TWI556913B - Ultra-hard alloy platen outer cutting edge and its manufacturing method - Google Patents

Ultra-hard alloy platen outer cutting edge and its manufacturing method Download PDF

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TWI556913B
TWI556913B TW100143755A TW100143755A TWI556913B TW I556913 B TWI556913 B TW I556913B TW 100143755 A TW100143755 A TW 100143755A TW 100143755 A TW100143755 A TW 100143755A TW I556913 B TWI556913 B TW I556913B
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platen
abrasive grains
outer peripheral
cutting blade
cutting edge
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TW100143755A
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Chinese (zh)
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TW201238715A (en
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Masaki Kasashima
Takehisa Minowa
Harukazu Maegawa
Yoshifumi Nagasaki
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Shinetsu Chemical Co
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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

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Description

超硬合金台板外周切斷刃及其製造方法 Superhard alloy platen peripheral cutting blade and manufacturing method thereof

本發明是關於適合用於稀土類燒結磁鐵的切斷之超硬合金台板外周切斷刃及其製造方法。 The present invention relates to a superhard alloy platen outer peripheral cutting blade suitable for use in cutting a rare earth sintered magnet and a method of manufacturing the same.

在稀土類永久磁鐵(燒結磁鐵)的切斷加工，實施了內周切斷或鏈式切割等的各種方法。其中利用外周刃所進行的切斷加工是最廣泛使用的切斷方法。該方法的特徵為，切斷機的價格便宜；使用超硬刃的話切割量沒有比該方式更大的；被加工物的尺寸精度好；加工速度也比較快等等；作為量產性優異的加工方法，廣泛利用於稀土類燒結磁鐵的切斷。 Various methods such as inner circumference cutting or chain cutting are performed on the cutting process of the rare earth permanent magnet (sintered magnet). Among them, the cutting process by the peripheral blade is the most widely used cutting method. The method is characterized in that the price of the cutting machine is cheap; if the super hard edge is used, the cutting amount is not larger than the method; the dimensional accuracy of the workpiece is good; the processing speed is also fast; etc.; and the mass production is excellent. The processing method is widely used for cutting of rare earth sintered magnets.

作為用於稀土類永久磁鐵的切斷之外周刃，在日本特開平9-174441號公報、日本特開平10-175171號公報、日本特開平10-175172號公報等，揭示有：在超硬合金台板的外周部，以苯酚樹脂、鍍Ni等來固定鑽石磨粒或cBN磨粒等的技術。藉由在台板使用超硬合金，與習知的合金工具鋼或高速度鋼相比，讓台板的機械強度提升，結果可讓加工切斷精度提升、利用以使用薄刃的切割量減少讓被加工物的良率提升、利用高速加工而減少加工成本。 In the case of the super-hard alloy, it is disclosed in JP-A-H09-175441, JP-A-10-175171, JP-A-10-175172, and the like. The outer peripheral portion of the platen is a technique in which diamond abrasive grains or cBN abrasive grains are fixed by phenol resin or Ni plating. By using a super-hard alloy on the platen, the mechanical strength of the platen is improved compared with the conventional alloy tool steel or high-speed steel, and as a result, the cutting precision is improved, and the cutting amount using the thin blade is reduced. The yield of the workpiece is improved, and high-speed machining is used to reduce the processing cost.

以該方式使用超硬合金台板的外周刃，雖然顯示了較習知的外周刃更優異的切斷及加工性能，可是來自市場方面的減少成本的需求沒有止境，希望開發出能達到更高精 度且更高速的加工的高性能切斷磨石。 The use of the outer peripheral edge of the super-hard alloy platen in this manner, although showing superior cutting and processing performance than the conventional peripheral blade, there is no end to the demand for cost reduction from the market, and it is hoped that development can be achieved higher. fine High-performance cutting stone with a higher speed and higher speed.

〔先前技術文獻〕 [Previous Technical Literature] 〔專利文獻〕 [Patent Document]

〔專利文獻1〕日本特開平9-174441號公報 [Patent Document 1] Japanese Patent Laid-Open No. Hei 9-174441

〔專利文獻2〕日本特開平10-175171號公報 [Patent Document 2] Japanese Patent Laid-Open No. Hei 10-175171

〔專利文獻3〕日本特開平10-175172號公報 [Patent Document 3] Japanese Patent Laid-Open No. Hei 10-175172

〔專利文獻4〕日本特開2005-193358號公報 [Patent Document 4] Japanese Patent Laid-Open Publication No. 2005-193358

〔專利文獻5〕日本特開平7-207254號公報 [Patent Document 5] Japanese Patent Laid-Open No. Hei 7-207254

〔專利文獻6〕日本特許第2942989號公報 [Patent Document 6] Japanese Patent No. 2942989

〔專利文獻7〕日本特開2005-219169號公報 [Patent Document 7] Japanese Patent Laid-Open Publication No. 2005-219169

〔專利文獻8〕國際公開96/23630號刊物 [Patent Document 8] International Publication No. 96/23630

〔專利文獻9〕日本特開2009-172751號公報 [Patent Document 9] Japanese Patent Laid-Open Publication No. 2009-172751

本申請人曾提出：在環狀的超硬合金台板的外周部以苯酚樹脂等的樹脂來固定鑽石磨粒的技術、或在超硬合金台板的外周部，以具有適當楊氏模量的金屬結合材，來固定鑽石磨粒或cBN磨粒等的技術(日本特開2009-172751號公報)。 The applicant has proposed a technique of fixing diamond abrasive grains with a resin such as phenol resin in the outer peripheral portion of a ring-shaped superhard alloy platen, or an outer peripheral portion of a superhard alloy platen to have an appropriate Young's modulus. A metal bonding material for fixing diamond abrasive grains or cBN abrasive grains or the like (JP-A-2009-172751).

用於切斷稀土類燒結磁鐵的外周切斷刃，是由切割刃部與台板的兩個部分所構成。藉由將佔了該外周切斷刃的大半部分的台板，替換成高剛性的超硬合金，讓機械強度 提升，與之前將合金工具鋼或高速度鋼作為台板的外周切斷刃相比，更提升了切斷加工的精度。除了該超硬合金台板之外，藉由將結合材替換成具有適當楊氏模量的金屬，使外周切斷刃全體的機械強度提升，與之前將苯酚樹脂或聚醯亞胺樹脂作為磨粒結合材的樹脂結合劑的外周切斷刃相比，更提升加工精度，且薄刃化導致材料良率提升，切斷速度的高速化導致加工成本的減低，可達到這樣三種高性能化。 The outer peripheral cutting blade for cutting the rare earth sintered magnet is composed of two portions of the cutting edge portion and the platen. Mechanical strength is achieved by replacing the platen that accounts for the majority of the peripheral cutting edge with a highly rigid superhard alloy The lifting is more accurate than the peripheral cutting edge of the alloy tool steel or high-speed steel as the platen. In addition to the super-hard alloy platen, by replacing the bonding material with a metal having an appropriate Young's modulus, the mechanical strength of the entire peripheral cutting blade is improved, and the phenol resin or the polyimide resin is previously used as a grinding machine. Compared with the outer peripheral cutting blade of the resin binder of the granular binder, the processing precision is improved, and the thinning of the blade leads to an increase in the material yield, and the speed of the cutting speed is reduced, so that the processing cost can be reduced, and the three types of high performance can be achieved.

並且關於超硬合金外周切斷刃的製造，是在台板的外周緣部附近形成磁場，該磁場，作用於預先以磁性體塗層的磨粒皮膜而使皮膜磁化，藉此使磨粒吸引於台板外周部，藉由在該狀態進行電鍍來固定磨粒之外周切斷刃的製造方法，藉此則可減少超硬合金外周切斷刃的製造成本。 Further, in the production of the outer peripheral cutting blade of the super-hard alloy, a magnetic field is formed in the vicinity of the outer peripheral edge portion of the platen, and the magnetic field acts on the abrasive coating film previously coated with the magnetic material to magnetize the coating film, thereby attracting the abrasive grains. By manufacturing plating in this state on the outer peripheral portion of the platen, the method of manufacturing the outer peripheral cutting edge of the abrasive grain is fixed, whereby the manufacturing cost of the outer peripheral cutting blade of the cemented carbide can be reduced.

藉由上述技術所提供的超硬合金台板外周切斷刃，雖然是顯示高性能的外周切斷刃，而在稀土類燒結磁鐵的切斷加工，會有因為傾斜地切斷磁鐵或在磁鐵的切斷面留下外周切斷刃的切割痕跡等而讓尺寸精度惡化的情況。具體來說，使用：外徑80~200mm、厚度0.1~1.0mm、內孔的直徑30~80mm的超硬合金台板外周切斷刃，進行每單位時間的切削體積為200mm3/min以上的高速、高負荷切斷加工時，會有尺寸公差在50μm以上的情況。在尺寸精度惡化的情況，則需要增加在磁鐵將切斷面精密研磨的拋光加工等的步驟，而需要在外周切斷刃實施使用磨石的修整處理或變更切斷條件。 The outer peripheral cutting blade of the super-hard alloy platen provided by the above technique exhibits a high-performance outer peripheral cutting blade, and the cutting process of the rare earth sintered magnet may cause the magnet to be obliquely cut or the magnet. The cut surface leaves a cutting mark or the like of the outer peripheral cutting edge to deteriorate the dimensional accuracy. Specifically, the outer peripheral cutting edge of the super-hard alloy platen having an outer diameter of 80 to 200 mm, a thickness of 0.1 to 1.0 mm, and a diameter of 30 to 80 mm of the inner hole is used, and the cutting volume per unit time is 200 mm 3 /min or more. When the high-speed, high-load cutting process is performed, the dimensional tolerance is 50 μm or more. In the case where the dimensional accuracy is deteriorated, it is necessary to increase the number of steps such as polishing processing in which the magnet is precisely polished on the cut surface, and it is necessary to perform the trimming treatment using the grindstone or the cutting condition on the outer peripheral cutting edge.

這種情形，例如對於軛部或磁鐵的餘隙要求嚴密管理的線性馬達或硬碟VCM(音頻線圈馬達)等，在所加工的磁鐵需要同時達到：包含切斷面的平面度的高尺寸精度與減低生產成本的情況，會成為妨礙。 In this case, for example, a linear motor or a hard disk VCM (audio coil motor) that requires strict management of the yoke or magnet clearance is required, and the processed magnet needs to simultaneously achieve high dimensional accuracy including the flatness of the cut surface. And the situation of reducing production costs will become an obstacle.

本發明鑑於上述情形，其目的為提供超硬合金台板外周切斷刃，能加工：具有高尺寸精度的稀土類燒結磁鐵，並且提供能以低成本來製造超硬合金台板外周切斷刃的方法。 The present invention has been made in view of the above circumstances, and an object thereof is to provide a peripheral hard cutting blade for a super-hard alloy platen, capable of processing: a rare earth sintered magnet having high dimensional accuracy, and providing a peripheral hard cutting blade capable of manufacturing a super-hard alloy platen at a low cost. Methods.

將稀土類燒結磁鐵傾斜切斷的現象，認為是因為外周切斷刃的刀鋒形狀沒有左右對稱，刃部朝容易切削的方向切進、或當將外周切斷刃安裝於加工機時刃部裝反所導致。而在磁鐵留下切割痕跡的現象，是藉由上述原因而傾斜切斷磁鐵的外周切斷刃，因為在切斷途中急遽改變行進方向，之前的切斷面與新產生的切斷面的接合處不順暢地連接，藉由成為落差而產生的情形。 The phenomenon that the rare earth sintered magnet is obliquely cut is considered to be because the blade shape of the outer peripheral cutting blade is not bilaterally symmetrical, the blade portion is cut in the direction in which the cutting is easy to be cut, or the blade portion is attached when the peripheral cutting blade is attached to the processing machine. Caused by the opposite. In the case where the magnet leaves a cutting mark, the outer peripheral cutting blade of the magnet is obliquely cut by the above-described reason, because the traveling direction is suddenly changed during the cutting, and the previous cut surface is joined to the newly formed cut surface. The situation is not smooth, but it is caused by the difference.

在切斷中外周切斷刃的行進方向急遽改變的情形，例如刀鋒的局部因為任何原因產生變形或脫落的情況，切割刃部的前端形狀急遽改變的情況，為了讓外周切斷刃的進給速度較在切割刃部的研磨速度更快，外周切斷刃的刀鋒變形，因為該變形而在外周切斷刃產生的內力，變得較外周切斷刃從被加工物受到的力(外力)更大，在對刀鋒施加變形的力解除的情況，在切斷中產生的漿液或來自系統 外的異物堵塞於切割槽，藉此妨礙外周切斷刃的行進的情況等所產生。於是，為了消除在這種狀況產生的切割痕跡，讓切割刃部的前端形狀不劇烈改變，且即使在切斷中有讓刀鋒的行進方向改變的力量施加的情況，也讓切割刃部某程度變形而讓切斷面滑順地連接的方式很有效。 In the case where the traveling direction of the cutting edge of the cutting edge is sharply changed, for example, the part of the blade edge is deformed or peeled off for any reason, and the shape of the tip end of the cutting blade portion is changed abruptly, in order to allow the cutting edge of the cutting edge to be fed. The speed is faster than the polishing speed at the cutting edge portion, and the blade edge of the outer peripheral cutting blade is deformed, and the internal force generated by the outer peripheral cutting blade becomes smaller than the force (external force) received by the outer peripheral cutting blade from the workpiece. Larger, in the case of a force that applies deformation to the blade, the slurry produced during the cutting or from the system The foreign matter is clogged in the cutting groove, thereby preventing the traveling of the outer peripheral cutting blade or the like. Therefore, in order to eliminate the cutting marks generated in such a situation, the shape of the tip end of the cutting edge portion is not changed drastically, and even if the force for changing the traveling direction of the blade edge is applied during the cutting, the cutting blade portion is allowed to some extent. The way in which the deformed surface allows the cut surfaces to be smoothly connected is effective.

在藉由電鍍或無電解電鍍將磨粒固定於台板而形成切割刃部的外周切斷刃，是使用有某程度的粒徑的粒子作為磨粒，所以所固定的磨粒，在磨粒與磨粒之間，以及在磨粒與台板之間，只有一部分接觸，以電鍍並未將其之間的間隙完全埋住。因此，在切割刃部，即使在電鍍後，也存在有間隙，也就是與切割刃部表面連通的空隙。 In the outer peripheral cutting blade in which the abrasive grains are fixed to the platen by electroplating or electroless plating to form the cutting edge portion, particles having a certain particle diameter are used as the abrasive grains, so that the abrasive grains are fixed in the abrasive grains. Between the abrasive particles and between the abrasive particles and the platen, only a portion of the contact is made for electroplating without completely burying the gap between them. Therefore, in the cutting edge portion, even after plating, there is a gap, that is, a gap communicating with the surface of the cutting edge portion.

對切斷中的外周切斷刃的負荷較少的情況，即使有這些間隙，藉由切削中所受到的力也不會產生很大的變形，仍能進行高精度的切斷，可是在進行讓超硬合金台板變形的高負荷切斷的狀況，就可能讓局部刀鋒變形或脫落。為了防止刀鋒的變形或脫落，提高刀鋒強度的方法很有效，而在切割刃部，如後述，能變形將切斷面滑順地連接的彈性也是必要的，不易變形而只是高強度則無法因應。 In the case where the load on the outer peripheral cutting blade during cutting is small, even if these gaps are present, the force received during the cutting does not cause a large deformation, and high-precision cutting can be performed, but the cutting is performed. The high load cut of the superhard alloy platen may cause the local blade to deform or fall off. In order to prevent the blade from being deformed or peeled off, the method of increasing the blade strength is effective, and in the cutting blade portion, as will be described later, it is necessary to deform the elasticity of the cut surface smoothly, and it is not easy to be deformed but only high strength cannot be adapted. .

因此，本發明者們，為了達成上述目的而仔細研究，針對同時達到高強度與彈性的切割刃部的構造、與切割刃部的機械性質加以研究，發現利用在上述磨粒與磨粒之間、磨粒與台板之間存在的間隙，在該間隙使熱可塑性樹脂熔融含浸而凝固，或含浸液體狀的熱硬化性樹脂組成物使其硬化的切割刃部很有效，形成有這種切割刃部的超硬合 金台板外周切斷刃，對於切斷加工的磁鐵的尺寸精度的提升很有效，而熱可塑性樹脂的熔融與含浸與凝固、或液體狀的熱硬化性樹脂組成物的含浸與硬化這樣的方法，對於外周切斷刃的高精度且廉價製造很有效，而達成本發明。 Therefore, the inventors of the present invention have studied in detail to achieve the above object, and have studied the structure of the cutting edge portion which simultaneously achieves high strength and elasticity, and the mechanical properties of the cutting edge portion, and found that it is utilized between the above abrasive grains and abrasive grains. a gap existing between the abrasive grains and the platen, in which the thermoplastic resin is melt-impregnated and solidified, or a liquid-curable thermosetting resin composition is used to harden the cutting edge portion, and the cutting is formed. Super hard joint of the blade The outer peripheral cutting blade of the gold platen is effective for improving the dimensional accuracy of the cut magnet, and the method of melting and impregnating and solidifying the thermoplastic resin or impregnating and hardening the liquid thermosetting resin composition. The present invention has been achieved in that high precision and low cost manufacturing of the peripheral cutting blade is effective.

