing the friction coefficient, while at the same time maintainingthe greatest geometrical accuracy.- This is important, for instance in the case of clamping members, clamping mandrels, friction wheels and the like. It is common to all applications of the method that" hard, usually microcrystalline particles of the desired size or shape are located in the surface zone of the-metal body occupying only a minor fraction thereof and projecting outwardly therefrom surrounded by the less hard main component of the surface zone the u permest layer of which has heen removed. 7
  • Such surface zones with hard and sharp particles projecting outwardly therefrom may be obtained by chemical or electrolytic dissolution of the outermost portin of the main componentcf the surface whichis softer,
  • the very hard particles in the heterogeneous surface portion can be produced for exam le by diffusing car- 3 bide-forming agents into the surface portion, for instance by the well known process of cementing.
  • the main component of the surface portion may be a metal of a certain hardness such as iron, nickel, chromium, tungsten, molybdenum, boron or cobalt which contains chemically bonded microcrystals of greater hardness such as the carbides or nitrides of iron, chromium, vanadium, tungsten, titanium or boron, as a heterogeneous component which will not be attacked during the subsequent electrolytic removal of the surface layer of the main component.
  • a metal of a certain hardness such as iron, nickel, chromium, tungsten, molybdenum, boron or cobalt which contains chemically bonded microcrystals of greater hardness such as the carbides or nitrides of iron, chromium, vanadium, tungsten, titanium or boron, as a heterogeneous component which will not be attacked during the subsequent electrolytic removal of the surface layer of the main component.
  • Another manner in which a heterogeneous surface portion of a metal body can be produced is the sintering together of a variety of metal powders of different hardness and different susceptibility to chemical or electrolytic attack whereby the softer metal will be such as to be dissolved by such chemical or electrolytic attack while the harder metal distributed therethrough and forming a minor part of the total surface portion will remain unaffected and thus will project outwardly after the uppermost surface layer of the softer portion has been removed.
  • a plurality of sintered layers produced in this manner may then be fused together to form a body or blank of the desired configuration.
  • the workpiece or surface portion is subjected to smoothing prior to removal of the softer component so that the desired accurate shape will be maintained by the outwardly projecting harder particles.
  • the invention utilizes the fact that the components of greater hardness, particularly the above-mentioned carbides do not dissolve at all or only to a very low degree during the treatment with chemical solutions or by electrolytic treatment which will dissolve the less hard pure iron (ferrite) at a high rate.
  • the metal body consists for instance of a heterogeneous mixture of two chemical components, then the nobler component will not be corroded by the electrolyte before the less noble component which ranges higher in the potential table has been completely dissolved.
  • the cementite (Fe C) is nobler than the iron.
  • Chromium has a potential of plus 1.30. It forms together with carbon a very hard component, namely chromium carbide which is nobler than chromium and thus will not be attacked under conditions in which the chromium will be dissolved.
  • chromium is not soluble in hydrochloric acid since its potential is above the potential of hydrogen.
  • a voltage of 1.36 volts against the chromium in an electrolytic cell the chromium will be dissolved but the chromium carbide will remain intact.
  • the main, component i.e., the softer component of the metal body or metal surface portion may be any metal in which is incorporated a minor proportion of harder crystalloids or the like.
  • the hardness of the main component i.e., of the softer component, is at least equal to the hardness of pure iron.
  • the metal body or metal surface portion thus should consist of a heterogeneous microstructure, i.e., chemically bonded microcrystals embedded in the main component and the hardness of the microcrystals is to be greater than that of the material which is to be treated with a tool formed according to the present invention.
  • the electrochemical potential of the metal of the softer main component must not be as high as that of the embedded microcrystals of the hard material. This condition is met for instance by the combination of iron and cementite (Fe C) and in the case of all hard metals, such as tungsten, the carbides and nitrites are nobler than the metallic main component.
  • the depth to which the softer main component is to be dissolved or the height to which the harder particles are to project outwardly depends on the purpose of the tool to be produced and on the size of the harder microstructures or crystals.
  • the less hard components of the structure may be removed to a greater or lesser depth, but so that a strong bond between the still partially embedded hard particles and the softer main component is maintained while the points of the very hard particles such as nitrides or carbides will project outwardly a suflicient distance from the remaining surface of the softer main component.
  • the metal body or surface portion Before removing the uppermost layer of the softer main component, the metal body or surface portion preferably is shaped to its desired dimensionally true geometrical configuration. In this manner it is achieved that the desired outer dimensions will then be represented by the tips of the projecting harder particles. This outermost surface consists then only of the spaced tips of the harder components of the heterogeneous metal surface portion and consequently will possess a very high resistance to wear. Furthermore, the cleaning or sharpening of a tool produced in the above described manner by means of the electrolytic process can be repeated several times. The coarse, sharp-edged surface produced by the present method can be used for tools and metal bodies of all kinds as well as for rollers and the like, since a very high resistance to pressure and bending can be obtained in addition to the high resistance to wear.
  • hardest carbides or carbide forming agents may advantageously be pressed and sin-tered with less hard or nonh-ardening metal powder in any desired grain size or mixture provided that the harder constituents will represent only a minor fraction of the total surface area, and in this manner, in accordance with the present invention, it is possible to produce in a relatively simple manner tools having a rough more or less fine or coarse surface and these tools will at the same time possess good edge-holding properties; It is also possible to produce different kinds of pitted surface structures, shallow cavities and the like by distributing the various types of powder in laminae or patterns, sintering, and thereafter electrolytically dissolving the outer most portion of the softer metal of the sintered body.
