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WO2005084879A1 - Outil diamant a pointe separee fixee et son procede de fabrication - Google Patents

Outil diamant a pointe separee fixee et son procede de fabrication Download PDF

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Publication number
WO2005084879A1
WO2005084879A1 PCT/KR2005/000590 KR2005000590W WO2005084879A1 WO 2005084879 A1 WO2005084879 A1 WO 2005084879A1 KR 2005000590 W KR2005000590 W KR 2005000590W WO 2005084879 A1 WO2005084879 A1 WO 2005084879A1
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WO
WIPO (PCT)
Prior art keywords
tip member
abrasives
shank
base material
bonding
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/KR2005/000590
Other languages
English (en)
Inventor
Min Seok Song
Mun Seok Park
Kee Jeong Cheong
Shin Kyung Kim
Joon Won Suh
Hwan Chul Lee
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SHINHAN DIAMOND INDUSTRIAL Co Ltd
Shinhan Diamond Ind Co Ltd
Original Assignee
SHINHAN DIAMOND INDUSTRIAL Co Ltd
Shinhan Diamond Ind Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by SHINHAN DIAMOND INDUSTRIAL Co Ltd, Shinhan Diamond Ind Co Ltd filed Critical SHINHAN DIAMOND INDUSTRIAL Co Ltd
Publication of WO2005084879A1 publication Critical patent/WO2005084879A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P5/00—Setting gems or the like on metal parts, e.g. diamonds on tools

Definitions

  • the present invention relates to a diamond tool manufactured through brazing and a method for manufacturing the same, and more particularly, to a diamond tool in which a shank and a cutting or grinding tip member are manufactured separately and then bonded to each other, a tip member thereof, and a method for manufacturing the diamond tool.
  • the invention is also applied to building-stone tools such as a saw, a core drill, a cutter, a saw blade, a polishing cup, a profiler and an end mill, and industrial precision tools such as a straight wheel, an ID wheel, a rotary dresser and an edge grinding wheel.
  • building-stone tools such as a saw, a core drill, a cutter, a saw blade, a polishing cup, a profiler and an end mill
  • industrial precision tools such as a straight wheel, an ID wheel, a rotary dresser and an edge grinding wheel.
  • a diamond tool comprises a shank and a diamond grinding stone portion (abrasive-impregnated section) attached to the shank to cut and grind a workpiece.
  • the abrasive-impregnated section comprises a plurality of diamond particles and a metallic bonding material.
  • the term "diamond” generally means a natural and synthetic diamond, cubic boron nitride (cBN), and additionally a super abrasive such as silicone carbide and alumina, and also a mixture of two or more thereof.
  • the shank is commonly formed of a metallic material such as stainless steel and carbon steel.
  • a sintered-tip welding method (hereinafter, referred to as a "sintering method"), an electroplating method, a brazing method, or the like.
  • a metallic bonding material and abrasives are mixed, press-compacted, and sintered to form a cutting tip, and then the sintered cutting tip is bonded to a shank through silver brazing, laser welding, resistance welding or the like.
  • abrasives are attached to a shank through a wet electroplating process using a bonding material such as nickel.
  • a liquid paste of a metallic bonding material and a binder is coated on the shank, abrasives are dispersed therein, and the dispersed abrasives are bonded to the shank at an elevated temperature.
  • Fig. 1 is a sectional view of abrasives 130 bonded to a shank 110 via a bonding material 120 respectively through a sintering method (Fig. 1 (a)), an electroplating method (Fig. 1 (b)), and a brazing method (Fig. 1 (c)).
  • Fig. 2 is a front view of a saw blade where abrasives 130 are attached to a shank 110 through a sintering method
  • Fig. 3 is a sectional view taken along line II-II in Fig. 2.
  • the cutting tip has a structure where a plurality of abrasives 130 are non-uniformly dispersed in the metallic bonding material 120.
  • This cutting tip is bonded to a shank 110 through a weldment 115 formed by laser welding, silver brazing, or resistance welding.
  • the cutting tip is provided with a blank 125 formed at the bonding area with the shank 110, as shown in Fig. 3.
  • the blank 125 has no abrasive 130 so that subsequent laser welding with the shank 110 can be easily performed.
  • FIG. 4 is a front view of a saw blade where abrasives 130 are bonded to a shank 110 through a brazing method or an electroplating method.
  • Fig. 5 is a sectional view taken along line III-III in Fig. 4. As described above, in the brazing or electroplating method, the abrasives are directly attached to the shank 110, and thus the abrasives 130 are bonded to the surface of the shank 110 in a mono-layer, as shown in Fig. 5.