本發明，第一要提供一種超硬合金台板外周切斷刃，在以楊氏模量450~700GPa的超硬合金形成，外徑80~200mm，內徑30~80mm，厚度0.1~1.0mm的圓形環狀薄板的台板的外周緣部上，具有切割刃部； 上述切割刃部，包含有：預先塗層磁性體而成的鑽石磨粒及/或cBN磨粒、將上述磨粒間及上述磨粒與台板之間連結的藉由電鍍或無電解電鍍所形成的金屬或合金、含浸於上述磨粒間及上述磨粒與台板之間的熔點為350℃以下的熱可塑性樹脂、或使含浸於上述磨粒間及上述磨粒與台板之間的硬化溫度為350℃以下的液體狀的熱硬化性樹脂組成物硬化的熱硬化性樹脂。 According to the present invention, a first outer peripheral cutting blade of a superhard alloy platen is provided, which is formed of a superhard alloy having a Young's modulus of 450 to 700 GPa, 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 circular annular sheet of the platen having a cutting edge portion on an outer peripheral edge portion thereof; The cutting edge portion includes diamond abrasive grains and/or cBN abrasive grains which are previously coated with a magnetic material, and electroplating or electroless plating is performed between the abrasive grains and the abrasive grains and the platen. a formed metal or alloy, a thermoplastic resin impregnated between the abrasive grains and between the abrasive grains and the platen having a melting point of 350 ° C or lower, or impregnated between the abrasive grains and between the abrasive grains and the platen A thermosetting resin in which a liquid thermosetting resin composition having a curing temperature of 350 ° C or less is cured.

作為所提供的上述外周切斷刃的較佳型態，提供上述含浸的樹脂為由：丙烯酸樹脂、環氧樹脂、苯酚樹脂、聚醯胺樹脂、聚醯亞胺樹脂、及這些樹脂的變性樹脂中所選出的一種以上，以及提供上述含浸的樹脂的帕松比(Poisson ratio)為0.3~0.48。 As a preferred form of the above-mentioned outer peripheral cutting blade, the impregnated resin is provided by an acrylic resin, an epoxy resin, a phenol resin, a polyamide resin, a polyimide resin, and a denatured resin of these resins. One or more selected ones, and a Poisson ratio providing the above impregnated resin is 0.3 to 0.48.

作為所提供的上述外周切斷刃的較佳型態，上述台板的飽和磁化量為40kA/m(0.05T)以上。 As a preferred form of the outer peripheral cutting blade provided, the platen has a saturation magnetization of 40 kA/m (0.05 T) or more.

作為所提供的上述外周切斷刃的較佳型態，上述磨粒的平均粒徑為10~300μm，且上述磨粒的質量磁化率χ g 為0.2以上。 In a preferred embodiment of the outer peripheral cutting blade provided, the abrasive grains have an average particle diameter of 10 to 300 μm , and the abrasive grains have a mass magnetic susceptibility χ g of 0.2 or more.

本發明，第二要提供一種超硬合金台板外周切斷刃的製造方法，接近於：以楊氏模量450~700GPa的超硬合金形成，外徑80~200mm，內徑30~80mm，厚度0.1~1.0mm的圓形環狀薄板的台板的外周緣部，來配設永久磁鐵， 藉由該永久磁鐵形成的磁場，將預先塗層有磁性體而成的鑽石磨粒及/或cBN磨粒，磁性吸引固定於上述台板的外周緣部附近， 在保持該吸引固定的狀態，藉由電鍍或無電解電鍍，將上述磨粒間及上述磨粒與台板之間連結，使磨粒固定於上述台板外周端部，而形成切割刃部， 對上述磨粒間及上述磨粒與台板之間存在的空隙，含浸熔點為350℃以下的熱可塑性樹脂、或含浸硬化溫度為350℃以下的液體狀的熱硬化性樹脂組成物而使其硬化。 According to the present invention, a second method for manufacturing a peripheral hard cutting blade of a superhard alloy platen is provided, which is similar to: a superhard alloy having a Young's modulus of 450 to 700 GPa, an outer diameter of 80 to 200 mm, and an inner diameter of 30 to 80 mm. A permanent magnet is disposed on the outer peripheral edge of the platen of a circular annular sheet having a thickness of 0.1 to 1.0 mm. The diamond abrasive grains and/or cBN abrasive grains which are previously coated with a magnetic material are magnetically attracted and fixed to the vicinity of the outer peripheral edge portion of the platen by the magnetic field formed by the permanent magnet. While maintaining the suction and fixation state, the abrasive grains and the abrasive grains are connected to the platen by electroplating or electroless plating, and the abrasive grains are fixed to the outer peripheral end portion of the platen to form a cutting edge portion. A gap between the abrasive grains and the gap between the abrasive grains and the platen is impregnated with a thermoplastic resin having a melting point of 350 ° C or lower, or a liquid thermosetting resin composition having a immersion hardening temperature of 350 ° C or lower. hardening.

作為所提供的上述製造方法的較佳型態，提供上述含浸的樹脂為由：丙烯酸樹脂、環氧樹脂、苯酚樹脂、聚醯胺樹脂、聚醯亞胺樹脂、及這些樹脂的變性樹脂中所選出的一種以上，以及提供上述含浸的樹脂的帕松比(Poisson ratio)為0.3~0.48。 As a preferred form of the above-described production method, the impregnated resin is provided by an acrylic resin, an epoxy resin, a phenol resin, a polyamide resin, a polyimide resin, and a denatured resin of these resins. One or more selected ones, and a Poisson ratio providing the above impregnated resin is 0.3 to 0.48.

作為所提供的上述製造方法的較佳型態，上述台板的飽和磁化量為40kA/m(0.05T)以上。 As a preferred mode of the above-described production method, the platen has a saturation magnetization of 40 kA/m (0.05 T) or more.

作為所提供的上述製造方法的較佳型態，上述磨粒的平均粒徑為10~300μm，且上述磨粒的質量磁化率χ g為 0.2以上。 In a preferred embodiment of the above-described production method, the abrasive grains have an average particle diameter of 10 to 300 μm , and the mass susceptibility χ g of the abrasive grains is 0.2 or more.

作為所提供的上述製造方法的較佳型態，藉由上述永久磁鐵，在從台板的外周端起算10mm以內的空間，形成8kA/m以上的磁場。 In a preferred embodiment of the above-described manufacturing method, a magnetic field of 8 kA/m or more is formed by a space of 10 mm or less from the outer peripheral end of the platen by the permanent magnet.

藉由採用本發明的超硬合金台板外周切斷刃，僅以切斷操作將被加工物的尺寸高精度地完成，能省略切斷後的後處理步驟，所以能廉價地提供具有高尺寸精度的稀土類磁鐵。 By using the outer peripheral cutting blade of the cemented carbide platen of the present invention, the size of the workpiece can be accurately completed only by the cutting operation, and the post-processing step after the cutting can be omitted, so that high dimensional accuracy can be provided at low cost. Rare earth magnets.

本發明的製造方法，能具有優異的成本績效(cost performance)來製造該超硬合金台板外周切斷刃。 The manufacturing method of the present invention can produce the superhard alloy platen peripheral cutting edge with excellent cost performance.

本發明的外周切斷刃，例如，如第1圖所示，在圓形薄板的台板10的外周緣部上，形成有切割刃部20，該切割刃部20，以藉由電鍍或無電解電鍍所形成的金屬或合金(金屬結合材)結合著鑽石磨粒及/或cBN磨粒。 In the outer peripheral cutting blade of the present invention, for example, as shown in Fig. 1, a cutting edge portion 20 is formed on the outer peripheral edge portion of the platen 10 of the circular thin plate, and the cutting blade portion 20 is plated or not. The metal or alloy (metal bond) formed by electrolytic plating incorporates diamond abrasive grains and/or cBN abrasive grains.

上述台板10是圓形薄板(在中央部形成有內孔12的環狀的薄板)，其所具有的尺寸為：厚度為0.1~1.0mm，較佳為0.2~0.8mm，外徑為80~200mm，較佳為100~180mm，內孔的直徑(內徑)為30~80mm，較佳為40~70mm。 The platen 10 is a circular thin plate (annular thin plate having an inner hole 12 formed at a central portion thereof) having a thickness of 0.1 to 1.0 mm, preferably 0.2 to 0.8 mm, and an outer diameter of 80. ~200mm, preferably 100~180mm, the diameter (inner diameter) of the inner hole is 30~80mm, preferably 40~70mm.

上述台板10的圓形薄板，如第1圖，具備有中央的 內孔與外側的圓周部。本發明，在說明外周切斷刃的尺寸時所使用的「徑方向」及「軸方向」，是相對於該圓形薄板的中心來使用，所謂厚度為軸方向尺寸，長度(高度)為徑方向尺寸。同樣地，「內側」或「內方」或者「外側」或「外方」也是相對於圓形薄板的中心或外周切斷刃的旋轉軸來使用。 The circular thin plate of the above-mentioned platen 10, as shown in Fig. 1, has a central The inner hole and the outer circumference. In the present invention, the "diameter direction" and the "axial direction" used in describing the size of the outer peripheral cutting blade are used with respect to the center of the circular thin plate. The thickness is the axial dimension and the length (height) is the diameter. Direction size. Similarly, "inside" or "inside" or "outside" or "outside" is also used with respect to the center of the circular sheet or the axis of rotation of the outer cutting edge.

作成在厚度0.1~1.0mm且外徑200mm以下的範圍，是因為可製作精度較佳的台板、以及能尺寸精度優異地長時間將稀土類燒結磁鐵等的被加工物(工件)切斷。厚度小於0.1mm的話，不管外徑如何，容易產生較大的翹曲，所以不易製作精度較佳的台板，而超過1.0mm的話，切斷加工量會變大。而將外徑作為ψ 200mm以下，是在現行的超硬合金的製造技術及加工技術可製作的尺寸的緣故。針對內孔的直徑，是配合加工機的切斷刃安裝軸的粗細度，為ψ 30~ψ 80mm。 In the range of the thickness of 0.1 to 1.0 mm and the outer diameter of 200 mm or less, it is possible to produce a platen having a high precision and a workpiece (workpiece) such as a rare earth sintered magnet which can be cut off for a long time with excellent dimensional accuracy. When the thickness is less than 0.1 mm, large warpage is likely to occur regardless of the outer diameter, so that it is difficult to produce a platen having a high precision, and if it exceeds 1.0 mm, the amount of cutting processing becomes large. The outer diameter of ψ 200 mm or less is the size that can be produced by the current manufacturing technology and processing technology of the super-hard alloy. The diameter of the inner hole is the thickness of the cutting shaft of the processing machine, which is ψ 30~ψ 80mm.

台板的材質為超硬合金，例如將WC、TiC、MoC、NbC、TaC、Cr3C2等的屬於週期表IVB、VB、VIB族的金屬的碳化物粉末，使用Fe、Co、Ni、Mo、Cu、Pb、Sn或其合金，進行燒結結合的合金較佳；其中尤其代表性的使用WC-Co類、WC-Ti類、C-Co類、WC-TiC-TaC-Co類，使用楊氏模量為450~700GPa者。在這些超硬合金，要具有能進行電鍍的程度的電傳導性、或能藉由鈀觸媒等賦予電傳導性者較佳。針對利用鈀觸媒等賦予電傳導性，能利用例如在對ABS樹脂電鍍時所使用的導電化處理劑等的 習知的技術。 The material of the platen is a super-hard alloy. For example, carbide powders of metals belonging to Group IVB, VB, and VIB of the periodic table such as WC, TiC, MoC, NbC, TaC, and Cr 3 C 2 are used, and Fe, Co, and Ni are used. Mo, Cu, Pb, Sn or alloys thereof are preferred for sintering bonded alloys; among them, WC-Co, WC-Ti, C-Co, WC-TiC-TaC-Co are particularly representatively used. Young's modulus is 450~700GPa. In these superhard alloys, it is preferable to have electrical conductivity capable of performing electroplating or to impart electrical conductivity by a palladium catalyst or the like. For the purpose of imparting electrical conductivity to a palladium catalyst or the like, for example, a known technique such as a conductive treatment agent used for plating an ABS resin can be used.

台板的磁性特性，雖然為了藉由磁性吸引將磨粒固定於台板，飽和磁化量越大越好，可是假設即使飽和磁化量較小，如後述藉由控制磁鐵位置或磁場的強度，就能將預先以磁性體塗層的磨粒磁性吸引於台板，所以只要40kA/m(0.05T)以上即可。 In order to fix the abrasive grains to the platen by magnetic attraction, the magnetic properties of the platen are as large as possible, but it is assumed that even if the amount of saturation magnetization is small, the position of the magnet or the strength of the magnetic field can be controlled as will be described later. Since the magnetic particles coated with the magnetic material are magnetically attracted to the platen in advance, it is only required to be 40 kA/m (0.05 T) or more.

台板的飽和磁化量，是從預定厚度的台板切出5mm見方的測試試料，使用振動樣品測磁儀(Vibrating Sample Magnetometer(VSM))，在24~25℃之間測定磁化曲線(4πI-H)，能將第一象限的磁化值的上限作為台板的飽和磁化量。 The saturation magnetization of the platen is a test piece of 5 mm square cut out from a platen of a predetermined thickness, and a magnetization curve (4πI-) is measured between 24 and 25 ° C using a Vibrating Sample Magnetometer (VSM). H), the upper limit of the magnetization value of the first quadrant can be used as the saturation magnetization of the platen.

台板外周部，為了提高與以金屬結合材固定磨粒所形成的切割刃部的結合強度，藉由實施倒45度角(倒C角)或倒圓角(倒R角)也有效。藉由實施這些倒角處理，即使在當調整刃厚時誤將台板與磨粒層的交界研磨過頭的情況，藉由讓金屬結合材留在交界處，仍可防止切割刃部脫落。倒角的角度或量，能加工的範圍取決於台板的厚度，所以因應於所使用的台板的厚度與固定的磨粒的平均粒徑來決定。 In order to increase the bonding strength with the cutting edge portion formed by fixing the abrasive grains with the metal bonding material, the outer peripheral portion of the platen is also effective by performing an inverted 45 degree angle (inverted C angle) or a rounded corner (inverted R angle). By performing these chamfering treatments, even when the boundary between the platen and the abrasive grain layer is mistakenly grounded when the blade thickness is adjusted, the cutting edge portion can be prevented from falling off by leaving the metal bonding material at the boundary. The angle or amount of chamfering, the extent of processing can be determined by the thickness of the platen, so it is determined by the thickness of the platen used and the average particle size of the fixed abrasive particles.

作為形成切割刃部的磨粒，雖然是使用鑽石磨粒及/或cBN磨粒，而這些磨粒需要預先藉由磁性體塗層。藉由磁性體所塗層的磨粒的大小或硬度，是因應目的來決定。 As the abrasive grains forming the cutting edge portion, although diamond abrasive grains and/or cBN abrasive grains are used, these abrasive grains need to be coated with a magnetic material in advance. The size or hardness of the abrasive particles coated by the magnetic body is determined according to the purpose.

例如，也可分別單獨使用鑽石(天然鑽石、工業用合成鑽石)磨粒、cBN(立方晶氮化硼)磨粒，也可使用鑽 石磨粒與cBN磨粒的混合磨粒。而也可因應於被加工物，將各磨粒從單結晶或多結晶中，分別單獨或混合使用等，來調節劈裂容易度(解理(Cleavage)傾向)。並且在這些磨粒表面，噴濺1μm程度的Fe、Co、Cr等的金屬，作為提高與後述的塗層磁性體的結合強度的方法也很有效。 For example, diamond (natural diamond, industrial synthetic diamond) abrasive grains, cBN (cubic boron nitride) abrasive grains, and mixed abrasive grains of diamond abrasive grains and cBN abrasive grains may be used alone. Further, in accordance with the workpiece, each of the abrasive grains may be used alone or in combination from a single crystal or a polycrystal to adjust the ease of cleaving (Cleavage tendency). Further, it is also effective to spray a metal such as Fe, Co, or Cr at a level of about 1 μm on the surface of the abrasive grains as a method of improving the bonding strength with a coating magnetic body to be described later.

磨粒的大小，雖然也根據台板的厚度，而平均粒徑為10~300μm較佳。平均粒徑小於10μm的話，磨粒與磨粒的間隙變小，所以切斷中容易產生堵塞，切斷能力會降低，平均粒徑超過300μm的話，可能會產生讓磁鐵的切斷面變粗糙等的缺點。在該範圍，考慮切斷加工性或使用壽命等，使用單獨或幾個特定大小的磨粒組合也可以。 The size of the abrasive grains is preferably from 10 to 300 μm , depending on the thickness of the platen. When the average particle diameter is less than 10 μm , the gap between the abrasive grains and the abrasive grains becomes small, so that clogging is likely to occur during cutting, and the cutting ability is lowered. When the average particle diameter exceeds 300 μm , the magnet may be cut off. The disadvantage of roughening the surface. In this range, it is also possible to use a combination of abrasive grains of a single or several specific sizes in consideration of cutting workability, service life, and the like.

用來塗層磨粒的磁性體，例如為了即使在飽和磁化量較低的超硬合金等的台板也能在短時間磁性吸引，且以電鍍法固定時不會脫落，讓其磨粒的質量磁化率χ g為0.2以上，最好為0.39以上，將從Ni、Fe及Co選出的一種金屬，從這些金屬選出的兩種以上所構成的合金、或從這些金屬或合金的一種以及從P及Mn所選出的一種或兩種的合金，藉由噴濺、電鍍、無電解電鍍等的習知的方法，塗層成讓皮膜的厚度為磨粒徑的0.5~100%，最好為2~80%。 The magnetic body for coating the abrasive grains can be magnetically attracted in a short time even in a platen such as a super-hard alloy having a low saturation magnetization amount, and does not fall off when fixed by electroplating, so that the abrasive grains are rubbed. The mass magnetic susceptibility χ g is 0.2 or more, preferably 0.39 or more, and a metal selected from Ni, Fe, and Co, an alloy composed of two or more selected from these metals, or a kind of one or more of these metals or alloys One or two alloys selected by P and Mn are coated by a conventional method such as sputtering, electroplating, electroless plating, etc., so that the thickness of the coating is 0.5 to 100% of the grinding particle diameter, preferably 2~80%.

