WO2012073855A1 - Lame de coupe à circonférence externe à plaque de base en alliage super-dur et son procédé de fabrication - Google Patents

Lame de coupe à circonférence externe à plaque de base en alliage super-dur et son procédé de fabrication Download PDF

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Publication number
WO2012073855A1
WO2012073855A1 PCT/JP2011/077311 JP2011077311W WO2012073855A1 WO 2012073855 A1 WO2012073855 A1 WO 2012073855A1 JP 2011077311 W JP2011077311 W JP 2011077311W WO 2012073855 A1 WO2012073855 A1 WO 2012073855A1
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WO
WIPO (PCT)
Prior art keywords
base plate
abrasive grains
cutting blade
outer peripheral
cemented carbide
Prior art date
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PCT/JP2011/077311
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English (en)
Japanese (ja)
Inventor
匡樹 笠嶋
美濃輪　武久
治和 前川
欣史 長崎
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信越化学工業株式会社
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Publication date
Application filed by 信越化学工業株式会社 filed Critical 信越化学工業株式会社
Priority to CN201180065608.7A priority Critical patent/CN103313825B/zh
Priority to SG2013041520A priority patent/SG190924A1/en
Priority to US13/990,121 priority patent/US20130252521A1/en
Priority to MYPI2017000178A priority patent/MY193551A/en
Priority to KR1020137016382A priority patent/KR20140005911A/ko
Priority to MYPI2017000179A priority patent/MY193556A/en
Priority to EP11844821.6A priority patent/EP2647469B1/fr
Publication of WO2012073855A1 publication Critical patent/WO2012073855A1/fr
Priority to PH12018500478A priority patent/PH12018500478A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
    • B24D5/12—Cut-off wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • 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
    • 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
    • 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
    • B24D3/10—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 for porous or cellular structure, e.g. for use with diamonds as abrasives
    • 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
    • B24D3/20—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 organic
    • B24D3/28—Resins or natural or synthetic macromolecular compounds

Definitions

  • the present invention relates to a cemented carbide base plate outer peripheral cutting blade suitable for cutting rare earth sintered magnets and a method for manufacturing the same.
  • JP-A-9-174441, JP-A-10-175171, JP-A-10-175172, etc. describe phenol resin on the outer periphery of a cemented carbide base plate.
  • a technique for fixing diamond abrasive grains or cBN abrasive grains by Ni plating or the like is disclosed.
  • the use of cemented carbide for the base plate has improved the mechanical strength of the base plate compared to conventional alloy tool steel and high-speed steel. Yield improvement and processing cost reduction by high-speed processing became possible.
  • the outer peripheral blade using the cemented carbide base plate shows cutting and processing performance superior to the conventional outer peripheral blade, but the demand for cost reduction from the market does not stop, and further high-precision and high-speed processing The development of a high-performance cutting wheel that achieves this is eagerly desired.
  • the applicant previously has a technique for fixing diamond abrasive grains with a resin such as phenol resin on the outer periphery of a ring-shaped cemented carbide base plate, and an appropriate Young's modulus on the outer periphery of the cemented carbide base plate.
  • a technique for fixing abrasive grains such as diamond abrasive grains and cBN abrasive grains with a metal binder has been proposed (Japanese Patent Laid-Open No. 2009-172751).
  • the outer peripheral cutting blade used for cutting the rare earth sintered magnet is composed of two parts, a cutting blade part and a base plate.
  • the mechanical strength is improved, compared with the peripheral cutting blades using the conventional alloy tool steel and high-speed steel as the base plate, Cutting accuracy has been improved.
  • the mechanical strength of the outer peripheral cutting blade is improved by changing the binder to a metal with an appropriate Young's modulus, and the conventional phenol resin or polyimide resin is bonded with abrasive grains.
  • three performance enhancements have been achieved: improved processing accuracy, improved material yield through thinner blades, and reduced processing costs through higher cutting speed.
  • a magnetic field is formed in the vicinity of the outer peripheral edge of the base plate, and the magnetic field acts on the abrasive film coated with a magnetic material in advance to magnetize the film,
  • the manufacturing cost of the cemented carbide outer peripheral cutting blade can be reduced by the method of manufacturing the outer peripheral cutting blade in which the abrasive grains are attracted to the outer peripheral portion of the base plate and plated in this state to fix the abrasive grains.
  • the cemented carbide base plate outer periphery cutting blade provided by the above-described technology is a high performance outer peripheral cutting blade, but in the rare earth sintered magnet cutting process, the magnet is cut obliquely or the cut surface of the magnet
  • the dimensional accuracy may deteriorate due to, for example, a trace of the outer peripheral cutting blade remaining.
  • the cutting volume per unit time is 200 mm 3 /
  • the dimensional tolerance may be 50 ⁇ m or more.
  • This invention is made in view of the said situation, provides the cemented carbide base plate outer periphery cutting blade which can process the rare earth sintered magnet which has a high dimensional accuracy, Furthermore, this cemented carbide base plate outer periphery cutting blade is provided. It aims at providing the method of manufacturing at low cost. Means for solving the problem
  • the phenomenon that the rare earth sintered magnet is cut obliquely is that the cutting edge shape of the outer cutting blade is not symmetrical, and the blade advances in a direction that makes it easy to cut, or when the outer cutting blade is attached to the processing machine. This is thought to be caused by the warping of the blade.
  • the phenomenon in which the traces remain on the magnet is newly generated from the previous cut surface by the outer peripheral cutting blade that cut the magnet obliquely for the above-mentioned reason, by suddenly changing the traveling direction during the cutting. It is thought that this occurs when the joint with the cut surface does not connect smoothly but becomes a step.
  • the advancing direction of the outer cutting blade suddenly changes during cutting, for example, when a part of the blade edge is deformed or dropped for some reason, or when the tip shape of the cutting blade portion changes suddenly, Since the feed speed of the outer peripheral cutting blade is faster than the grinding speed, the cutting edge of the outer peripheral cutting blade is deformed, and the internal force generated on the outer peripheral cutting blade due to the deformation becomes larger than the force (external force) that the outer peripheral cutting blade receives from the work piece. When the force that deformed the cutting edge is released, sludge generated during cutting or foreign matter from the outside of the system is clogged in the kerf, which is considered to occur when the outer peripheral cutting blade is prevented from advancing. .
  • the cutting edge portion is not affected even when the tip shape of the cutting edge portion changes abruptly and a force that changes the advancing direction of the cutting edge is applied during cutting. It is effective to deform to some extent and to smoothly connect the cut surfaces.
  • the abrasive grains having a certain size are used as the abrasive grains.
  • the abrasive grains and between the abrasive grains and the base plate only a part can be contacted, and the gap between them is not completely filled with plating. Therefore, even after plating, the cutting blade portion has a gap, that is, a gap communicating with the surface of the cutting blade portion.
  • the present inventors diligently studied in order to achieve the above object, and examined the configuration of the cutting blade portion that achieves both high strength and elasticity, and the mechanical properties of the cutting blade portion.
  • a gap existing between the abrasive grains and the base plate is used between the abrasive grains, and the gap is melted and impregnated with a thermoplastic resin, or solidified, or impregnated with a liquid thermosetting resin composition and cured.
  • the cutting blade part is effective, the cemented carbide base plate outer peripheral cutting blade with such a cutting edge part is effective in improving the dimensional accuracy of the magnet to be cut, and the melting of the thermoplastic resin It has been found that the methods of impregnation and solidification, or impregnation and curing of a liquid thermosetting resin composition are effective for high-accuracy and inexpensive production of the outer peripheral cutting blade, leading to the present invention.
