JP2003326464A - Cutting wheel and method of manufacturing the wheel - Google Patents
Cutting wheel and method of manufacturing the wheelInfo
- Publication number
- JP2003326464A JP2003326464A JP2002106784A JP2002106784A JP2003326464A JP 2003326464 A JP2003326464 A JP 2003326464A JP 2002106784 A JP2002106784 A JP 2002106784A JP 2002106784 A JP2002106784 A JP 2002106784A JP 2003326464 A JP2003326464 A JP 2003326464A
- Authority
- JP
- Japan
- Prior art keywords
- layer
- abrasive grain
- grain layer
- flange
- cutting wheel
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000005520 cutting process Methods 0.000 title claims abstract description 180
- 238000004519 manufacturing process Methods 0.000 title claims description 14
- 239000006061 abrasive grain Substances 0.000 claims abstract description 224
- 230000002093 peripheral effect Effects 0.000 claims abstract description 169
- 239000010953 base metal Substances 0.000 claims abstract description 53
- 239000002245 particle Substances 0.000 claims description 49
- 238000000034 method Methods 0.000 claims description 16
- 238000007788 roughening Methods 0.000 claims description 14
- 238000007493 shaping process Methods 0.000 claims description 9
- 238000003754 machining Methods 0.000 claims description 7
- 238000005498 polishing Methods 0.000 claims 1
- 229910003460 diamond Inorganic materials 0.000 abstract description 13
- 239000010432 diamond Substances 0.000 abstract description 13
- 239000010410 layer Substances 0.000 description 255
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 38
- 238000007747 plating Methods 0.000 description 26
- 230000000052 comparative effect Effects 0.000 description 25
- 229910052759 nickel Inorganic materials 0.000 description 17
- 229910052751 metal Inorganic materials 0.000 description 15
- 239000002184 metal Substances 0.000 description 15
- 229910045601 alloy Inorganic materials 0.000 description 10
- 239000000956 alloy Substances 0.000 description 10
- 238000010586 diagram Methods 0.000 description 8
- 239000011651 chromium Substances 0.000 description 4
- 239000002826 coolant Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000010949 copper Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 102200082816 rs34868397 Human genes 0.000 description 3
- 125000006850 spacer group Chemical group 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 229910017755 Cu-Sn Inorganic materials 0.000 description 2
- 229910017927 Cu—Sn Inorganic materials 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
- 239000010941 cobalt Substances 0.000 description 2
- 229910017052 cobalt Inorganic materials 0.000 description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- IIACRCGMVDHOTQ-UHFFFAOYSA-M sulfamate Chemical compound NS([O-])(=O)=O IIACRCGMVDHOTQ-UHFFFAOYSA-M 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- 101100316860 Autographa californica nuclear polyhedrosis virus DA18 gene Proteins 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000012776 electronic material Substances 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- -1 or the like Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000002250 progressing effect Effects 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
Landscapes
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
- Polishing Bodies And Polishing Tools (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、例えば電子材料や
半導体製品等の微小な部品の高精度な切断加工や溝入れ
加工に用いられる切断用ホイールに関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cutting wheel used for highly accurate cutting and grooving of minute parts such as electronic materials and semiconductor products.
【０００２】[0002]
【従来の技術】このような部品としては、ハードディス
クのヘッドとして用いられるＧＭＲヘッド等がある。こ
のＧＭＲヘッドは、例えば縦１．２ｍｍ、横０．９ｍ
ｍ、厚さ０．３ｍｍ程度のごく微小な部品である。この
ような微小な部品は、まず複数の部品を一体の基板とし
て製作して、その後切断用ホイールによって基板のまま
各部品にまとめて溝入れ加工を施したり、基板を個々の
部品に切り分けている。この加工に用いられる切断用ホ
イールとしては、円柱形状をなす工具本体の外周に、略
薄板リング状の砥石を、互いの間にスペーサを挟み込ん
で工具本体の軸線方向に複数枚設けたものがある。この
ように複数の砥石を設けた切断用ホイールを用いること
で、基板の複数箇所で切断加工または溝入れ加工を同時
に行うことができる。2. Description of the Related Art As such a part, there is a GMR head used as a head of a hard disk. This GMR head has a length of 1.2 mm and a width of 0.9 m, for example.
m is a very small part with a thickness of about 0.3 mm. For such minute parts, first, a plurality of parts are manufactured as an integrated board, and then a cutting wheel is used to groov each part as it is, or the board is cut into individual parts. . As a cutting wheel used for this processing, there is one in which a plurality of substantially thin plate ring-shaped grindstones are provided on the outer periphery of a tool body having a cylindrical shape in the axial direction of the tool body with a spacer interposed therebetween. . By using the cutting wheel provided with a plurality of grindstones in this way, it is possible to simultaneously perform cutting or grooving at a plurality of locations on the substrate.
【０００３】[0003]
【発明が解決しようとする課題】しかし、このような切
断用ホイールでは、複数の砥石及びスペーサを用いてい
るため、これら各部材の厚みのばらつき及び各部材の組
み付け精度のばらつきが累積して、組み上がりの砥石の
位置、すなわちワークの切断位置に影響する。このた
め、この切断用ホイールでは、ワークの加工精度の確保
が困難である。また、この切断用ホイールでは、各部材
間の隙間を完全に無くすことは困難なので、使用を続け
るうちにワークの加工精度が低下しやすい。さらに、近
年、ワークである基板はますます小型化されており、こ
れに伴い、基板の加工に供する切断用ホイールについて
も、より薄い砥石で正確な加工を行うという要求が強ま
っている。特に、ＧＭＲヘッドのスライダーの加工にお
いては、切断に用いる砥石の厚さが１００μｍ以下とな
ってきている。このような寸法では、砥石の厚みのばら
つきが相対的に大きくなるので、切断用ホイールの形状
精度を維持することが一層困難である。また、ワークの
切断ピッチも狭くなってきているため、砥石間にスペー
サを入れることが困難である。However, in such a cutting wheel, since a plurality of grindstones and spacers are used, the variation in the thickness of each member and the variation in the assembly accuracy of each member are accumulated, It affects the position of the assembled grindstone, that is, the cutting position of the work. Therefore, with this cutting wheel, it is difficult to secure the processing accuracy of the work. Further, with this cutting wheel, it is difficult to completely eliminate the gaps between the respective members, so that the machining accuracy of the work is likely to decrease as the cutting wheel is used. Furthermore, in recent years, substrates, which are workpieces, have become smaller and smaller, and accordingly, there has been an increasing demand for a cutting wheel used for processing substrates to perform accurate processing with a thinner grindstone. In particular, in processing a slider of a GMR head, the thickness of a grindstone used for cutting has become 100 μm or less. With such a size, the variation in the thickness of the grindstone becomes relatively large, so that it is more difficult to maintain the shape accuracy of the cutting wheel. Further, since the cutting pitch of the work is becoming narrower, it is difficult to insert a spacer between the grindstones.
【０００４】本発明は、このような事情に鑑みてなされ
たもので、加工精度が良い切断用ホイール及びその製造
方法を提供することを目的とする。The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a cutting wheel having a high processing accuracy and a manufacturing method thereof.