  • the brazing method In the brazing method, strong chemical bonding is occurred in the interface between the abrasives and the metallic bonding material, and thus the abrasives are rarely released during the use of tools. In addition, it does not necessitate a time- and cost-consuming dressing process, and can be used in a bi-directional cutting and grinding process. Accordingly, diamond tools manufactured through a brazing method have good cutting performance, as compared with ones manufactured by a sintering or electroplating method, and in particular provides appropriate characteristics to a dry process or DIY (do-it-yourself) products. Furthermore, the brazing method can maximize exposure of the abrasives, precisely control the abrasive spacing, and form a chip pocket to thereby enable smooth flowability of slurry and grinding liquid. Moreover, in case where Ni-Cr alloy is used, the presence of Cr leads to good corrosion resistance.
  • Fig. 6 explains a process of bonding abrasives to a shank according to a brazing method.
  • a bonding material 120 containing brazing metal powder in the form of paste is coated on a shank 110 (Fig. 6 (a)), and then, a plurality of abrasives 130 are dispersed in the coated paste (Fig. 6 (b)).
  • the paste bonding material 120 which is used to bond the abrasives 130 to the shank 110, commonly contains metal powder and a binder providing flowability to the metal power.
  • a drying process may be provided between the bonding material coating and the abrasive dispersion.
  • the coated bonding material 120 and the abrasives 130 dispersed therein are dried at a certain temperature (Fig. 6 (c)). Thereafter, the resultant product is held in a vacuum furnace or a reduction/inert gas atmosphere furnace at a certain elevated temperature, where the metal power in the bonding material can flow in a liquid phase state and react chemically, such that the brazing metallic bonding material is melted and adhered to the shank 110 and the abrasives 110 (Fig. 6 (d)). At this time, the holding temperature depends on the type of the commercialized pastes, for example, about 600 ⁇ 1300°C.
  • FIG. 7 shows an example in which abrasives 130 are attached to the shank 110 through a metallic bonding material as shown in Fig. 6 (d).
  • a cutting tool such as a saw blade 100, for example having abrasives dispersed in a bonding paste, is placed in a furnace 300 maintained in a desired atmosphere required for brazing the saw blade 100. Then the furnace 300 is heated by means of a high frequency induction coil 310, for example, up to about 600-1300 °C, thereby bonding the abrasives to the shank.
  • Fig. 8 shows a process of bonding abrasives to a shank through an electroplating method that can provide a non-uniform mono-layer of abrasives or a uniform abrasive layer and is suitable for manufacturing a diamond tool of complicated structure.
  • a non-conductive film 115 is coated on a portion of a shank that abrasives are not to be attached, in order to prevent that portion from being electroplated.
  • Abrasives 130 are uniformly disposed on the surface in the shank that the non-conductive film 115 is not coated (Fig. 8 (b)), and the resultant product is put in an electroplating bath to perform a wet electroplating process.
  • the area coated with the non-conductive film 115 and the non-conductive abrasives are not electroplated, and only the area in the shank that the abrasives 130 are disposed is electroplated.
  • the abrasives 130 are bonded through a bonding material 120 formed by the electroplating (Fig. 8 (c)).
  • the non- conductive film 115 is removed for subsequent procedures such as a coloring process (Fig. 8 (d)).
  • the shank and the abrasives are heat-treated together in a vacuum or gas atmosphere furnace of high temperature, so that thermal stress and thus thermal deformation is caused in the shank due to the high temperature.
  • This thermal deformation leads to wobbling by unbalance of a tool when it rotates.
  • the heat-treatment in the furnace may deteriorate significantly the mechanical property of the shank such as strength, hardness, toughness, and the like.
  • only the abrasive-impregnated section to be welded to a shank is heat-treated in a furnace.
  • the entire tool including the shank is heat-treated inside a furnace, or immersed in an electroplating both. Accordingly, the brazing and electroplating methods necessitate a furnace or an electroplating both having an adequate size to accommodate the entire tool including the shank, contrary to the sintering method.
  • a large-sized saw blade having, for example, a diameter of l ⁇ 2.5m
  • a large scaled furnace or electroplating bath is required for receiving the whole saw blade including the shank.
  • the shank is unnecessarily heat-treated to thereby waste energy.
  • the present invention is conceived to solve the above problems in the prior art, and an object of the invention is to provide a diamond tool in which a shank and a tip member having abrasives attached thereto are manufactured separately and then bonded to each other to avoid heat-treatment unnecessary to the shank and thermal deformation resulting therefrom, a tip member thereof, and a method for manufacturing the diamond tool.
  • Another object of the invention is to provide a diamond tool that can be manufactured less expensively even in case of a large-scale diamond, a tip member thereof, and a method for manufacturing the diamond tool.
  • a tip member to be attached to a shank of a diamond tool comprising a base material; and a plurality of abrasives attached to at least a part of a surface of the base material except a bonding portion of the tip member that is to be bonded to the shank.
  • a plurality of depressed portions may be formed in the surface of the base material, and a plurality of abrasives may be attached to inner spaces of the depressed portions.
  • each of the depressed portions may comprise a dimple type depressed portion, a groove type depressed portion, or a through-hole type depressed portion.
  • a groove may be formed in a top surface of the tip member and a through-hole may be formed in a lateral face of the tip member.