  • the present invention firstly provides a circular ring-shaped sheet base made of a cemented carbide having a Young's modulus of 450 to 700 GPa and having an outer diameter of 80 to 200 mm, an inner diameter of 30 to 80 mm, and a thickness of 0.1 to 1.0 mm.
  • a cemented carbide base plate outer periphery cutting blade having a cutting edge on the outer peripheral edge of the plate, The cutting blade portion is formed by electroplating or electroless plating that connects diamond abrasive grains and / or cBN abrasive grains, which are previously coated with a magnetic material, and between the abrasive grains and between the abrasive grains and the base plate.
  • a thermoplastic resin having a melting point of 350 ° C.
  • a cemented carbide base plate outer peripheral cutting blade comprising a thermosetting resin obtained by curing a liquid thermosetting resin composition having a curing temperature of 350 ° C. or less impregnated therebetween.
  • the resin used for the impregnation is one or more selected from an acrylic resin, an epoxy resin, a phenol resin, a polyamide resin, a polyimide resin, and a modified resin thereof, and a resin used for the impregnation
  • the outer peripheral cutting blade having a Poisson's ratio of 0.3 to 0.48 is provided.
  • the said outer periphery cutting blade whose saturation magnetization of the said base plate is 40 kA / m (0.05T) or more is provided.
  • the second aspect of the present invention is a circular ring-shaped sheet base made of a cemented carbide having a Young's modulus of 450 to 700 GPa and having an outer diameter of 80 to 200 mm, an inner diameter of 30 to 80 mm, and a thickness of 0.1 to 1.0 mm.
  • a permanent magnet is disposed in the vicinity of the outer peripheral edge of the plate, By magnetic field formed by the permanent magnet, diamond abrasive grains and / or cBN abrasive grains, which are pre-coated with a magnetic material, are magnetically attracted and fixed in the vicinity of the outer peripheral edge of the base plate, With the suction and fixing maintained, the cutting blade is formed by connecting the abrasive grains and between the abrasive grains and the base plate by electroplating or electroless plating to fix the abrasive grains to the outer peripheral edge of the base plate.
  • a liquid thermosetting resin composition having a melting point of 350 ° C. or lower or a curing temperature of 350 ° C.
  • the cemented carbide base plate outer periphery cutting blade characterized by impregnating and hardening.
  • the resin used for the impregnation is one or more selected from an acrylic resin, an epoxy resin, a phenol resin, a polyamide resin, a polyimide resin, and a modified resin thereof, and a resin used for the impregnation
  • the Poisson's ratio is 0.3 to 0.48.
  • the said manufacturing method is provided with the saturation magnetization of the said baseplate being 40 kA / m (0.05T) or more.
  • the present invention provides the above production method wherein the average grain size of the abrasive grains is 10 to 300 ⁇ m, and the production method wherein the mass magnetic susceptibility ⁇ g of the abrasive grains is 0.2 or more. Furthermore, as a preferable aspect thereof, the above manufacturing method is provided in which a magnetic field of 8 kA / m or more is formed in a space within 10 mm from the outer peripheral edge of the base plate by the permanent magnet.
  • the cemented carbide base plate outer peripheral cutting blade of the present invention By adopting the cemented carbide base plate outer peripheral cutting blade of the present invention, it is possible to finish the dimension of the crop with high accuracy only by cutting operation, and the post-processing step after cutting can be omitted, so it has high dimensional accuracy. Rare earth magnets can be provided at low cost. Moreover, the manufacturing method of this invention can manufacture this cemented carbide base plate outer periphery cutting blade with the outstanding cost performance.
  • FIG. 1 It is a figure which shows the outer periphery cutting blade of this invention
  • (A) is a top view
  • (B) is sectional drawing in line BB in (A)
  • (C) is an expanded sectional view of the C section in (B) It is.
  • tool main body which clamped the base plate of FIG. (A)-(D) is a partially omitted cross-sectional view showing the state of the cutting blade portion formed on the base plate.
  • 4 is a photomicrograph of the side surface of the cutting edge of the outer peripheral cutting blade of Example 1.
  • 5 is a graph showing the relationship between the number of cut rare earth sintered magnets cut using the outer peripheral cutting blades manufactured in Examples 1 to 4 and Comparative Example 1 and the cutting accuracy.
  • 6 is a graph showing the relationship between the amount of deformation and stress of the cutting edge portion of the outer peripheral cutting blade manufactured in Examples 1 to 4 and Comparative Example 1.
  • diamond abrasive grains and / or cBN abrasive grains are formed by electroplating or electroless plating on the outer peripheral edge portion of a base plate 10 of a circular thin plate.
  • a cutting blade 20 bonded with a metal or an alloy (metal binding material) is formed.
  • the base plate 10 is a circular thin plate (a donut-shaped thin plate with an inner hole 12 formed in the center), and has a thickness of 0.1 to 1.0 mm, preferably 0.2 to 0.8 mm.
  • the diameter is 80 to 200 mm, preferably 100 to 180 mm, and the diameter (inner diameter) of the inner hole is 30 to 80 mm, preferably 40 to 70 mm.
  • the circular thin plate of the base plate 10 has a central inner hole and an outer circumferential portion as shown in FIG.
  • the “radial direction” and “axial direction” used in explaining the dimensions of the outer peripheral cutting blade are used relative to the center of the circular thin plate, and the thickness is the axial dimension, and the length (Height) is a radial dimension.
  • “inside” or “inside” or “outside” or “outside” is also used relative to the center of the circular thin plate or the rotation axis of the outer peripheral cutting blade.
  • the reason why the thickness is in the range of 0.1 to 1.0 mm and the outer diameter is 200 mm or less is that it is possible to manufacture an accurate base plate, and to cultivate the workpiece (workpiece) such as a rare earth sintered magnet over a long period of time with high dimensional accuracy. It is because it can cut stably. If the thickness is less than 0.1 mm, a large warp is likely to occur regardless of the outer diameter, so that it is difficult to manufacture an accurate base plate. If the thickness exceeds 1.0 mm, the cutting cost increases.
  • the reason why the outer diameter is set to 200 mm or less depends on the size that can be manufactured by the current manufacturing technology and processing technology of cemented carbide. The diameter of the inner hole is set to ⁇ 30 to ⁇ 80 mm according to the thickness of the cutting blade mounting shaft of the processing machine.
  • the material of the base plate is a cemented carbide, for example, a metal powder belonging to the periodic table IVB, VB, VIB group such as WC, TiC, MoC, NbC, TaC, Cr 3 C 2 , Fe, Co, Ni, Alloys sintered and bonded using Mo, Cu, Pb, Sn, or alloys thereof are preferred, and among these, WC—Co, WC—Ti, C—Co, and WC—TiC—TaC—Co are particularly preferred.
  • the one having a Young's modulus of 450 to 700 GPa is used.
  • a known material such as a conductive treatment agent used when plating on an ABS resin can be used.
  • the saturation magnetization is large in order to fix the abrasive grains to the base plate by magnetic attraction.
  • the saturation magnetization is small, as described later, the magnet position and the strength of the magnetic field are strong.
  • the thickness it is possible to magnetically attract abrasive grains pre-coated with a magnetic material to the base plate, so that it may be 40 kA / m (0.05 T) or more.
  • a 5 mm square measurement sample is cut out from a base plate of a predetermined thickness, and a magnetization curve (4 ⁇ IH) is measured between 24 and 25 ° C. using a Vibrating Sample Magnetometer (VSM).
  • VSM Vibrating Sample Magnetometer
  • the upper limit of the magnetization value in the quadrant can be the saturation magnetization of the base plate.
  • the chamfering angle and amount are determined according to the thickness of the base plate to be used and the average particle size of the abrasive grains to be fixed because the processable range depends on the thickness of the base plate.