【０００５】[0005]
【課題を解決するための手段】本発明にかかる切断用ホ
イールは、円柱形状をなす台金の外周に、砥粒を金属結
合相中に分散配置してなる砥粒層が全周にわたって形成
される切断用ホイールであって、前記砥粒層には、周面
全周にわたる凹部と、該凹部によって前記台金の軸線方
向に隔てられて外周部がワークの切削に供される複数の
フランジ状凸部とが形成されていることを特徴としてい
る。In the cutting wheel according to the present invention, an abrasive grain layer, in which abrasive grains are dispersed and arranged in a metallic bond phase, is formed on the entire periphery of a cylindrical base metal. A cutting wheel according to claim 1, wherein the abrasive grain layer has a concave portion extending over the entire circumferential surface, and a plurality of flange-shaped outer circumferential portions that are separated by the concave portion in the axial direction of the base metal and are used for cutting a workpiece. It is characterized in that a convex portion is formed.
【０００６】このように構成される切断用ホイールで
は、円柱形状をなす台金の外周に形成される砥粒層に、
凹部によって台金の軸線方向に隔てられる複数のフラン
ジ状凸部が形成されている。ワークの切削に作用する複
数のフランジ状凸部は、台金に設けられる砥粒層に一体
的に形成されているので、フランジ状凸部の位置精度を
高精度とすることができ、また、使用を続けることによ
るフランジ状凸部の位置のずれが生じない。ここで、砥
粒としては、例えばダイヤモンドやｃＢＮ等の超砥粒が
用いられる。In the cutting wheel configured as described above, the abrasive grain layer formed on the outer periphery of the cylindrical base metal is
A plurality of flange-shaped protrusions are formed which are separated by the recesses in the axial direction of the base metal. Since the plurality of flange-shaped convex portions that act on the cutting of the work are integrally formed in the abrasive grain layer provided on the base metal, the positional accuracy of the flange-shaped convex portions can be made high, and, The position of the flange-shaped convex portion does not shift due to continued use. Here, as the abrasive grains, for example, superabrasive grains such as diamond or cBN are used.
【０００７】ここで、ワークから切り出される部品が例
えばハードディスクのヘッドである場合、何らかの理由
でヘッドから破片が脱落した際に、この破片によってハ
ードディスクの記録面が損傷してしまう恐れがあるの
で、部品の切断面をバリやクラック等のない鏡面に加工
することが望まれている。従来は、ワークの切断と切断
面の鏡面加工を同時に行うため、砥粒を細かくした切断
用ホイールを用いてワークの切断を行っていた。しか
し、このように砥粒を細かくすると切断用ホイールの切
れ味が不良となるため、ワークに割れや加工による変質
等のダメージを与えてしまったり、ワークの加工精度が
低下してしまうという不都合があった。また、切れ味を
重視して、砥粒を粗くした切断用ホイールを用いた場合
には、ワークにチッピングやクラック等が発生しやす
く、切断面をさらに二次加工して補正する必要があっ
た。Here, if the part cut out from the work is, for example, a head of a hard disk, and if the debris falls off from the head for some reason, the debris may damage the recording surface of the hard disk. It is desired to process the cut surface of No. 1 to a mirror surface without burrs or cracks. Conventionally, the work is cut using a cutting wheel with fine abrasive grains in order to cut the work and mirror-finish the cut surface at the same time. However, if the abrasive grains are made fine in this way, the sharpness of the cutting wheel becomes poor, so there is the inconvenience that damage to the work such as cracking and alteration due to processing, or reduction of the processing accuracy of the work It was Further, when a cutting wheel having roughened abrasive grains is used with an emphasis on sharpness, chipping, cracks, and the like are likely to occur in the work, and it is necessary to perform secondary processing on the cut surface to correct it.
【０００８】そこで、本発明にかかる切断用ホイールに
おいて、砥粒層は、台金上に形成されて仕上げ用砥粒が
分散される内周層と、内周層上に形成されて仕上げ用砥
粒よりも平均粒径の大きい粗加工用砥粒が分散される外
周層とを有し、凹部の深さＧは外周層の厚みＴを超える
深さとされ、各フランジ状凸部において、内周層は、外
周層よりも軸線方向の両側に張り出している構成として
もよい。この構成では、ワークの切削に供されるフラン
ジ状凸部のうち、重切削を強いられる外周部（特に外周
部の中央部）には、平均粒径の大きい（すなわち粗い）
粗加工用砥粒が分散される外周層が形成されているの
で、切れ味が確保される。そして、内周層は、外周層よ
りも台金の軸線方向の両側に張り出しているので、外周
層による切断面は、より平均粒径の小さい（すなわち細
かい）仕上げ用砥粒が分散される内周層によって仕上げ
切削される。すなわち、この切断用ホイールでは、一度
の切削加工でワークに粗加工と仕上げ加工との両方が施
される。Therefore, in the cutting wheel according to the present invention, the abrasive grain layer is formed on the base metal to disperse the finishing abrasive grains, and the abrasive grain layer is formed on the inner peripheral layer to finish the abrasive grains. An outer peripheral layer in which roughening abrasive grains having an average particle size larger than that of the grains are dispersed, and the depth G of the recess is set to be greater than the thickness T of the outer peripheral layer. The layer may be configured so as to project to both sides in the axial direction with respect to the outer peripheral layer. With this configuration, of the flange-shaped convex portions used for cutting the work, the outer peripheral portion (particularly the central portion of the outer peripheral portion) in which heavy cutting is forced has a large average particle diameter (that is, coarse).
Since the outer peripheral layer in which the roughening abrasive particles are dispersed is formed, sharpness is secured. Further, since the inner peripheral layer projects to both sides in the axial direction of the base metal more than the outer peripheral layer, the cut surface by the outer peripheral layer has a smaller average grain size (that is, finer) Finish cut by the peripheral layer. That is, with this cutting wheel, the workpiece is subjected to both roughing and finishing in one cutting operation.
【０００９】また、本発明にかかる切断用ホイールにお
いて、砥粒層は、前記凹部及び前記フランジ状凸部が形
成されて粗加工用砥粒が分散される砥粒層本体と、砥粒
層本体のフランジ状凸部の側面に設けられて粗加工用砥
粒よりも平均粒径の小さい仕上げ用砥粒が分散される側
面砥粒層とを有している構成としてもよい。この構成で
は、ワークの切削に供されるフランジ状凸部のうち、重
切削を強いられる外周部の中央部には、平均粒径の大き
い粗加工用砥粒が分散された砥粒層本体が露出している
ので、切れ味が確保される。そして、フランジ状凸部の
側面には、より平均粒径の小さい仕上げ用砥粒が分散さ
れた側面砥粒層が形成されているので、ワークの切断面
が側面砥粒層によって仕上げ切削される。すなわち、こ
の切断用ホイールにおいても、一度の切削加工でワーク
に粗加工と仕上げ加工との両方が施される。Further, in the cutting wheel according to the present invention, the abrasive grain layer has an abrasive grain layer main body in which the concave portions and the flange-shaped convex portions are formed to disperse the abrasive grains for rough machining, and the abrasive grain layer main body. It may be configured to have a side surface abrasive grain layer provided on the side surface of the flange-shaped convex portion and in which finishing abrasive grains having an average particle diameter smaller than that of the roughening abrasive grains are dispersed. In this configuration, among the flange-shaped convex portions used for cutting the work, the abrasive grain layer main body in which the roughening abrasive grains having a large average grain size are dispersed is provided in the central portion of the outer peripheral portion where heavy cutting is forced. Since it is exposed, sharpness is secured. Then, since the side surface abrasive grain layer in which the finishing abrasive grains having a smaller average particle size are dispersed is formed on the side surface of the flange-shaped convex portion, the cut surface of the workpiece is finish cut by the side surface abrasive grain layer. . That is, also in this cutting wheel, the workpiece is subjected to both roughing and finishing by one cutting.