  • a plurality of abrasives may be attached to a surface of the shank and an upper side of the depressed portions to which the abrasives and a bonding material are attached.
  • the portion of the base material to which the plurality of abrasives are attached may have a thickness larger than that of the bonding portion.
  • the abrasives may comprise synthetic or natural diamond, cubic boron nitride (cBN), silicone carbide, alumina, and a mixture of two or more thereof.
  • the present invention also provides a diamond tool, comprising a shank; and one or more tip members described above, wherein a bonding portion of each of the tip members is bonded to the shank.
  • positioning members may be provided in the bonding portion of the tip member and a bonding region of the shank to which the tip member is bonded.
  • the positioning member may comprise a prominence and depression formed such that the bonding portion of the tip member is engaged with the bonding region of the shank.
  • the shank and a base material for the tip member may be formed of an identical material.
  • the thickness of the bonding portion of the tip member may be different from that of the shank.
  • the diamond tool may include a saw, a core drill, a cutter, a saw blade, a polishing cup, a profiler, an end mill, a straight wheel, an ID wheel, a rotary dresser, or an edge grinding wheel.
  • the present invention further provides a method for manufacturing a diamond tool, comprising the steps of manufacturing a tip member by attaching a plurality of abrasives to a part of a surface of a base material; preparing a shank of the diamond tool; and attaching the tip member to the shank.
  • the step of the manufacturing the tip member may comprise the step of attaching the plurality of abrasives to the base material through brazing.
  • the step of the manufacturing the tip member may comprise the steps of coating a bonding material in the form of paste on the part of the surface of the base material of the tip member; dispersing the plurality of abrasives in the coated bonding material; drying the bonding material; and heating the base material to perform fusion-bonding.
  • the step of the manufacturing the tip member may comprise the steps of preparing a mixture of a bonding material in the form of paste and the plurality of abrasives; coating the mixture on the part of the surface of the base material of the tip member; and performing fusion-bonding by heating the base material.
  • the step of the manufacturing the tip member may comprise the step of attaching the plurality of abrasives to the base material through electroplating.
  • the step of the manufacturing the tip member may comprise the steps of coating a non-conductive film on a part of the surface of the base material of the tip member except the portion thereof to which the abrasives are to be attached; dispersing the plurality of abrasives on another part of the surface of the base material except the part thereof on which the non-conductive film is coated; and electroplating the base material.
  • the method may further comprise the step of removing the non-conductive film after the step of electroplating the base material.
  • the tip member may be bonded to the shank through silver brazing, resistance welding or laser welding.
  • the step of performing the fusion-bonding may be carried out using a batch-type vacuum furnace, a reduction/inert gas atmosphere furnace, or a continuous-type gas atmosphere furnace.
  • the reduction/inert gas may comprise hydrogen gas.
  • the tip member and the shank are separately manufactured and then bonded to each other, contrary to a conventional technique where a grinding/cutting tip and a shank are usually formed of an identical base material and abrasives are bonded to a part of the base material.
  • Fig. 1 is a sectional view of abrasives bonded to a shank respectively through a sintering method (Fig. 1 (a)), an electroplating method (Fig.
  • Figs. 2 and 3 are a front view and a sectional view of a saw blade where abrasives are bonded to a shank through a sintering method.
  • Figs. 4 and 5 are a front view and a sectional view of a saw blade where abrasives are bonded to a shank through a brazing or electroplating method.
  • Fig. 6 shows a process of bonding abrasives to a shank through a conventional brazing method.
  • Fig. 7 is a schematic view illustrating the brazing method through heat treatment after abrasives are dispersed on the shank.
  • Fig. 8 shows a process of bonding abrasives to a shank through an electroplating method.
  • Fig. 9 is a schematic view explaining a diamond tool according to the present invention.
  • Fig. 10 is a schematic perspective view showing a tip member according to the present invention.
  • Figs. 11 and 12 are sectional views schematically showing a tip member according to the invention.
  • Figs. 13 and 14 show modified examples of a diamond tool according to the invention.
  • Figs. 15 and 16 shows other modified examples of a diamond tool according to the invention.
  • Fig. 17 shows a process of manufacturing a tip member having multiple abrasive layers through a brazing method according to the invention.
  • Fig. 18 shows a process of manufacturing a tip member having multiple abrasive layers through an electroplating method according to the invention.
  • FIGs. 19 and 20 are sectional views showing another examples of a depressed portion formed in the surface of a tip member.
  • Figs. 21 to 23 are a perspective view, a font view and a sectional view showing another example of a depressed portion formed in the surface of a tip member.
  • Figs. 24 to 26 are a perspective view, a font view and a sectional view showing yet another example of a depressed portion formed in the surface of a tip member.
  • Figs. 27 to 29 are a perspective view, a front view and a sectional view showing a further example of a depressed portion formed in the surface of a tip member.
  • Fig. 30 is a sectional view of a tip member having multiple abrasive layers according to the invention.