  • machining 'by means of such surface contact tools may be carried out with advantage, as for example honing which up to now was difiicult with respect to stepped bores or blind holes.
  • the favorable heat conducting properties of the metallic body of the tool are of special advantage since they reduce the cutting temperature and the adverse effects such as dis-' tortion of the tool, dimensional inaccuracy, etc.
  • fine flutes or grooves are desirable which may be arranged in any suitable manner, for example, at the periphery of the metal removing surfaces.
  • Various methods may be employed for producing these grooves or shallow recesses, such as hard and soft components arranged in alternate laminae prior to pressing and sintering to form the metal 'body, or such grooves may be formed by material removing processes, such as electrolytic removal with cally increased removal of material along the lines of contact of two different bodies such as, for example, in the case of painted surface portions.
  • FIG. 1 is a schematic cross-sectional view of a machined portion of a metal body consisting of a softer main component and having distributed therethrough harder microcrystalline particles, prior to chemical or electrolytic treatment according to the present invention
  • FIG. 2 is a schematic fragmentary view of the metal body of FIG. 1 after chemical or electrolytic treatment according to the present invention.
  • FIG. 3 schematically illustrates a file formed in accordance with the present invention.
  • the metal body of FIGS. 1 and 2 comprises a softer component 1 consisting for instance of iron and having embedded in the surface region thereof harder particles such as iron carbide 2, said surface and particles being shaped by grinding.
  • FIG. 3 shows a file comprising a handle 3 and a working portion 4 on which are indicated in an exaggerated manner the outwardly producing harder carbide particles 2.
  • the roughness of the steel pieces was about 2 microns. After degreasing and grinding the steel pieces, the same were successively subjected to electrolysis in the following two solutions: 1
  • Solution B by weight phosphoric acid, density 1.84 20% by weight sulfuric acid, density 1.7
  • the solutions were maintained at about 25 C. and a direct current of 50 volts between cathode and anode was passed through the solution, the steel piece serving as anode.
  • the cathode was formed by a helical cooling pipe, and a current-density of about 4.5 amperes per 100 cm. was maintained.
  • the metal bodies were uniformly moved in the electrolyte. After treatment for six minutes in S0- lution A and for ten minutes in Solution B a suflicient roughness of the surface portions of the steel pieces which were thus exposed to electrolysis was attained so that by applying the thus treated steel piece to a hardened steel ball a grinding effect was achieved.
  • the degree of roughness which can be achieved depends on the size of the particles which are not affected by the electrolytic dissolution of the softer main component, such as carbides, nitrides, harder metals or diamonds.
  • the softer main component should be dissolved only to such depth that the hard particles still remain I firmly anchored in the remaining portion of the softer material. Thus, when larger hard particles are embedded in the softer main component a greater degree of roughness can be obtained.
  • the harder particles will form between about 10% and 40% of the planar surface area and the softer main component between and 60%.
  • the harder particles which are embedded in the softer main component preferably will have a maximum dimension of between about 5 microns and two millimeters.
  • the treating solution which is used for removing the surface layer of the softer main component may be such as to effect only a chemical dissolution, or may be used as electrolyte as described in the example.
  • the degree of roughness obtained will depend on the composition of the solution, the length of treatment, the composition of the softer main component and the current applied.
  • hydrochloric acid, sulfuric acid, titanium tetrachloride, and oxalic acid may be used. It is also possible to treat the metal bodies in a corrosive gas atmosphere which will selectively attack only the softer main component.
  • the portion of the metals forming hard carbides during cementing of the alloy such :as chromium, silicon, wolfram vanadium or the like, may be diminished. Otherwise the temperature during cementing may be increased and the duration of cementing may be diminished, so as to get a minor amount of hard carbides.
  • the tool may be built by pressing and sintering together alternating hard and softer plies of sintered metal, the harder or both kinds of plies containing hard micro-crystalline particles embedded in a larger amount of softer binding metal, by which pressing and sintering together the plies are directed vertically to the operating surface, i.e. so that there small edges are forming the operating surface. Then the operating surface portion is ground and thereupon the outer portions of the softer metals of the two kinds of plies are chemically or electrolytically removed. Thereby not only the hard particles are laid bare but also the outer portions of the softer plies including its hard particles are removed more than the outer portions of the harder plies. In this way outer grooves between the harder layers are formed in order to receive filings during operating of the tool.
  • the particles are galvanized onto a metal body, so that the particles are wholly covered by the metal, e.g. bronze, or the particles and pulverized metal are sintered together in the desired mixture. Then the operating surface of the body is ground and thereupon the outer portion of the binder metal is electrically removed, as described above.
  • the metal e.g. bronze
  • the particles and pulverized metal are sintered together in the desired mixture. Then the operating surface of the body is ground and thereupon the outer portion of the binder metal is electrically removed, as described above.
  • metal carbide particles have a maximum dimension of between about 5 microns and 2 millimeters.
  • said metal carbide is selected from the group consisting of the carbides of iron, chromium, vanadium, tungsten, titanium and boron.
  • said material metal carbide is selected from the group consisting of iron carbide and tungsten carbide.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
  • Electrochemistry (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Powder Metallurgy (AREA)
US369048A 1956-07-02 1964-04-21 Method of forming an abrasive surface including grinding and chemically dressing Expired - Lifetime US3375181A (en)