磨粒的磁化率是取決於塗層的磁化體的磁化率與塗層時的厚度，所以為了藉由磨粒的大小而得到所需要的吸引力，則需要針對磁性體的種類加以考慮，例如以無電解鎳 磷電鍍方式提高磷含有率而磁化率較小者，藉由實施熱處理，也可提高某程度磁化率，以在磁化率較小的塗層上實施磁化率較大的塗層的方式，也能以不同磁化率的塗層複層化，所以配合狀況在適度的範圍內進行調節。 The magnetic susceptibility of the abrasive grains depends on the magnetic susceptibility of the magnetized body of the coating layer and the thickness of the coating layer. Therefore, in order to obtain the desired attraction force by the size of the abrasive grains, it is necessary to consider the kind of the magnetic body, for example, Electroless nickel Phosphorus plating method can increase the phosphorus content and the magnetic susceptibility is small. By performing heat treatment, it is possible to increase the magnetic susceptibility to a certain degree, and to apply a coating having a large magnetic susceptibility to a coating having a small magnetic susceptibility. Coatings with different magnetic susceptibility are stratified, so the blending condition is adjusted within a moderate range.

如此使磨粒的質量磁化率χ g為0.2以上，最好為0.39以上的話，藉由接近後述的台板外周緣部所形成的磁場，迅速地將磨粒磁化，所以以台板與永久磁鐵保持具(夾具主體)所形成的後述的第3圖的間隙64的全部部分，大致均等地將磨粒磁性吸引。如果磨粒的質量磁化率χ g小於0.2的話，磨粒不會被上述間隙順利地吸引，在電鍍中磨粒會脫落等而無法形成磨粒層(切割刃部)，或者在磨粒層產生孔部等，結果可能會減弱磨粒層的機械強度。 When the mass susceptibility χ g of the abrasive grains is 0.2 or more, and preferably 0.39 or more, the abrasive grains are rapidly magnetized by a magnetic field formed near the outer peripheral edge portion of the platen to be described later, so that the platen and the permanent magnet are used. All the portions of the gap 64 of Fig. 3, which will be described later, which are formed by the holder (clamp body), magnetically attract the abrasive grains substantially uniformly. If the mass magnetic susceptibility χ g of the abrasive grains is less than 0.2, the abrasive grains are not smoothly attracted by the above-mentioned gap, and the abrasive grains may fall off during electroplating to form an abrasive grain layer (cutting edge portion) or may be generated in the abrasive grain layer. Holes, etc., may weaken the mechanical strength of the abrasive layer.

磨粒的質量強化率，能用以下的方法測定。首先，在外徑ψ 8mm、高度5mm左右，內徑ψ 6mm的樹脂製容器內，讓磨粒儘可能薄且均勻地廣佈成1~2層左右，然後從容器取出，測定磨粒的重量，將其再次回到容器，在其上面覆蓋熔點50℃左右的石蠟，將全體放入60℃的烤爐加熱。接著，在石蠟熔化的狀態蓋住容器將其冷卻。接著，該試料在溫度24~25℃，用VSM(振動樣品測磁儀：Vibrating Sample Magnetometer)，來測定初磁化曲線(4πI-H)。從曲線的反曲點的傾斜度求出該初磁化曲線的微分磁化率，除以試料重量則成為磨粒的質量磁化率χ g。磁場以Ni標準試料來校正，磨粒的密度使用振實體積密度來測定。 The mass strengthening rate of the abrasive grains can be measured by the following method. First, in a resin container having an outer diameter of mm 8 mm, a height of about 5 mm, and an inner diameter of mm 6 mm, the abrasive grains are spread as thin as possible and uniformly into about one to two layers, and then taken out from the container to measure the weight of the abrasive grains. This was returned to the vessel again, and a paraffin wax having a melting point of about 50 ° C was placed thereon, and the whole was placed in an oven at 60 ° C to heat. Next, the container is covered in a state in which the paraffin is melted to cool it. Next, the sample was measured at a temperature of 24 to 25 ° C using a VSM (Vibrating Sample Magnetometer) to determine the initial magnetization curve (4πI-H). The differential magnetic susceptibility of the initial magnetization curve is obtained from the inclination of the inflection point of the curve, and is divided by the weight of the sample to become the mass magnetic susceptibility χ g of the abrasive grains. The magnetic field was corrected using a Ni standard sample, and the density of the abrasive particles was measured using the tapped bulk density.

所塗層的磁性體的厚度，在作成切割刃部時所作的間隙的大小也會有影響，所以特別需要適當的範圍。最小厚度，在以電鍍方式塗層的情況也能幾乎無間隙地將磨粒全體塗層的厚度也就是2.5μm以上較佳。例如，上述磨粒的較佳平均粒徑範圍的最大值300μm的情況，只要0.5%以上，尤其為0.8%以上即可。藉由將塗層的厚度作成該方式，則當作為外周切斷刃切斷加工時，也能獲得保持力能減少磨粒的脫落，而藉由適當選擇所塗層的磁性體的種類，則在電鍍步驟中不會脫落，藉由磁場將磨粒吸引到台板外周緣部上或附近。 The thickness of the coated magnetic body also affects the size of the gap which is formed when the cutting edge portion is formed. Therefore, an appropriate range is particularly required. The minimum thickness, in the case of coating by electroplating, is also preferably a thickness of the entire coating of the abrasive grains of 2.5 μm or more with almost no gap. For example, in the case where the maximum value of the preferred average particle diameter range of the abrasive grains is 300 μm , it may be 0.5% or more, particularly 0.8% or more. By setting the thickness of the coating layer in this manner, when the cutting process is performed as the outer peripheral cutting blade, the holding force can be obtained to reduce the drop of the abrasive grains, and by appropriately selecting the type of the magnetic body to be coated, It does not fall off during the electroplating step, and the abrasive grains are attracted to or near the outer peripheral edge portion of the platen by the magnetic field.

最大厚度，例如在上述磨粒的較佳平均粒徑範圍的最小值10μm的情況，在切斷加工沒有有效功能的部分、或妨礙磨粒的自生作用的部分增加，加工能力會降低，所以相對於磨粒的平均粒徑作至100%較佳。 The maximum thickness, for example, in the case where the minimum value of the preferred average particle diameter range of the above-mentioned abrasive grains is 10 μm , the portion which does not have an effective function in the cutting process, or the portion which hinders the autogenous action of the abrasive grains increases, the processing ability is lowered, Therefore, it is preferable to make the average particle diameter of the abrasive grains to 100%.

將磨粒結合的金屬結合材，是後述的電鍍金屬(合金)。在切割刃部的形成，需要將永久磁鐵配設成接近台板的外周緣部，例如可採用，在較台板的外周端更內側的台板面上，或在較外周端更內側而從台板側面起算的距離在20mm以內的空間內，藉由配置殘留磁通密度為0.3T以上的兩個以上的永久磁鐵，在從台板的至少外周端起算10mm以內的空間形成8kA/m以上的磁場，並且在預先塗層磁性體而成的鑽石磨粒及/或cBN磨粒，使該磁場作用而產生磁性吸引力，藉由其吸引力將該磨粒磁性吸引固定於台板外周緣部上或附近，保持該狀態在台板外周緣部上 實施電鍍或無電解電鍍，而將其固定於台板外周緣部上的方法。 The metal bonding material in which the abrasive grains are bonded is a plating metal (alloy) to be described later. In the formation of the cutting edge portion, it is necessary to arrange the permanent magnet so as to be close to the outer peripheral edge portion of the platen, for example, on the platen surface which is more inner side than the outer peripheral end of the platen, or on the inner side of the outer peripheral end. When two or more permanent magnets having a residual magnetic flux density of 0.3 T or more are disposed in a space of 20 mm or less from the side of the platen, 8 kA/m or more is formed in a space of 10 mm or less from at least the outer peripheral end of the platen. The magnetic field, and the diamond abrasive grains and/or cBN abrasive grains which are pre-coated with magnetic materials, cause the magnetic field to act to generate magnetic attraction force, and the abrasive particles are magnetically attracted and fixed to the outer periphery of the platen by the attraction force thereof. On or near the top, keep this state on the outer peripheral edge of the platen A method of performing electroplating or electroless plating while fixing it to the outer peripheral portion of the platen.

作為此時所用的夾具，可以使用一對夾具主體，該夾具主體具有：由具有較台板的外徑更大的外徑的絕緣體所構成的外殼、以及在該外殼配置固定成較台板的外周端更內側的永久磁鐵。電鍍能將台板保持於該夾具主體之間來進行。 As the jig used at this time, a pair of jig main bodies having an outer casing composed of an insulator having an outer diameter larger than the outer diameter of the platen, and the outer casing being fixed to the lower platen may be used. A permanent magnet on the inner side of the outer peripheral end. Electroplating can be performed by holding the platen between the jig bodies.

第2圖、第3圖，是顯示當該電鍍時所用的夾具的一個例子，50、50是一對夾具主體，該夾具主體50、50，分別具有：為絕緣體製的外殼52、52、以及安裝於該外殼52、52的永久磁鐵54、54；在夾具主體50、50之間保持著台板1。將永久磁鐵54、54埋設於外殼52、52內的方式較佳，而也可將其設置成與台板1抵接。 2 and 3 are views showing an example of a jig used for the plating, and 50 and 50 are a pair of jig main bodies, and the jig main bodies 50 and 50 respectively have outer casings 52 and 52 which are insulating systems, and The permanent magnets 54, 54 attached to the outer casings 52, 52; the platen 1 is held between the jig bodies 50, 50. The manner in which the permanent magnets 54, 54 are embedded in the outer casings 52, 52 is preferable, and it may be provided to abut against the platen 1.

在內建於夾具的永久磁鐵，在以電鍍法析出金屬結合材固定磨粒期間，需要持續將磨粒吸引於台板的磁力。所需要的磁力，雖然根據台板外周緣部與磁鐵的距離、或預先將磨粒塗層的磁性體的磁化量或磁化率，而是藉由使用永久磁鐵所得到，該永久磁鐵其殘留磁通密度為0.3T以上，保磁力為0.2MA/m以上，較佳為殘留磁通密度為0.6T以上，保磁力為0.8MA/m以上，更好為殘留磁通密度為1.0T以上，保磁力為1.0MA/m以上。 In the permanent magnet built in the jig, during the precipitation of the abrasive grains by the electroplating method, it is necessary to continuously attract the magnetic force of the abrasive grains to the platen. The required magnetic force is obtained by using a permanent magnet according to the distance between the outer peripheral edge portion of the platen and the magnet, or the magnetization amount or magnetic susceptibility of the magnetic body coated with the abrasive grain in advance, and the residual magnet of the permanent magnet. The pass density is 0.3T or more, the coercive force is 0.2MA/m or more, preferably the residual magnetic flux density is 0.6T or more, the coercive force is 0.8MA/m or more, and more preferably the residual magnetic flux density is 1.0T or more. The magnetic force is 1.0 MA/m or more.

永久磁鐵的殘留磁通密度，其值越大，則所形成的磁場的梯度會越大，所以在想要局部吸引磨粒的情況很適合。因此，為了防止：在電鍍中所產生的電鍍液的攪拌或台 板與夾具的擺動導致的振動，讓磨粒從台板脫離的情形，使用0.3T以上的殘留磁通密度的永久磁鐵較佳。 The residual magnetic flux density of the permanent magnet, the larger the value, the larger the gradient of the formed magnetic field, so it is suitable for the case where it is desired to locally attract the abrasive grains. Therefore, in order to prevent: the stirring or the plating of the plating solution generated in the plating It is preferable to use a permanent magnet having a residual magnetic flux density of 0.3 T or more in the case where the vibration caused by the oscillation of the plate and the jig is released from the platen.

保磁力其值越大，則則即使暴露於高溫的電鍍液也能長時間將磨粒強力磁性吸引於台板，針對所用的磁鐵的位置、形狀、大小的自由度變大，而夾具製作變得容易，所以從符合所需要的殘留磁通密度中選擇即可。 The larger the value of the coercive force is, the more the electroplating liquid exposed to the high temperature can strongly attract the abrasive grains to the platen for a long time, and the degree of freedom of the position, shape, and size of the magnet used becomes large, and the jig is changed. It is easy to select, so it is possible to select from the required residual magnetic flux density.

永久磁鐵的塗層，也考慮在磁鐵接觸電鍍液的情況，以儘可能減少塗層材對電鍍液的溶出或與電鍍液中的金屬種置換的條件來選擇，來提高永久磁鐵的耐蝕性。例如，使用Ni電鍍液析出金屬結合材的話，Cu、Sn、Ni的金屬、或環氧樹脂或丙烯酸樹脂的塗層較適合。 The coating of the permanent magnet is also considered to be selected in order to reduce the corrosion resistance of the permanent magnet by selecting the conditions in which the magnet contacts the plating solution to minimize the elution of the plating material to the plating solution or the metal species in the plating solution. For example, when a metal bonding material is deposited using a Ni plating solution, a coating of a metal of Cu, Sn, Ni, or an epoxy resin or an acrylic resin is suitable.

內建於夾具之永久磁鐵的形狀與尺寸及數量，是根據台板的超硬合金的大小、所需要的磁場的位置與方向與強度。例如，想均勻地將磨粒固定於台板外周緣部的情況，則將配合台板的外徑的環狀或圓弧狀的磁鐵、或其中一邊的長度為數mm左右的長方體狀磁鐵，沿著台板外周無間隙地連續配置。而也能以減少磁鐵花費的成本的目的，在該磁鐵之間設置均等的空間而減少其數量來配置。 The shape, size and number of permanent magnets built into the fixture are based on the size of the superhard alloy of the platen and the position and direction and strength of the required magnetic field. For example, when it is desired to uniformly fix the abrasive grains to the outer peripheral edge portion of the platen, a ring-shaped or arc-shaped magnet having an outer diameter of the platen or a rectangular parallelepiped magnet having a length of about several mm may be used. The platen is continuously arranged without any gaps in the periphery. Further, it is also possible to reduce the number of the magnets by arranging an equal space between the magnets for the purpose of reducing the cost of the magnets.

雖然也根據所用的磁鐵的殘留磁通密度，而藉由將磁鐵間隔加大，設置：將預先藉由磁性體塗層的磨粒予以吸引的部分以及不吸引的部分，作出有固定磨粒的部分以及沒有磨粒的部分，而作成矩形的切割刃部也可以。 Depending on the residual magnetic flux density of the magnet used, by increasing the spacing of the magnets, it is provided that the portions which are previously attracted by the abrasive grains of the magnetic coating and the portions which are not attracted are provided with fixed abrasive grains. The portion and the portion having no abrasive grains may be formed into a rectangular cutting edge portion.

使台板外周緣部產生的磁場，能藉由在夾著台板的兩個夾具主體處固定的永久磁鐵的位置與磁化方向的組合， 而能作出各方式，反覆磁場解析與實証來決定成在從台板的至少外周端起算10mm以內的空間形成8kA/m以上，較佳為40 kA/m以上的磁場。磁場的強度小於8kA/m的話，預先藉由磁性體塗層的磨粒的吸引力不夠，在該狀態電鍍的話，在電鍍中磨粒會移動，而可能形成間隙較多的切割刃部、或將磨粒固定成樹枝狀而切刃部的尺寸大於所需要的尺寸。結果，在整形加工中切刃部會脫落、或讓整形加工花費的時間變長，往往會讓製造成本增加。 The magnetic field generated at the outer peripheral portion of the platen can be combined with the magnetization direction by the position of the permanent magnet fixed at the two clamp bodies sandwiching the platen. Further, it is possible to determine the magnetic field of 8 kA/m or more, preferably 40 kA/m or more, in a space of 10 mm or less from at least the outer peripheral end of the platen. When the intensity of the magnetic field is less than 8 kA/m, the attraction of the abrasive grains previously coated with the magnetic material is insufficient. In the case of electroplating in this state, the abrasive grains may move during the plating, and a cutting edge portion having a large gap may be formed, or The abrasive particles are fixed in a dendritic shape and the size of the cutting edge portion is larger than the required size. As a result, the cutting edge portion may fall off during the shaping process, or the time taken for the shaping process may become long, which tends to increase the manufacturing cost.

永久磁鐵的位置，雖然儘可能接近想吸引磨粒的部分越好，大致來說，在較台板的外周端更內側的台板面上、或較外周端更內側且從台板面起算的距離為20mm以內的空間內，在距離10mm以內的空間內更好。在該範圍的特定位置將具有0.3T以上的殘留磁通密度的永久磁鐵，以包含其全部或局部的方式配置兩個以上(每一個夾具主體一個以上)，則能在台板的至少外周端起算10mm以內的空間內形成8 kA/m以上的磁場，所以像合金工具鋼或高速度鋼的飽和磁化量較大容易感應磁力的材質當然較理想，而即使像超硬合金的飽和磁化量較低而磁力的感應較小的材質，也能在台板外周緣部讓磁力形成適當的磁場。藉由將預先以磁性體塗層的磨粒進入該磁場內，則將塗層皮膜磁化，所以結果可將磨粒吸引保持於所需要的台板外周緣部上或附近。 The position of the permanent magnet is as close as possible to the portion that is intended to attract the abrasive grains. Generally, it is on the platen surface that is more inside than the outer peripheral end of the platen, or is more inside than the outer peripheral end and starts from the platen surface. Within a space of 20 mm or less, it is better in a space within 10 mm. A permanent magnet having a residual magnetic flux density of 0.3 T or more at a specific position in the range may be disposed at least at the outer peripheral end of the platen by arranging two or more of the permanent magnets including all or part of them (one or more of each jig body) A magnetic field of 8 kA/m or more is formed in a space of less than 10 mm, so a material having a large saturation magnetization such as an alloy tool steel or a high-speed steel is of course preferable, and even a saturation magnetization amount such as a superhard alloy is preferable. The material with low magnetic induction and small magnetic force can also make the magnetic field form an appropriate magnetic field at the outer peripheral edge of the platen. By inserting the abrasive grains previously coated with the magnetic body into the magnetic field, the coating film is magnetized, so that the abrasive grains can be attracted and held on or near the outer peripheral edge portion of the desired platen.