【００１０】また、このように構成される切断用ホイー
ルにおいては、仕上げ用砥粒の平均粒径Ｄ１が２５μｍ
よりも大きいと、ワークにチッピングやクラック等が生
じやすくなり、切断面の仕上がりが悪くなってしまう。
また、平均粒径Ｄ１が１．６μｍよりも小さいと、切れ
味が不良であるため、ワークにダメージを与えたり、加
工精度が低下してしまう。一方、粗加工用砥粒の平均粒
径Ｄ２が５０μｍよりも大きいと、ワークに大きなチッ
ピングやクラック等が生じやすくなり、その後の内周層
による切断面の仕上げに大きな負担が生じることとな
る。また、平均粒径Ｄ２が５μｍよりも小さいと、切れ
味が不良であるため、ワークにダメージを与えたり、加
工精度が低下してしまう。このため、本発明にかかる切
断用ホイールにおいては、仕上げ用砥粒の平均粒径Ｄ１
は２５μｍ〜１．６μｍの範囲内とし、粗加工用砥粒の
平均粒径Ｄ２は、５０μｍ〜５μｍの範囲内とすること
が好ましい。In the cutting wheel thus constructed, the average grain size D1 of the finishing abrasive grains is 25 μm.
If it is larger than that, chipping, cracks and the like are likely to occur on the work, and the finish of the cut surface is deteriorated.
Further, if the average particle diameter D1 is smaller than 1.6 μm, the sharpness is poor, so that the work is damaged or the processing accuracy is deteriorated. On the other hand, when the average grain size D2 of the roughening abrasive grains is larger than 50 μm, large chipping, cracks and the like are likely to occur on the work, and a great burden is imposed on the subsequent finishing of the cut surface by the inner peripheral layer. Further, if the average particle diameter D2 is smaller than 5 μm, the sharpness is poor, so that the work is damaged or the processing accuracy is deteriorated. Therefore, in the cutting wheel according to the present invention, the average grain size D1 of the finishing abrasive grains is
Is preferably in the range of 25 μm to 1.6 μm, and the average particle diameter D2 of the abrasive grains for roughing is preferably in the range of 50 μm to 5 μm.
【００１１】また、このように構成される切断用ホイー
ルにおいては、粗加工用砥粒の平均粒径Ｄ２が、仕上げ
用砥粒の平均粒径Ｄ１の１．３倍よりも小さいと、内周
層と外周層の双方の効果（または砥粒層本体と側面砥粒
層の双方の効果）が小さくなってしまう。一方、平均粒
径Ｄ２が平均粒径Ｄ１の３倍よりも大きいと、ワークに
クラックやチッピングが発生し、その後の内周層（また
は側面砥粒層）による切削によってもクラックやチッピ
ングが除去できなくなってしまう。このため、粗加工用
砥粒の平均粒径Ｄ２は、仕上げ用砥粒の平均粒径Ｄ１の
１．３倍〜３倍の範囲内とすることが好ましい。In the cutting wheel thus constructed, if the average grain size D2 of the rough-working abrasive grains is smaller than 1.3 times the average grain size D1 of the finishing abrasive grains, the inner circumference is reduced. The effect of both the layer and the outer peripheral layer (or the effect of both the abrasive grain layer body and the side abrasive grain layer) becomes small. On the other hand, when the average particle diameter D2 is larger than three times the average particle diameter D1, cracks and chippings occur in the work, and the cracks and chippings can be removed by subsequent cutting with the inner peripheral layer (or the side surface abrasive grain layer). It's gone. For this reason, it is preferable that the average grain size D2 of the rough-working abrasive grains is within a range of 1.3 to 3 times the average grain size D1 of the finishing abrasive grains.
【００１２】[0012]
【発明の実施の形態】〔第一の実施の形態〕以下より、
本発明の第一の実施の形態にかかる切断用ホイールにつ
いて、図１から図３を用いて説明する。図１は本実施形
態にかかる切断用ホイールを示す図であって、（ａ）は
平面図、（ｂ）は（ａ）のＡ−Ａ矢視断面図、図２は本
実施形態にかかる切断用ホイールの製造工程を概略的に
示す図、図３は本実施形態にかかる切断用ホイールによ
るワークの切断の様子を概略的に示す図である。本実施
の形態にかかる切断用ホイール１は、円柱形状をなす台
金２の外周に、砥粒層３が全周にわたって形成されるも
のである。台金２としては、例えばＳ４５Ｃ等の鋼材が
用いられ、砥粒層３は、金属結合相内に、人工または天
然ダイヤモンドやｃＢＮ等の超砥粒を分散配置して形成
されるものである。DETAILED DESCRIPTION OF THE INVENTION [First Embodiment] From the following,
The cutting wheel according to the first embodiment of the present invention will be described with reference to FIGS. 1 to 3. 1A and 1B are views showing a cutting wheel according to the present embodiment, wherein FIG. 1A is a plan view, FIG. 1B is a sectional view taken along the line AA of FIG. FIG. 3 is a diagram schematically showing the manufacturing process of the work wheel, and FIG. 3 is a diagram schematically showing how the work is cut by the cutting wheel according to the present embodiment. In the cutting wheel 1 according to the present embodiment, an abrasive grain layer 3 is formed on the entire outer circumference of a base metal 2 having a cylindrical shape. As the base metal 2, for example, a steel material such as S45C is used, and the abrasive grain layer 3 is formed by dispersing superabrasive grains such as artificial or natural diamond and cBN in the metallic bond phase.
【００１３】砥粒層３には、周面全周にわたる凹部６
と、凹部６によって台金２の軸線Ｏ方向に隔てられて外
周部がワークの切削に供される複数のフランジ状凸部７
とが形成されている。フランジ状凸部７は、砥粒層３に
おいて台金２の軸線Ｏに略直交させて形成されている。
ここで、一つのワークから得られる部品の数を多くする
ために、ワークの切断代は極力小さくすることが望まし
い。このため、フランジ状凸部の前記軸線方向の幅Ｗ１
は、０．３ｍｍ以内とすることが好ましい。また、本実
施の形態では、凹部６の軸線Ｏ方向の幅Ｗ２は、ワーク
から切り出される部材の幅の二倍としている。ここで、
図１（ｂ）は砥粒層３の概略形状を示すためのものであ
って、各部の正確な寸法比を示すものではない。The abrasive grain layer 3 has a concave portion 6 extending over the entire circumference.