  • Figs. 31 and 32 show core drills to which the present invention is applied. Best Mode for Carrying Out the Invention
  • a typical saw blade has the shape of a circular disk and is provided with a plurality of cutting tips formed at regular intervals along the circumference thereof so as to protrude in radial directions. Abrasives are attached in these cutting tips, which participate in the cutting or grinding work.
  • Fig. 9 shows a saw blade 200 as an example of a diamond tool according to the invention.
  • the saw blade 200 comprises a shank 220 and plural tip members 210 having abrasives attached thereto, which cut or grind a workpiece.
  • the tip members 210 are bonded to the shank 220 through silver brazing, laser welding, or resistance welding.
  • the tip member 210 includes a grinding/cutting portion 210a to which abrasives are attached, and a bonding portion 210b through which the tip member 210 is bonded to a shank 220.
  • the tip member 210 is formed by providing a base material having the same shape as the cutting tip or part of the cutting tip of the saw blade 200 and bonding plural abrasives to the grinding/cutting portion 210a.
  • the bonding portion 210b of the tip member 210 does not have abrasives so as to be bonded to the shank 220.
  • a diamond tool is constructed such that an abrasive containing portion has a thickness larger by about 10-45% than that of the shank to thereby provide a same appropriate clearance to both sides of the shank, thus preventing impact to the shank, degradation of the shank, and deterioration of cutting performance, which might be caused by contact and friction with a workpiece. That is, in the tip member 210, the thickness tl of the grinding/cutting portion 210a is preferred to be larger than the thickness t2 of the bonding portion 210b.
  • a shank having a uniform thickness is used and abrasives are bonded to the shank through a brazing or electroplating method to thereby form an abrasive portion.
  • the abrasive portion can be made to have a desired thickness larger than the remaining shank portion.
  • a clearance does not need to be formed, beforehand, in a base material for the tip member 210.
  • the thickness of the shank 220 can be the same as that of the tip member 210.
  • the tip member 210 may be made to have a relatively higher height and then bonded to a shank 220 having a thickness larger than the tip member 210, considering the cutting depth of a workpiece by the diamond tool.
  • the thickness of the cutting portion is relatively thin, but a thicker shank can be used, so that the strength of diamond tool can be improved.
  • a clearance is preferred to be formed in the base material of the tip member 210. That is, in the base material, the thickness of the grinding/cutting portion 210a is preferred to be made larger than that of the bonding portion 210b.
  • abrasives are bonded to all the surface of the tip member excepting the bottom face thereof or the bottom face and part of adjacent side face, so that the bottom face can serve as a bonding portion 210b or the height of the boding portion 210b in Fig. 10 can be made lower.
  • the tip member 210 can be attached to a shank 220 having a thickness smaller than that of the tip member 210, without forming beforehand a clearance in the base material for the tip member 210.
  • the bonding of abrasives to the grinding/cutting portion 210a of the tip member 210 may be performed through a conventional brazing method shown in Fig. 6. That is, a bonding material 120 in the form of paste, which is composed of brazing metal powder and a binder, is coated on the surface of the grinding/cutting portion 210a of the tip member 210, and then plural abrasives 130 are dispersed in the coated paste. The coated paste may be pre-dried before dispersing the abrasives 130.
  • the bonding material 120 with the abrasives 130 dispersed therein is dried at a desired temperature, and thereafter, heat-treated at a desired temperature of a reduction or inert atmosphere such that the brazing metal powder is melted and adhered to the grinding/cutting portion 210a and the abrasives 130 to thereby form a tip member 210.
  • a reduction or inert atmosphere high purity hydrogen is used.
  • the shank 220 is manufactured so as to have the same thickness as the bonding portion 210b of the tip member 210 or have a thickness smaller than that thereof.
  • the finished tip member 210 is bonded to the shank 220 through silver brazing, laser welding, or resistance welding.
  • the shank 220 and the tip member 210 are formed, preferably, of materials that can be easily bonded to each other, more preferably, of a same material.
  • the above procedures, where the paste bonding material 120 is coated and plural abrasives 130 are dispersed therein, may be replaced by a process, in which a mixture of bonding paste material 120 and plural abrasives 130 is coated on the surface of a base material for the tip member 210.
  • Abrasives may be attached to the grinding/cutting portion 210a through a conventional electroplating method, as shown in Fig. 8. That is, in a base material for the tip member 210, a non-conductive film 115 is coated in the bonding portion thereof.
  • the abrasives 130 are disposed uniformly in the grinding/cutting portion 210a, where the non-conductive film 115 is not coated, and the resultant product is put in an electroplating bath to perform a wet electroplating process, such that only the area not coated with the non-conductive film 115 is electroplated.
  • the abrasives are bonded through a bonding material formed by the electroplating.
  • the non-conductive film 120 is removed for subsequent procedures such as a coloring process.
  • the tip member 210 When the tip member 210 is bonded to a shank 220, it must be bonded at a correct position on the shank 220.
  • the boding portion 210b of the tip member 210 and the shank 220 are provided with a positioning member 21 la, 21 lb, 221a, 221b in order for the tip member 210 to be bonded at the correct position on the shank 220, as shown in Figs. 13 and 14.