從台板外周端起算的磁鐵的位置，例如，從外周端起算0.5mm外側(作為外周切斷刃時的與旋轉軸分離側)的 情況，即使是在非常接近台板外周端的位置，在不包含上述範圍的情況，台板外周端附近的磁場強度雖然變強，可是容易產生磁場梯度反轉的區域，所以表示磨粒從台板浮起這樣的動作，磨粒容易脫落。即使在較台板外周端更內側，從外周端起算的距離超過20mm的情況，在從台板的外周端起算10mm以內的空間形成的磁場的強度容易小於8 kA/m，所以磁性吸引磨粒的力量可能會不夠。在該情況，將磁場的強度上升，雖然也有將磁鐵加大的方法，而在該方法會將想吸引磨粒的部位附近的磁場強度全體提升，而容易讓磨粒附著在不想吸引磨粒的位置而較不適當。而且將該磁鐵加大的方法，用來保持磁鐵的夾具也會變大，所以實際並不適當。 The position of the magnet from the outer peripheral end of the platen is, for example, 0.5 mm outside from the outer peripheral end (the side separated from the rotating shaft when the outer peripheral cutting blade is separated) In the case where the position is very close to the outer peripheral end of the platen, the magnetic field intensity near the outer peripheral end of the platen is strong, but the region where the magnetic field gradient is reversed is likely to occur, so that the abrasive grains are from the platen. When such an action is lifted, the abrasive grains are easily peeled off. Even when the distance from the outer peripheral end is more than 20 mm on the inner side of the outer peripheral end of the platen, the strength of the magnetic field formed in the space within 10 mm from the outer peripheral end of the platen is easily less than 8 kA/m, so the magnetic attraction abrasive grains are attracted. The power may not be enough. In this case, the strength of the magnetic field is increased, and there is a method of increasing the magnet. In this method, the magnetic field strength in the vicinity of the portion where the abrasive grains are to be attracted is raised, and the abrasive grains are easily attached to the abrasive grains. Location is less appropriate. Moreover, the method of increasing the magnet and the holder for holding the magnet also become large, so that it is not practical.

夾具的形狀，是配合所使用的台板的形狀。其尺寸是用當以夾具夾住台板時對於台板能將永久磁鐵固定在所需要的位置的尺寸。例如，台板的大小為外徑ψ 125mm、厚度0.26mm，永久磁鐵的大小為L2.5mm×W2mm×t1.5mm的情況，可以使用外徑125mm以上，厚度20mm左右的圓板。 The shape of the clamp is the shape of the platen used. The size is the size that can be used to fix the permanent magnet to the desired position when the platen is clamped by the clamp. For example, when the size of the platen is ψ125 mm and thickness is 0.26 mm, and the size of the permanent magnet is L2.5 mm×W2 mm×t1.5 mm, a circular plate having an outer diameter of 125 mm or more and a thickness of about 20 mm can be used.

更具體來說，夾具的外徑，為了能確保所需要的磨粒層的高度(朝徑方向的突出量)(第1圖(C)的H2)，為台板的外徑+(磨粒層的高度×2)以上，其厚度，雖然根據材質，而是要能確保在藉由出入高溫的電鍍液時的劇烈溫度變化等而不會產生翹曲等的程度的強度的厚度。與磨粒相接的部分的夾具厚度，也可作薄成讓磨粒層可得到朝台板的厚度方向突出的量(第1圖(C)的T3)，使用 與突出量同等的厚度的遮蔽膠帶，作成與其他部分相同厚度也可以。 More specifically, the outer diameter of the jig is the outer diameter of the platen + (abrasive grain) in order to ensure the required height of the abrasive grain layer (the amount of protrusion in the radial direction) (H2 in Fig. 1 (C)) The thickness of the layer is not less than 2), and the thickness of the layer is such a thickness that the strength of the layer is not caused by warpage or the like due to a sharp temperature change when the plating solution having a high temperature is introduced, depending on the material. The thickness of the jig of the portion that is in contact with the abrasive grains can also be made thin so that the abrasive grain layer can be obtained in the thickness direction of the platen (T3 in Fig. 1(C)), The masking tape having the same thickness as the amount of protrusion may be formed to have the same thickness as the other portions.

夾具的材質，由於將夾著台板的夾具全體含浸於高溫的電鍍液使金屬結合材析出，所以用電鍍不會析出的絕緣體較佳，其中希望能具有：耐藥性、至90℃程度的耐熱性、即使反覆受到出入電鍍液時所產生的急遽溫度變化也能保有穩定尺寸的耐熱衝擊性。並且也需要尺寸穩定性，即使當含浸於高溫的電鍍液時，不會因為成形時或加工時所累積的內部應力等產生翹曲而在其與台板之間產生間隙的情形。當然也需要加工性，能在任意位置以沒有裂紋或缺口的高精度來加工出用來內建永久磁鐵的溝部。 In the material of the jig, since the metal bonding material is deposited by impregnating the entire high-temperature plating solution with the jig sandwiching the platen, it is preferable that the insulator is not deposited by electroplating, and it is desirable to have resistance to 90 ° C. The heat resistance and the rapid temperature change caused by the inflow and out of the plating solution can maintain the thermal shock resistance of a stable size. Further, dimensional stability is also required, and even when it is impregnated with a plating solution having a high temperature, a gap is not generated between the platen and the platen due to warpage caused by internal stress or the like accumulated during molding or processing. Of course, workability is also required, and the groove for the built-in permanent magnet can be machined at any position with high precision without cracks or notches.

具體來說，可以使用PPS、PEEK、POM、PAR、PSF、PES等的工程塑膠或氧化鋁等的陶瓷。使用這種材質，也考慮機械強度決定厚度等的尺寸，設置：用來保持永久磁鐵的溝部、或當使用電鍍法的情況***需要的供電電極等的溝部。將以該方式製作的一對的兩個夾具主體與一片台板一體化。當一體化時，以能進行電鍍的方式使用用來通電於台板之電極等來緊固的話，就能同時達到確保供電部與緊固，也能將全體小型化。當然，作成一次能對複數台板電鍍，例如，如第2圖所示，作成能將夾具連結的構造的話，可更有效率的生產。 Specifically, engineering plastics such as PPS, PEEK, POM, PAR, PSF, PES, or ceramics such as alumina can be used. In the case of using such a material, the size of the thickness or the like is determined in consideration of the mechanical strength, and the groove portion for holding the permanent magnet or the groove portion for supplying the power supply electrode or the like required for the plating method is provided. The two clamp main bodies of the pair produced in this manner are integrated with one platen. When it is integrated, it is possible to ensure the power supply unit and the fastening at the same time by using an electrode or the like for energizing the platen, and the entire size can be reduced. Of course, it is possible to plate a plurality of platens at a time. For example, as shown in Fig. 2, a structure capable of connecting the jigs can be produced more efficiently.

也就是說在第2圖，56、56是分別在外殼52、52的中央部安裝的兼作台板緊壓件的電鍍用陰極體，該陰極體56、56，接觸於：用來將一對夾具主體50、50支承、固 定的導電性的支承棒58，可從該支承棒58通電。第2圖的夾具，是將兩組的一對夾具主體50、50分離預定間隔而安裝於支承棒58。在第2圖中，60是接頭，62是端蓋。該第2圖的夾具為電鍍用，在無電解電鍍用的情況，則不需要陰極棒，取而代之設置非導電性的緊壓件也可以，支承棒也不一定需要導電性。 That is, in Figs. 2, 56 and 56, a cathode body for plating which is also used as a platen pressing member which is attached to the central portion of the outer casings 52 and 52, and the cathode bodies 56 and 56 are in contact with each other for: The clamp main body 50, 50 is supported and fixed A constant conductive support rod 58 is energizable from the support rod 58. In the jig of Fig. 2, the pair of jig bodies 50, 50 of the two sets are separated from each other by a predetermined interval and attached to the support bar 58. In Fig. 2, 60 is a joint and 62 is an end cap. The jig of the second drawing is for electroplating. In the case of electroless plating, a cathode rod is not required, and a non-conductive pressing member may be provided instead, and the supporting rod does not necessarily need to have conductivity.

在使用這種夾具進行電鍍的情況，將塗層有磁性體的磨粒根據需要用天秤等量取任意的質量，當以保持著永久磁鐵的一對夾具主體夾住台板時，被吸引保持於藉由台板外周部與夾具所形成的間隙。第3圖說明該間隙，在從一對夾具主體50、50(外殼52、52)的台板1朝前側突出的突出部52a、52a與台板1的前端部之間形成間隙64，將磨粒磁性吸引於該間隙64。 In the case of electroplating using such a jig, the abrasive grains coated with the magnetic body are subjected to an arbitrary mass by a scale as needed, and are attracted while holding the platen with a pair of jig bodies holding the permanent magnets. The gap formed by the outer peripheral portion of the platen and the jig. Fig. 3 illustrates the gap, and a gap 64 is formed between the protruding portions 52a and 52a projecting from the platen 1 of the pair of jig bodies 50 and 50 (the outer casings 52 and 52) toward the front side and the front end portion of the platen 1 to grind The magnetic properties of the particles are attracted to the gap 64.

所保持的磨粒的量，取決於：所使用的台板的外徑與厚度、磨粒的大小及所需要的切割刃部的高度或寬度。將用來保持磨粒的電鍍反覆進行數次，讓在台板外周的全部位置每單位體積的磨粒的量成為均等，且以電鍍法堅固地固定磨粒。 The amount of abrasive particles retained depends on the outer diameter and thickness of the platen used, the size of the abrasive particles, and the desired height or width of the cutting edge. The plating for holding the abrasive grains was repeated several times, and the amount of abrasive grains per unit volume at all positions on the outer periphery of the platen was made uniform, and the abrasive grains were firmly fixed by electroplating.

以該方式形成切割刃部，而切割刃部的磨粒的體積率，為10~80體積%，尤其為30~75體積%的範圍較佳。小於10體積%，有助於切斷的磨粒的比率較少，切斷時的阻力增加。超過80體積%的話，切斷中的刀鋒變形量較少，所以在切斷面會殘留切割痕跡而被加工物的尺寸精度或外觀較差。根據這些理由，所以不得不降低切斷速度，所 以因應目的藉由將塗層於磨粒的磁性體的厚度改變，來改變粒徑調整體積率較佳。 The cutting edge portion is formed in this manner, and the volume fraction of the abrasive grains of the cutting edge portion is preferably from 10 to 80% by volume, particularly preferably from 30 to 75% by volume. When it is less than 10% by volume, the ratio of the abrasive grains which contributes to cutting is small, and the resistance at the time of cutting increases. When the amount is more than 80% by volume, the amount of deformation of the blade during cutting is small. Therefore, the cutting mark remains on the cut surface, and the dimensional accuracy or appearance of the workpiece is inferior. For these reasons, I have to reduce the cutting speed. It is preferred to change the particle size adjustment volume ratio by changing the thickness of the magnetic material coated on the abrasive grains in accordance with the purpose.

如第1圖(C)所示，切割刃部20是以夾持部22a、22b與主體(20)所構成，以夾持部22a、22b夾持台板的外周緣部，主體(20)較台板10的外周部更朝前方突出形成。這裡主體與夾持部的說明是為了方便，這些構造是一體地形成切割刃部。該切割刃部20的厚度形成為較台板10的厚度更厚的方式很有效，以該方式形成第3圖所示的間隙64較佳。 As shown in Fig. 1(C), the cutting blade portion 20 is constituted by the sandwiching portions 22a and 22b and the main body (20), and the outer peripheral edge portion of the platen is sandwiched by the sandwiching portions 22a and 22b, and the main body (20) The outer peripheral portion of the platen 10 is formed to protrude forward. Here, the description of the main body and the nip portion is for convenience, and these configurations integrally form a cutting edge portion. The thickness of the cutting blade portion 20 is formed to be thicker than the thickness of the platen 10, and it is preferable to form the gap 64 shown in Fig. 3 in this manner.

在該情況，在第1圖(C)，將切割刃部的台板外周部夾持的一對夾持部22a、22b的長度H1，分別為0.1~10mm，尤其為0.5~5mm較佳。該一對的夾持部22a、22b的厚度T3，分別為5μm(0.005mm)以上，較佳為5~2000μm，更好為10~1000μm，於是，該一對夾持部22a、22b的合計厚度(也就是切割刃部較台板更厚的部分的厚度)為0.01mm以上較佳，更好為0.01~4mm，最好為0.02~2mm。夾持部22a、22b的長度H1小於0.1mm的話，雖然有防止台板外周緣部的缺口或裂紋的效果，可是會有台板的補強效果較少，無法防止因為切斷時的阻力導致台板變形的情況。H1超過10mm的情況，可能會讓相對於補強台板的成本績效(cost performance)降低。另一方面，T3小於5μm的話，無法提高台板的機械強度，而無法將切割漿液有效地排出。 In this case, in the first drawing (C), the length H1 of the pair of sandwiching portions 22a and 22b sandwiched between the outer peripheral portions of the platen portion of the cutting blade portion is preferably 0.1 to 10 mm, particularly preferably 0.5 to 5 mm. The thickness T3 of the pair of holding portions 22a and 22b is 5 μm (0.005 mm) or more, preferably 5 to 2000 μm , more preferably 10 to 1000 μm , and thus the pair of holdings The total thickness of the portions 22a and 22b (that is, the thickness of the portion where the cutting edge portion is thicker than the platen) is preferably 0.01 mm or more, more preferably 0.01 to 4 mm, and most preferably 0.02 to 2 mm. When the length H1 of the nip portions 22a and 22b is less than 0.1 mm, there is an effect of preventing the chipping or cracking of the outer peripheral edge portion of the platen, but the reinforcing effect of the platen is small, and the table due to the resistance at the time of cutting cannot be prevented. The case of plate deformation. A situation where H1 exceeds 10 mm may reduce the cost performance relative to the reinforcing platen. On the other hand, if T3 is less than 5 μm , the mechanical strength of the platen cannot be increased, and the cutting slurry cannot be efficiently discharged.

如第4圖(A)~(D)所示，夾持部22a、22b，也 可由金屬結合材24與磨粒26所形成(第4圖(A))，也可僅藉由金屬結合材形成(第4圖(B))，僅藉由金屬結合材將台板10覆蓋，也可再將其覆蓋形成金屬結合材與磨粒的層(第4圖(C))。在第4圖(C)的外側以覆蓋全體的方式使金屬結合材析出成為(第4圖(D))的話，可以更提升切割刃部的強度。 As shown in Fig. 4 (A) to (D), the holding portions 22a and 22b are also The metal bonding material 24 and the abrasive grains 26 may be formed (Fig. 4(A)), or may be formed only by a metal bonding material (Fig. 4(B)), and the platen 10 may be covered only by the metal bonding material. It may be covered with a layer of a metal bond and abrasive grains (Fig. 4(C)). When the metal bonding material is deposited on the outer side of the fourth drawing (C) so as to cover the entire surface (Fig. 4(D)), the strength of the cutting edge portion can be further enhanced.

並且如第4圖(B)~(D)，作為僅藉由金屬結合材24來形成與夾持部的台板10相接的部分的方法，例如採用：僅使要形成台板的夾持部的部分露出，將其他部分遮蔽，在該狀態進行電鍍之後，安裝上述夾具，將磨粒26充填於間隙64來進行電鍍的方法，在將磨粒26電沉積之後，例如，在電沉積部分露出的外徑的第2圖的外殼52、52，將台板10遮蔽，進一步進行電鍍，藉此如第4圖(D)，則能形成：作為切割刃部最外層的僅由金屬結合材24構成的層部。 Further, as shown in FIGS. 4(B) to 4(D), as a method of forming a portion that is in contact with the platen 10 of the nip portion only by the metal bonding material 24, for example, only the clamping of the platen to be formed is employed. A portion of the portion is exposed, the other portion is shielded, and after the plating is performed in this state, the jig is attached, and the abrasive grains 26 are filled in the gap 64 to perform electroplating, after the electrode 26 is electrodeposited, for example, in the electrodeposited portion. The exposed outer casings 52 and 52 of the outer diameter of the second embodiment are shielded from the platen 10 and further electroplated. Thus, as shown in Fig. 4(D), only the metal bonding material can be formed as the outermost layer of the cutting edge portion. The layer formed by 24 layers.

切割刃部20的較台板10更朝前側突出的突出部的突出長度(第1圖(C)的H2)，雖然是根據所固定的磨粒的大小，而0.1~10mm，尤其為0.3~8mm較佳。突出長度小於0.1mm的話，藉由切斷時的衝擊或磨耗讓切割刃部消失為止的時間較短，結果會讓刃部的使用壽命變短，超過10mm的話，雖然也根據刃厚(第1圖的T2)，而可能會讓切割刃部容易變形，切斷面彎曲而切斷的磁鐵的尺寸精度變差。切割刃部，是由：金屬結合材24及磨粒26與後述的含浸樹脂所形成。 The protruding length of the protruding portion of the cutting blade portion 20 that protrudes toward the front side from the table top 10 (H2 in Fig. 1(C)) is 0.1 to 10 mm, especially 0.3 mm, depending on the size of the abrasive grains to be fixed. 8mm is preferred. When the protruding length is less than 0.1 mm, the time until the cutting edge portion disappears due to the impact or wear at the time of cutting is short, and the service life of the blade portion is shortened. In the case of T2) in the figure, the cutting edge portion may be easily deformed, and the dimensional accuracy of the magnet cut by the cut surface may be deteriorated. The cutting blade portion is formed of a metal bonding material 24 and abrasive grains 26 and an impregnating resin to be described later.