And a plurality of flange-shaped protrusions 7 which are separated by the recesses 6 in the direction of the axis O of the base metal 2 and whose outer peripheral portion is used for cutting the workpiece.
And are formed. The flange-shaped convex portion 7 is formed in the abrasive grain layer 3 so as to be substantially orthogonal to the axis O of the base metal 2.
Here, in order to increase the number of parts obtained from one work, it is desirable that the cutting margin of the work be as small as possible. Therefore, the width W1 of the flange-shaped convex portion in the axial direction is W1.
Is preferably 0.3 mm or less. In addition, in the present embodiment, the width W2 of the recess 6 in the direction of the axis O is twice the width of the member cut out from the work. here,
FIG. 1 (b) is for showing a schematic shape of the abrasive grain layer 3 and does not show an accurate dimensional ratio of each part.
【００１４】砥粒層３は、台金２上に形成されて仕上げ
用砥粒が分散される内周層８と、内周層８上に形成され
て仕上げ用砥粒よりも平均粒径の大きい粗加工用砥粒が
分散されてなる外周層９とを有している。ここで、凹部
６の深さＧは、外周層９の厚みＴを超える深さとされて
いる。内周層８及び外周層９は、例えば超砥粒が分散さ
れたメタル焼結体によって構成される他、めっき等によ
って超砥粒が分散された状態で形成されるＮｉ（ニッケ
ル）、Ｃｕ（銅）、Ｃｏ（コバルト）、Ｃｒ（クロム）
等の金属層、またはこれらの合金からなる金属層によっ
て構成されてもよい。The abrasive grain layer 3 is formed on the base metal 2 and in which the finishing abrasive grains are dispersed, and the abrasive grain layer 3 is formed on the inner peripheral layer 8 and has an average particle diameter larger than that of the finishing abrasive grains. And an outer peripheral layer 9 in which large abrasive grains for roughing are dispersed. Here, the depth G of the recess 6 exceeds the thickness T of the outer peripheral layer 9. The inner peripheral layer 8 and the outer peripheral layer 9 are made of, for example, a metal sintered body in which superabrasive grains are dispersed, and Ni (nickel), Cu () formed in a state in which the superabrasive grains are dispersed by plating or the like. Copper), Co (Cobalt), Cr (Chromium)
And the like, or a metal layer made of an alloy thereof.
【００１５】また、各フランジ状凸部７において、内周
層８は、外周層９よりも前記軸線Ｏ方向の両側に張り出
している。本実施の形態では、フランジ状凸部７は、外
周層９の外周面から内周部８の外周部にかけて、径方向
内側に向かうにつれて漸次軸線Ｏ方向の幅が広げられる
テーパー形状に形成している。ここで、フランジ状凸部
７の側面において、テーパー形状とされる部分よりも径
方向内側の部分は、軸線Ｏに略垂直に交差する平面とさ
れている。Further, in each of the flange-shaped convex portions 7, the inner peripheral layer 8 projects beyond the outer peripheral layer 9 on both sides in the direction of the axis O. In the present embodiment, the flange-shaped convex portion 7 is formed in a tapered shape in which the width in the axis O direction gradually increases from the outer peripheral surface of the outer peripheral layer 9 to the outer peripheral portion of the inner peripheral portion 8 toward the radially inner side. There is. Here, on the side surface of the flange-shaped convex portion 7, a portion radially inward of the tapered portion is a plane that intersects the axis O substantially perpendicularly.
【００１６】内周層８に分散される仕上げ用砥粒の平均
粒径Ｄ１は２５μｍ〜１．６μｍの範囲内とされ、外周
層９に分散される粗加工用砥粒の平均粒径Ｄ２は、５０
μｍ〜５μｍの範囲内とされている。また、粗加工砥粒
の平均粒径Ｄ２は、仕上げ用砥粒の平均粒径Ｄ１の１．
３倍〜３倍の範囲内とされている。本実施の形態では、
粗加工用砥粒の平均粒径Ｄ２は１１μｍとされており、
仕上げ用砥粒の平均粒径Ｄ１は７μｍとされている。The average grain size D1 of the finishing abrasive grains dispersed in the inner peripheral layer 8 is in the range of 25 μm to 1.6 μm, and the average grain size D2 of the rough machining abrasive grains dispersed in the outer peripheral layer 9 is , 50
It is set within the range of μm to 5 μm. The average grain size D2 of the rough-working abrasive grains is 1.
It is set within the range of 3 to 3 times. In this embodiment,
The average grain size D2 of the roughening abrasive grains is set to 11 μm,
The average grain size D1 of the finishing abrasive grains is 7 μm.
【００１７】以下より、このように構成される切断用ホ
イール１の製造工程について説明する。The manufacturing process of the cutting wheel 1 having the above-described structure will be described below.
【００１８】〔内周層形成工程〕まず、台金２の外周
に、砥粒層３を構成する内周層８を形成する。本実施の
形態では、内周層８は、仕上げ用砥粒が分散されたメタ
ル焼結体によって構成している。このような内周層８
は、台金２の外周に、Ｃｕ−Ｓｎ系のメタル焼結体原料
をマトリックスとして平均粒径Ｄ１の超砥粒を分散させ
てこれを焼結することによって形成される。[Inner peripheral layer forming step] First, the inner peripheral layer 8 forming the abrasive grain layer 3 is formed on the outer periphery of the base metal 2. In the present embodiment, the inner peripheral layer 8 is made of a metal sintered body in which finishing abrasive grains are dispersed. Such inner layer 8
Is formed by dispersing super-abrasive grains having an average grain size D1 on the outer periphery of the base metal 2 using a Cu—Sn-based metal sintered body material as a matrix and sintering this.
【００１９】〔外周層形成工程〕次に、内周層８の外周
に、砥粒層３を構成する外周層９を形成する。本実施の
形態では、内周層８の外周にめっき処理によって粗加工
用砥粒が分散されたニッケルまたはニッケル基合金層を
形成し、これを外周層９としている。このような外周層
９は、例えば図２に概略的に示す砥粒層製造装置１０を
用いて製造される。砥粒層製造装置１０は、攪拌機が配
設されためっき槽１１を有している。めっき槽１１内に
は、めっき槽１１の内面から離間させ、かつ電源の陰極
が接続された状態で、内周層８が形成された台金２が設
置される。めっき槽１１中には、台金２の内周層８の外
周面と対向させてニッケル製の陽極板１２が配置されて
いる。[Outer peripheral layer forming step] Next, the outer peripheral layer 9 constituting the abrasive grain layer 3 is formed on the outer periphery of the inner peripheral layer 8. In the present embodiment, a nickel or nickel-based alloy layer in which rough-working abrasive grains are dispersed is formed by plating on the outer periphery of the inner peripheral layer 8 and is used as the outer peripheral layer 9. Such an outer peripheral layer 9 is manufactured using, for example, an abrasive grain layer manufacturing apparatus 10 schematically shown in FIG. The abrasive grain layer manufacturing apparatus 10 has a plating tank 11 in which a stirrer is arranged. A base metal 2 having an inner peripheral layer 8 formed thereon is installed in the plating tank 11 while being separated from the inner surface of the plating tank 11 and connected to a cathode of a power source. In the plating tank 11, an anode plate 12 made of nickel is arranged so as to face the outer peripheral surface of the inner peripheral layer 8 of the base metal 2.