  • Diamond abrasive grains and / or cBN abrasive grains are used as the abrasive grains forming the cutting edge portion, and these abrasive grains need to be coated with a magnetic material in advance.
  • the size and hardness of the abrasive grains coated with the magnetic material are determined according to the purpose.
  • diamond naturally diamond, industrial synthetic diamond
  • cBN cubic boron nitride
  • abrasive grains may be used alone, or mixed abrasive grains of diamond abrasive grains and cBN abrasive grains may be used. Is possible. Further, depending on the crop, it is possible to adjust the ease of cracking by using each abrasive grain alone or in combination from single crystals or polycrystals. Furthermore, sputtering a metal such as Fe, Co, Cr or the like on the surface of these abrasive grains to about 1 ⁇ m is also effective as a method for increasing the bond strength with a magnetic material to be described later.
  • the size of the abrasive grains is preferably 10 to 300 ⁇ m in average particle diameter, although it depends on the thickness of the base plate. If the average particle size is less than 10 ⁇ m, the gap between the abrasive grains is reduced, so that clogging is likely to occur during cutting, and the cutting ability is reduced. If the average particle size exceeds 300 ⁇ m, the cut surface of the magnet There is a risk that problems such as roughening may occur. In such a range, the abrasive grains having a specific size may be used singly or in combination in consideration of cutting workability and life.
  • the magnetic material that coats the abrasive grains can be magnetically attracted in a short time even with a base plate such as a cemented carbide with low saturation magnetization, and the mass magnetic susceptibility ⁇ g of the abrasive grains is such that it does not fall off when fixed by plating.
  • An alloy of one or two selected from P and Mn is formed by a known method such as sputtering, electroplating or electroless plating, so that the thickness of the coating is 0.5 to 100%, preferably 2 to Coat to 80%.
  • the magnetic susceptibility of the abrasive grains depends on the magnetic susceptibility of the magnetic material to be coated and the thickness at the time of coating, it is necessary to consider the type of magnetic material so that the necessary attractive force can be obtained depending on the size of the abrasive grains. For example, even if the phosphorus content is high and the magnetic susceptibility is low, such as electroless nickel phosphorus plating, it is possible to increase the magnetic susceptibility to some extent by applying heat treatment, and on the coating with a low magnetic susceptibility. Since it is possible to form a multilayer with different magnetic susceptibility coatings so that a coating with a high magnetic susceptibility is applied, the adjustment is made within an appropriate range according to the situation.
  • the mass magnetic susceptibility ⁇ g of the abrasive grains is 0.2 or more, preferably 0.39 or more, the abrasive grains are rapidly magnetized by the magnetic field formed in the vicinity of the outer peripheral edge of the base plate described later. Therefore, the abrasive grains are magnetically attracted almost evenly in all portions of the gap 64 of FIG. 3 described later formed by the base plate and the permanent magnet holder (jig main body). If the mass magnetic susceptibility ⁇ g of the abrasive grains is less than 0.2, can the abrasive grains not be attracted well into the gaps and the abrasive grains fall off during plating, etc. to form an abrasive grain layer (cutting edge)? Or, since a hole or the like is generated in the abrasive layer, the mechanical strength of the abrasive layer may be weakened as a result.
  • the mass magnetic susceptibility of the abrasive grains can be measured by the following method. First, spread out thinly and uniformly as much as possible in a resin container with an outer diameter of ⁇ 8mm, a height of about 5mm, and an inner diameter of ⁇ 6mm, then remove it from the container and measure the weight of the abrasive Then, after returning to the container again, a paraffin having a melting point of about 50 ° C. is placed thereon, and the whole is put into an oven at 60 ° C. and heated. Next, the container is covered with the paraffin dissolved and cooled. Next, the initial magnetization curve (4 ⁇ I-H) of this sample is measured at a temperature of 24 to 25 ° C.
  • VSM Vehicle Sample Magnetometer
  • the differential magnetic susceptibility in the initial magnetization curve is obtained from the slope at the inflection point of the curve, and divided by the sample weight to obtain the mass magnetic susceptibility ⁇ g of the abrasive grains.
  • the magnetic field is calibrated with a Ni standard sample, and the density of the abrasive grains is measured using the tap bulk density.
  • the thickness of the magnetic material to be coated has an influence on the size of the gap created when the cutting edge is formed, and therefore it is necessary to make it particularly suitable.
  • the minimum thickness is preferably 2.5 ⁇ m or more, which is a thickness that allows the entire abrasive grain to be coated with almost no gap even when coating by plating.
  • the maximum value 300 ⁇ m of the preferable average particle size range of the above-described abrasive grains it may be 0.5% or more, particularly 0.8% or more.
  • the coating thickness in this way, it is possible to obtain a holding force that can reduce the falling off of abrasive grains even when cutting as an outer peripheral cutting blade, and also to select the type of magnetic material to be coated appropriately Thus, the abrasive grains are attracted to or near the outer peripheral edge of the base plate by the magnetic field without falling off during the plating process.
  • the maximum thickness is 10 ⁇ m, which is the minimum value of the preferable average particle size range of the above-mentioned abrasive grains
  • the portion that does not function effectively in the cutting process and the portion that hinders the self-generated action of the abrasive grains increase, and the processing capability decreases.
  • the average grain size of the abrasive grains is up to 100%.
  • the metal binder for bonding the abrasive grains is a plated metal (alloy) described later.
  • a permanent magnet in the vicinity of the outer peripheral edge of the base plate, for example, on the base plate surface inside the outer peripheral end of the base plate, or inside the outer peripheral end.
  • two or more permanent magnets having a residual magnetic flux density of 0.3 T or more are arranged, so that 8 kA is provided in a space within 10 mm from at least the outer peripheral edge of the base plate.
  • the magnetic field is applied to diamond abrasive grains and / or cBN abrasive grains, which are formed with a magnetic field of at least / m and coated with a magnetic material in advance, thereby generating a magnetic attractive force, and these abrasive grains are generated by the attractive force.
  • a pair of jig bodies having the following can be used.
  • Plating can be performed by holding a base plate between these jig bodies.
  • FIGS. 2 and 3 show an example of a jig used for the plating.
  • Reference numerals 50 and 50 denote a pair of jig bodies, and the jig bodies 50 and 50 are made of insulating covers 52 and 52, respectively.
  • permanent magnets 54 and 54 attached to these covers 52 and 52, and the base plate 1 is held between the jig main bodies 50 and 50.
  • the permanent magnets 54 and 54 are preferably embedded in the covers 52 and 52, but may be provided so as to contact the base plate 1.
  • the permanent magnet built in the jig needs to have enough magnetic force to keep attracting the abrasive grains to the base plate while depositing the metal binder by the plating method and fixing the abrasive grains.
  • the required magnetic force depends on the distance between the outer peripheral edge of the base plate and the magnet, and the magnetization and magnetic susceptibility of the magnetic material previously coated with abrasive grains, but the residual magnetic flux density is 0.3 T or more, the coercive force is 0.
  • a permanent magnet of 2 MA / m or more preferably a residual magnetic flux density of 0.6 T or more and a coercive force of 0.8 MA / m or more, more preferably a residual magnetic flux density of 1.0 T or more and a coercive force of 1.0 MA / m or more. It is obtained with.
  • the permanent magnet coating should be selected under the condition that the elution of the coating material into the plating solution and the substitution of the metal species in the plating solution is as small as possible, considering the case where the magnet touches the plating solution. Increase corrosion resistance.
  • the metal binder is deposited using a Ni plating solution, Cu, Sn, Ni metal, epoxy resin or acrylic resin coating is suitable.