金屬結合材，是藉由電鍍所形成的金屬或合金，從Ni、Fe、Co、Cu及Sn所選出的一種金屬、由從這些金屬所選出的兩種以上所構成的合金、或這些金屬或合金的一種與由P及Mn所選出的一種或兩種的合金較佳，將其藉由電鍍析出成將磨粒間以及磨粒與台板之間予以連結。 a metal bond material, which is a metal or alloy formed by electroplating, a metal selected from Ni, Fe, Co, Cu, and Sn, an alloy composed of two or more selected from these metals, or these metals or One of the alloys is preferably one or two alloys selected from P and Mn, which are deposited by electroplating to join between the abrasive grains and between the abrasive grains and the platen.

在以電鍍形成金屬結合材的方法，雖然大致分為電沉積法(電鍍法)與無電解電鍍法兩種，而在本發明，是將容易控制在結合材殘留的內部應力且生產成本較便宜的電沉積法、與只要電鍍液進入的話就能較均勻地析出金屬結合材的無電解電鍍法，以讓在切割刃部所包含的間隙成為後述適當的範圍的方式，分別單獨或組合來使用。 In the method of forming a metal bonding material by electroplating, although it is roughly classified into two types, an electrodeposition method (electroplating method) and an electroless plating method, in the present invention, it is easy to control the internal stress remaining in the bonding material and the production cost is relatively low. The electroless deposition method and the electroless plating method in which the metal bonding material can be deposited more uniformly as long as the plating solution enters, so that the gaps included in the cutting edge portion can be used individually or in combination as described below. .

鍍Ni或鍍Cu等的單一金屬，例如在使用電鍍法是用磺胺酸Ni電鍍液的情況，主成分的磺胺酸鎳的濃度，電鍍時的電流密度，電鍍液的溫度為適當的範圍，且也可實施鄰苯磺醯亞胺或對甲基苯磺醯胺等的有機添加物的添加、或加上Zn、S、Mn等的元素，調整皮膜的應力等。其他在Ni-Fe合金、Ni-Mn合金、Ni-P合金、Ni-Co合金、Ni-Sn合金等的電鍍合金的情況，將合金中的Fe、Mn、P、Co、Sn的含有量、電鍍液的溫度等調整成適當的範圍等，來調整皮膜的應力。當然在這些合金電鍍的情況，能調整應力的有機添加物的併用也很有效。 a single metal such as Ni plating or Cu plating, for example, when a plating solution is used with a sulfa Ni plating solution, a concentration of a main component of nickel sulfamate, a current density during plating, and a temperature of a plating solution are in an appropriate range, and It is also possible to add an organic additive such as o-benzenesulfonimide or p-toluenesulfonamide or to add an element such as Zn, S or Mn to adjust the stress of the film. In the case of a plating alloy such as a Ni-Fe alloy, a Ni-Mn alloy, a Ni-P alloy, a Ni-Co alloy, or a Ni-Sn alloy, the content of Fe, Mn, P, Co, and Sn in the alloy, The temperature of the plating solution is adjusted to an appropriate range or the like to adjust the stress of the film. Of course, in the case of these alloy plating, the combination of the organic additives capable of adjusting the stress is also effective.

電鍍能使用使單一金屬或合金析出的以往習知的電鍍液，採用該電鍍液的平常的電鍍條件，用習知的方法來進行。 A conventional plating solution for depositing a single metal or an alloy can be used for electroplating, and can be carried out by a conventional method using ordinary plating conditions of the plating solution.

作為適當的電鍍液，例如磺胺酸鎳為250~600g/L、硫酸鎳為50~200g/L、氯化鎳為5~70g/L、硼酸為20~40g/L、鄰苯磺醯亞胺為適量的磺胺酸瓦特鎳電鍍液、焦磷酸銅為30~150g/L、焦磷酸鉀為100~450g/L、25%氨水為1~20mL/L、硝酸鉀為5~20g/L的焦磷酸銅電鍍液等。而作為無電解電鍍液，例如硫酸鎳為10~50g/L、次亞磷酸鈉為10~50g/L、醋酸鈉為10~30g/L、檸檬酸鈉為5~30g/L、硫尿為適量的無電解鎳磷合金電鍍液等。 As a suitable plating solution, for example, 250 to 600 g/L of nickel sulfamate, 50 to 200 g/L of nickel sulfate, 5 to 70 g/L of nickel chloride, 20 to 40 g/L of boric acid, and o-benzenesulfonimide It is an appropriate amount of sulfamic acid Watt nickel plating solution, copper pyrophosphate is 30~150g/L, potassium pyrophosphate is 100~450g/L, 25% ammonia is 1~20mL/L, and potassium nitrate is 5~20g/L. Copper phosphate plating solution, etc. As an electroless plating solution, for example, nickel sulfate is 10 to 50 g/L, sodium hypophosphite is 10 to 50 g/L, sodium acetate is 10 to 30 g/L, sodium citrate is 5 to 30 g/L, and sulfur is used. An appropriate amount of electroless nickel-phosphorus alloy plating solution.

藉由這種方法，在台板的外周部以接近最終形狀的尺寸，高精度地形成：鑽石磨粒、cBN磨粒或鑽石磨粒與cBN磨粒的混合磨粒。 By this method, the outer peripheral portion of the platen is formed with high precision in a size close to the final shape: diamond abrasive grains, cBN abrasive grains or mixed abrasive grains of diamond abrasive grains and cBN abrasive grains.

在本發明，在以上述方法所得到的，切割刃部的磨粒間以及磨粒與台板之間存在的空隙，含浸熔點350℃以下的熱可塑性樹脂、或含浸硬化溫度為350℃以下的液體狀的熱硬化性樹脂組成物，將其硬化成為熱硬化性樹脂。藉此，在本發明的超硬合金台板外周切斷刃，在切割刃部的內部及表面的磨粒間及磨粒與台板之間，包含有：熔點350℃以下的熱可塑性樹脂、或硬化溫度為350℃以下的液體狀的熱硬化性樹脂組成物的硬化物也就是熱硬化性樹脂。 In the present invention, the gap between the abrasive grains of the cutting edge portion and between the abrasive grains and the platen obtained by the above method is impregnated with a thermoplastic resin having a melting point of 350 ° C or lower, or an impregnation hardening temperature of 350 ° C or lower. A liquid thermosetting resin composition is cured to a thermosetting resin. Thereby, the outer peripheral cutting blade of the superhard alloy platen of the present invention includes a thermoplastic resin having a melting point of 350 ° C or less between the abrasive grains and the abrasive grains and the platen in the inside of the cutting edge portion and the surface of the cutting blade portion. The cured product of the liquid thermosetting resin composition having a curing temperature of 350 ° C or lower is also a thermosetting resin.

作為所含浸的熱可塑性樹脂及熱硬化性樹脂，例如環氧樹脂、丙烯酸樹脂、苯酚樹脂、聚醯胺樹脂、聚醯亞胺樹脂、及這些樹脂的變性樹脂；可使用從這些之中選出的一種以上。 As the impregnated thermoplastic resin and thermosetting resin, for example, an epoxy resin, an acrylic resin, a phenol resin, a polyamide resin, a polyimide resin, and a denatured resin of these resins; those selected from these can be used. More than one.

作為將熱可塑性樹脂及熱硬化性樹脂含浸於切割刃部 的方法，具體來說，在熱可塑性樹脂的情況，例如將加工成ψ 0.1~2.0mm、較佳為ψ 0.8~1.5mm的線狀、粉狀、或與切割刃部的形狀尺寸相同且厚度為0.05~1.5mm的環狀的薄膜狀的熱可塑性樹脂，放置於切割刃部，在加熱板這樣的加熱器上、烤爐中等，將升溫到熔點以上且熔融的樹脂，含浸於切割刃部，然後漸漸冷卻回到室溫的方法。在熱硬化性樹脂的情況，例如，將包含有機溶劑、硬化劑等的液狀的熱硬化性樹脂組成物，放置於切割刃部浸透，升溫到硬化溫度以上，使其硬化，漸漸冷卻回到室溫的方法。其他，在於切割刃部的附近有些許餘隙的下模具，在將含浸前的外周切斷刃放入之後，將預先量取的樹脂或樹脂組成物充填，嵌合上模具，將上下適度加壓同時加熱，將樹脂或樹脂組成物含浸於切割刃部，冷卻然後解除壓力，將其從模具取出。加熱之後，為了不殘留應變，將其漸漸冷卻。 Impregnating the thermoplastic resin and the thermosetting resin to the cutting edge The method, specifically, in the case of a thermoplastic resin, for example, is processed into a linear shape, a powder shape of 0.1 to 2.0 mm, preferably 0.8 to 1.5 mm, or the same shape and thickness as that of the cutting edge portion. The annular film-shaped thermoplastic resin of 0.05 to 1.5 mm is placed on the cutting edge portion, and is heated on the heater such as a hot plate or an oven to impregnate the cutting edge with a resin that has been heated to a melting point or higher and melted. Then gradually cool down to room temperature. In the case of the thermosetting resin, for example, a liquid thermosetting resin composition containing an organic solvent, a curing agent, or the like is placed in the cutting edge portion to be infiltrated, heated to a curing temperature or higher, and hardened, and gradually cooled back. Room temperature method. In the other case, the lower mold having a slight clearance in the vicinity of the cutting edge portion is filled with the resin or the resin composition which is measured in advance before the outer peripheral cutting blade is placed before the impregnation, and the mold is fitted and the upper and lower portions are appropriately added. The pressure is simultaneously heated, and the resin or resin composition is impregnated into the cutting edge portion, cooled, and then the pressure is released, and taken out from the mold. After heating, it is gradually cooled in order not to leave strain.

在將濕潤性較高的樹脂進行含浸的情況，將台板以不鏽鋼、鐵、銅等的金屬夾住然後通電，藉由使該金屬發熱，來將台板及切割刃部加熱，使發熱的切割刃部接觸到樹脂熔化的熔液或液狀的樹脂組成物，而進行含浸。 When the resin having high wettability is impregnated, the platen is sandwiched between metal such as stainless steel, iron, or copper, and then energized, and the metal is heated to heat the platen and the cutting edge portion to generate heat. The cutting blade portion is in contact with the melted molten metal or the liquid resin composition to be impregnated.

以該方式所得到的切割刃部，讓磨粒、將塗層於磨粒的磁性體、金屬結合材、含浸於間隙的樹脂成為適度分散的狀態。 In the cutting blade portion obtained in this manner, the abrasive grains, the magnetic material coated with the abrasive grains, the metal bonding material, and the resin impregnated into the gap are appropriately dispersed.

含浸於該切割刃部的樹脂的物性，適合為以下所示。熔點為350℃以下的範圍較佳。熱可塑性樹脂的情況，為 了防止：在超硬合金台板產生應變而尺寸精度惡化、機械強度變化、超硬合金台板與切割刃部的熱膨脹差明顯而讓切割刃部變形、或殘留有應變；而針對熔點的上限溫度，為350℃以下，較佳為300℃以下。另一方面，熱硬化樹脂的情況，為了在室溫附近含浸組成物，只要有足夠的流動性即可，熔點為10℃以上較佳。 The physical properties of the resin impregnated into the cutting edge portion are as follows. A melting point of 350 ° C or less is preferred. In the case of thermoplastic resin, Prevention: Strain occurs in the super-hard alloy platen, the dimensional accuracy is deteriorated, the mechanical strength changes, the difference in thermal expansion between the super-hard alloy platen and the cutting edge portion is obvious, and the cutting edge portion is deformed or strain is left; and the upper limit for the melting point is The temperature is 350 ° C or lower, preferably 300 ° C or lower. On the other hand, in the case of the thermosetting resin, in order to impregnate the composition at around room temperature, it is preferable that the melting point is 10 ° C or more as long as it has sufficient fluidity.

樹脂的彈性，帕松比(Poisson ratio)為0.3~0.48，較佳為0.33~0.44者較適合。帕松比(Poisson ratio)低於0.3的情況，缺乏柔軟性，很難讓切斷面滑順地連接。帕松比(Poisson ratio)高於0.48的情況，硬度等其他物性不夠，刀鋒的變形會過大。帕松比(Poisson ratio)，是使用供含浸的樹脂的15×15×15mm的試料，藉由脈衝超音波法所測定。 The resin has a Poisson ratio of 0.3 to 0.48, preferably 0.33 to 0.44. When the Poisson ratio is less than 0.3, the flexibility is lacking, and it is difficult to make the cut surface smoothly connected. When the Poisson ratio is higher than 0.48, other physical properties such as hardness are insufficient, and the deformation of the blade is too large. The Poisson ratio was measured by a pulse ultrasonic method using a 15 × 15 × 15 mm sample containing an impregnated resin.

樹脂的硬度，只要其程度為不會妨礙：即使在切斷中磨粒磨掉、破壞、脫落等，下個磨粒也會露出而有助於切斷的作用(磨粒的自生作用)即可，其硬度低於：覆蓋磨粒的磁性體或固定磨粒的金屬結合材較佳。而且必須即使暴露於在切削加工時所用的加工油或冷卻液，也不會產生強度變化或腐蝕。 The hardness of the resin is not hindered as long as the abrasive grains are worn away, broken, peeled off, etc. during the cutting, and the next abrasive grains are exposed to contribute to the cutting action (the self-generating action of the abrasive grains). Preferably, the hardness is lower than: the magnetic material covering the abrasive grains or the metal bonding material of the fixed abrasive grains is preferred. Moreover, it is necessary to cause no change in strength or corrosion even when exposed to the processing oil or coolant used in the cutting process.

用來含浸樹脂的切割刃部，因應需要，可使用利用氧化鋁、碳化矽、鑽石等的磨石所進行的研磨加工、或放電加工等調整成所需要的尺寸。此時，雖然根據刃厚，而在刀鋒實施C0.1以上或R0.1以上的倒角的方式，除了能減少切斷面的切割痕跡，且能有效減低磁鐵端面的缺口。 The cutting edge portion for impregnating the resin can be adjusted to a desired size by grinding or electric discharge machining using a grindstone such as alumina, tantalum carbide or diamond, if necessary. In this case, the chamfering of C0.1 or more or R0.1 or more is performed on the blade edge according to the blade thickness, and the cutting marks of the cut surface can be reduced, and the notch of the magnet end face can be effectively reduced.

適用本發明的外周切斷刃的切斷，作為其被加工物(被切斷物)，對於R-Co類稀土類燒結磁鐵，R-Fe-B類稀土類燒結磁鐵(R是包含Y的稀土類元素的至少一種)的切斷很有效。這些磁鐵，例如以下述方式所製造。 The cutting of the outer peripheral cutting blade of the present invention is applied to the workpiece (cut object), and the R-Fe-based rare earth sintered magnet and the R-Fe-B rare earth sintered magnet (R is Y-containing). The cutting of at least one of the rare earth elements is effective. These magnets are manufactured, for example, in the following manner.

R-Co類稀土類燒結磁鐵，具有：RCo5類、R2Co17類等。其中，例如，在R2Co17類，是由：質量百分率20~28%的R、5~30%的Fe、3~10%的Cu、1~5%的Zr、及剩餘部Co所構成。以該成分比秤量原料來進行溶解、鑄造，將所得到的合金微粉碎至平均粒徑1~20μm，而得到R2Co17類磁鐵石粉末。然後在磁場中成形，並且以1100~1250℃燒結0.5~5小時，接著以較燒結溫度更低0~50℃的温度，進行溶體化0.5~5小時，最後以700~950℃保持一定時間後，實施冷卻的時效處理。 The R-Co rare earth sintered magnet has RCo type 5 and R 2 Co 17 type. Among them, for example, R 2 Co 17 is composed of R of 20 to 28% by mass, Fe of 5 to 30%, Cu of 3 to 10%, Zr of 1 to 5%, and Co of the remainder. . The ratio of component to be weighed raw materials were dissolved, casting the alloy obtained finely pulverized to a mean particle diameter of 1 ~ 20μm, to obtain a R 2 Co 17 magnet powder stone. Then, it is formed in a magnetic field, and is sintered at 1100~1250 ° C for 0.5 to 5 hours, and then melted at a temperature lower than the sintering temperature by 0 to 50 ° C for 0.5 to 5 hours, and finally maintained at 700 to 950 ° C for a certain period of time. After that, the aging treatment of cooling is carried out.

R-Fe-B類稀土類燒結磁鐵，是由：質量百分率5~40%的R、50~90%的Fe、0.2~8%的B所構成；為了改善磁性特性或耐蝕性，添加：C、Al、Si、Ti、V、Cr、Mn、Co、Ni、Cu、Zn、Ga、Zr、Nb、Mo、Ag、Sn、Hf、Ta、W等的添加元素。這些添加元素的添加量，在Co的情況，質量百分率為30%以下，其他元素的情況則質量百分率為8%以下。以該成分比秤量原料來進行溶解、鑄造，將所得到的合金微粉碎至平均粒径1~20μm，而得到R-Fe-B類磁鐵粉末。然後在磁場中成形，並且以1000~1200℃燒結0.5~5小時，在400~1000℃保持一定時間後，實施冷卻的時效處理。 The R-Fe-B rare earth sintered magnet is composed of R of 50 to 40% by mass, Fe of 50 to 90%, and B of 0.2 to 8%. In order to improve magnetic properties or corrosion resistance, add: C Additive elements such as Al, Si, Ti, V, Cr, Mn, Co, Ni, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Sn, Hf, Ta, W, and the like. The addition amount of these additive elements is 30% or less in the case of Co, and 8% or less in the case of other elements. This component was dissolved and cast by weighing the raw material, and the obtained alloy was finely pulverized to an average particle diameter of 1 to 20 μm to obtain an R-Fe-B-based magnet powder. Then, it is formed in a magnetic field, and is sintered at 1000 to 1200 ° C for 0.5 to 5 hours, and after being kept at 400 to 1000 ° C for a certain period of time, the aging treatment of cooling is performed.