  • the positioning member 21 la, 21 lb, 221a, 221b assists in bonding the tip member at the correct position on the shank. It also increases the resistant force against the circumferential external force exerted by a workpiece when the tool rotates (clockwise in Fig.
  • the positioning member is not limited to the prominence and depression shown in Figs. 13 and 14, which is designed such that the bonding portion of the tip member is tooth-engaged with the bonding area of the shank. It may employ other types of prominence and depression such as protrusions and grooves, as long as they conform and fit to each other.
  • the positioning member may include a marking indicated in the tip member and the shank.
  • the aforementioned tip member of a diamond tool is manufactured by attaching abrasives to a base material, which has the same shape as a common-type cutting tip or a part of the cutting tip.
  • a number of tip members must be attached to a shank, and thus such a time-consuming procedure must be repeated many times.
  • Figs. 15 and 16 show a modification according to the invention in order to solve the above disadvantages.
  • the base material for tip member is designed such that plural tip members 410a can be formed in a single piece of base material, thereby enabling easy bonding of the tip member 410a to a circular shank.
  • the tip member 410a can be divided into several pieces, as shown in Fig. 16.
  • the tip member 410 of Fig. 15 is divided into four tip members 410b such that they can be easily brazed or electroplated in a small furnace or a small electroplating bath, but easily bonded to the shank, as compared with the tip member 210 shown in Fig. 9.
  • the aforementioned tip member of the invention is formed through a brazing or electroplating method.
  • a brazing or electroplating method typically a mono-layer of abrasive is formed, as shown in Figs. 1(b) and 1 (c), and thus the service life thereof is shortened, as compared with a diamond tool manufactured through a sintering method.
  • the present invention proposes a method for forming multiple abrasive layers using a brazing or electroplating method.
  • Fig. 17 shows a process of forming a tip member with multiple abrasive layers according to the invention.
  • Fig. 17 shows only a part of the tip member to which abrasives are to be attached.
  • a plurality of depressed portion 520 are formed in a base material 510 for the tip member.
  • the depth d, the width w and the spacing s of the depressed portion are to be determined, based on the size of abrasives.
  • the depth d and the width w of the depressed portion 520 are predetermined, and these depressed portions are formed so as to be spaced apart from one another with certain desired spacing s provided between neighboring depressed portions.
  • a bonding material 530a in the form of paste containing brazing metal powder and a binder is coated inside the depressed portions 520 of the base material in Fig. 17 (a). Then, a plurality of abrasives 540a are filled in the bonding paste coated in the depressed portion 520 and thereafter the bonding material 530a with the abrasives contained therein are primarily dried at a desired temperature (Fig. 17 (c)).
  • the bonding paste 530a may be pre-dried before the abrasives 540a is dispersed in the coated paste.
  • a bonding paste 530b in the form of paste comprising brazing metal powder and a binder is coated again on the top of the depressed portion 520 filled with the bonding paste 530a and the abrasives 540a and on the surface of the base material 510 (i.e., the top surface of the wall) (Fig. 17 (d)).
  • a plurality of abrasives 540b are dispersed in the bonding paste 530b coated on the surface of the base material 510 and they are secondarily dried at a desired temperature (Fig. 17 (e)).
  • the resultant product is heat-treated in a vacuum or reduction/inert gas atmosphere brazing furnace at a certain desired temperature, such that the brazing metal powder can be melted and adhered to the abrasives 540a and 540b and the base material 510, as shown in Fig. 17 (f).
  • the vacuum furnace is mostly a batch type furnace so that a good productivity cannot be expected, but in the reduction/inert gas atmospheric furnace, a continuous brazing process using a conveyor can be utilized to thereby enhance the production efficiency significantly.
  • the bonding paste 530a or 530b is first coated in the depressed portions and then the plural abrasives 540a or 540b are dispersed in the coated bonding paste 530a or 530b.
  • the bonding paste 530a and the abrasives 540a may be first mixed and the mixture may be then coated in the depressed portion 520.
  • the bonding paste 530b and the abrasive 540b may be first mixed to form a mixture, which may be then coated above the previous coated mixture and the top surface of the wall 521 (the surface of the base material 510).
  • the bonding material 530a filled in the depressed portion 520 and the bonding material 530b coated on the surface of the base material 510 may be the same as or different from each other.
  • the upper abrasive layer comprises the bonding material 530b and the abrasive 540b
  • the lower abrasive layer comprises the bonding material 530a, the abrasive 540a, and the wall 521 (part of the base material 510) between the depressed portions. Therefore, the composition of the bonding paste 530a and the bonding paste 530b may be made to become different from each other, and the metal powder contained in each bonding paste 530a, 530b may also be made different. In this way, the lower abrasive layer, which is to be exposed after the upper abrasive layer is released or fallen apart, can have a uniform and consistent cutting or grinding characteristic as in the upper abrasive layer.