  • the shape, size, and number of permanent magnets built in the jig depend on the size of the cemented carbide used as the base plate, the position, direction, and strength of the desired magnetic field. For example, if you want to uniformly fix abrasive grains to the outer peripheral edge of the base plate, a ring-shaped or arc-shaped magnet that matches the outer diameter of the base plate, or a rectangular parallelepiped magnet with a side length of about several millimeters Are arranged continuously without gaps along the outer periphery of the base plate. In order to reduce the cost of the magnets, a space may be provided between these magnets to reduce the number of magnets.
  • a portion where the abrasive grains previously coated with the magnetic material are attracted and a portion where the abrasive particles are not attracted are provided by increasing the magnet spacing. It is also possible to form a rectangular cutting blade portion by forming a portion having a portion and a portion having no portion.
  • the magnetic field generated in the outer peripheral edge of the base plate can be generated in various ways depending on the combination of the position of the permanent magnet fixed to the two jig bodies sandwiching the base plate and the direction of the magnetization direction.
  • the magnetic field analysis and verification are repeated so that a magnetic field of 8 kA / m or more, preferably 40 kA / m or more is formed in a space within 10 mm from the outer peripheral edge. If the strength of the magnetic field is less than 8 kA / m, the attractive force of the abrasive grains that have been coated with the magnetic material is insufficient. Therefore, if plating is performed in this state, the abrasive grains move during plating, and there are many gaps.
  • a cutting blade part may be formed, or an abrasive grain may be fixed in dendritic shape, and the dimension of a cutting blade part may become larger than desired. As a result, the cutting blade part falls off during the shaping process, or the time required for the shaping process becomes long, and the manufacturing cost may increase.
  • the position of the permanent magnet is preferably as close as possible to the portion where the abrasive grains are to be attracted, but roughly, the distance from the base plate surface on the base plate surface inside the outer peripheral end of the base plate or inside the outer peripheral end is 20 mm. Within the space that is within, more preferably within the space that is within the distance of 10 mm.
  • a magnetic field of 8 kA / m or more can be formed at least in a space within 10 mm from the outer peripheral edge, not only materials such as alloy tool steel and high-speed steel that have a large saturation magnetization and are easy to induce magnetic force, Even with a material such as a hard alloy that has a low saturation magnetization and a small induction of magnetic force, a magnetic field with an appropriate magnetic force can be formed on the outer peripheral edge of the base plate. Since the coating film is magnetized by taking the abrasive grains coated in advance in the magnetic field, it is possible to attract and hold the abrasive grains on or near the desired outer periphery of the base plate. .
  • the position of the magnet from the outer peripheral edge of the base plate is very close to the outer peripheral edge of the base plate, for example, 0.5 mm outside from the outer peripheral end (the side away from the rotation axis when the outer peripheral cutting blade is used).
  • the magnetic field strength near the outer peripheral edge of the base plate will be strong, but a region in which the magnetic field gradient is reversed tends to occur.
  • the abrasive grains are easy to fall off.
  • the strength of the magnetic field that can be formed in a space within 10 mm from the outer peripheral end of the base plate is less than 8 kA / m.
  • the dimension is set so that the permanent magnet can be fixed to a desired position with respect to the base plate when the base plate is sandwiched by a jig.
  • the base plate has an outer diameter of 125 mm and a thickness of 0.26 mm
  • the permanent magnet has a size of L2.5 mm ⁇ W2 mm ⁇ t1.5 mm
  • a disc having an outer diameter of 125 mm or more and a thickness of about 20 mm is used. Can be used.
  • the outer diameter of the jig is set such that the desired height of the abrasive grain layer (protruding amount in the radial direction) (H2 in FIG. 1C) can be secured.
  • the height of the abrasive grain layer is set to 2 ⁇ or more, and the thickness thereof depends on the material, but the strength is such that warp or the like does not occur due to a rapid temperature change when being put in and out of the high-temperature plating solution.
  • the jig thickness of the part in contact with the abrasive grains may be made thin so as to obtain an amount (T3 in FIG. 1C) that the abrasive grain layer protrudes in the thickness direction of the base plate, or equivalent to the protruding amount. You may make it the same thickness as another part using the masking tape of thickness.
  • the material of the jig is preferably an insulator from which no plating is deposited because the entire jig sandwiching the base plate is immersed in a high-temperature plating solution to deposit a metal binder, and among them, chemical resistance is about 90 ° C. It is desirable to have a heat shock resistance that can maintain a stable dimension even when repeatedly subjected to a rapid temperature change that occurs during loading and unloading into the plating solution. Further, even when immersed in a high-temperature plating solution, dimensional stability is required so that a warp is not caused by an internal stress accumulated during molding or processing and a gap is not formed between the base plate and the base plate. Of course, workability is also required that can process a groove for incorporating a permanent magnet at an arbitrary position with high accuracy without cracking or chipping.
  • engineering plastics such as PPS, PEEK, POM, PAR, PSF, and PES, and ceramics such as alumina can be used.
  • the thickness and other dimensions are determined in consideration of mechanical strength, and a groove for holding a permanent magnet or a groove for receiving a power supply electrode or the like necessary when using an electroplating method is provided.
  • Two pairs of jig bodies manufactured in this way are integrated with one base plate.
  • 56 and 56 are electroplating cathode bodies that also serve as base plate holders mounted at the center of the covers 52 and 52, respectively.
  • These cathode bodies 56 and 56 are a pair of jig bodies. 50 and 50 are brought into contact with a conductive support bar 58 for supporting and fixing, and the support bar 58 can be energized.
  • the jig shown in FIG. 2 is one in which two pairs of jig bodies 50 are attached to the support bar 58 with a predetermined distance therebetween.
  • 60 is a joint and 62 is an end cap.
  • the jig shown in FIG. 2 is for electroplating.
  • a cathode body is not necessary, and a non-conductive presser may be provided instead.
  • the support rod is not necessarily conductive. Need not be.
  • FIG. 3 illustrates this gap.
  • the protrusions 52 a and 52 a protruding forward from the base plate 1 of the pair of jig main bodies 50 and 50 (covers 52 and 52) and the tip of the base plate 1.
  • a gap 64 is formed in the gap, and the abrasive grains are magnetically attracted into the gap 64.
  • the amount of abrasive grains to be held depends on the outer diameter and thickness of the base plate used, the size of the abrasive grains, and the desired height and width of the cutting edge.
  • the abrasive grains are held and plating is repeated several times so that the amount of abrasive grains per unit volume can be made uniform at all positions on the outer periphery of the base plate and the abrasive grains can be firmly fixed by plating. It is also preferable to do this.
  • the cutting blade portion is formed in this way, and the volume ratio of the abrasive grains in the cutting blade portion is preferably in the range of 10 to 80% by volume, particularly 30 to 75% by volume. If it is less than 10% by volume, the proportion of abrasive grains contributing to cutting is small, and the resistance during cutting increases. If it exceeds 80% by volume, the amount of deformation of the cutting edge during cutting is reduced, so that traces remain on the cut surface and deteriorate the dimensional accuracy and appearance of the crop. For these reasons, the cutting speed has to be slowed down. Therefore, it is preferable to adjust the volume ratio by changing the particle diameter by changing the thickness of the magnetic material coated on the abrasive grains according to the purpose.
  • the cutting blade portion 20 is composed of sandwiching portions 22a and 22b and a main body (20), and sandwiches the outer peripheral edge portion of the base plate by the sandwiching portions 22a and 22b.
  • the main body (20) is formed so as to protrude forward from the outer peripheral portion of the base plate 10.
  • description of a main body and a clamping part is for convenience, and these form the cutting blade part integrally.
  • the thickness of this cutting blade part 20 is formed so that it may become thicker than the thickness of the baseplate 10, Therefore Therefore, it is preferable to form the clearance gap 64 shown by FIG.