本發明的外周切斷刃，尤其讓刀鋒的壓縮剪斷應力在預定的範圍的話，則能有效讓在切斷面不會殘留切割痕跡，能以高尺寸精度切出稀土類磁鐵。例如，在外周切斷刃，調整為：切割刃部的厚度為0.1~1.0mm，外徑為80~200mm，刀鋒的倒角以R或C為0.1以上之後，讓外周切斷刃成為水平，使用：以只有切割刃部露出的厚度5mm的圓形鐵板上下夾住外周切斷刃之支承夾具，按壓時保持成讓台板部分不會翹曲，在從超硬合金台板的外周朝外側離開0.3mm的位置，將切割刃部，以接觸部的長度(切割刃部的突出量-0.3mm)、寬度為10mm的壓頭，在外周切斷刃的旋轉軸方向(切割刃部的厚度方向)以線速1mm/min按壓，將該動作持續至切割刃部斷裂，來測定相對於壓頭的移動量之應力。在該情況壓頭的移動量變大的話，確認為曲線圖顯示直線性的區域，也就是壓頭的移動量與應力成比例的區域。計算出該變形量與應力的比例區域的傾斜度的話，在100~10000N/mm的範圍，能有效於在切斷面不會殘留切割痕跡，且能切出高尺寸精度的磁鐵。 In the outer peripheral cutting blade of the present invention, in particular, when the compression shear stress of the blade is within a predetermined range, the cutting mark can be effectively prevented from remaining on the cut surface, and the rare earth magnet can be cut with high dimensional accuracy. For example, the outer peripheral cutting blade is adjusted so that the thickness of the cutting edge portion is 0.1 to 1.0 mm, the outer diameter is 80 to 200 mm, and the chamfering of the blade edge is set to R or C of 0.1 or more, and the outer peripheral cutting blade is made horizontal. Use: The support jig that clamps the outer peripheral cutting edge with a circular iron plate having a thickness of 5 mm exposed only by the cutting edge portion, and is held so that the platen portion does not warp when pressed, on the outer circumference of the superhard alloy platen. When the outer side is separated by a position of 0.3 mm, the cutting edge portion has a length of the contact portion (the protruding amount of the cutting edge portion is -0.3 mm) and a head having a width of 10 mm, and the cutting axis is in the direction of the rotation axis of the cutting edge (the cutting edge portion) The thickness direction was pressed at a linear velocity of 1 mm/min, and this operation was continued until the cutting blade portion was broken to measure the stress with respect to the amount of movement of the indenter. In this case, when the amount of movement of the indenter is increased, it is confirmed that the graph shows a linear region, that is, a region in which the amount of movement of the indenter is proportional to the stress. When the inclination of the ratio of the deformation amount to the stress is calculated, in the range of 100 to 10000 N/mm, it is possible to effectively prevent the cutting marks from remaining on the cut surface and to cut out the magnet having high dimensional accuracy.

〔實施例〕 [Examples]

以下顯示實施例及比較例，具體說明本發明，而本發明並不限於下述實施例。 The present invention will be specifically described below by showing examples and comparative examples, but the present invention is not limited to the following examples.

〔實施例1〕 [Example 1]

將質量百分率WC為90%，Co為10%的超硬合金，加 工成外徑ψ 125mm×內徑ψ 40mm×厚度0.3mm的環狀具有孔的圓板，成為台板。該台板的楊氏模量為600GPa，飽和磁化量為127kA/m(0.16T)。 a superhard alloy with a mass percentage WC of 90% and a Co of 10%. A circular disk having an outer diameter ψ 125 mm × an inner diameter ψ 40 mm × a thickness of 0.3 mm and having a hole is formed into a platen. The platen has a Young's modulus of 600 GPa and a saturation magnetization of 127 kA/m (0.16 T).

將該台板以黏貼帶遮蔽成僅讓從外周端起朝內側1.0mm的部分露出，在市面販賣的脫脂鹼水溶液以40℃含浸10分鐘後，進行水洗，在50℃的焦磷酸鈉30~80g/L的水溶液以2~8A/dm2通電同時進行電解。接著，將超硬合金台板在純水中進行超音波洗淨之後，將其含浸於50℃的磺胺酸瓦特鎳電鍍液，以5~20A/dm2通電進行基體電鍍之後，將遮蔽帶剝落進行水洗。 The platen was shielded by an adhesive tape so that only a portion of 1.0 mm from the outer peripheral end was exposed, and the commercially available defatted alkali aqueous solution was impregnated at 40 ° C for 10 minutes, and then washed with water to a sodium pyrophosphate at 50 ° C for 30 minutes. 80g / L of aqueous solution of 2 ~ 8A / dm 2 electrolysis energized simultaneously. Next, after supersonic cleaning of the superhard alloy platen in pure water, it is impregnated with a sulfamic acid Watt nickel plating solution at 50 ° C, and after electroplating the substrate with 5 to 20 A/dm 2 , the masking tape is peeled off. Washed with water.

接著在外徑ψ 130mm，厚度10mm的PPS樹脂製圓盤的一側面，形成外徑ψ 123mm，內徑ψ 119mm，深度1.5mm的溝部，於該溝部，將長度2.5mm×寬度2mm×厚度1.5mm的永久磁鐵(shinetsu-rare-earth-magnet製的N39UH，Br=1.25T)，將厚度方向作為圓盤的深度方向，以均等間隔每一個圓盤排列75個之後，製作以環氧樹脂埋住溝部將磁鐵固定的外殼，以由該兩片外殼所構成的夾具主體，將磁鐵側作為內側來夾持台板。此時，磁鐵是與台板外周端朝台板側面內側方向相距1mm。針對從台板外周端到10mm為止的空間內所形成的磁場進行磁場解析，磁場強度為8kA/m(0.01T)以上。 Next, on one side of the PPS resin disk having an outer diameter of mm130 mm and a thickness of 10 mm, a groove portion having an outer diameter ψ 123 mm, an inner diameter ψ 119 mm, and a depth of 1.5 mm was formed, and in the groove portion, the length was 2.5 mm × width 2 mm × thickness 1.5 mm. Permanent magnet (N39UH, shinetsu-rare-earth-magnet, Br=1.25T), the thickness direction is taken as the depth direction of the disc, and 75 discs are arranged at equal intervals, and then epoxy resin is buried. The outer casing in which the magnet is fixed in the groove portion sandwiches the platen with the magnet body side as the inner side of the jig body composed of the two outer casings. At this time, the magnet is spaced apart from the outer peripheral end of the platen by 1 mm toward the inner side of the side surface of the platen. The magnetic field analysis was performed on the magnetic field formed in the space from the outer peripheral end of the platen to 10 mm, and the magnetic field strength was 8 kA/m (0.01 T) or more.

將預先以NiP電鍍而質量磁化率χ g為0.588，平均粒徑為135μm的鑽石磨粒0.4g，全周均等地磁性吸引到以夾具與台板作出的凹部。接著在磁性吸引著磨粒的狀態 ，將每個夾具含浸於50℃的磺胺酸瓦特鎳電鍍液，在5~20A/dm2的範圍通電進行電鍍，然後進行水洗。然後磁性吸引0.4g的鑽石磨粒，再次反覆與上述同樣的電鍍而進行水洗的操作。 0.4 g of diamond abrasive grains having a mass magnetic susceptibility χ g of 0.588 and an average particle diameter of 135 μm , which were previously electroplated with NiP, were magnetically attracted to the concave portions formed by the jig and the platen. Next, in the state where the abrasive grains were magnetically attracted, each jig was impregnated with a sulfamic acid Watt nickel plating solution at 50 ° C, electroplated in a range of 5 to 20 A/dm 2 , and then washed with water. Then, 0.4 g of diamond abrasive grains were magnetically attracted, and the same washing operation as above was carried out to perform a water washing operation.

為了讓所得到的磨粒層兩側面露出，將夾具主體交換成外徑ψ 123mm，厚度10mm的PPS樹脂製圓盤，含浸在50℃的磺胺酸瓦特鎳電鍍液，在5~20A/dm2的範圍通電，電鍍析出成覆蓋切割刃部全體，進行水洗，從夾具卸下而進行乾燥。 In order to expose both sides of the obtained abrasive grain layer, the jig body was exchanged into a PPS resin disk having an outer diameter of mm123 mm and a thickness of 10 mm, and a sulfamate nickel nickel plating solution impregnated at 50 ° C at 5 to 20 A/dm 2 . The range was energized, and the plating was deposited to cover the entire cutting blade portion, washed with water, and removed from the jig to be dried.

接著，將丙二酚A二環氧甘油醚與雙氰胺作為樹脂主成分而溶解於有機溶媒的液狀環氧樹脂組成物，塗佈於外周切斷刃的切割刃部側面，保持3分鐘，保持其狀態放入180℃的烤爐保持約120分鐘之後，切斷加熱而在烤爐內自然冷卻。該硬化的環氧樹脂的帕松比(Poisson ratio)為0.34。在第5圖顯示切割刃部的刀鋒側面的顯微鏡照片。 Next, a liquid epoxy resin composition in which propylene glycol A diglycidyl ether and dicyandiamide are used as a main component of the resin and dissolved in an organic solvent is applied to the side surface of the cutting edge portion of the outer peripheral cutting blade for 3 minutes. After maintaining the state in an oven at 180 ° C for about 120 minutes, the heating was cut off and naturally cooled in the oven. The hardened epoxy resin had a Poisson ratio of 0.34. Fig. 5 shows a micrograph of the blade side of the cutting edge.

然後使用工具研磨盤，以讓磨粒層從超硬合金台板的突出為朝單側為50μm的方式，以磨石研磨來調整磨粒層的突出與厚度及外徑之後，進行修整，而得到形成有厚度0.4mm，外徑127mm的磨粒層(切割刃部)的超硬合金台板外周切斷刃。 Then use a tool to grind the disc so that the abrasive layer is protruded from the superhard alloy platen to a single side of 50 μm , and after grinding the grindstone to adjust the protrusion and thickness and outer diameter of the abrasive layer, perform trimming. Further, a superhard alloy platen outer peripheral cutting edge having an abrasive grain layer (cutting edge portion) having a thickness of 0.4 mm and an outer diameter of 127 mm was obtained.

〔實施例2〕 [Example 2]

將質量百分率WC為90%，Co為10%的超硬合金，加工成外徑ψ 125mm×內徑ψ 40mm×厚度0.3mm的環狀具有 孔的圓板，成為台板。 A superhard alloy having a mass percentage WC of 90% and a Co of 10% is processed into a ring shape having an outer diameter ψ 125 mm × an inner diameter ψ 40 mm × a thickness of 0.3 mm. The circular plate of the hole becomes a platen.

將該台板以黏貼帶遮蔽成僅讓從外周端起朝內側1.5mm的部分露出，在市面販賣的脫脂鹼水溶液以40℃含浸10分鐘後，進行水洗，在50℃的焦磷酸鈉30~80g/L的水溶液以2~8A/dm2通電同時進行電解。接著，將超硬合金台板在純水中進行超音波洗淨之後，將其含浸於50℃的磺胺酸瓦特鎳電鍍液，以5~20A/dm2通電進行基體電鍍之後，將遮蔽帶剝落進行水洗。 The platen was shielded by an adhesive tape so as to be exposed only to a portion 1.5 mm from the outer peripheral end, and the commercially available defatted alkali aqueous solution was impregnated at 40 ° C for 10 minutes, and then washed with water to a sodium pyrophosphate at 50 ° C for 30 minutes. 80g / L of aqueous solution of 2 ~ 8A / dm 2 electrolysis energized simultaneously. Next, after supersonic cleaning of the superhard alloy platen in pure water, it is impregnated with a sulfamic acid Watt nickel plating solution at 50 ° C, and after electroplating the substrate with 5 to 20 A/dm 2 , the masking tape is peeled off. Washed with water.

接著在外徑ψ 130mm，厚度10mm的PPS樹脂製圓盤的一側面，形成外徑ψ 123mm，內徑ψ 119mm，深度1.5mm的溝部，於該溝部，將長度1.8mm×寬度2mm×厚度1.5mm的永久磁鐵(shinetsu-rare-earth-magnet製的N32Z，Br=1.14T)，將厚度方向作為圓盤的深度方向，以均等間隔每一個圓盤排列105個之後，製作以環氧樹脂埋住溝部將磁鐵固定的外殼，以由該兩片外殼所構成的夾具主體，將磁鐵側作為內側來夾持台板。此時，磁鐵是與台板外周端朝台板側面內側方向相距1.5mm。針對從台板外周端到10mm為止的空間內所形成的磁場進行磁場解析，磁場強度為16kA/m(0.02T)以上。 Next, on one side of the PPS resin disk having an outer diameter of 130 mm and a thickness of 10 mm, a groove portion having an outer diameter ψ 123 mm, an inner diameter ψ 119 mm, and a depth of 1.5 mm was formed, and in the groove portion, the length was 1.8 mm × width 2 mm × thickness 1.5 mm. Permanent magnet (N32Z manufactured by shinetsu-rare-earth-magnet, Br=1.14T), the thickness direction is taken as the depth direction of the disk, and 105 disks are arranged at equal intervals, and then epoxy resin is buried. The outer casing in which the magnet is fixed in the groove portion sandwiches the platen with the magnet body side as the inner side of the jig body composed of the two outer casings. At this time, the magnet is spaced apart from the outer peripheral end of the platen toward the inner side of the side of the platen by 1.5 mm. The magnetic field analysis was performed on the magnetic field formed in the space from the outer peripheral end of the platen to 10 mm, and the magnetic field strength was 16 kA/m (0.02 T) or more.

將預先以NiP電鍍而質量磁化率χ g為0.588，平均粒徑為135μm的鑽石磨粒0.4g，全周均等地磁性吸引到以夾具與台板作出的凹部。接著在磁性吸引著磨粒的狀態，將每個夾具含浸於50℃的磺胺酸瓦特鎳電鍍液，在5~20A/dm2的範圍通電進行電鍍，然後進行水洗。然後磁性 吸引0.4g的鑽石磨粒，再次反覆三次與上述同樣的電鍍而進行水洗的操作。 0.4 g of diamond abrasive grains having a mass magnetic susceptibility χ g of 0.588 and an average particle diameter of 135 μm , which were previously electroplated with NiP, were magnetically attracted to the concave portions formed by the jig and the platen. Next, in the state where the abrasive grains were magnetically attracted, each jig was impregnated with a sulfamic acid Watt nickel plating solution at 50 ° C, electroplated in a range of 5 to 20 A/dm 2 , and then washed with water. Then, 0.4 g of diamond abrasive grains were magnetically attracted, and the same plating as above was repeated three times to perform a water washing operation.

為了讓所得到的磨粒層兩側面露出，將夾具主體交換成外徑ψ 123mm，厚度10mm的PPS樹脂製圓盤，含浸在50℃的磺胺酸瓦特鎳電鍍液，在5~20A/dm2的範圍通電，電鍍析出成覆蓋切割刃部全體，進行水洗，從夾具卸下而進行乾燥。 In order to expose both sides of the obtained abrasive grain layer, the jig body was exchanged into a PPS resin disk having an outer diameter of mm123 mm and a thickness of 10 mm, and a sulfamate nickel nickel plating solution impregnated at 50 ° C at 5 to 20 A/dm 2 . The range was energized, and the plating was deposited to cover the entire cutting blade portion, washed with water, and removed from the jig to be dried.

接著，將在實施例1使用的液狀環氧樹脂組成物，塗佈於外周切斷刃的切割刃部的側面保持5分鐘，保持其狀態放入180℃的烤爐保持約120分鐘之後，切斷加熱而在烤爐內自然冷卻。 Next, the liquid epoxy resin composition used in Example 1 was applied to the side surface of the cutting edge portion of the outer peripheral cutting blade for 5 minutes, and held in an oven at 180 ° C for about 120 minutes. The heating is cut off and naturally cooled in the oven.

然後使用工具研磨盤，以讓磨粒層從超硬合金台板的突出為朝單側為50μm的方式，以磨石研磨來調整磨粒層的突出與厚度及外徑之後，進行修整，而得到形成有厚度0.4mm，外徑129mm的磨粒層(切割刃部)的超硬合金台板外周切斷刃。 Then use a tool to grind the disc so that the abrasive layer is protruded from the superhard alloy platen to a single side of 50 μm , and after grinding the grindstone to adjust the protrusion and thickness and outer diameter of the abrasive layer, perform trimming. Further, a superhard alloy platen outer peripheral cutting edge having an abrasive grain layer (cutting edge portion) having a thickness of 0.4 mm and an outer diameter of 129 mm was obtained.

〔實施例3〕 [Example 3]

將質量百分率WC為90%，Co為10%的超硬合金，加工成外徑ψ 125mm×內徑ψ 40mm×厚度0.3mm的環狀具有孔的圓板，成為台板。 A superhard alloy having a mass percentage WC of 90% and a Co of 10% was processed into a circular disk having an outer diameter of ψ 125 mm × an inner diameter ψ 40 mm × a thickness of 0.3 mm to form a platen.

將該台板以黏貼帶遮蔽成僅讓從外周端起朝內側1.0mm的部分露出，在市面販賣的脫脂鹼水溶液以40℃含浸10分鐘後，進行水洗，在50℃的焦磷酸鈉30~80g/L 的水溶液以2~8A/dm2通電同時進行電解。接著，將超硬合金台板在純水中進行超音波洗淨之後，將其含浸於50℃的磺胺酸瓦特鎳電鍍液，以5~20A/dm2通電進行基體電鍍之後，將遮蔽帶剝落進行水洗。 The platen was shielded by an adhesive tape so that only a portion of 1.0 mm from the outer peripheral end was exposed, and the commercially available defatted alkali aqueous solution was impregnated at 40 ° C for 10 minutes, and then washed with water to a sodium pyrophosphate at 50 ° C for 30 minutes. The 80 g/L aqueous solution was electrolyzed while being energized at 2-8 A/dm 2 . Next, after supersonic cleaning of the superhard alloy platen in pure water, it is impregnated with a sulfamic acid Watt nickel plating solution at 50 ° C, and after electroplating the substrate with 5 to 20 A/dm 2 , the masking tape is peeled off. Washed with water.

