Outer blade cutting wheel and making method

Patent metadata

Field	Value
Publication number	US-11364591-B2
Application number	US-201414227491-A
Country	US
Kind code	B2
Filing date	Mar 27, 2014
Priority date	Dec 28, 2007
Publication date	Jun 21, 2022
Grant date	Jun 21, 2022

Abstract

In an outer blade cutting wheel comprising an annular thin disc base of cemented carbide having an outer diameter of 80-200 mm, an inner diameter of 30-80 mm, and a thickness of 0.1-1.0 mm, and a blade section disposed on an outer periphery of the base, the blade section comprises diamond grains and/or CBN grains bound with a metal bond having a Young's modulus of 0.7-4.0×1011 Pa and has a thickness which is greater than the thickness of the base by at least 0.01 mm. The outer blade cutting wheel is capable of cutting a workpiece at a high accuracy and a reduced allowance, improves machining yields, and reduces machining costs.

First claim

The invention claimed is:

1. A method for preparing an outer blade cutting wheel comprising providing a base in the form of an annular thin disc of cemented carbide having an outer diameter of 80 to 200 mm defining an outer periphery, an inner diameter of 30 to 80 mm, and a thickness of 0.1 to 1.0 mm,
forming an undercoat consisting of a metal bond on an outer periphery of the base in such a manner that the outer periphery of the base is sandwiched between portions of the undercoat in a thickness direction of the base, the undercoat being formed by electroplating, and
after forming the undercoat, brazing abrasive grains with the metal bond onto the undercoat to form a layer in which the abrasive grains are bound with the metal bond,
so as to form a blade section,
wherein:
the blade section has a pair of clamp portions and a body,
each of the pair of clamp portions comprises an overlying layer consisting of the abrasive grains and the metal bond on one of the portions of the undercoat sandwiching the outer periphery of the base in the thickness direction of the base,
the body extends radially outward beyond the outer periphery of the base, the body consisting of the abrasive grains and the metal bond,
the abrasive grains comprise diamond grains, CBN grains or a mixture of diamond grains and CBN grains, the metal bond having a Young's modulus of 0.7×10 11 to 4.0×10 11 Pa,
the blade section has a thickness which is greater than the thickness of said base by at least 0.01 mm,
the metal bond binds the abrasive grains to the outer periphery of the base and comprises:
an alloy consisting of Ni and Co;
an alloy consisting of Ni and Co, and at least one element selected from the group consisting of Zn, S and Fe;
an alloy consisting of Ni and phosphorus; or
an alloy consisting of Ni, phosphorus, and at least one element selected from the group consisting of Zn, S and Fe.

2. The method of claim 1 wherein said metal bond has a Vickers hardness of 100 to 550 and a density of 2.5 to 12 g/cm 3 .

3. The method of claim 1 wherein the abrasive grains are clad with a magnetic material formed by plating or sputtering, or a ductile metal.

4. The method of claim 1 wherein said metal bond comprises an alloy consisting of Ni and phosphorus.

5. The method of claim 1 wherein prior to said brazing, the abrasive grains are at least one of the group consisting of: clad by electroless copper plating and clad by electroless nickel plating.

6. A method for preparing an outer blade cutting wheel comprising providing a base in the form of an annular thin disc of cemented carbide having an outer diameter of 80 to 200 mm defining an outer periphery, an inner diameter of 30 to 80 mm, and a thickness of 0.1 to 1.0 mm,
forming an undercoat consisting of a metal bond on an outer periphery of the base in such a manner that the outer periphery of the base is sandwiched between portions of the undercoat in a thickness direction of the base, the undercoat being formed by electroplating, and
after forming the undercoat, brazing abrasive grains with the metal bond onto the undercoat to form a layer in which the abrasive grains are bound with the metal bond,
so as to form a blade section,
wherein:
the blade section has a pair of clamp portions and a body,
each of the pair of clamp portions comprises an overlying layer consisting of the abrasive grains and the metal bond on one of the portions of the undercoat sandwiching the outer periphery of the base in the thickness direction of the base,
the body extends radially outward beyond the outer periphery of the base, the body consisting of the abrasive grains and the metal bond,
the abrasive grains comprise diamond grains, CBN grains or a mixture of diamond grains and CBN grains, the metal bond having a Young's modulus of 0.7×10 11 to 4.0×10 11 Pa,
the blade section has a thickness which is greater than the thickness of said base by at least 0.01 mm,
the metal bond binds the abrasive grains to the outer periphery of the base and comprises:
an alloy consisting of Ni, at least one metal selected from the group consisting of Fe, Cu and Sn, and;
an alloy consisting of Ni, at least one metal selected from the group consisting of Fe, Cu and Sn, and Zn and S;
an alloy consisting of Ni—Mn, and S; or
an alloy consisting of Ni—Mn, at least one metal selected from the group consisting of Zn and Fe, and S.

7. The method of claim 6 wherein said metal bond has a Vickers hardness of 100 to 550 and a density of 2.5 to 12 g/cm 3 .

8. The method of claim 6 wherein the abrasive grains are clad with a magnetic material formed by plating or sputtering, or a ductile metal.

9. The method of claim 6 wherein prior to said brazing, the abrasive grains are at least one of the group consisting of: clad by electroless copper plating and clad by electroless nickel plating.

10. A method for preparing an outer blade cutting wheel comprising providing a base in the form of an annular thin disc of cemented carbide having an outer diameter of 80 to 200 mm defining an outer periphery, an inner diameter of 30 to 80 mm, and a thickness of 0.1 to 1.0 mm,
forming an undercoat consisting of a metal bond on an outer periphery of the base in such a manner that the outer periphery of the base is sandwiched between portions of the undercoat in a thickness direction of the base, the undercoat being formed by electroplating, and
after forming the undercoat, brazing abrasive grains with the metal bond onto the undercoat to form a layer in which the abrasive grains are bound with the metal bond,
so as to form a blade section,
wherein:
the blade section has a pair of clamp portions and a body,
each of the pair of clamp portions comprises an overlying layer consisting of the abrasive grains and the metal bond on one of the portions of the undercoat sandwiching the outer periphery of the base in the thickness direction of the base,
the body extends radially outward beyond the outer periphery of the base, the body consisting of the abrasive grains and the metal bond,
the undercoat is at least as thick as the overlying layer,
the abrasive grains comprise diamond grains, CBN grains or a mixture of diamond grains and CBN grains, the metal bond having a Young's modulus of 0.7×10 11 to 4.0×10 11 Pa,
the blade section has a thickness which is greater than the thickness of said base by at least 0.01 mm,
the metal bond binds the abrasive grains to the outer periphery of the base and comprises:
an alloy consisting of Ni and Co;
an alloy consisting of Ni and Co, and at least one element selected from the group consisting of Zn, S and Fe;
an alloy consisting of Ni and phosphorus; or
an alloy consisting of Ni, phosphorus, and at least one element selected from the group consisting of Zn, S and Fe.

Assignees

• Shinetsu Chemical Co

Inventors

• Kasashima Masaki
• Minowa Takehisa
• Yamaguchi Takaharu
• Sato Koji

Classifications

• B24D3/06 Primary

  metallic {or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements} · CPC title

• B24D5/12 Primary

  Cut-off wheels · CPC title

• B24D3/00

  Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents · CPC title

• B24D18/0018

  by electrolytic deposition · CPC title

• B28D5/022

  by cutting with discs or wheels · CPC title