JP2000006033A - Resin bond super-abrasive grain wheel and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a product with high performance and without secular change by molding super-abrasive grain in a specified width in a rotary shaft direction of a resin bond super-abrasive grain wheel having super-abrasive grain layers coupled by a resin system coupling material plural number of times and integrally sticking super-abrasive grain on the surface of a seamless and integrated cylindrically metallic support. SOLUTION: On the surface of a seamless and integrated cylindrically metallic support, a super-abrasive grain layer is molded in width of 20 mm or more in a rotary shaft direction of a wheel plural number of times and a seamless and integrated super- abrasive grain layer of a width of 50 mm or more is fixed in the direction. Because the super-abrasive grain layer is seamless and is integrated, excellent grinding performance in which not only a projections to be left for cutting is not generated on the surface of a workpiece but also surface roughness is increased because a feed mark is generated on the surface of the workpiece is displayed. Because the metallic support is also seamless and integrated, deviation and unbalance of the metallic support at the time of high speed revolution are not generated and a grinding work with extremely high performance and high safety is made possible.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin-bonded superabrasive wheel used for ceramics, cemented carbide, glass, metal materials and the like, and a method for producing the same.

[0002]

2. Description of the Related Art A super-abrasive grain wheel using super-abrasive grains represented by diamond and CBN includes phenol resin,
A resin-bonded superabrasive wheel using a thermosetting resin such as a polyimide resin, a polyamideimide resin, and an epoxy resin is well known. Resin-bonded superabrasive wheels consist of one of these thermosetting resins, diamond or CBN, Cu, SiC, Al ₂ O ₃ ,
A filler such as SiO ₂ , MoS ₂ , Ag, mica, graphite, and h-BN is mixed, and the mixture is filled in a mold. The mixture is molded while being heated and pressed, and the superabrasive layer is fixed to the base metal. Things.

[0003] In the case of a resin-bonded superabrasive wheel, the most commonly used metal base metal is aluminum alloy or steel, and the surface of the base metal depends on the shape, purpose, dimensions, and type of binder of the wheel. The method is divided into two types: a case where the superabrasive layer is directly fixed to the base metal and a case where a superabrasive layer holding layer called a base is first provided on the surface of the base metal and the superabrasive layer is fixed to the surface.

[0004] In any case, in the forming process, the outer diameter of the base metal is determined by the thickness (X dimension) of the superabrasive layer, and this is set in a die. The gap is only about 1 to 10 mm. To fill the gap with the mixture of the thermosetting resin, the superabrasives and the filler and uniformly cure, the change in the physicochemical properties of the resin in this process must be accurately determined. It is necessary to grasp and precisely determine molding conditions such as temperature, pressure, and time. Particularly important is the timing setting of the pressurization, which must be performed when the viscosity of the resin is in an appropriate range, and even if the viscosity is too high,
If it is too low, good molding does not proceed.

However, even when a resin having good fluidity is used, the dimension in the pressing direction (width of the superabrasive layer) is 50 m.
When molding large wheels exceeding m, the gap between the mold and the base metal is so narrow that the resin does not spread all the way to the mold and the superabrasive layer becomes uneven, bubbles, gaps and cracks occur. In some cases, molding failure occurred.

In particular, in a resin bonded superabrasive wheel for centerless grinding, the width of the superabrasive layer is at least 100.
mm, depending on the application, because there is also 150-355 mm and can not be formed at once, for the above reason, the width of the super-abrasive layer is 25 to 50 mm and a plurality of super-abrasive wheels are formed, and this is bolted, It was manufactured by bonding with an adhesive or the like. The problem here is the seam between multiple superabrasive wheels, which creates a gap corresponding to the grain size of the superabrasive grains. However, the surface roughness of the workpiece becomes coarse, which causes defective products. In particular, it cannot be applied to infeed centerless grinding and infeed total-type grinding in which only a cut is made without moving a workpiece or a superabrasive wheel in the axial direction, because the effect of seams appears remarkably.

