JP2002011659A - Super abrasive tool and method of manufacturing the same - Google Patents

Abstract

(57) [Summary] [PROBLEMS] A super abrasive tool using diamond and CBN (cubic boron nitride), in particular to improve the sharpness of a diamond rotary dresser and enable high-precision and high-efficiency dressing over a long period of time. To A plurality of projections are provided substantially uniformly on the surface of a superabrasive layer. By providing the projections, the number of working abrasive grains is reduced to improve the bite to the workpiece (or whetstone), and a chip pocket with sufficient capacity is secured to smoothly discharge chips and to achieve extremely high efficiency and Enables high-precision machining.
In order to provide the projection, a reverse plating method is applied. The process includes the steps of temporarily fixing a spherical object on the inner peripheral wall of the matrix and forming a plating layer, removing the spherical object, and fixing diamond abrasive grains on the surface with the plating layer. It consists of a step of setting the base metal, joining the diamond layer and the base metal with the low melting point metal, and a step of removing the matrix.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to diamond, C
The present invention relates to a superabrasive tool using BN (cubic boron nitride) and a method for manufacturing the same. Especially among them, WA,
The present invention relates to a diamond rotary dresser (hereinafter referred to as RD) used for high-precision and high-efficiency dressing of conventional grindstones such as GC, vitrified bond superabrasive grains, and resin bond superabrasive grains.

[0002]

2. Description of the Related Art An example of a conventional RD is disclosed in, for example, JP-A-59-47162. Only one diamond abrasive is fixed to the base metal by the binder, and the surface shape of the diamond layer is of a cylindrical shape. This type of RD is mainly used for dressing by traversing the surface of a grindstone. In actual dressing, since the contact area between the RD and the grindstone is small and the dressing conditions can be changed over a wide range, the sharpness of the RD hardly causes a problem. As an example of another type of RD, Japanese Patent Publication No. 1-22
An RD having a general shape disclosed in Japanese Patent Publication No. 115 is known. In the case of this general form RD, the grinding wheel axis and the RD axis are arranged in parallel, and the RD is subjected to plunge dressing in which only a cut is made. R for plunge dressing
Since the contact area between D and the grindstone is large, sharpness of the RD is an important factor for smooth dressing.
In addition, since the surface roughness of the RD is transferred to the grindstone as it is, the effect of the completion accuracy of the RD on the dressing accuracy is extremely large. As a method for improving the sharpness of the RD, for example, the following four methods (1) to (4) are used. (1) A method in which a portion (diamond free zone) where diamond abrasive grains are not fixed is provided in a stripe shape to reduce the number of working abrasive grains. This is one of the most effective methods for improving sharpness. (2) Glass beads, ceramic beads, resin beads, and the like are mixed in a predetermined ratio with diamond abrasive grains in advance, and the mixture is fixed to a base metal to reduce the degree of concentration of diamond and reduce the number of working abrasive grains. Method. (3) A method of optimizing the degree of concentration of diamond by using a handset method or the like with diamond abrasive grains. (4) Put a groove in the exposed end of the diamond abrasive of RD,
A method of providing sharp cutting edges.

[0003]

However, the above-mentioned methods (1) to (4) are effective methods for improving sharpness, but have the following problems. Regarding (1), there is a problem that the diamond free zone becomes a groove and becomes an intermittent dressing, vibration is easily generated during the dressing work, and the vibration is transferred to the grindstone, and the surface roughness of the formed grindstone becomes rough. there were. There was also a problem that the dressing sound became loud. Regarding (2), the method invented to solve the above-mentioned disadvantage of (1) can uniformly improve the sharpness of the entire RD diamond layer, and can be applied to all-type RD. Although this is an excellent method, the mixing ratio of the glass beads must be changed each time depending on the specification of the RD, and thus there is a problem that a dedicated plating tank is required for each. Regarding (3), since a human must set diamond abrasive grains one by one, there is a problem that a long man-hour is required, productivity is low, and cost is increased. The method (4) is the most excellent method that can be processed after the RD is completed, and that can control the sharpness arbitrarily according to the way of groove. In addition, it is also possible to recover the sharpness by forming a groove in the RD whose sharpness has been reduced by long-term use, and has a feature that the applicable range is extremely wide. Although such an extremely useful method, the only problem is that an expensive laser beam irradiation device is required, and the equipment is expensive.