接著以實施例1所用的夾具主體來夾持台板，將預先以NiP電鍍而質量磁化率χ g為0.392，平均粒徑為130μm的鑽石磨粒0.4g，全周均等地磁性吸引到以夾具與台板作出的凹部。接著在磁性吸引著磨粒的狀態，將每個夾具含浸於40℃的焦磷酸銅電鍍液，在1~20A/dm2的範圍通電進行電鍍，進行水洗，從夾具卸下而進行乾燥。 Next, the platen was held by the jig main body used in Example 1, and 0.4 g of diamond abrasive grains having a mass magnetic susceptibility χ g of 0.392 and an average particle diameter of 130 μm , which were previously electroplated with NiP, were magnetically attracted to the entire circumference. A recess made with a clamp and a platen. Next, in the state where the abrasive grains were magnetically attracted, each jig was impregnated with a copper pyrophosphate plating solution at 40 ° C, electroplated in a range of 1 to 20 A/dm 2 , washed with water, and removed from the jig to be dried.

接著，將在實施例1使用的液狀環氧樹脂組成物，塗佈於外周切斷刃的切割刃部的側面保持5分鐘，保持其狀態放入180℃的烤爐保持約120分鐘之後，切斷加熱而在烤爐內自然冷卻。 Next, the liquid epoxy resin composition used in Example 1 was applied to the side surface of the cutting edge portion of the outer peripheral cutting blade for 5 minutes, and held in an oven at 180 ° C for about 120 minutes. The heating is cut off and naturally cooled in the oven.

然後使用工具研磨盤，以讓磨粒層從超硬合金台板的突出為朝單側為50μm的方式，以磨石研磨來調整磨粒層的突出與厚度及外徑之後，進行修整，而得到形成有厚度0.4mm，外徑126mm的磨粒層(切割刃部)的超硬合金台板外周切斷刃。 Then use a tool to grind the disc so that the abrasive layer is protruded from the superhard alloy platen to a single side of 50 μm , and after grinding the grindstone to adjust the protrusion and thickness and outer diameter of the abrasive layer, perform trimming. Further, a superhard alloy platen outer peripheral cutting blade having an abrasive grain layer (cutting edge portion) having a thickness of 0.4 mm and an outer diameter of 126 mm was obtained.

〔實施例4〕 [Example 4]

將質量百分率WC為95%，Co為5%的超硬合金，加工成外徑ψ 125mm×內徑ψ 40mm×厚度0.3mm的環狀具有孔的圓板，成為台板。該台板的楊氏模量為580GPa，飽 和磁化量為40kA/m(0.05T)。 A superhard alloy having a mass percentage WC of 95% and a Co of 5% was processed into a circular disk having a diameter of ψ 125 mm × an inner diameter ψ 40 mm × a thickness of 0.3 mm to form a platen. The plate has a Young's modulus of 580GPa, full And the amount of magnetization is 40kA/m (0.05T).

將該台板以黏貼帶遮蔽成僅讓從外周端起朝內側1.0mm的部分露出，在市面販賣的脫脂鹼水溶液以40℃含浸10分鐘後，進行水洗，在50℃的焦磷酸鈉30~80g/L的水溶液以2~8A/dm2通電同時進行電解。接著，將超硬合金台板在純水中進行超音波洗淨之後，將其含浸於50℃的磺胺酸瓦特鎳電鍍液，以5~20A/dm2通電進行基體電鍍之後，將遮蔽帶剝落進行水洗。 The platen was shielded by an adhesive tape so that only a portion of 1.0 mm from the outer peripheral end was exposed, and the commercially available defatted alkali aqueous solution was impregnated at 40 ° C for 10 minutes, and then washed with water to a sodium pyrophosphate at 50 ° C for 30 minutes. 80g / L of aqueous solution of 2 ~ 8A / dm 2 electrolysis energized simultaneously. Next, after supersonic cleaning of the superhard alloy platen in pure water, it is impregnated with a sulfamic acid Watt nickel plating solution at 50 ° C, and after electroplating the substrate with 5 to 20 A/dm 2 , the masking tape is peeled off. Washed with water.

接著以實施例1所用的夾具主體來夾持台板，將預先以NiP電鍍而質量磁化率χ g為0.392，平均粒徑為130μm的鑽石磨粒0.3g，全周均等地磁性吸引到以夾具與台板作出的凹部。接著在磁性吸引著磨粒的狀態，將每個夾具含浸於80℃的無電解鎳、磷合金電鍍液進行無電解電鍍之後，進行水洗。然後，磁性吸引0.3g鑽石磨粒，反覆兩次與上述同樣地進行電鍍而水洗的操作，從夾具卸下而進行乾燥。 Next, the platen was held by the jig body used in Example 1, and 0.3 g of diamond abrasive grains having a mass magnetic susceptibility χ g of 0.392 and an average particle diameter of 130 μm which were previously electroplated with NiP were magnetically attracted to the entire circumference. A recess made with a clamp and a platen. Next, in the state where the abrasive grains were magnetically attracted, each jig was impregnated with an electroless nickel or phosphorus alloy plating solution at 80 ° C for electroless plating, and then washed with water. Then, 0.3 g of diamond abrasive grains were magnetically attracted, and the operation of performing electroplating and water washing in the same manner as described above was carried out, and the operation was carried out by being removed from the jig and dried.

接著，將包含：甲基丙烯酸甲酯、甲基丙烯酸二酯、氯磺化聚乙烯以及異丙苯過氧化氫之液狀丙烯酸樹脂組成物，塗佈於外周切斷刃的切斷刃部側面，放入80℃的烤爐緩緩地減壓至真空狀態，然後加熱60分鐘之後，在減壓狀態的庫內冷卻。該硬化的丙烯酸樹脂的帕松比(Poisson ratio)為0.4。 Next, a liquid acrylic resin composition containing methyl methacrylate, methacrylic acid diester, chlorosulfonated polyethylene, and cumene hydroperoxide is applied to the side of the cutting edge portion of the outer peripheral cutting edge. It was placed in an oven at 80 ° C and gradually depressurized to a vacuum state, and then heated for 60 minutes, and then cooled in a reduced pressure state. The hardened acrylic resin had a Poisson ratio of 0.4.

然後使用工具研磨盤，以讓磨粒層從超硬合金台板的突出為朝單側為50μm的方式，以磨石研磨來調整磨粒層 的突出與厚度及外徑之後，進行修整，而得到形成有厚度0.4mm，外徑127mm的磨粒層(切割刃部)的超硬合金台板外周切斷刃。 Then use a tool to grind the disc so that the abrasive layer is protruded from the superhard alloy platen to a single side of 50 μm , and after grinding the grindstone to adjust the protrusion and thickness and outer diameter of the abrasive layer, perform trimming. Further, a superhard alloy platen outer peripheral cutting edge having an abrasive grain layer (cutting edge portion) having a thickness of 0.4 mm and an outer diameter of 127 mm was obtained.

〔比較例1〕 [Comparative Example 1]

將質量百分率WC為90%，Co為10%的超硬合金，加工成外徑ψ 125mm×內徑ψ 40mm×厚度0.3mm的環狀具有孔的圓板，成為台板。 A superhard alloy having a mass percentage WC of 90% and a Co of 10% was processed into a circular disk having an outer diameter of ψ 125 mm × an inner diameter ψ 40 mm × a thickness of 0.3 mm to form a platen.

將該台板以黏貼帶遮蔽成僅讓從外周端起朝內側1.0mm的部分露出，在市面販賣的脫脂鹼水溶液以40℃含浸10分鐘後，進行水洗，在50℃的焦磷酸鈉30~80g/L的水溶液以2~8A/dm2通電同時進行電解。接著，將超硬合金台板在純水中進行超音波洗淨之後，將其含浸於50℃的磺胺酸瓦特鎳電鍍液，以5~20A/dm2通電進行基體電鍍之後，將遮蔽帶剝落進行水洗。 The platen was shielded by an adhesive tape so that only a portion of 1.0 mm from the outer peripheral end was exposed, and the commercially available defatted alkali aqueous solution was impregnated at 40 ° C for 10 minutes, and then washed with water to a sodium pyrophosphate at 50 ° C for 30 minutes. 80g / L of aqueous solution of 2 ~ 8A / dm 2 electrolysis energized simultaneously. Next, after supersonic cleaning of the superhard alloy platen in pure water, it is impregnated with a sulfamic acid Watt nickel plating solution at 50 ° C, and after electroplating the substrate with 5 to 20 A/dm 2 , the masking tape is peeled off. Washed with water.

接著以實施例1所用的夾具主體來夾持台板，將預先以NiP電鍍而質量磁化率χ g為0.392，平均粒徑為130μm的鑽石磨粒0.4g，全周均等地磁性吸引到以夾具與台板作出的凹部。接著在磁性吸引著磨粒的狀態，將每個夾具含浸於50℃的磺胺酸瓦特鎳電鍍液，在5~20A/dm2的範圍通電進行電鍍，然後進行水洗。然後磁性吸引0.4g的鑽石磨粒，再次反覆與上述同樣的電鍍而進行水洗的操作。 Next, the platen was held by the jig main body used in Example 1, and 0.4 g of diamond abrasive grains having a mass magnetic susceptibility χ g of 0.392 and an average particle diameter of 130 μm , which were previously electroplated with NiP, were magnetically attracted to the entire circumference. A recess made with a clamp and a platen. Next, in the state where the abrasive grains were magnetically attracted, each jig was impregnated with a sulfamic acid Watt nickel plating solution at 50 ° C, electroplated in a range of 5 to 20 A/dm 2 , and then washed with water. Then, 0.4 g of diamond abrasive grains were magnetically attracted, and the same washing operation as above was carried out to perform a water washing operation.

為了讓所得到的磨粒層兩側面露出，將夾具主體交換成外徑ψ 123mm，厚度10mm的PPS樹脂製圓盤，含浸在 50℃的磺胺酸瓦特鎳電鍍液，在5~20A/dm2的範圍通電，電鍍析出成覆蓋切割刃部全體，進行水洗，從夾具卸下而進行乾燥。 In order to expose both sides of the obtained abrasive grain layer, the jig body was exchanged into a PPS resin disk having an outer diameter of mm123 mm and a thickness of 10 mm, and a sulfamate nickel nickel plating solution impregnated at 50 ° C at 5 to 20 A/dm 2 . The range was energized, and the plating was deposited to cover the entire cutting blade portion, washed with water, and removed from the jig to be dried.

然後使用工具研磨盤，以讓磨粒層從超硬合金台板的突出為朝單側為50μm的方式，以磨石研磨來調整磨粒層的突出與厚度及外徑之後，進行修整，而得到形成有厚度0.4mm，外徑127mm的磨粒層(切割刃部)的超硬合金台板外周切斷刃。 Then use a tool to grind the disc so that the abrasive layer is protruded from the superhard alloy platen to a single side of 50 μm , and after grinding the grindstone to adjust the protrusion and thickness and outer diameter of the abrasive layer, perform trimming. Further, a superhard alloy platen outer peripheral cutting edge having an abrasive grain layer (cutting edge portion) having a thickness of 0.4 mm and an outer diameter of 127 mm was obtained.

在表1，顯示實施例1~4以及比較例1的超硬合金台板外周切斷刃的製造良率。這裡所謂的電鍍良率，是直到藉由電鍍固定磨粒的步驟為止所實施的總數(各15片)之中，沒有磨粒的脫落或磨粒層的欠缺為良品，以百分率來顯示該電鍍良品的比例，所謂加工良率，是相對於所得到的電鍍良品，將電鍍後的步驟實施至修整為止，沒有磨粒層的欠缺為良品，以百分率來顯示加工良品相對於電鍍良品的總數的比例。所謂的綜合良率，是電鍍良率與加工良率的累積，代表相對於供外周切斷刃的製作之台板，成為外周切斷刃的完成品的良品的良率。 Table 1 shows the manufacturing yields of the outer peripheral cutting edges of the cemented carbide sheets of Examples 1 to 4 and Comparative Example 1. Here, the electroplating yield is a total number (15 sheets each) which is carried out until the step of fixing the abrasive grains by electroplating, and the absence of the abrasive grains or the lack of the abrasive layer is good, and the plating is shown in percentage. The ratio of the good product, the so-called processing yield, is based on the obtained electroplated product, and the step after electroplating is carried out until the trimming. The lack of the abrasive layer is good, and the percentage of the processed product relative to the total number of electroplated products is shown as a percentage. proportion. The so-called overall yield is the accumulation of the plating yield and the processing yield, and represents the yield of the finished product of the peripheral cutting blade with respect to the platen for the peripheral cutting blade.

從表1可看出，相較於比較例1，實施例的良率較好，尤其是電鍍後的加工的良率較好，本發明的製造方法在生產性方面也很優異。 As can be seen from Table 1, the yield of the examples was better than that of Comparative Example 1, and in particular, the yield after the plating was good, and the production method of the present invention was excellent in productivity.

在第6圖顯示了，使用超硬合金台板外周切斷刃，實施將稀土類燒結磁鐵切斷的操作時，用來評估磁鐵的切斷精度的結果。切斷精度的評估方法如以下。 Fig. 6 shows the results of evaluating the cutting accuracy of the magnet when the operation of cutting the rare earth sintered magnet is performed using the outer peripheral cutting blade of the cemented carbide platen. The evaluation method of the cutting accuracy is as follows.

首先，將實施例1~4以及比較例1的超硬合金台板外周切斷刃，各兩片總共10片，以間隔1.5mm，將旋轉軸插通於台板的孔部組成為多切斷刃。藉由該多切斷刃，以轉數4500rpm，進給速度30mm/min，從寬度(W)40mm×長度(L)130mm×高度(H)20mm的Nd-Fe-B類稀土類燒結磁鐵，將W40mm×L(=厚度(t))1.5mm×H20mm的磁鐵，切出1010次，將在實施例及比較例的各兩片的外周切斷刃之間切斷者，作為評估對象的切斷磁鐵。針對切斷磁鐵，將每從切斷第一片到100片作為尺寸測量週期(全部10個週期)，在各週期將最初的10片(也就是最初的週期為第1~10片，接著為第101~110片，最後為第1001~1010片)作為樣本。針對各週期的10片，每一片以微測儀測定中央一點與角落四點的總共五點的厚度(t)，將五點之中最大值與最小值的差當作切斷精度(μm)，計算出10片的切斷精度的平均值。將各尺寸測量週期的平均值作成曲線圖為第6圖。 First, the outer peripheral cutting blades of the superhard alloy platens of Examples 1 to 4 and Comparative Example 1 were used in a total of 10 pieces, and the holes were inserted into the hole portions of the platen at intervals of 1.5 mm. Broken edge. The Nd-Fe-B rare earth sintered magnet having a width (W) of 40 mm × a length (L) of 130 mm × a height (H) of 20 mm by a multi-cutting blade at a feed speed of 4,500 rpm and a feed speed of 30 mm/min. When the magnet of W40 mm × L (= thickness (t)) of 1.5 mm × H20 mm was cut out 1010 times, and cut between the outer cutting blades of the two sheets of the examples and the comparative examples, the cutting was performed. magnet. For the cutting magnet, the first 10 pieces are cut from the first piece to the 100 pieces, and the first 10 pieces are used in each cycle (that is, the first cycle is the first to the tenth, and then The first 101~110 pieces, and the last ones are the 1001~1010 pieces) as samples. For each of the 10 cycles of each cycle, each slice is measured by a micrometer to measure the thickness (t) of the total five points of the center point and the corner four points, and the difference between the maximum value and the minimum value among the five points is regarded as the cutting precision (μm). The average value of the cutting accuracy of 10 pieces was calculated. The average value of each dimension measurement period is plotted as a graph.

比較例1的情況，尺寸測量3週期以後(切斷片數第301片以後)，切斷精度變差，而實施例1~4的情況，是 直到第10週期(切斷片數直到第1010片)，切斷精度還未降低，所以可了解本發明的超硬合金台板外周切斷刃的使用耐久性很高。 In the case of Comparative Example 1, after three cycles of dimensional measurement (after 301 pieces of the number of cut sheets), the cutting accuracy was deteriorated, and in the cases of Examples 1 to 4, Until the 10th cycle (the number of cut pieces up to the 1010th piece), the cutting accuracy has not been lowered, so that the durability of the outer peripheral cutting blade of the cemented carbide platen of the present invention is high.

在第7圖顯示將所得到的外周切斷刃的彈性(柔軟性)評估的結果。這裡評估了外周切斷刃的刀鋒的壓縮剪斷應力。在各個例子的外周切斷刃，將刀鋒的倒角調整為R或C的0.1以上之後，在從超硬合金台板的外周起朝外側遠離0.3mm的位置，將切割刃部以接觸部的長度(切割刃部的突出量-0.3mm)、寬度為10mm的壓頭，朝外周切斷刃的旋轉軸方向(切割刃部的厚度方向)以線速1mm/min按壓時之相對於壓頭的移動量之應力，使用島津製作所強度試驗機AG-1進行測定，按壓是持續至切割刃部斷裂為止。在該測定，外周切斷刃成為水平，使用：以只有切割刃部露出的厚度5mm的圓形鐵板上下夾住外周切斷刃之支承夾具，按壓時保持成讓台板部分不會翹曲。 Fig. 7 shows the results of evaluation of the elasticity (softness) of the obtained outer peripheral cutting blade. Here, the compression shear stress of the blade of the peripheral cutting edge is evaluated. After cutting the blade on the outer circumference of each example and adjusting the chamfering of the blade edge to 0.1 or more of R or C, the cutting edge portion is at a contact portion from a position away from the outer periphery of the cemented carbide platen toward the outer side by 0.3 mm. The length (the projection amount of the cutting edge portion is -0.3 mm) and the indenter having a width of 10 mm are opposite to the indenter when the rotation axis direction of the outer peripheral cutting blade (the thickness direction of the cutting blade portion) is pressed at a linear velocity of 1 mm/min. The stress of the amount of movement was measured using a Shimadzu Corporation strength tester AG-1, and the pressing was continued until the cutting blade was broken. In this measurement, the outer peripheral cutting blade was horizontal, and a support jig that sandwiched the outer peripheral cutting blade with a circular iron having a thickness of 5 mm exposed only by the cutting blade portion was used, and the pressing portion was held so that the platen portion was not warped. .