Recently, the peripheral speed of the wheel is 60 m / s.
High-speed grinding and high-speed centerless grinding of ec or more are attracting attention, and in order to realize high-efficiency and high-quality grinding, an integrated super-abrasive wheel without a base metal and super-abrasive layer is required. I have. In the conventional manufacturing method, multiple super-abrasive wheels are fastened with bolts, adhesives, etc., so that the mutual super-abrasive wheels may be misaligned, causing wheel imbalance during high-speed rotation. there were. In addition, it was considered that even during normal use, the grinding accuracy was reduced due to minute deformation of the wheel due to the difference in the coefficient of thermal expansion of the members, and the adhesive was aged over time due to long-term use.

[0008]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems. That is, it is an object of the present invention to provide a resin-bonded super-abrasive grain wheel which is used for processing ceramics, cemented carbide, glass, metal materials and the like, and which does not change over time.

[0009]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention relates to a method in which superabrasive grains are bonded to a surface of a seamlessly integrated cylindrical metal base metal by a resin-based bonding material. A resin-bonded superabrasive wheel having a superabrasive layer formed thereon, wherein the superabrasive layer is formed a plurality of times in a width of 20 mm or more in the rotation axis direction of the wheel to be integrated with a width of 50 mm or more in the direction. Is fixed. Also,
The matrix of the resin-based binder is a phenol resin or an epoxy resin.
The present invention is also directed to in-feed centerless grinding or in-feed full-type grinding at a wheel peripheral speed of 60 m / sec or more, and has an outer diameter of Φ150 mm or more. A method for manufacturing a resin-bonded superabrasive wheel, characterized in that a superabrasive layer is formed a plurality of times while laminating a superabrasive layer to form a seamless superabrasive layer.

Hereinafter, the present invention will be described in detail. The greatest features of the present invention are ceramics, cemented carbide, glass,
Resin-bonded super-abrasive wheels used for surface grinding, cylindrical grinding, and centerless grinding of metal materials, etc., and a super-abrasive layer is formed on the surface of a seamless and seamless cylindrical metal base metal. 20mm in the rotation axis direction of the wheel
That is, it is molded a plurality of times with the above-mentioned width, and a seamless, integrated superabrasive layer having a width of 50 mm or more is fixed in that direction. Because the super-abrasive layer is seamless and integrated, not only is there no projection left on the workpiece surface, but there is no feed mark on the surface of the workpiece and the surface roughness is not rough. It demonstrates grinding performance. Furthermore, since the base metal is also seamless and integral, it is possible to perform extremely high-performance and highly safe grinding work without causing any deviation or unbalance of the base metal during high-speed rotation. Also, there is no danger of minute deformation or aging of the wheel due to thermal expansion.

A thermosetting resin such as a phenolic resin, a polyimide resin, a polyamideimide resin, and an epoxy resin can be used as the matrix of the resinous binder. In order to form a superabrasive layer, a phenol resin or epoxy resin that has good fluidity during heating and spreads to every corner of the mold is preferred.In consideration of the heat resistance of the binder and the holding power of the superabrasive, phenol resin is used. Most preferred. As the mixing ratio of the superabrasive grains and the total of the fillers increases, the fluidity of the resin is hindered, which may cause molding failure.

The grinding method to be used has a wheel peripheral speed of 6
It can be used for all types of machining such as surface grinding at 0 m / sec or more, cylindrical grinding, etc., but it does not move the workpiece or wheel in the axial direction, and provides only infeed. In the processing, good surface roughness of the workpiece can be obtained without generation of protrusions and streaks left behind, which is extremely effective.

In order to form the superabrasive layer, the superabrasive layer is formed a plurality of times to form an integrated superabrasive layer without any seams. It is not only necessary to take measures to prevent unevenness, but it is also important to perform the pressing operation in the molding process in a timely manner when the viscosity of the resin is in an appropriate range. That is, it is extremely important to accurately determine the curability (reactivity) of the thermosetting resin according to the type of the thermosetting resin and determine the molding conditions. Further, when the boundary surface at the time of lamination is formed so as to form an angle of 0.1 to 45 degrees with respect to the circumferential direction of the wheel, better surface roughness is obtained. What is necessary is just to manufacture in the range of 5 degrees-10 degrees.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION
This will be described in detail in the following Examples.