[0004]

In order to solve the above problems, the present invention is characterized in that a plurality of projections are provided on the surface of a superabrasive layer. By providing projections, the number of working abrasive grains is reduced to improve the bite to the grinding stone.In addition, a chip pocket with sufficient capacity is secured to smoothly discharge chips and extremely efficient and highly accurate dressing. Is what makes it possible. Preferably,
The projections are preferably provided substantially uniformly over the entire grinding surface.

[0005] The rough shape of the projection is characterized in that it is spherical, conical, prismatic or cylindrical. The shape of the projection is not limited to the above, but may be irregular. Further, it may be composed of a plurality of shapes selected from these.

Furthermore, the protrusion height of the projection is 0.01 m.
m to 5 mm. The reason why the protrusion height is limited to 0.01 mm to 5 mm is that the protrusion height of the protrusion is less than 0.01 mm, the desired effect cannot be obtained because a sufficient chip pocket cannot be secured, and even if it exceeds 5 mm. This is because no further effect can be expected. Preferably, the protrusion height of the protrusion is 0.02
mm to 3 mm, most preferably 0.05 to 2 m
m.

The above structure can be applied to all superabrasive tools, resin bond wheels, metal bond wheels, electrodeposited wheels, vitrified bond wheels, etc., but is particularly preferably applied to RD. This is because the present invention can be applied easily and at low cost by applying the reverse plating method using a matrix described below.

The present invention also proposes a method of manufacturing the above-mentioned superabrasive tool, in which a step of temporarily fixing a spherical object to an inner peripheral wall of a matrix and forming a plating layer; Removing, fixing the diamond abrasive grains on the surface with a plating layer, and setting the base metal at the center of the matrix,
The method comprises the steps of joining a diamond layer and a base metal with a low melting point metal, and removing the mother die. More specifically, a matrix 1 is manufactured, put into a plating tank, and a glass ball 2 is temporarily fixed to the matrix with nickel plating 3. In addition to glass balls, non-metallic balls such as ceramic balls or resin balls can be used. The thickness of the nickel plating at this time is the protrusion height of the protrusion. Next, the glass ball is removed, and placed in a plating bath to fix the diamond abrasive grains 4 to the inner peripheral wall of the matrix. Next, the base metal 5 is placed at the center of the matrix, and the low melting point alloy 6
Joins the diamond layer and the base metal. Next, the matrix is turned and removed, the base metal is finished, and the diamond layer is truing-dressed to complete the RD.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described in the section of Examples.

[0010]

(Example 1) A steel mold (outer diameter 150 mm,
(Inner diameter 100mm, height 30mm) is manufactured, masked, put into a plating tank, and alumina ceramic ball of Φ1mm is temporarily fixed by nickel plating on the entire inner peripheral wall of the matrix, and then the thickness of nickel plating is reduced. 0.1
The nickel plating was continued until the thickness reached mm. Next, the matrix was taken out of the plating tank, all the alumina ceramic balls were removed, and the nickel plating layer was processed to a thickness of 0.07 mm. Next, it was placed in a plating bath for diamond attachment, and diamond abrasive grains (# 40 / # 50) were fixed to the inner peripheral wall of the matrix by nickel plating. Next, the base metal was set at the center of the matrix, and the base metal and the diamond layer were joined using a low melting point alloy. Then, the base metal was finished by lathe processing, and the diamond layer was truing and dressed to complete the RD of the present invention.