  • the length H1 of the pair of sandwiching portions 22a and 22b for sandwiching the outer peripheral portion of the base plate of the cutting blade portion is 0.1 to 10 mm, particularly 0.5 to 5 mm. It is preferable.
  • the thickness T3 of the pair of sandwiching portions 22a and 22b is 5 ⁇ m (0.005 mm) or more, more preferably 5 to 2,000 ⁇ m, and still more preferably 10 to 1,000 ⁇ m.
  • the total thickness of the pair of sandwiching portions 22a and 22b (that is, the thickness of the portion where the cutting blade portion is thicker than the base plate) is preferably 0.01 mm or more, more preferably 0.01 to 4 mm, and still more preferably 0.02 to 2 mm.
  • the length H1 of the clamping portions 22a and 22b is less than 0.1 mm, there is an effect of preventing chipping and cracking of the outer peripheral edge of the base plate, but there is little reinforcing effect of the base plate, and the base plate is deformed by resistance during cutting. May not be prevented. Moreover, when H1 exceeds 10 mm, there exists a possibility that the cost performance with respect to reinforcing a baseplate may fall. On the other hand, if T3 is less than 5 ⁇ m, the mechanical strength of the base plate cannot be increased, and cutting sludge may not be effectively discharged.
  • the sandwiching portions 22a and 22b may be formed of a metal binder 24 and abrasive grains 26 [FIG. 4A].
  • the base plate 10 may be covered only with the metal binder and further covered to form a layer of the metal binder and abrasive grains. [FIG. 4C].
  • the strength of the cutting blade portion can be further increased by depositing a metal binding material so as to cover the entire outside of FIG. 4 (C), as shown in FIG. 4 (D).
  • FIGS. 4B to 4D as a method of forming the portion of the sandwiching portion in contact with the base plate 10 by using only the metal binder 24, for example, a portion where the sandwiching portion of the base plate is to be formed.
  • the plating is performed with the above-described jig mounted, the gap 26 filled with the abrasive grains 26, and plating is performed.
  • electrodeposition for example, by masking the base plate 10 with the cover 52, 52 of FIG. 2 having an outer diameter that exposes the electrodeposition portion, and further plating, as shown in FIG.
  • a layer made of only the metal binder 24 can be formed.
  • the protruding length (H2 in FIG. 1C) of the protruding portion protruding forward from the base plate 10 of the cutting blade portion 20 is 0.1 to 10 mm, particularly 0.3 depending on the size of the abrasive grains to be fixed. It is preferably ⁇ 8 mm. If the protrusion length is less than 0.1 mm, the time until the cutting blade portion disappears due to impact or wear during cutting is short, resulting in a shortened blade life. Although it depends on T2 of 1), the cutting blade portion is likely to be deformed, and the dimensional accuracy of the cut magnet may be deteriorated due to a wavy cut surface.
  • the cutting blade part is formed from the metal binder 24 and the abrasive grain 26, and the impregnation resin mentioned later.
  • the metal binding material is a metal or alloy formed by plating, one metal selected from Ni, Fe, Co, Cu and Sn, an alloy consisting of two or more selected from these metals, or these metals or alloys An alloy of one of these and one or two selected from P and Mn is preferable, and this is deposited by plating so as to connect between the abrasive grains and between the abrasive grains and the base plate.
  • Electrodeposition method electroroplating method
  • electroless plating method it is easy to control the internal stress remaining in the binding material.
  • the electrodeposition method with a low production cost and the electroless plating method that deposits the metal binder relatively uniformly as long as the plating solution enters, so that the gap included in the cutting edge is within the appropriate range described later. are used alone or in combination.
  • Ni plating or Cu plating for example, Ni sulfamate plating solution, the concentration of nickel sulfamate as the main component, the current density during plating, and the temperature of the plating solution It may be carried out by adjusting the stress of the film by adding an organic additive such as orthobenzenesulfonimide and paratoluenesulfonamide, or adding elements such as Zn, S and Mn.
  • an organic additive such as orthobenzenesulfonimide and paratoluenesulfonamide, or adding elements such as Zn, S and Mn.
  • the film stress is adjusted by adjusting the temperature of the plating solution to a suitable range.
  • the combined use of organic additives capable of adjusting the stress is effective.
  • the plating can be performed by a known method using a conventionally known plating solution for depositing a single metal or alloy and adopting normal plating conditions in the plating solution.
  • Suitable electroplating solutions include, for example, nickel sulfamate 250 to 600 g / L, nickel sulfate 50 to 200 g / L, nickel chloride 5 to 70 g / L, boric acid 20 to 40 g / L, orthobenzene sulfone.
  • the electroless plating solution includes 10-50 g / L of nickel sulfate, 10-50 g / L of sodium hypophosphite, 10-30 g / L of sodium acetate, 5-30 g / L of sodium citrate, thio
  • An electroless nickel / phosphorous alloy plating solution with an appropriate amount of urea may be used.
  • diamond abrasive grains, cBN abrasive grains, or mixed abrasive grains of diamond abrasive grains and cBN abrasive grains are formed on the outer periphery of the base plate with a size close to the final shape with high accuracy.
  • the gap between the abrasive grains of the cutting blade portion and between the abrasive grains and the base plate obtained by the above-described method is impregnated with a thermoplastic resin having a melting point of 350 ° C. or lower, or A liquid thermosetting resin composition having a curing temperature of 350 ° C. or lower is impregnated and cured to obtain a thermosetting resin.
  • a thermoplastic resin having a melting point of 350 ° C. or less between the grains and between the abrasive grains and the base plate, and inside the cutting blade part, or A cured product of a liquid thermosetting resin composition having a curing temperature of 350 ° C. or lower, that is, a thermosetting resin is included.
  • thermoplastic resin and thermosetting resin examples include an epoxy resin, an acrylic resin, a phenol resin, a polyamide resin, a polyimide resin, and a modified resin thereof. One or more selected from these resins can be used.
  • thermoplastic resin for example, a wire having a diameter of ⁇ 0.1 to 2.0 mm, preferably ⁇ 0.8 to 1.5 mm.
  • a thermoplastic resin processed into a ring-shaped thin film with a thickness of 0.05 to 1.5 mm that is the same as the shape, powder, or shape of the cutting blade is placed on the cutting blade and heated like a hot plate.
  • the temperature is raised above the melting point on the vessel or in an oven, the molten resin is impregnated into the cutting blade, and then gradually cooled to return to room temperature.
  • thermosetting resin for example, a liquid thermosetting resin composition containing an organic solvent, a curing agent and the like is placed on the cutting blade portion to penetrate, heated to a temperature higher than the curing temperature, cured.
  • a method of gradually cooling to room temperature is mentioned.
  • the upper mold is fitted with a pre-measured resin or resin composition, It is also possible to use a method in which a cutting blade is impregnated with a resin or a resin composition by heating it while pressing it moderately up and down, cooled and then depressurized, and taken out from a mold. After heating, cool gradually so that no strain remains.
  • the base plate and the cutting blade are heated by energizing the base plate with a metal such as stainless steel, iron, copper, etc. It is also possible to impregnate the molten blade or the liquid resin composition in which the resin is melted by bringing the heated cutting blade portion into contact therewith.
  • the cutting blade portion thus obtained is in a state where the abrasive grains, the magnetic material coated with the abrasive grains, the metal binder, and the resin impregnated in the gap are appropriately dispersed.
  • the melting point is preferably in the range of 350 ° C. or lower.
  • a thermoplastic resin with respect to the upper limit temperature of the melting point, distortion occurs in the cemented carbide base plate, dimensional accuracy deteriorates, mechanical strength changes, thermal expansion of the cemented carbide base plate and the cutting edge portion.