【００２０】外周層９を形成する際には、めっき槽１１
に、めっき液として、超砥粒であるダイヤモンド粉末
（平均粒径はＤ２）が分散されためっき液Ｍを入れ、め
っき液Ｍを攪拌機によって攪拌しながら通電する。台金
２の表面及び内周層８の外周面を除く他の表面にはマス
キングが施されており、内周層８の外周面にのみ、超砥
粒を含む所定の厚さの砥粒層を析出させて、この砥粒層
を外周層９とする。When forming the outer peripheral layer 9, the plating bath 11 is used.
Into, as a plating solution, a plating solution M in which diamond powder (average particle diameter is D2) which is superabrasive particles is dispersed is put, and the plating solution M is energized while being stirred by a stirrer. The surface of the base metal 2 and the other surfaces except the outer peripheral surface of the inner peripheral layer 8 are masked, and only the outer peripheral surface of the inner peripheral layer 8 has an abrasive grain layer containing superabrasive grains and having a predetermined thickness. Is deposited, and this abrasive grain layer is used as the outer peripheral layer 9.
【００２１】〔砥粒層整形工程〕次に、上記の工程で得
られた砥粒層３に整形を施して、凹部６とフランジ状凸
部７を形成する。凹部６は、例えば型彫り放電加工機や
ワイヤ放電加工機等の放電加工機によって砥粒層３の外
周部の一部を除去することによって形成される。このよ
うにして砥粒層３の外周部に凹部６を形成することで、
砥粒層３において凹部６によって台金２の軸線Ｏ方向に
隔てられる部分が、フランジ状凸部７をなす。また、こ
の砥粒層整形工程では、凹部６の形成に加えて、さらに
フランジ状凸部７の外周部の整形も行う。すなわち、フ
ランジ状凸部７を、外周層９の外周面から内周部８の外
周部にかけて、径方向内側に向かうにつれて漸次軸線Ｏ
方向の幅が広げられるテーパー形状に形成する。このよ
うにして砥粒層３の整形を行うことで、本発明にかかる
切断用ホイール１を得る。[Abrasive Grain Layer Shaping Step] Next, the abrasive grain layer 3 obtained in the above step is shaped to form the concave portion 6 and the flange-shaped convex portion 7. The concave portion 6 is formed by removing a part of the outer peripheral portion of the abrasive grain layer 3 by an electric discharge machine such as a die-sinking electric discharge machine or a wire electric discharge machine. By forming the concave portion 6 on the outer peripheral portion of the abrasive grain layer 3 in this manner,
Portions of the abrasive grain layer 3 that are separated from each other by the recesses 6 in the direction of the axis O of the base metal 2 form the flange-shaped protrusions 7. In addition, in this abrasive grain layer shaping step, in addition to forming the concave portion 6, the outer peripheral portion of the flange-shaped convex portion 7 is further shaped. That is, the flange-shaped convex portion 7 extends gradually from the outer peripheral surface of the outer peripheral layer 9 to the outer peripheral portion of the inner peripheral portion 8 toward the inner side in the radial direction, and the axis O gradually increases.
It is formed in a tapered shape whose width in the direction is widened. By shaping the abrasive grain layer 3 in this manner, the cutting wheel 1 according to the present invention is obtained.
【００２２】この切断用ホイール１は、台金２を図示し
ない駆動軸に対して同軸にして固定し、この状態で駆動
軸の軸線まわりに回転駆動させ、砥粒層３のフランジ状
凸部７の外周部でワークを切断（研削）加工する。この
切断用ホイール１においては、フランジ状凸部７のう
ち、まず外周部によってワークＷの切削が行われる。こ
のように重切削を強いられる外周部（特に外周部の中央
部）には、平均粒径の大きい（粗い）粗加工用砥粒が分
散される外周層９が形成されているので、切れ味が確保
される。このとき、ワークＷには若干のチッピングが生
じてもよい。In this cutting wheel 1, a base metal 2 is coaxially fixed to a drive shaft (not shown), and in this state, it is rotationally driven around the axis of the drive shaft to form a flange-shaped convex portion 7 of the abrasive grain layer 3. The work is cut (ground) at the outer peripheral portion of. In the cutting wheel 1, the work W is first cut by the outer peripheral portion of the flange-shaped convex portion 7. In this way, the outer peripheral layer 9 in which the roughening abrasive grains having a large average particle diameter (coarse) is dispersed is formed in the outer peripheral portion (particularly the central portion of the outer peripheral portion) where heavy cutting is forced, so that the sharpness is sharp. Secured. At this time, the work W may be slightly chipped.
【００２３】そして、内周層８は、外周層９よりも軸線
Ｏ方向の両側に張り出しているので、図３に示すよう
に、切り込み量が大きくなるにつれて、または切断用ホ
イール１が送り方向に移動するにつれて、外周層９によ
る切断面は、より平均粒径の小さい（細かい）仕上げ用
砥粒が分散される内周層８によって仕上げ切削される。
このとき、外周層９の切削によってワークＷにチッピン
グが生じていても、外周層９によって切削が行われた領
域は内周層８による切削によって除去されて、鏡面に仕
上げられる。すなわち、この切断用ホイール１によれ
ば、一度の切削加工で粗加工と仕上げ加工の両方が行わ
れる。ここで、この切断加工の際に、ワークＷの切断面
全体を内周層８によって鏡面に仕上げるため、切断用ホ
イール１のワークＷに対する切り込み深さは、少なくと
もフランジ状凸部７の側面において軸線Ｏに垂直な部分
がワークＷの裏面側まで達する深さに設定される。Since the inner peripheral layer 8 projects to both sides in the direction of the axis O with respect to the outer peripheral layer 9, as shown in FIG. 3, as the cutting depth increases, or the cutting wheel 1 moves in the feeding direction. As it moves, the cut surface of the outer peripheral layer 9 is finish-cut by the inner peripheral layer 8 in which (fine) finishing abrasive grains having a smaller average particle diameter are dispersed.
At this time, even if the work W is chipped due to the cutting of the outer peripheral layer 9, the region cut by the outer peripheral layer 9 is removed by the cutting of the inner peripheral layer 8 to be mirror-finished. That is, according to the cutting wheel 1, both roughing and finishing are performed by one cutting. Here, since the entire cut surface of the work W is mirror-finished by the inner peripheral layer 8 at the time of this cutting processing, the cutting depth of the cutting wheel 1 with respect to the work W is at least at the side surface of the flange-shaped convex portion 7 along the axis line. The depth perpendicular to O reaches the back side of the work W.