(Example 2) A steel mold (outer diameter 150 m)
m, an inner diameter of 100 mm, and a height of 30 mm), which are then masked, placed in a plating tank, and temporarily fixed with a 1.5 mm alumina ceramic ball over the entire inner peripheral wall of the matrix by nickel plating. Nickel plating was continued until the plating thickness became 0.15 mm.
Next, the matrix was taken out of the plating tank, all the alumina ceramic balls were removed, and the nickel plating layer was processed to a thickness of 0.13 mm. Next, it was placed in a plating bath for diamond attachment, and the diamond abrasive grains were fixed to the inner peripheral wall of the matrix by nickel plating, followed by 2 mm build-up plating to form a diamond layer. Next, the base metal was set at the center of the matrix, and the base metal and the diamond layer were joined using a low melting point alloy. Then, the base metal was finished by lathe processing, and the diamond layer was truing and dressed to complete the RD of the present invention.

Embodiment 3 A steel mold (outer diameter 150 m)
m, an inner diameter of 100 mm, and a height of 30 mm), which are then masked, placed in a plating bath, and temporarily fixed with alumina plating balls of Φ2.0 mm over the entire inner peripheral wall of the matrix by nickel plating. Nickel plating was continued until the plating thickness became 0.2 mm. Next, the matrix was taken out of the plating tank, all the alumina ceramic balls were removed, and the nickel plating layer was processed to a thickness of 0.18 mm. Next, it was placed in a plating bath for diamond attachment, and the diamond abrasive grains were fixed to the inner peripheral wall of the matrix by nickel plating, followed by 2 mm build-up plating to form a diamond layer. Next, the base metal was set at the center of the matrix, and the base metal and the diamond layer were joined using a low melting point alloy. And finish the base metal by lathe processing,
The RD of the present invention was completed by truing and dressing the diamond layer. In order to confirm the effect of the present invention, as a conventional example, a comparison was made with an RD having the same size and the same diamond grain size without any protrusion. Tables 1-3 show the dressing conditions, grinding conditions, and the results.

[0013]

[Table 1]

[0014]

[Table 2]

[0015]

[Table 3]

As described above, the RD of the present invention is as follows.
It has excellent sharpness and enables highly accurate and highly efficient dressing over a long period of time.

[Brief description of the drawings]

FIG. 1 shows a partial cross-sectional view of one embodiment of the present invention.

FIG. 2 shows a partial sectional view of a matrix.

FIG. 3 shows a partial sectional view in which a spherical object is set.

FIG. 4 is a partial cross-sectional view in which a spherical object is temporarily fixed by plating.

FIG. 5 shows a partial cross-sectional view from which a spherical object has been removed.

FIG. 6 is a partial cross-sectional view in which superabrasives are set.

FIG. 7 is a partial cross-sectional view in which superabrasive grains are fixed.

FIG. 8 is a partial cross-sectional view in which a base metal is joined.

FIG. 9 shows a partial cross-sectional view with the matrix removed.

[Explanation of symbols]

 P Super-abrasive tool T Protrusion protrusion height 1 Matrix 2 Spherical object 3 Plating layer 4 Super-abrasive grain 5 Base metal 6 Low melting point alloy

Claims (5)

[Claims] 1. A superabrasive tool comprising a plurality of projections provided on a surface of a superabrasive layer. 2. The superabrasive tool according to claim 1, wherein the projection has a rough shape such as a spherical shape, a conical shape, a prismatic shape, and a cylindrical shape. 3. The protrusion height of the projection is 0.01 to 5 mm.
The superabrasive tool according to claim 1 or 2, wherein: 4. The superabrasive tool according to claim 1, wherein the superabrasive tool is a diamond rotary dresser. 5. A step of temporarily fixing a spherical object on an inner peripheral wall of a matrix to form a plating layer; a step of removing the spherical object and fixing diamond abrasive grains on a surface thereof by a plating layer; 5. A superabrasive grain according to claim 1, comprising a step of setting a base metal, bonding the diamond layer and the base metal with a low melting point metal, and a step of removing the matrix. Tool manufacturing method.