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Application Number Priority Date Filing Date Title
DEK29247A DE1151158B (de) 1956-07-02 1956-07-02 Verfahren zur Erzeugung von feinrauhen Arbeitsflaechen an metallischen Werkstuecken durch elektrolytisches und/oder chemisches AEtzen

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3962003A (en) * 1973-11-08 1976-06-08 Xerox Corporation Method of forming magnetic brush support member
US3986303A (en) * 1974-02-27 1976-10-19 Norton Company Radially adjustable grinding wheel for grinding concave surfaces to constant primary and secondary radii
US4106977A (en) * 1975-05-09 1978-08-15 Audi Nsu Auto Union Aktiengesellschaft Process for production of oil control rings
US4170513A (en) * 1978-06-06 1979-10-09 Fernand Piche Enterprises Limited Recovery of tungsten carbide from scrap mining bits
US4896464A (en) * 1988-06-15 1990-01-30 International Business Machines Corporation Formation of metallic interconnects by grit blasting
US5170245A (en) * 1988-06-15 1992-12-08 International Business Machines Corp. Semiconductor device having metallic interconnects formed by grit blasting
US6030277A (en) * 1997-09-30 2000-02-29 Cummins Engine Company, Inc. High infeed rate method for grinding ceramic workpieces with silicon carbide grinding wheels
US20120017741A1 (en) * 2009-04-29 2012-01-26 Nv Bekaert Sa Sawing wire with abrasive particles partly embedded in a metal wire and partly held by an organic binder
US20130161137A1 (en) * 2011-12-27 2013-06-27 Robert Bosch Gmbh Brake disk

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3332804C2 (de) * 1983-09-12 1986-10-23 Hollingsworth Gmbh, 7265 Neubulach Verfahren zum Behandeln der Kanten eines Sägezahndrahtes für Garnituren in Textilmaschinen
JP5964394B2 (ja) 2014-11-19 2016-08-03 ファナック株式会社 電動機の回転子、電動機、工作機械、および回転子の製造方法

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GB346473A (en) * 1930-01-18 1931-04-16 Firth Sterling Steel Co Improvements in and relating to methods of making compositions of matter having cutting or abrading characteristics
US2020117A (en) * 1930-05-21 1935-11-05 Calibron Products Inc Cutting, grinding, and burnishing tool and the production thereof
US2137329A (en) * 1937-05-11 1938-11-22 Carborundum Co Abrasive article and its manufacture
US2305539A (en) * 1938-05-23 1942-12-15 Dow Chemical Co Electrode
US2343569A (en) * 1941-11-03 1944-03-07 Standard Oil Co California Pretreated bearing surface and method of producing the same
US2411867A (en) * 1942-12-19 1946-12-03 Brenner Bert Industrial diamond tool and method of producing same
US2498982A (en) * 1945-09-10 1950-02-28 Arthur Percy Warren Abrasive type cutting element and the manufacture thereof
US2678571A (en) * 1951-05-03 1954-05-18 Firth Brown Tools Ltd Method of making cutting tools
US2726650A (en) * 1952-05-26 1955-12-13 Failla Michael Grinding wheel dresser
US2820281A (en) * 1956-11-30 1958-01-21 Red Devil Tools Abrasive article
GB792841A (en) * 1955-02-25 1958-04-02 Percy Allan Charlesworth Improvements in the electro chemical treatment of metals and alloys
US3013449A (en) * 1955-09-23 1961-12-19 Alton E Tobey Abrading disk