【００２４】ここで、凹部６の軸線Ｏ方向の幅Ｗ２、す
なわちワークの切断に作用するフランジ状凸部７間の距
離がワークの切断に作用する部材の幅と同一とすると、
ワークを切断した際にフランジ状凸部７間に部材を挟み
込んでしまう恐れがある。このため、本実施の形態で
は、凹部６の軸線Ｏ方向の幅Ｗ２は、ワークから切り出
される部材の幅の二倍としている。この場合には、まず
一度目の切断加工では、互いに凹部６によって隔てられ
る各フランジ状凸部７によって、ワークにおいて切断す
べきラインを一本おきに切断する。そして、二度目の切
断加工では、各フランジ状凸部７によって、切断すべき
ラインのうち、一度目の切断加工で切断したラインから
一本ずれたラインを切断する。これによって、フランジ
状凸部７間に部材を挟み込んでしまうことなく、ワーク
から部材を所望の幅で切り出すことができる。Here, assuming that the width W2 of the concave portion 6 in the direction of the axis O, that is, the distance between the flange-shaped convex portions 7 acting on the cutting of the work is the same as the width of the member acting on the cutting of the work,
When the work is cut, the member may be sandwiched between the flange-shaped convex portions 7. Therefore, in the present embodiment, the width W2 of the recess 6 in the direction of the axis O is twice the width of the member cut out from the work. In this case, in the first cutting process, the flange-shaped convex portions 7 separated from each other by the concave portions 6 cut every other line to be cut in the work. Then, in the second cutting process, each of the flange-shaped convex portions 7 cuts a line deviated from the line cut in the first cutting process by one line among the lines to be cut. As a result, the member can be cut out from the work with a desired width without sandwiching the member between the flange-shaped convex portions 7.
【００２５】このように構成される切断用ホイール１に
よれば、ワークの切削に作用する複数のフランジ状凸部
７は、台金２に設けられる砥粒層３に一体的に形成され
ているので、フランジ状凸部７の位置精度を高精度とす
ることができ、また、使用を続けることによるフランジ
状凸部７の位置のずれが生じない。このように、本実施
の形態にかかる切断用ホイール１によれば、加工精度を
良好にすることができる。According to the cutting wheel 1 constructed as described above, the plurality of flange-shaped convex portions 7 acting on the cutting of the work are integrally formed on the abrasive grain layer 3 provided on the base metal 2. Therefore, the positional accuracy of the flange-shaped convex portion 7 can be made high, and the positional deviation of the flange-shaped convex portion 7 due to continued use does not occur. As described above, according to the cutting wheel 1 of the present embodiment, the processing accuracy can be improved.
【００２６】さらに、この切断用ホイール１では、ワー
クの切削に供されるフランジ状凸部７のうち、重切削を
強いられる外周部（特に外周部の中央部）に平均粒径の
大きい粗加工用砥粒が用いられる外周層９が形成されて
いるので、切れ味が確保される。そして、内周層８は、
外周層９よりも台金２の軸線Ｏ方向の両側に張り出して
いるので、外周層９による切断面は、より平均粒径の小
さい仕上げ用砥粒が用いられる内周層８によって仕上げ
切削される。すなわち、この切断用ホイール１では、一
度の切削加工でワークに粗加工と仕上げ加工との両方が
施されるので、一度の切削加工で、切断面をバリ等のな
い鏡面に加工することが可能となり、加工精度と切削加
工の効率とを双方とも向上させることができる。Further, in this cutting wheel 1, of the flange-shaped convex portions 7 used for cutting the work, the outer peripheral portion (particularly the central portion of the outer peripheral portion) subjected to heavy cutting is rough-processed with a large average grain size. Since the outer peripheral layer 9 using the abrasive grains for use is formed, sharpness is secured. And the inner peripheral layer 8 is
Since it extends beyond the outer peripheral layer 9 on both sides of the base metal 2 in the direction of the axis O, the cut surface of the outer peripheral layer 9 is finish cut by the inner peripheral layer 8 in which finishing abrasive grains having a smaller average particle size are used. . That is, in this cutting wheel 1, since the workpiece is subjected to both roughing and finishing in one cutting operation, it is possible to machine the cutting surface into a mirror surface free from burrs etc. in one cutting operation. Therefore, both the processing accuracy and the cutting efficiency can be improved.
【００２７】なお、上記第一の実施形態において、フラ
ンジ状凸部７を、外周層９の外周面から内周部８の外周
部にかけて、径方向内側に向かうにつれて漸次軸線Ｏ方
向の幅が広げられるテーパー形状に形成した例を示した
が、これに限らず、フランジ状凸部７の形状は、各フラ
ンジ状凸部７において、内周層８が外周層９よりも前記
軸線Ｏ方向の両側に張り出している形状とされていれば
よい。例えば、フランジ状凸部７は、図４（ａ）に示す
ように、内周層８及び外周層９を四角形断面形状に形成
してもよく、また図４（ｂ）に示すように、内周層８の
外周部も含めた外周層９の表面を曲面状に形成してもよ
い。In the first embodiment, the width of the flange-shaped convex portion 7 gradually increases in the axial direction O from the outer peripheral surface of the outer peripheral layer 9 to the outer peripheral portion of the inner peripheral portion 8 toward the inner side in the radial direction. However, the present invention is not limited to this, and the shape of the flange-shaped convex portions 7 is such that the inner peripheral layer 8 is located on both sides in the axis O direction of the flange-shaped convex portions 7 rather than the outer peripheral layer 9. It only needs to have a shape that overhangs. For example, as shown in FIG. 4A, the flange-shaped convex portion 7 may be formed by forming the inner peripheral layer 8 and the outer peripheral layer 9 into a quadrangular sectional shape, and as shown in FIG. The surface of the outer peripheral layer 9 including the outer peripheral portion of the peripheral layer 8 may be formed into a curved surface.
【００２８】〔第二の実施の形態〕以下より、本発明の
第二の実施の形態にかかる切断用ホイールについて、図
５から図７を用いて説明する。図５は本実施形態にかか
る切断用ホイールを示す断面図、図６は本実施形態にか
かる切断用ホイールの製造工程を概略的に示す図、図７
は本実施形態にかかる切断用ホイールによるワークの切
断の様子を概略的に示す図である。本実施の形態にかか
る切断用ホイール２１は、第一の実施の形態に示す切断
用ホイール１と同様に、円柱形状をなす台金２の外周
に、凹部６及びフランジ状凸部７が形成される砥粒層３
が全周にわたって形成されるものであって、砥粒層３を
内周層８及び外周層９によって構成する代わりに、砥粒
層基部２２及び側面砥粒層２３によって構成したもので
ある。[Second Embodiment] A cutting wheel according to a second embodiment of the present invention will be described below with reference to FIGS. 5 to 7. FIG. 5 is a cross-sectional view showing the cutting wheel according to the present embodiment, FIG. 6 is a view schematically showing a manufacturing process of the cutting wheel according to the present embodiment, and FIG.