  • the metal powders contained in the bonding materials of the upper and lower abrasive layers are melted at the same time.
  • the metal powder of the bonding material 530a is filled in the depressed portion 520, the melted metal powder is held in place, along with the abrasives 540a, due to the surface tension thereof, and thus cannot easily flow with the melted metal powder of the bonding material of the upper abrasive layer. Accordingly, the abrasives dispersed in the upper and lower abrasive layers are retained in their places without being scattered or disturbed, thereby enabling avoidance of a deviation with the thickness thereof.
  • the abrasives 540a filled in the plural depressed portions 520, which are formed in the surface of the base material 510, constitute a lower abrasive layer
  • the abrasives 540b disposed on the above abrasive 540a and the surface of the base material 510 constitute an upper abrasive layer, i.e., multiple abrasive layers are formed on the base material.
  • the tip member having the above construction when in use, the upper abrasives 540b of the upper abrasive layer are fallen apart therefrom, the lower abrasive layer is subsequently exposed and the lower abrasives 540a contained therein come to participate in the grinding and cutting work, thereby extending the service life of the tool. That is, although the lower abrasives 540a of the lower abrasive layer are retained inside the depressed portion 520, the wall 521 between the depressed portions 520 (in Fig. 17(a)) is easily abraded during a cutting or grinding process such that the abrasives 540a inside the depressed portion 520 come to protrude above the surface of the tool and participate in the cutting or grinding work. Therefore, the width w, the depth d, and the spacing s of the depressed portions 520 can be optimized, preferably, such that the wall 521 can be appropriately abraded.
  • the minimum width and depth of the depressed portion are preferred to be designed so as to be larger than the abrasive size, so that some of the abrasives can be held, in its entirety, inside the depressed portion, as shown in Fig. 17.
  • the spacing s between the neighboring depressed portions is designed preferably such that the upper and lower abrasive layers can have a same abrasive concentration and thus exhibit a uniform and consistent cutting or grinding speed or performance.
  • the tip member having multiple abrasive layers of the invention may be manufactured through an electroplating method, instead of the above brazing method.
  • a process of manufacturing a tip member with multiple abrasive layers using an electroplating method will be described. In Fig. 18, only a part of the tip member to which abrasives are to be attached is partially illustrated.
  • a plurality of depressed portions 520 are first formed in a base material 510.
  • the top surface of the wall 521 is coated with a non-conductive film 526 in order to prevent the top surface of the wall from being electroplated.
  • Abrasives 540a are filled inside the depressed portion 520 (Fig. 18 (c)) and then a wet electroplating process is performed in an electroplating bath.
  • the electroplating is not processed on the non-conductive abrasives, but processed from the base material and gradually forms a bonding material 530a simultaneously while embedding the abrasives into the bonding material 530a being formed by the electroplating (Fig. 18 (d)).
  • the bonding material 530a is formed adequately inside the depressed portion 520, the base material 510 is removed from the electroplating bath, thereby completing a primary electroplating to form a lower abrasive layer. Thereafter, the non-conductive film 526 coated on top of the wall 521 is removed (Fig.
  • abrasives 540b are then uniformly disposed on the lower abrasive layer and on the top of the wall 521 (Fig. 18 (f)).
  • both the depressed portion 520 and the wall 521 become conductive and thus a secondary electroplating can be performed thereon to thereby form an upper abrasive layer (Fig. 18 (g)).
  • a diamond tool with two or more abrasive layers can be manufactured.
  • a bonding paste is preferably filled in the depressed portion 520 and the abrasives are then dispersed.
  • the abrasives 540a are filled inside the depressed portion 520 and a bonding material is then electroplated inside the depressed portion 520, and at the same time the abrasives 540a are fixed into the bonding material and the base material.
  • the upper and lower abrasive layers may be formed through a combination of the brazing method and the electroplating method. That is, the upper and lower abrasive layers may be formed using either one of the brazing method and the electroplating method. Alternatively, the lower abrasive layer may be formed by the brazing method and the upper abrasive layer may be formed through the electroplating method, and vice versa. In a case where the lower and upper abrasive layers are formed respectively through a brazing method and an electroplating method, just after the step of Fig. 17 (c), the base material is to be heat-treated to bond the abrasives to the base material before performing next steps for electroplating.
  • the diamond tools manufactured through the above brazing and electroplating methods according to the invention can be modified in various ways.
  • the base material can be heat-treated to perform fusion-bonding (brazing), thereby providing a diamond tool to be used without an upper abrasive layer.
  • the resultant product without an upper abrasive layer in which the abrasive 540a and the bonding material 530a are provided in the depressed portion 520, can be used as a diamond tool.
  • the width w of and spacing s between the depressed portions 520 are not changed and the depth d of the depressed portion is made to be almost the same as the abrasive size a, two-layered abrasives can be formed, thereby providing an identical cutting and grinding characteristic to the upper and lower abrasive layers when in use.