如第7圖所示，在任何例子，壓頭的移動量變大的話，曲線顯示直線性的區域，也就是確認了壓頭的移動量與應力成比例的區域。在表2顯示計算出該直線區域的傾斜度(應力/壓頭的移動量)的結果。 As shown in Fig. 7, in any case, when the amount of movement of the indenter becomes large, the curve shows a linear region, that is, a region in which the amount of movement of the indenter is proportional to the stress. Table 2 shows the results of calculating the inclination of the straight line region (the amount of movement of the stress/indenter).

當上述切斷的評估時，使用實施例的外周切斷刃切斷所得到的磁鐵片，切斷面的外觀都很良好，而使用比較例的外周切斷刃切斷所得到的磁鐵片，在3週期以後(切斷片數第301片以後)，產生有在切斷面有切割痕跡(落差)的樣本。而確認了：藉由上述的外周切斷刃的彈性(柔軟性)評估所示的壓頭的移動量與應力的傾斜度並未過大，具有某程度柔軟性的本發明的外周切斷刃，在切斷面不會殘留切割痕跡，而能切出高尺寸精度的磁鐵。 In the evaluation of the above-mentioned cutting, the magnet piece obtained by cutting the outer peripheral cutting blade of the example was used, and the appearance of the cut surface was good, and the obtained magnet piece was cut by the outer peripheral cutting blade of the comparative example. After three cycles (after the 301th cut piece number), there was a sample having a cut mark (drop) on the cut surface. Further, it was confirmed that the amount of movement of the indenter and the inclination of the stress are not excessively large by the elasticity (flexibility) of the outer peripheral cutting blade, and the outer peripheral cutting blade of the present invention having a certain degree of flexibility is A cutting mark is not left on the cut surface, and a magnet of high dimensional accuracy can be cut out.

根據以上結果，藉由本發明的超硬合金台板外周切斷刃進行切斷，不用進行切斷後的加工處理，能將稀土類燒結磁鐵等的被加工物，僅以切斷則能高精度地加工，可提供高尺寸精度的被加工物。 According to the above results, the outer peripheral cutting blade of the superhard alloy platen of the present invention is cut, and the processed material such as the rare earth sintered magnet can be accurately cut only by cutting without performing the processing after the cutting. Machining provides high-precision workpieces.

1、10‧‧‧台板 1, 10‧‧‧ board

12‧‧‧內孔 12‧‧‧ Inner hole

20‧‧‧切割刃部 20‧‧‧ cutting blade

24‧‧‧金屬結合材 24‧‧‧Metal bonding materials

26‧‧‧磨粒 26‧‧‧ abrasive grain

50‧‧‧夾具主體 50‧‧‧Clamp body

52‧‧‧外殼 52‧‧‧Shell

54‧‧‧永久磁鐵 54‧‧‧ permanent magnet

56‧‧‧電鍍用陰極體 56‧‧‧Cathode body for electroplating

58‧‧‧支承棒 58‧‧‧Support rod

60‧‧‧接頭 60‧‧‧Connectors

62‧‧‧端蓋 62‧‧‧End cover

64‧‧‧間隙 64‧‧‧ gap

第1圖是本發明的外周切斷刃的顯示圖，(A)為俯視圖，(B)為在(A)的線B-B的剖面圖，(C)為(B)的C部分的放大剖面圖。 Fig. 1 is a view showing the outer peripheral cutting edge of the present invention, wherein (A) is a plan view, (B) is a cross-sectional view taken on line BB of (A), and (C) is an enlarged cross-sectional view of part C of (B). .

第2圖是顯示在本發明使用的夾具的一實施例的立體圖。 Fig. 2 is a perspective view showing an embodiment of a jig used in the present invention.

第3圖是夾持第2圖的台板的夾具主體的前端部的放大剖面圖。 Fig. 3 is an enlarged cross-sectional view showing the front end portion of the jig main body of the platen of Fig. 2;

第4圖(A)~(D)是顯示分別在台板形成的切割刃部的狀態的局部省略剖面圖。 4(A) to 4(D) are partially omitted cross-sectional views showing a state in which the cutting edge portions formed on the platen are respectively formed.

第5圖是實施例1的外周切斷刃的切割刃部的刀鋒側 面的顯微鏡照片。 Fig. 5 is a blade side of a cutting edge portion of the outer peripheral cutting edge of the first embodiment Microscopic photo of the face.

第6圖是顯示使用在實施例1~4及比較例1製作的外周切斷刃來進行切斷加工的稀土類燒結磁鐵的切斷片數與切斷精度的關係的曲線圖。 Fig. 6 is a graph showing the relationship between the number of cut pieces of the rare earth sintered magnet and the cutting precision using the outer peripheral cutting blades produced in Examples 1 to 4 and Comparative Example 1.

第7圖是顯示在實施例1~4及比較例1製作的外周切斷刃的切割刃部的變形量與應力的關係的曲線圖。 Fig. 7 is a graph showing the relationship between the amount of deformation and the stress of the cutting edge portion of the outer peripheral cutting blades produced in Examples 1 to 4 and Comparative Example 1.

Claims (13)

一種超硬合金台板外周切斷刃，以楊氏模量450~700GPa的超硬合金形成，外徑80~200mm，內徑30~80mm，厚度0.1~1.0mm的圓形環狀薄板的台板，在該台板的外周緣部上具有切割刃部；其特徵為：上述切割刃部，包含有：預先塗層磁性體而成的鑽石磨粒及/或cBN磨粒、將上述磨粒間及上述磨粒與台板之間連結的藉由電鍍或無電解電鍍所形成的金屬或合金、含浸於上述磨粒間及上述磨粒與台板之間的熔點為350℃以下的熱可塑性樹脂、或使含浸於上述磨粒間及上述磨粒與台板之間的硬化溫度為350℃以下的液體狀的熱硬化性樹脂組成物硬化的熱硬化性樹脂，且由以下方法所測定之{應力(N)/壓頭的移動量(mm)}的值為100~10000；[測定方法]在外周切斷刃，調整為：切割刃部的厚度為0.1~1.0mm，外徑為80~200mm，刀鋒的倒角以R或C為0.1以上之後，讓外周切斷刃成為水平，使用：以只有切割刃部露出的厚度5mm的圓形鐵板上下夾住外周切斷刃之支承夾具，按壓時保持成讓台板部分不會翹曲，在從超硬合金台板的外周朝外側離開0.3mm的位置，將切割刃部，以接觸部的長度(切割刃部的突出量-0.3mm)、寬度為10mm的壓頭，在外周切斷刃的旋轉軸方向(切割刃部的 厚度方向)以線速1mm/min按壓，將該動作持續至切割刃部斷裂，來測定相對於壓頭的移動量之應力；此時若壓頭的移動量變大的話則確認壓頭的移動量(mm)與應力(N)成比例的區域，來算出將該移動量(mm)與應力(N)之比例區域予以圖表化時的傾斜度(N/mm)。 A superhard alloy platen peripheral cutting blade formed of a superhard alloy having a Young's modulus of 450 to 700 GPa, a circular annular sheet 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 plate having a cutting edge portion on an outer peripheral edge portion of the platen; wherein the cutting blade portion includes diamond abrasive grains and/or cBN abrasive grains which are previously coated with a magnetic body, and the abrasive grains are a metal or alloy formed by electroplating or electroless plating between the abrasive grains and the platen, a thermoplasticity impregnated between the abrasive grains and between the abrasive grains and the platen, having a melting point of 350 ° C or less a resin or a thermosetting resin which is cured by a liquid thermosetting resin composition which is impregnated between the abrasive grains and between the abrasive grains and the platen at a curing temperature of 350 ° C or lower, and is measured by the following method. {The value of the stress (N)/head movement amount (mm)} is 100 to 10000; [Measurement method] The cutting edge is cut at the outer circumference, and the thickness of the cutting edge portion is 0.1 to 1.0 mm, and the outer diameter is 80. ~200mm, after the chamfer of the blade is R or C is 0.1 or more, let the outer cutting edge become horizontal, use: only cut The support jig of the outer peripheral cutting blade is sandwiched between the circular iron plate having a thickness of 5 mm exposed by the blade portion, and is held so that the platen portion does not warp when pressed, and is 0.3 mm away from the outer periphery of the superhard alloy platen. Position, the cutting edge portion, the length of the contact portion (the protruding amount of the cutting edge portion -0.3 mm), and the indenter having a width of 10 mm, in the direction of the rotation axis of the outer peripheral cutting blade (the cutting edge portion) The thickness direction is pressed at a linear velocity of 1 mm/min, and the operation is continued until the cutting blade portion is broken to measure the stress with respect to the amount of movement of the indenter; at this time, if the amount of movement of the indenter becomes large, the amount of movement of the indenter is confirmed. (mm) A region proportional to the stress (N), and the inclination (N/mm) when the ratio of the amount of movement (mm) to the stress (N) is plotted is calculated. 如申請專利範圍第1項的超硬合金台板外周切斷刃，其中提供上述含浸的樹脂為由：丙烯酸樹脂、環氧樹脂、苯酚樹脂、聚醯胺樹脂、聚醯亞胺樹脂、及這些樹脂的變性樹脂中所選出的一種以上。 The outer peripheral cutting blade of the super-hard alloy platen according to claim 1, wherein the impregnated resin is provided by: an acrylic resin, an epoxy resin, a phenol resin, a polyamide resin, a polyimide resin, and the like. One or more selected from the resin's denatured resins. 如申請專利範圍第1或2項的超硬合金台板外周切斷刃，其中提供上述含浸的樹脂的帕松比(Poisson ratio)為0.3~0.48。 The outer peripheral cutting blade of the superhard alloy platen according to claim 1 or 2, wherein the Poisson ratio of the impregnated resin is 0.3 to 0.48. 如申請專利範圍第1或2項的超硬合金台板外周切斷刃，其中上述台板的飽和磁化量為40kA/m(0.05T)以上。 The outer peripheral cutting blade of the superhard alloy platen according to claim 1 or 2, wherein the platen has a saturation magnetization of 40 kA/m (0.05 T) or more. 如申請專利範圍第1或2項的超硬合金台板外周切斷刃，其中上述磨粒的平均粒徑為10~300μm。 The outer peripheral cutting edge of the superhard alloy platen according to claim 1 or 2, wherein the abrasive grains have an average particle diameter of 10 to 300 μm. 如申請專利範圍第1或2項的超硬合金台板外周切斷刃，其中上述磨粒的質量磁化率χ g為0.2以上。 The outer peripheral cutting blade of the super-hard alloy platen according to claim 1 or 2, wherein the abrasive grains have a mass magnetic susceptibility χ g of 0.2 or more. 一種超硬合金台板外周切斷刃的製造方法，其特徵為：以楊氏模量450~700GPa的超硬合金形成，外徑80~200mm，內徑30~80mm，厚度0.1~1.0mm的圓形環狀薄板的台板，接近於該台板的外周緣部來配設永久磁鐵，藉由該永久磁鐵形成的磁場，將預先塗層有磁性體而 成的鑽石磨粒及/或cBN磨粒，磁性吸引固定於上述台板的外周緣部附近，在保持該吸引固定的狀態，藉由電鍍或無電解電鍍，將上述磨粒間及上述磨粒與台板之間連結，使磨粒固定於上述台板外周端部，而形成切割刃部，對上述磨粒間及上述磨粒與台板之間存在的空隙，含浸熔點為350℃以下的熱可塑性樹脂、或含浸硬化溫度為350℃以下的液體狀的熱硬化性樹脂組成物而使其硬化，且切割刃部由以下方法所測定之{應力(N)/壓頭的移動量(mm)}的值為100~10000：[測定方法]在外周切斷刃，調整為：切割刃部的厚度為0.1~1.0mm，外徑為80~200mm，刀鋒的倒角以R或C為0.1以上之後，讓外周切斷刃成為水平，使用：以只有切割刃部露出的厚度5mm的圓形鐵板上下夾住外周切斷刃之支承夾具，按壓時保持成讓台板部分不會翹曲，在從超硬合金台板的外周朝外側離開0.3mm的位置，將切割刃部，以接觸部的長度(切割刃部的突出量-0.3mm)、寬度為10mm的壓頭，在外周切斷刃的旋轉軸方向(切割刃部的厚度方向)以線速1mm/min按壓，將該動作持續至切割刃部斷裂，來測定相對於壓頭的移動量之應力；此時若壓頭的移動量變大的話則確認壓頭的移動量(mm)與應力(N)成比例的區域，來算出將該移動量(mm)與應力(N)之比例區域予以圖表化時的傾斜度(N/mm)。 The invention discloses a method for manufacturing a peripheral hard cutting blade of a superhard alloy platen, which is characterized in that: a superhard alloy having a Young's modulus of 450 to 700 GPa is formed, 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 platen of a circular annular plate is provided with a permanent magnet close to an outer peripheral edge portion of the platen, and a magnetic field formed by the permanent magnet is pre-coated with a magnetic body. The formed diamond abrasive grains and/or cBN abrasive grains are magnetically attracted and fixed to the vicinity of the outer peripheral edge portion of the platen, and the abrasive grains and the abrasive grains are formed by electroplating or electroless plating while maintaining the suction and fixation state. And connecting the platen to fix the abrasive grains to the outer peripheral end of the platen to form a cutting edge portion, and impregnating the gap between the abrasive grains and the abrasive grains and the platen at a melting point of 350 ° C or less The thermoplastic resin or the liquid thermosetting resin composition having a immersion-hardening temperature of 350 ° C or lower is cured, and the cutting edge portion is measured by the following method {stress (N) / amount of movement of the indenter (mm) The value of }} is 100~10000: [Measurement method] Cut the blade on the outer circumference, and adjust it to: the thickness of the cutting edge is 0.1~1.0mm, the outer diameter is 80~200mm, and the chamfer of the blade is R or C is 0.1. After that, the outer peripheral cutting blade is made horizontal, and the support jig that sandwiches the outer peripheral cutting edge with a circular iron having a thickness of 5 mm exposed only by the cutting edge portion is used, and the pressing portion is held so that the platen portion does not warp. , leaving 0.3mm away from the outer circumference of the super-hard alloy platen, The cutting blade portion has a length of the contact portion (the projection amount of the cutting edge portion is -0.3 mm) and a head having a width of 10 mm, and the linear axis speed is 1 mm at the rotation axis direction of the outer peripheral cutting blade (the thickness direction of the cutting blade portion). /min pressing, the operation is continued until the cutting blade is broken, and the stress with respect to the amount of movement of the indenter is measured; at this time, if the amount of movement of the indenter becomes large, the amount of movement (mm) and stress (N) of the indenter are confirmed. In the proportional region, the inclination (N/mm) when the ratio of the amount of movement (mm) to the stress (N) is plotted is calculated. 如申請專利範圍第7項的超硬合金台板外周切斷刃的製造方法，其中提供上述含浸的樹脂為由：丙烯酸樹脂、環氧樹脂、苯酚樹脂、聚醯胺樹脂、聚醯亞胺樹脂、及這些樹脂的變性樹脂中所選出的一種以上。 The method for producing a peripheral hard cutting blade of a superhard alloy platen according to claim 7, wherein the impregnated resin is provided by: an acrylic resin, an epoxy resin, a phenol resin, a polyamide resin, and a polyimide resin. And one or more selected from the denatured resins of these resins. 如申請專利範圍第7或8項的超硬合金台板外周切斷刃的製造方法，其中提供上述含浸的樹脂的帕松比(Poisson ratio)為0.3~0.48。 A method for producing a peripheral hard cutting blade of a superhard alloy platen according to claim 7 or 8, wherein the Poisson ratio of the impregnated resin is 0.3 to 0.48. 如申請專利範圍第7或8項的超硬合金台板外周切斷刃的製造方法，其中上述台板的飽和磁化量為40kA/m(0.05T)以上。 The method for producing a peripheral hard cutting blade of a superhard alloy platen according to claim 7 or 8, wherein the platen has a saturation magnetization of 40 kA/m (0.05 T) or more. 如申請專利範圍第7或8項的超硬合金台板外周切斷刃的製造方法，其中上述磨粒的平均粒徑為10~300μm。 The method for producing a peripheral hard cutting blade of a superhard alloy platen according to claim 7 or 8, wherein the abrasive grains have an average particle diameter of 10 to 300 μm. 如申請專利範圍第7或8項的超硬合金台板外周切斷刃的製造方法，其中上述磨粒的質量磁化率χ g為0.2以上。 The method for producing a peripheral hard cutting blade of a superhard alloy platen according to claim 7 or 8, wherein the abrasive grain has a mass magnetic susceptibility χ g of 0.2 or more. 如申請專利範圍第7或8項的超硬合金台板外周切斷刃的製造方法，其中藉由上述永久磁鐵，在從台板的外周端起算10mm以內的空間，形成8kA/m以上的磁場。 The method for producing a superhard alloy platen outer peripheral cutting edge according to the seventh or eighth aspect of the invention, wherein a magnetic field of 8 kA/m or more is formed by a space of 10 mm or less from the outer peripheral end of the platen by the permanent magnet. .
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