  • 350 ° C. or lower preferably 300 ° C. or lower is suitable.
  • the melting point is preferably 10 ° C. or higher.
  • Resin elasticity having a Poisson's ratio of 0.3 to 0.48, preferably 0.33 to 0.44 is suitable.
  • the Poisson's ratio is lower than 0.3, the flexibility is poor and it is difficult to connect the cut surfaces smoothly.
  • the Poisson's ratio is higher than 0.48, other physical properties such as hardness are insufficient, so that the deformation of the cutting edge becomes too large.
  • the Poisson's ratio can be measured by a pulse ultrasonic method using a 15 ⁇ 15 ⁇ 15 mm sample of resin to be impregnated.
  • the hardness of the resin may be such that even if the abrasive grains are worn, destroyed, or dropped during cutting, the next abrasive grains are exposed and do not interfere with the action contributing to cutting (the self-generating action of the abrasive grains). It is preferable to use a material that is lower than the magnetic material that coats the metal and the metal binding material that fixes the abrasive grains. In addition, it is necessary to prevent strength change and corrosion even when exposed to processing oil or coolant used for cutting.
  • the cutting blade part impregnated with resin is adjusted to a desired dimension by grinding with a grindstone such as aluminum oxide, silicon carbide, diamond, or electric discharge machining, if necessary.
  • a grindstone such as aluminum oxide, silicon carbide, diamond, or electric discharge machining, if necessary.
  • chamfering C0.1 or more or R0.1 or more on the cutting edge reduces not only traces of the cut surface, but also reduces the chip end of the magnet. It is effective because it is possible.
  • Cutting to which the outer peripheral cutting blade of the present invention is applied includes R-Co-based rare earth sintered magnets, R-Fe-B-based rare earth sintered magnets (R is a rare earth element including Y). It is effective in the cutting
  • R is a rare earth element including Y. It is effective in the cutting
  • These magnets are manufactured as follows, for example.
  • R—Co based rare earth sintered magnets include RCo 5 and R 2 Co 17 systems.
  • the R 2 Co 17 system is composed of 20 to 28% R, 5 to 30% Fe, 3 to 10% Cu, 1 to 5% Zr, and the balance Co in mass percentages.
  • the raw materials are weighed at such a component ratio, melted and cast, and the obtained alloy is finely pulverized to an average particle size of 1 to 20 ⁇ m to obtain an R 2 Co 17- based magnet powder. Thereafter, it is molded in a magnetic field, further sintered at 1,100 to 1,250 ° C. for 0.5 to 5 hours, and then solutionized at a temperature 0 to 50 ° C. lower than the sintering temperature for 0.5 to 5 hours. Then, after aging at 700 to 950 ° C. for a certain time, an aging treatment for cooling is performed.
  • the R—Fe—B rare earth sintered magnet is composed of 5 to 40% R, 50 to 90% Fe, and 0.2 to 8% B by mass percentage.
  • Additive elements such as C, Al, Si, Ti, V, Cr, Mn, Co, Ni, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Sn, Hf, Ta, and W are added.
  • the addition amount of these additive elements is 30% or less in terms of mass percentage in the case of Co, and 8% or less in terms of mass percentage in the case of other elements.
  • the raw materials are weighed at such a component ratio, melted and cast, and the obtained alloy is pulverized to an average particle size of 1 to 20 ⁇ m to obtain an R—Fe—B based magnet powder. Thereafter, it is molded in a magnetic field, further sintered at 1,000 to 1,200 ° C. for 0.5 to 5 hours, held at 400 to 1,000 ° C. for a certain time, and then subjected to aging treatment for cooling.
  • Such an outer peripheral cutting blade of the present invention can cut out a rare earth magnet with high dimensional accuracy without leaving a trace on the cutting surface, particularly when the compression shear stress of the cutting edge is within a predetermined range, and is effective. It is.
  • the thickness of the cutting blade portion is 0.1 to 1.0 mm
  • the outer diameter is 80 to 200 mm
  • the chamfering of the blade edge is adjusted to 0.1 or more with R or C, and then the outer peripheral cutting blade is horizontal.
  • the base plate does not warp when pressed and is removed from the outer periphery of the cemented carbide base plate.
  • the cutting blade portion is indented in the direction of the rotation axis of the outer cutting blade (cutting blade) with an indenter having a contact portion length (cutting blade protrusion amount ⁇ 0.3 mm) and a width of 10 mm.
  • Example 1 A cemented carbide having a mass percentage of WC of 90% and Co of 10% was processed into a donut-shaped perforated disk having an outer diameter of ⁇ 125 mm, an inner diameter of ⁇ 40 mm, and a thickness of 0.3 mm to obtain a base plate.
  • the base plate had a Young's modulus of 600 GPa and a saturation magnetization of 127 kA / m (0.16 T).
  • This base plate is masked with an adhesive tape so that only the inner 1.0 mm portion from the outer peripheral edge is exposed, immersed in a commercially available alkaline degreasing solution at 40 ° C. for 10 minutes, washed with water, and sodium pyrophosphate at 50 ° C. Electrolysis was carried out in a 30 to 80 g / L aqueous solution while energizing at 2 to 8 A / dm 2 . Next, the cemented carbide base plate is ultrasonically cleaned in pure water, immersed in a sulfamic acid watt nickel plating solution at 50 ° C., energized in a range of 5 to 20 A / dm 2 , and subjected to base plating, followed by masking. The tape was peeled off and washed with water.
  • a groove having an outer diameter of ⁇ 123 mm, an inner diameter of ⁇ 119 mm, and a depth of 1.5 mm is formed on one side of a PPS resin disk having an outer diameter of ⁇ 130 mm and a thickness of 10 mm, and the length is 2.5 mm ⁇ width 2 mm ⁇ thickness.
  • the grooves were made of epoxy resin.
  • a cover in which the magnet was fixed by being buried was prepared, and the base plate was sandwiched between the two jig covers with the magnet side inside.
  • the magnet was 1 mm away from the outer peripheral edge of the base plate toward the inner side of the base plate side surface.
  • the magnetic field intensity was 8 kA / m (0.01T) or more.
  • NiP-plated mass magnetic susceptibility ⁇ g of 0.588 and diamond abrasive grains of 0.4 g having an average particle size of 135 ⁇ m were magnetically attracted to a recess made of a jig and a base plate so as to be even all around.
  • the jig was immersed in a sulfamic acid watt nickel plating solution at 50 ° C., electroplated by applying current in the range of 5 to 20 A / dm 2 , and then washed with water. Thereafter, 0.4 g of diamond abrasive grains were magnetically attracted, and the operation of plating and washing in the same manner as described above was repeated again.
  • the jig body was replaced with a PPS resin disk having an outer diameter of ⁇ 123 mm and a thickness of 10 mm so that both sides of the obtained abrasive layer were exposed, and immersed in a sulfamic acid watt nickel plating solution at 50 ° C. After energizing in the range of 20 A / dm 2 to deposit the plating so as to cover the entire cutting blade, it was washed with water, removed from the jig, and dried.
  • FIG. 5 shows a photomicrograph of the side surface of the cutting edge portion.
  • Example 2 A cemented carbide having a mass percentage of WC of 90% and Co of 10% was processed into a donut-shaped perforated disk having an outer diameter of ⁇ 125 mm, an inner diameter of ⁇ 40 mm, and a thickness of 0.3 mm to obtain a base plate.