FIG. 6 is a diagram schematically showing how a work is cut by the cutting wheel according to the present embodiment. In the cutting wheel 21 according to the present embodiment, like the cutting wheel 1 according to the first embodiment, a recess 6 and a flange-shaped projection 7 are formed on the outer periphery of a base metal 2 having a cylindrical shape. Abrasive grain layer 3
Is formed over the entire circumference, and the abrasive grain layer 3 is constituted by the abrasive grain layer base portion 22 and the side surface abrasive grain layer 23, instead of being constituted by the inner peripheral layer 8 and the outer peripheral layer 9.
【００２９】本実施の形態において砥粒層３を構成する
砥粒層本体２２は、前記粗加工用砥粒が分散されるもの
であって、その外周には、凹部６及びフランジ状凸部７
が形成されている。また、本実施の形態において砥粒層
３を構成する側面砥粒層２３は、砥粒層本体２２のフラ
ンジ状凸部７の側面に形成されるものであって、前記仕
上げ用砥粒が分散されている。ここで、砥粒層本体２２
及び側面砥粒層２３は、例えば超砥粒が分散されたメタ
ル焼結体によって構成される他、めっき等によって超砥
粒が分散された状態で形成されるＮｉ（ニッケル）、Ｃ
ｕ（銅）、Ｃｏ（コバルト）、Ｃｒ（クロム）等の金属
層、またはこれらの合金からなる金属層によって構成さ
れてもよい。この切断用ホイール２１において、フラン
ジ状凸部７の外周部の形状は任意である。本実施の形態
では、フランジ状凸部７の外周部は、断面視略四角形状
としている。In the present embodiment, the abrasive grain layer main body 22 constituting the abrasive grain layer 3 is one in which the roughening abrasive grains are dispersed, and the concave portion 6 and the flange-shaped convex portion 7 are provided on the outer periphery thereof.
Are formed. Further, the side surface abrasive grain layer 23 constituting the abrasive grain layer 3 in the present embodiment is formed on the side surface of the flange-shaped convex portion 7 of the abrasive grain layer main body 22, and the finishing abrasive grains are dispersed. Has been done. Here, the abrasive grain layer body 22
The side surface abrasive grain layer 23 is formed of, for example, a metal sintered body in which superabrasive grains are dispersed, and Ni (nickel), C formed in a state in which the superabrasive grains are dispersed by plating or the like.
It may be formed of a metal layer of u (copper), Co (cobalt), Cr (chromium), or the like, or a metal layer of an alloy thereof. In this cutting wheel 21, the shape of the outer peripheral portion of the flange-shaped convex portion 7 is arbitrary. In the present embodiment, the outer peripheral portion of the flange-shaped convex portion 7 has a substantially rectangular shape in cross section.
【００３０】以下より、このように構成される切断用ホ
イール２１の製造工程について説明する。The manufacturing process of the cutting wheel 21 thus constructed will be described below.
【００３１】〔砥粒層本体形成工程〕まず、台金２の外
周に、砥粒層３を構成する砥粒層本体２２を形成する。
本実施の形態では、砥粒層本体２２は、超砥粒が分散さ
れたメタル焼結体によって構成している。[Abrasive Grain Layer Main Body Forming Step] First, the abrasive grain layer main body 22 constituting the abrasive grain layer 3 is formed on the outer periphery of the base metal 2.
In this embodiment, the abrasive grain layer body 22 is made of a metal sintered body in which superabrasive grains are dispersed.
【００３２】〔砥粒層本体整形工程〕次に、上記の工程
で得られた砥粒層本体２２に整形を施して、図６（ａ）
に示すように、凹部６とフランジ状凸部７を形成する。
凹部６は、例えば型彫り放電加工機やワイヤ放電加工機
等の放電加工機によって砥粒層本体２２の外周部の一部
を除去することによって形成される。このようにして砥
粒層本体２２の外周部に凹部６を形成することで、砥粒
層本体２２において凹部６によって台金２の軸線Ｏ方向
に隔てられる部分が、フランジ状凸部７をなす。[Abrasive Grain Layer Main Body Shaping Step] Next, the abrasive grain layer main body 22 obtained in the above step is subjected to a shaping step, and then, as shown in FIG.
As shown in, the concave portion 6 and the flange-shaped convex portion 7 are formed.
The concave portion 6 is formed by removing a part of the outer peripheral portion of the abrasive grain layer body 22 by an electric discharge machine such as a die-sinking electric discharge machine or a wire electric discharge machine. By forming the concave portion 6 on the outer peripheral portion of the abrasive grain layer main body 22 in this manner, the portion of the abrasive grain layer main body 22 separated by the concave portion 6 in the axis O direction of the base metal 2 forms the flange-shaped convex portion 7. .
【００３３】〔側面砥粒層形成工程〕次に、図６（ｂ）
に示すように、砥粒層本体２２においてフランジ状凸部
７の側面に、砥粒層３を構成する側面砥粒層２３を形成
する。本実施の形態では、砥粒層本体２２の外周にめっ
き処理によって仕上げ用砥粒が分散されたニッケルまた
はニッケル基合金層Ｎを形成し、このうちフランジ状凸
部７の側面に形成される部分を側面砥粒層２３としてい
る。このような側面砥粒層２３は、第一の実施の形態に
おいて切断用ホイール１の外周層を形成する際と同様
に、図２に示す砥粒層製造装置１０を用いて、砥粒層本
体２２の外周にめっき処理を施すことによって製造され
る。ここで、フランジ状凸部７の外周面にニッケルまた
はニッケル基合金層Ｎが形成されないよう、フランジ状
凸部７の外周面にマスクを施した状態でこのめっき処理
を行ってもよい。[Side Side Abrasive Layer Forming Step] Next, FIG.
As shown in, the side surface abrasive grain layer 23 forming the abrasive grain layer 3 is formed on the side surface of the flange-shaped convex portion 7 in the abrasive grain layer main body 22. In the present embodiment, a nickel or nickel-based alloy layer N in which finishing abrasive grains are dispersed is formed on the outer periphery of the abrasive grain layer body 22 by plating, and a portion formed on the side surface of the flange-shaped convex portion 7 Is used as the side surface abrasive grain layer 23. Such a side surface abrasive grain layer 23 is formed by using the abrasive grain layer manufacturing apparatus 10 shown in FIG. 2 as in the case of forming the outer peripheral layer of the cutting wheel 1 in the first embodiment. It is manufactured by plating the outer circumference of 22. Here, this plating treatment may be performed in a state where a mask is applied to the outer peripheral surface of the flange-shaped convex portion 7 so that the nickel or nickel-based alloy layer N is not formed on the outer peripheral surface of the flange-shaped convex portion 7.