  • the size of the depressed portion 520 can made to be smaller than those of the abrasives such that the abrasives are partially inserted into the depressed portion 520 and thus only the inserted portions of the abrasives are bonded to the base material through brazing or electroplating.
  • the ratio d/a of the depth of depressed portion to the abrasive size is to be at least 1/4, and the ratio w/a of the width of depressed portion to the abrasive size is also preferred to be at least 1/4.
  • the ratio s/w of the spacing to the width of the depressed portion is preferred to be within a range of 0.2 to 0.8, in a case where the abrasive concentration is substantially the same in the upper and lower layers.
  • the depressed portion 520 is illustrated to have a rectangular cross section, but not limited thereto. As illustrated in Figs. 19 and 20, the depressed portion may have a semi-elliptic cross section 520a or a V-shaped cross section 520b. In addition, the depressed portion may have a semi-circular cross section, a U-shaped cross section, a wavy cross section, or the like.
  • the upper end portion of the wall 521 is illustrated to have a right-angled edge, but it may be formed so as to have a round shape 521R, as shown in Figs. 19 and 20, thereby facilitating the flowability of paste and improving the adhesiveness of abrasives near the edge. This round shape 521R can be applied to the rectangular cross section shown in Figs. 17 and 18.
  • the present invention has been described in connection with the only illustrated cross section of the depressed portion 520.
  • the term "depressed portion” includes all the shapes, which are sunken under the surface of the base material.
  • the shape of the depressed portion includes a dimple type such as a semi-sphere, a semi-ellipsoid, an inverse cone, a rectangular block, a cylinder or the like.
  • this depressed portion includes a space between projected portions, which may be formed on the surface of the base material through a coating process, an electroplating process, a bonding process or the like.
  • Figs. 21, 24 and 27 are perspective views showing tip members, where in the surface of the tip member is formed respectively a dimple type depressed portion 520c, an elongated groove type depressed portion 520d, and a through-hole type depressed portion 520e.
  • Figs. 22, 25 and 28 are front views of the tip members shown in Figs. 21, 24 and 27, respectively.
  • Figs. 23, 26 and 29 are sectional views taken along line M-M, N-N, and O-O in Figs. 22, 25 and 28, respectively.
  • the size of the depressed portions 520c to 520e is exaggerated, relative to the tip member of the saw blade, for the purpose of clear illustration of the shape thereof.
  • the number of the depressed portions is illustrated more or less than the actual number thereof.
  • the shape, the size and the number of depressed portions are to be designed appropriately, depending on the strength and ductility of a workpiece, etc.
  • the aforementioned depressed portions with various shapes may be combined with each other in various ways.
  • the top surface of the tip member i.e., a main cutting face
  • the side surface of the tip member i.e., a sub-cutting face
  • a depressed portion 520e of a through-hole type formed in such a way to pass through in the thickness direction.
  • FIG. 30 shows a cross section of a diamond tool according to the invention, wherein abrasives are bonded to a base material 510 with a depressed portion 520d of a groove type and a depressed portion 520e of a through-hole type using the methods illustrated in Figs. 17 and 18.
  • abrasives 540al are bonded through a bonding material 530a.
  • abrasives 540a2, 540a3, 540a4 are bonded through a bonding material 530a.
  • abrasives 540bl and 540b2 are bonded through a bonding material 530b.
  • release of the abrasives 540a2, wear of the base material between the abrasives 540a2 and 540a3, release of the abrasives 540a3, wear of the base material between the abrasives 540a3 and 540a4, and release of the abrasives 540a4 occur sequentially in a direction designated by an arrow A, thereby extending significantly the service life of the tool.
  • Fig. 31 shows a core drill 500a comprising plural tip members 510a and a shank 520a
  • Fig. 32 shows another core drill 500b comprising a single piece of tip member 510b and a shank 520b.
  • their basic constitutions are the same as the previous embodiments, except for the shapes of the tip member and the shank.
  • a tip member of a diamond tool for cutting and grinding a workpiece and a shank of the diamond tool for supporting the tip member are separately manufactured, only a part of the diamond tool, i.e., the tip member, is required to be heat-treated without heat treatment of the entire diamond tool. Accordingly, the diamond tool does not suffer thermal deformation, which may be caused by unnecessary heat treatment, thereby avoiding degradation in its mechanical properties and reducing the wobbling caused by unbalance of a tool.
  • the sintered tip has a blank, through which the tip is bonded to a shank, for an easy bonding between them.
  • the blank of the sintered tip and the shank are formed of different materials, thus failing to achieve a maximum bonding force through welding.
  • the tip member and the shank can be formed of an identical material, thus maximizing the bonding force between the tip member and the shank.
  • the tip members are manufactured through a brazing or electroplating method
  • the tip members only, excepting the shank can be sold or purchased in the country or abroad.