  • This base plate is masked with an adhesive tape so that only the inner 1.5 mm portion from the outer peripheral edge is exposed, immersed in a commercially available alkaline degreasing aqueous solution at 40 ° C. for 10 minutes, washed with water, and sodium pyrophosphate at 50 ° C. Electrolysis was carried out in a 30 to 80 g / L aqueous solution while energizing at 2 to 8 A / dm 2 .
  • the cemented carbide base plate is ultrasonically cleaned in pure water, immersed in a sulfamic acid watt nickel plating solution at 50 ° C., energized in a range of 5 to 20 A / dm 2 , and subjected to base plating, followed by masking.
  • the tape was peeled off and washed with water.
  • a groove having an outer diameter of ⁇ 123 mm, an inner diameter of ⁇ 119 mm, and a depth of 1.5 mm is formed on one side of a PPS resin disk having an outer diameter of ⁇ 130 mm and a thickness of 10 mm.
  • the groove has a length of 1.8 mm ⁇ width of 2 mm ⁇ thickness.
  • the magnet was 1.5 mm away from the outer peripheral edge of the base plate toward the inner side of the base plate side surface.
  • the magnetic field strength was 16 kA / m (0.02T) or more.
  • NiP-plated mass magnetic susceptibility ⁇ g of 0.588 and diamond abrasive grains of 0.4 g having an average particle size of 135 ⁇ m were magnetically attracted to a recess made of a jig and a base plate so as to be even all around.
  • the jig was immersed in a sulfamic acid watt nickel plating solution at 50 ° C., electroplated by applying current in the range of 5 to 20 A / dm 2 , and then washed with water. Thereafter, 0.4 g of diamond abrasive grains were magnetically attracted, and the operation of plating and washing in the same manner as described above was repeated three times.
  • the jig body was replaced with a PPS resin disk having an outer diameter of ⁇ 123 mm and a thickness of 10 mm so that both sides of the obtained abrasive layer were exposed, and immersed in a sulfamic acid watt nickel plating solution at 50 ° C. After energizing in the range of 20 A / dm 2 to deposit the plating so as to cover the entire cutting blade, it was washed with water, removed from the jig, and dried.
  • Example 1 the liquid epoxy resin composition used in Example 1 was applied to the side surface of the cutting edge of the outer peripheral cutting blade and held for 5 minutes, and then kept in that state in an oven at 180 ° C. for about 120 minutes. The heat was turned off and the product was naturally cooled in the oven.
  • Example 3 A cemented carbide having a mass percentage of WC of 90% and Co of 10% was processed into a donut-shaped perforated disk having an outer diameter of ⁇ 125 mm, an inner diameter of ⁇ 40 mm, and a thickness of 0.3 mm to obtain a base plate.
  • This base plate is masked with an adhesive tape so that only the inner 1.0 mm portion from the outer peripheral edge is exposed, immersed in a commercially available alkaline degreasing solution at 40 ° C. for 10 minutes, washed with water, and sodium pyrophosphate at 50 ° C. Electrolysis was carried out in a 30 to 80 g / L aqueous solution while energizing at 2 to 8 A / dm 2 . Next, the cemented carbide base plate is ultrasonically cleaned in pure water, immersed in a sulfamic acid watt nickel plating solution at 50 ° C., energized in a range of 5 to 20 A / dm 2 , and subjected to base plating, followed by masking. The tape was peeled off and washed with water.
  • the base plate is sandwiched between the jig main bodies used in Example 1, and 0.4 g of diamond abrasive grains having a mass magnetic susceptibility ⁇ g of 0.392 and an average grain size of 130 ⁇ m preliminarily NiP-plated are made of the jig and the base plate. Magnetic attraction was applied to the dent so that the entire circumference was even.
  • the entire jig is immersed in a copper pyrophosphate plating solution at 40 ° C., electroplated by energization in the range of 1 to 20 A / dm 2 , washed with water, and cured. Removed from the ingredients and dried.
  • Example 1 the liquid epoxy resin composition used in Example 1 was applied to the side surface of the cutting edge of the outer peripheral cutting blade and held for 5 minutes, and then kept in that state in an oven at 180 ° C. for about 120 minutes. The heat was turned off and the product was naturally cooled in the oven.
  • Example 4 A cemented carbide having a mass percentage of WC of 95% and Co of 5% was processed into a donut-shaped perforated disk having an outer diameter of ⁇ 125 mm, an inner diameter of ⁇ 40 mm, and a thickness of 0.3 mm to obtain a base plate.
  • the base plate had a Young's modulus of 580 GPa and a saturation magnetization of 40 kA / m (0.05 T).
  • This base plate is masked with an adhesive tape so that only the inner 1.0 mm portion from the outer peripheral edge is exposed, immersed in a commercially available alkaline degreasing solution at 40 ° C. for 10 minutes, washed with water, and sodium pyrophosphate at 50 ° C. Electrolysis was carried out in a 30 to 80 g / L aqueous solution while energizing at 2 to 8 A / dm 2 . Next, the cemented carbide base plate is ultrasonically cleaned in pure water, immersed in a sulfamic acid watt nickel plating solution at 50 ° C., energized in a range of 5 to 20 A / dm 2 , and subjected to base plating, followed by masking. The tape was peeled off and washed with water.
  • the base plate is sandwiched between the jig main bodies used in Example 1, and 0.3 g of diamond abrasive grains having a mass magnetic susceptibility ⁇ g of 0.392 and an average grain size of 130 ⁇ m preliminarily NiP-plated are made of the jig and the base plate. Magnetic attraction was applied to the dent so that the entire circumference was even.
  • the abrasive grains being magnetically attracted, the entire jig was immersed in an electroless nickel / phosphorous alloy plating solution at 80 ° C. to perform electroless plating, and then washed with water. Thereafter, 0.3 g of diamond abrasive grains were magnetically attracted, and the operation of plating and washing in the same manner as described above was repeated twice, removed from the jig, and dried.
  • a liquid acrylic resin composition containing methyl methacrylate, methacrylic acid diester, chlorosulfonated polyethylene and cumene hydroperoxide was applied to the side surface of the cutting edge of the outer peripheral cutting blade, placed in an oven at 80 ° C., and gently in a vacuum state After the pressure was reduced to 60 minutes, the mixture was heated for 60 minutes, and then cooled in the chamber while maintaining the reduced pressure state.
  • the cured acrylic resin has a Poisson's ratio of 0.4.
  • This base plate is masked with an adhesive tape so that only the inner 1.0 mm portion from the outer peripheral edge is exposed, immersed in a commercially available alkaline degreasing solution at 40 ° C. for 10 minutes, washed with water, and sodium pyrophosphate at 50 ° C. Electrolysis was carried out in a 30 to 80 g / L aqueous solution while energizing at 2 to 8 A / dm 2 . Next, the cemented carbide base plate is ultrasonically cleaned in pure water, immersed in a sulfamic acid watt nickel plating solution at 50 ° C., energized in a range of 5 to 20 A / dm 2 , and subjected to base plating, followed by masking. The tape was peeled off and washed with water.
  • the base plate is sandwiched between the jig main bodies used in Example 1, and 0.4 g of diamond abrasive grains having a mass magnetic susceptibility ⁇ g of 0.392 and an average grain size of 130 ⁇ m preliminarily NiP-plated are made of the jig and the base plate. Magnetic attraction was applied to the dent so that the entire circumference was even.
  • the jig was immersed in a sulfamic acid watt nickel plating solution at 50 ° C., electroplated by applying current in the range of 5 to 20 A / dm 2 , and then washed with water. Thereafter, 0.4 g of diamond abrasive grains were magnetically attracted, and the operation of plating and washing in the same manner as described above was repeated again.