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DE425827C (de) * 1924-05-07 1926-02-26 Ludwig Schmidt Verfahren zur Bearbeitung der Oberflaeche von Mahlwalzen fuer die Getreidemuellerei
DE548633C (de) * 1931-04-29 1932-04-16 Metallgesellschaft Ag Verfahren zur Herstellung von Lagern
DE622823C (de) * 1934-05-08 1935-12-09 Aeg Verfahren zur Herstellung von Schneidwerkzeugen, bei denen harte Schneidteilchen in eine tragende Grundmassen aus sinterungsfaehigen Stoffen eingebettet sind
DE695182C (de) * 1939-01-25 1940-08-19 Mahle Kg Verfahren zur Erzeugung von Poren auf Laufflaechentmaschinen
DE915540C (de) * 1943-04-23 1954-07-22 Otto Kienzle Dr Ing Schleifen der Passflaechen von Presspassungsteilen
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Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB346473A (en) * 1930-01-18 1931-04-16 Firth Sterling Steel Co Improvements in and relating to methods of making compositions of matter having cutting or abrading characteristics
US2020117A (en) * 1930-05-21 1935-11-05 Calibron Products Inc Cutting, grinding, and burnishing tool and the production thereof
US2137329A (en) * 1937-05-11 1938-11-22 Carborundum Co Abrasive article and its manufacture
US2305539A (en) * 1938-05-23 1942-12-15 Dow Chemical Co Electrode
US2343569A (en) * 1941-11-03 1944-03-07 Standard Oil Co California Pretreated bearing surface and method of producing the same
US2411867A (en) * 1942-12-19 1946-12-03 Brenner Bert Industrial diamond tool and method of producing same
US2498982A (en) * 1945-09-10 1950-02-28 Arthur Percy Warren Abrasive type cutting element and the manufacture thereof
US2678571A (en) * 1951-05-03 1954-05-18 Firth Brown Tools Ltd Method of making cutting tools
US2726650A (en) * 1952-05-26 1955-12-13 Failla Michael Grinding wheel dresser
GB792841A (en) * 1955-02-25 1958-04-02 Percy Allan Charlesworth Improvements in the electro chemical treatment of metals and alloys
US3013449A (en) * 1955-09-23 1961-12-19 Alton E Tobey Abrading disk
US2820281A (en) * 1956-11-30 1958-01-21 Red Devil Tools Abrasive article

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3962003A (en) * 1973-11-08 1976-06-08 Xerox Corporation Method of forming magnetic brush support member
US3986303A (en) * 1974-02-27 1976-10-19 Norton Company Radially adjustable grinding wheel for grinding concave surfaces to constant primary and secondary radii
US4106977A (en) * 1975-05-09 1978-08-15 Audi Nsu Auto Union Aktiengesellschaft Process for production of oil control rings
US4170513A (en) * 1978-06-06 1979-10-09 Fernand Piche Enterprises Limited Recovery of tungsten carbide from scrap mining bits
US4896464A (en) * 1988-06-15 1990-01-30 International Business Machines Corporation Formation of metallic interconnects by grit blasting
US5170245A (en) * 1988-06-15 1992-12-08 International Business Machines Corp. Semiconductor device having metallic interconnects formed by grit blasting
US6030277A (en) * 1997-09-30 2000-02-29 Cummins Engine Company, Inc. High infeed rate method for grinding ceramic workpieces with silicon carbide grinding wheels
US6220933B1 (en) 1997-09-30 2001-04-24 Cummins Engine Company, Inc. High infeed rate method for grinding ceramic workpieces with silicon carbide grinding wheels
US20120017741A1 (en) * 2009-04-29 2012-01-26 Nv Bekaert Sa Sawing wire with abrasive particles partly embedded in a metal wire and partly held by an organic binder
US8720429B2 (en) * 2009-04-29 2014-05-13 Nv Bekaert Sa Sawing wire with abrasive particles partly embedded in a metal wire and partly held by an organic binder
US20130161137A1 (en) * 2011-12-27 2013-06-27 Robert Bosch Gmbh Brake disk
CN103185088A (zh) * 2011-12-27 2013-07-03 罗伯特·博世有限公司 制动盘
US9394955B2 (en) * 2011-12-27 2016-07-19 Robert Bosch Gmbh Brake disk

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