  • users themselves can manufacture various diamond tools by bonding the tip member to an appropriate shank, for example, using silver brazing or laser welding. Therefore, the transportation cost for the entire tool including a shank can be saved.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

La présente invention a trait à un outil diamant fabriqué par brasage ou par dépôt électrolytique et son procédé de fabrication. La présente invention vise à fournir un outil diamant dans lequel la queue et l'élément de pointe comportant des abrasifs fixés sont fabriqués séparément et ensuite assemblés pour éviter un traitement thermique inutile pouvant entraîner sa déformation, son élément de pointe, et un procédé de fabrication de l'outil diamant. A cet effet, l'outil diamant de l'invention comporte une queue et un élément de pointe assemblé à la queue. L'élément de pointe comporte un matériau de base et une pluralité d'abrasifs fixés à au moins une partie de la surface du matériau de base sauf pour la portion d'assemblage de l'élément de pointe qui est assemblée à la queue. La portion d'assemblage de l'élément de pointe est assemblée à la queue.
PCT/KR2005/000590 2004-03-05 2005-03-03 Outil diamant a pointe separee fixee et son procede de fabrication Ceased WO2005084879A1 (fr)

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KR1020040015192A KR100592711B1 (ko) 2004-03-05 2004-03-05 팁이 부착된 절삭 공구 및 그 제조 방법
KR10-2004-0015192 2004-03-05

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Cited By (5)

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US7497212B2 (en) 2004-12-08 2009-03-03 Ehwa Diamond Industrial Co., Ltd. Cutting tool and method for manufacturing the cutting tool
WO2009125931A3 (fr) * 2008-04-11 2009-12-23 Lee Hwan Chul Outil de coupe et procédé de fabrication correspondant
CN102029653A (zh) * 2009-09-26 2011-04-27 鄂州市团结奇锐锯业有限公司 金刚石圆锯片基体再生处理方法
US9194189B2 (en) 2011-09-19 2015-11-24 Baker Hughes Incorporated Methods of forming a cutting element for an earth-boring tool, a related cutting element, and an earth-boring tool including such a cutting element
WO2021001157A1 (fr) 2019-07-02 2021-01-07 WIKUS-Sägenfabrik Wilhelm H. Kullmann GmbH & Co. KG Outil d'usinage par enlèvement de copeaux sous forme de bande à particules tampon

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KR101370636B1 (ko) * 2007-12-20 2014-03-10 재단법인 포항산업과학연구원 다이아몬드 절삭 휠 제조방법
KR101299783B1 (ko) * 2011-09-02 2013-08-23 대구텍 유한회사 절삭 인서트
KR101252406B1 (ko) * 2011-09-07 2013-04-08 이화다이아몬드공업 주식회사 절삭성이 우수한 브레이징 본드 타입 다이아몬드 공구 제조 방법
US9694512B2 (en) 2011-09-07 2017-07-04 Ehwa Diamond Industrial Co., Ltd. Brazing bond type diamond tool with excellent cuttability and method of manufacturing the same
KR101643335B1 (ko) * 2015-01-27 2016-07-27 한솔테크닉스(주) 에지 그라인딩 장치
KR20170001126A (ko) 2015-06-25 2017-01-04 심용섭 다이아몬드 공구
KR20170001127A (ko) 2015-06-25 2017-01-04 심용섭 다이아몬드 공구
KR200494089Y1 (ko) 2020-01-07 2021-07-29 이경이 절삭팁 및 그것을 포함하는 절삭용 톱날
KR102710199B1 (ko) 2021-12-29 2024-09-26 레커픽스 주식회사 다이아몬드 로타리 드레샤의 바디부와 지립부를 접합시키기 위한 금속 조성물

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7497212B2 (en) 2004-12-08 2009-03-03 Ehwa Diamond Industrial Co., Ltd. Cutting tool and method for manufacturing the cutting tool
WO2009125931A3 (fr) * 2008-04-11 2009-12-23 Lee Hwan Chul Outil de coupe et procédé de fabrication correspondant
CN102029653A (zh) * 2009-09-26 2011-04-27 鄂州市团结奇锐锯业有限公司 金刚石圆锯片基体再生处理方法
US9194189B2 (en) 2011-09-19 2015-11-24 Baker Hughes Incorporated Methods of forming a cutting element for an earth-boring tool, a related cutting element, and an earth-boring tool including such a cutting element
US9771497B2 (en) 2011-09-19 2017-09-26 Baker Hughes, A Ge Company, Llc Methods of forming earth-boring tools
WO2021001157A1 (fr) 2019-07-02 2021-01-07 WIKUS-Sägenfabrik Wilhelm H. Kullmann GmbH & Co. KG Outil d'usinage par enlèvement de copeaux sous forme de bande à particules tampon
DE102019117796A1 (de) * 2019-07-02 2021-01-07 WIKUS-Sägenfabrik Wilhelm H. Kullmann GmbH & Co. KG Zerspanungswerkzeug mit Pufferpartikeln
US12076804B2 (en) 2019-07-02 2024-09-03 W1KUS-Sagenfabrik Wilhelm H. Kullmann GmbH & Co. KG Band-shaped machining tool having buffer particles

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KR20050089674A (ko) 2005-09-08

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