  • the jig body was replaced with a PPS resin disk having an outer diameter of ⁇ 123 mm and a thickness of 10 mm so that both sides of the obtained abrasive layer were exposed, and immersed in a sulfamic acid watt nickel plating solution at 50 ° C. After energizing in the range of 20 A / dm 2 to deposit the plating so as to cover the entire cutting blade, it was washed with water, removed from the jig, and dried.
  • Table 1 shows the manufacturing yield of the cemented carbide base plate outer peripheral cutting blades of Examples 1 to 4 and Comparative Example 1.
  • the plating yield is the ratio of non-defective plating to the non-defective ones that are free of abrasive grains and missing the abrasive layer of the total number (15 each) that have been applied until the step of fixing the abrasive grains by plating.
  • the processing yield is obtained by performing the post-plating process up to dressing on the obtained non-plated product, and treating the non-degraded abrasive layer as a non-defective product.
  • the ratio of non-processed products to the total number is shown in 100 minutes.
  • the overall yield is the product of the plating yield and the processing yield, and means the yield of non-defective products as a finished product of the outer peripheral cutting blade with respect to the base plate used for manufacturing the outer peripheral cutting blade.
  • FIG. 6 shows the result of evaluating the cutting accuracy of a magnet when an operation of cutting a rare earth sintered magnet using a cemented carbide base plate outer peripheral cutting blade was performed.
  • the evaluation method of cutting accuracy is as follows.
  • W40 mm ⁇ L ( thickness (t)) 1.5 mm ⁇ H 20 mm magnet cut out 1,010 times and cut between two outer peripheral cutting blades of each of the examples and comparative examples.
  • every 100 sheets from the first cut are taken as dimension measurement cycles (10 cycles in total), and in each cycle, the first 10 sheets (that is, the first cycle is the 1st to the 10th, the next is the 101 to 110 sheets) The first and the last one were sampled from 1,001 to 1,010 sheets).
  • the thickness (t) of a total of 5 points (1 in the center and 4 in the corners) is measured with a micrometer, and the difference between the maximum value and the minimum value among the 5 points is cut.
  • As the accuracy ( ⁇ m) an average value of the cutting accuracy of 10 sheets was calculated.
  • FIG. 6 is a plot of this average value in each dimension measurement cycle.
  • the result of evaluating the elasticity (flexibility) of the obtained outer peripheral cutting blade is shown in FIG.
  • the compression shear stress of the cutting edge of the outer peripheral cutting blade was evaluated.
  • the cutting blade portion is positioned at a position 0.3 mm away from the outer periphery of the cemented carbide base plate, The length of the contact portion (the protruding amount of the cutting blade portion -0.3 mm) and the indenter with a width of 10 mm were pressed at a linear speed of 1 mm / min in the rotation axis direction of the outer peripheral cutting blade (thickness direction of the cutting blade portion).
  • the stress relative to the amount of movement of the indenter was measured using a Shimadzu strength tester AG-1. The pressing was continued until the cutting edge was broken. In this measurement, a support jig that sandwiches the outer peripheral cutting blade from above and below with a circular iron plate having a thickness of 5 mm that exposes only the cutting blade portion horizontally is held so that the base plate portion does not warp when pressed. .
  • the magnet pieces obtained by cutting using the outer peripheral cutting blades of the examples all had good cutting surface appearance, but were cut using the outer peripheral cutting blades of the comparative examples.
  • a sample having a cut (step) on the cut surface was generated after 3 cycles (after 301 sheets to be cut).
  • the movement amount, stress, and inclination of the indenter shown by the above-described evaluation of the elasticity (flexibility) of the outer cutting blade are not too large, and the outer cutting blade of the present invention having a certain degree of flexibility cuts into the cutting surface. It was confirmed that a magnet with high dimensional accuracy can be cut out without leaving a trace.
  • the workpiece such as rare earth sintered magnets can be finished with high precision only by cutting, without performing finishing treatment after cutting. Therefore, it becomes possible to provide the crop with high dimensional accuracy.

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  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

L'invention concerne une lame de coupe à circonférence externe à plaque de base en alliage super-dur, qui est formée à partir d'un alliage super-dur et a une partie lame de coupe sur la bordure périphérique externe d'une plaque de base en forme annulaire circulaire mince. La partie lame de coupe contient : des grains abrasifs de cBN et/ou des grains abrasifs de diamant formés par pré-revêtement par une matière magnétique ; un métal ou un alliage formé par électro-placage ou placage sans courant, qui se connecte entre les grains abrasifs et entre les grains abrasifs et la plaque de base ; et une résine thermoplastique ayant un point de fusion non supérieur à 350°C, imprégnée entre les grains abrasifs et entre les grains abrasifs et la plaque de base, ou une résine thermodurcissable formée par durcissement d'une composition de résine thermodurcissable à l'état liquide à une température de durcissement non supérieure à 350°C imprégnée entre les grains abrasifs et entre les grains abrasifs et la plaque de base. L'invention porte également sur le procédé de fabrication de ladite lame de coupe à circonférence externe de plaque de base en alliage super-dur.
PCT/JP2011/077311 2010-11-29 2011-11-28 Lame de coupe à circonférence externe à plaque de base en alliage super-dur et son procédé de fabrication WO2012073855A1 (fr)

Priority Applications (8)

Application Number Priority Date Filing Date Title
CN201180065608.7A CN103313825B (zh) 2010-11-29 2011-11-28 硬质合金基底外刃切割轮及其制造方法
SG2013041520A SG190924A1 (en) 2010-11-29 2011-11-28 Super hard alloy baseplate outer circumference cutting blade and manufacturing method thereof
US13/990,121 US20130252521A1 (en) 2010-11-29 2011-11-28 Super hard alloy baseplate outer circumference cutting blade and manufacturing method thereof
MYPI2017000178A MY193551A (en) 2010-11-29 2011-11-28 Cemented carbide base outer blade cutting wheel and making method
KR1020137016382A KR20140005911A (ko) 2010-11-29 2011-11-28 초경 합금 베이스 플레이트 외주 절단날 및 그 제조 방법
MYPI2017000179A MY193556A (en) 2010-11-29 2011-11-28 Cemented carbide base outer balde cutting wheel and making method
EP11844821.6A EP2647469B1 (fr) 2010-11-29 2011-11-28 Lame de coupe à circonférence externe à plaque de base en alliage super-dur et son procédé de fabrication
PH12018500478A PH12018500478A1 (en) 2010-11-29 2018-03-06 Super hard alloy baseplate outer circumference cutting blade and manufacturing method thereof

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP2010264821 2010-11-29
JP2010-264828 2010-11-29
JP2010264828 2010-11-29
JP2010-264821 2010-11-29

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WO2012073855A1 true WO2012073855A1 (fr) 2012-06-07

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US (1) US20130252521A1 (fr)
EP (1) EP2647469B1 (fr)
KR (1) KR20140005911A (fr)
CN (1) CN103313825B (fr)
MY (3) MY193551A (fr)
PH (1) PH12018500478A1 (fr)
SG (1) SG190924A1 (fr)
TW (1) TWI556913B (fr)
WO (1) WO2012073855A1 (fr)

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US20130252521A1 (en) 2013-09-26
MY193551A (en) 2022-10-18
TW201238715A (en) 2012-10-01
CN103313825B (zh) 2016-08-10
MY170393A (en) 2019-07-27
EP2647469A1 (fr) 2013-10-09
KR20140005911A (ko) 2014-01-15
MY193556A (en) 2022-10-19
SG190924A1 (en) 2013-07-31
CN103313825A (zh) 2013-09-18
TWI556913B (zh) 2016-11-11
EP2647469B1 (fr) 2020-06-03
PH12018500478B1 (en) 2019-02-18
PH12018500478A1 (en) 2019-02-18
EP2647469A4 (fr) 2017-08-30

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