[0015]

(Example 1) A diamond abrasive # 230/270 was dry-mixed with a binder containing a phenol resin as a matrix so that the concentration of diamond was 100, the mixed powder was filled in a mold, and the mixture was filled into a 30 mm-sized mold. Molding three times in width,
A super-abrasive layer is fixed to the surface of an aluminum alloy base metal, and the outer diameter is Φ300 mm and the super-abrasive layer has a width of 90 mm according to JIS standard B.
A 4A type 1A1 resin bonded diamond wheel was manufactured. When the wheel of Example 1 was mounted on a centerless grinding machine and the round bar of cemented carbide was ground, the sharpness was good and a higher surface roughness than that of a conventional wheel having a seam was obtained.

(Example 2) Diamond abrasive grains # 270/325 were used as a binder containing a phenol resin as a matrix and SiC particles of 10 μm as a filler.
The mixture was dry-mixed until it became 5, and the mixed powder was filled in a mold, molded 5 times with a width of 40 mm, and the superabrasive layer was fixed on the surface of the aluminum alloy base metal. Outer diameter Φ
JIS standard B4 with 450mm, super-abrasive layer width 200mm
A 1A1 type resin-bonded diamond wheel of No. 131 was manufactured. However, the boundary surface at the time of laminating the mixed powder was formed at an angle of 1 degree with respect to the circumferential direction of the wheel. When the wheel of Example 2 was mounted on a centerless grinder and the ceramic round bar was subjected to in-feed grinding, good sharpness and good surface roughness were obtained.

Example 3 CBN was used as a binder containing a phenol resin as a matrix and Cu particles of 20 μm as a filler.
Abrasive grains # 170/200 were dry-mixed to a CBN concentration of 100 until uniform, and the mixed powder was filled in a mold and molded twice with a width of 25 mm to form an aluminum alloy base metal. Super abrasive layer is fixed on the surface, outer diameter Φ150mm,
1 according to JIS B4131 with a superabrasive grain layer width of 50 mm
An A1-type resin-bonded CBN wheel was manufactured, and truing and dressing was performed using a diamond rotary dresser to obtain a complete CBN wheel. When the wheel of Example 3 was mounted on a grinder and a steel round bar was subjected to in-feed total-shape grinding, the sharpness was good, and a uniform and extremely good surface roughness was obtained.

[0018]

According to the present invention, since the superabrasive layers are seamlessly integrated, no uncut projections or feed marks are formed on the workpiece surface. In addition, since the base metal is also seamless and integral, no unbalance occurs during high-speed rotation, and extremely high-precision and highly safe grinding work can be performed over a long period of time.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an embodiment of the present invention.

FIG. 2 is a partial sectional view of FIG.

FIG. 3 is a perspective view of a conventional product in which three wheels are joined by bolts.

FIG. 4 is a partial sectional view of FIG. 3;

[Explanation of symbols]

 1 integrated superabrasive layer 2 integrated base metal 3 superabrasive layer 4 base metal 5 volts

Claims (4)

[Claims] 1. A resin bonded superabrasive wheel having a superabrasive layer in which superabrasive grains are bonded by a resin-based bonding material on a surface of a seamlessly integrated cylindrical metal base metal, A resin-bonded superabrasive wheel, wherein the abrasive layer is integrally formed with a width of at least 50 mm in the direction by forming the abrasive layer in a width of at least 20 mm in the direction of the rotation axis of the wheel. 2. The resin-bonded superabrasive wheel according to claim 1, wherein the matrix of the resin-based binder is a phenol resin or an epoxy resin. 3. The resin according to claim 1, wherein the outer diameter is not less than 150 mm for in-feed centerless grinding or in-feed total-type grinding at a wheel peripheral speed of 60 m / sec or more. Bond super abrasive wheel. 4. A method for manufacturing a resin-bonded superabrasive wheel, comprising forming a superabrasive layer with a width of 20 mm or more a plurality of times to form a seamless superabrasive layer.