【００３４】そして、図６（ｃ）に示すように、砥粒層
本体２２の外周に形成したニッケルまたはニッケル基合
金層Ｎのうち、フランジ状凸部７の外周面に位置する部
分を研磨等によって除去してフランジ状凸部７の外周部
で砥粒層本体２２を露出させることで、本発明にかかる
切断用ホイール２１を得る。ここで、めっき処理の際に
フランジ状凸部７の外周面にマスクを施していた場合に
は、フランジ状凸部７の外周面にはニッケルまたはニッ
ケル基合金層Ｎは形成されないので、めっき処理後にニ
ッケルまたはニッケル基合金層Ｎを除去する作業は不要
であり、めっき処理後に前記マスクを除去することで、
フランジ状凸部７の外周部で砥粒層本体２２が露出され
た切断用ホイール２１を得る。Then, as shown in FIG. 6C, of the nickel or nickel-based alloy layer N formed on the outer periphery of the abrasive grain layer body 22, the portion located on the outer peripheral surface of the flange-shaped convex portion 7 is polished or the like. The cutting wheel 21 according to the present invention is obtained by removing the abrasive grain layer main body 22 by removing the abrasive grain layer main body 22 at the outer peripheral portion of the flange-shaped convex portion 7 by removing it. Here, when a mask is applied to the outer peripheral surface of the flange-shaped convex portion 7 during the plating treatment, the nickel or nickel-based alloy layer N is not formed on the outer peripheral surface of the flange-shaped convex portion 7, so the plating treatment The work of removing the nickel or nickel-based alloy layer N later is unnecessary, and by removing the mask after the plating treatment,
The cutting wheel 21 in which the abrasive grain layer main body 22 is exposed at the outer peripheral portion of the flange-shaped convex portion 7 is obtained.
【００３５】この切断用ホイール２１は、台金２を図示
しない駆動軸に対して同軸にして固定し、この状態で駆
動軸の軸線まわりに回転駆動させ、砥粒層３のフランジ
状凸部７の外周部でワークを切断（研削）加工する。こ
の切断用ホイール２１においては、フランジ状凸部７の
うち、まず外周部によってワークＷの切削が行われる。
このように重切削を強いられる外周部の中央部には、平
均粒径の大きい粗加工用砥粒が用いられる砥粒層本体２
２が露出されており、この荒切削用砥粒がワークの切削
に作用するので、切れ味が確保される。In this cutting wheel 21, the base metal 2 is fixed coaxially with a drive shaft (not shown), and in this state, the base metal 2 is rotationally driven around the axis of the drive shaft to form the flange-shaped convex portion 7 of the abrasive grain layer 3. The work is cut (ground) at the outer peripheral portion of. In the cutting wheel 21, the work W is first cut by the outer peripheral portion of the flange-shaped convex portion 7.
In this manner, the abrasive grain layer main body 2 in which the rough-abrasive grains having a large average grain size are used in the central portion of the outer peripheral portion where heavy cutting is forced
2 is exposed, and the abrasive grains for rough cutting act on the cutting of the work, so that the sharpness is secured.
【００３６】そして、図７に示すように、フランジ状凸
部７の側面には、砥粒層本体２２よりも平均粒径の小さ
い側面砥粒層２３が形成されているので、ワークＷの切
断面は、より細かい超砥粒が用いられる側面砥粒層２３
によって仕上げ切削される。このとき、ワークＷにおい
て砥粒層本体２２によって切削される領域にチッピング
が生じていても、ワークＷの切断面は側面砥粒層２３に
よる仕上げ切削によって、鏡面に仕上げられる。すなわ
ち、この切断用ホイール２１によれば、一度の切削加工
で粗加工と仕上げ加工の両方が行われる。As shown in FIG. 7, since the side surface abrasive grain layer 23 having an average grain size smaller than that of the abrasive grain layer body 22 is formed on the side surface of the flange-shaped convex portion 7, the work W is cut. The surface is a side surface abrasive layer 23 in which finer superabrasive particles are used.
Finish cut by. At this time, even if chipping occurs in a region of the work W that is cut by the abrasive grain layer body 22, the cut surface of the work W is mirror-finished by the finish cutting by the side face abrasive grain layer 23. That is, according to the cutting wheel 21, both rough processing and finish processing are performed by one cutting process.
【００３７】また、本実施の形態では、フランジ状凸部
７の側面に設けられる側面砥粒層２３を、超砥粒が分散
されるニッケルまたはニッケル基合金からなる金属結合
相によって形成している。この金属結合相からなる側面
砥粒層２３は硬度が高く、磨耗が進行しにくいので、フ
ランジ状凸部７の形状を長期にわたって維持することが
でき、寿命を向上させることができる。また、この金属
結合相は剛性が高いので、フランジ状凸部７はこの金属
結合相からなる側面砥粒層２３により補強されることと
なって、ワークＷの切削の際に応力を受けてもフランジ
状凸部７にたわみや変形が生じにくくなり、ワークＷの
切断精度が向上するとともに、フランジ状凸部７の折損
等が生じにくくなる。Further, in the present embodiment, the side surface abrasive grain layer 23 provided on the side surface of the flange-shaped convex portion 7 is formed of a metal bonding phase made of nickel or a nickel base alloy in which superabrasive particles are dispersed. . Since the side surface abrasive grain layer 23 made of the metal-bonded phase has high hardness and is less likely to wear, the shape of the flange-shaped convex portion 7 can be maintained for a long period of time, and the life can be improved. Further, since the metal-bonded phase has high rigidity, the flange-shaped convex portions 7 are reinforced by the side surface abrasive grain layer 23 made of the metal-bonded phase, and even if stress is applied during cutting of the work W. The flange-shaped convex portion 7 is less likely to be bent or deformed, the cutting accuracy of the work W is improved, and the flange-shaped convex portion 7 is less likely to be broken.
【００３８】ここで、上記各実施の形態に示す切断用ホ
イールにおいて、ワークの仕上げ切削に供される内周層
８または側面砥粒層２３に分散される仕上げ用砥粒の平
均粒径Ｄ１が２５μｍよりも大きいと、ワークにチッピ
ングやクラック等が生じやすくなり、切断面の仕上がり
が悪くなってしまう。また、平均粒径Ｄ１が１．６μｍ
よりも小さいと、切れ味が不良であるため、ワークにダ
メージを与えたり、加工精度が低下してしまう。一方、
ワークの粗加工に供される外周層９または砥粒層本体２
１に分散される粗加工用砥粒の平均粒径Ｄ２が５０μｍ
よりも大きいと、ワークに大きなチッピングやクラック
等が生じやすくなり、その後の内周層８または側面砥粒
層２３による切断面の仕上げに大きな負担が生じること
となる。また、平均粒径Ｄ２が５μｍよりも小さいと、
切れ味が不良であるため、ワークにダメージを与えた
り、加工精度が低下してしまう。このため、本発明にか
かる切断用ホイールにおいては、仕上げ用砥粒の平均粒
径Ｄ１は２５μｍ〜１．６μｍの範囲内とし、粗加工用
砥粒の平均粒径Ｄ２は、５０μｍ〜５μｍの範囲内とす
ることが好ましい。Here, in the cutting wheel shown in each of the above-mentioned embodiments, the average particle diameter D1 of the finishing abrasive grains dispersed in the inner peripheral layer 8 or the side surface abrasive grain layer 23 used for the finish cutting of the work is If it is larger than 25 μm, chipping, cracks and the like are likely to occur on the work, and the finish of the cut surface deteriorates. The average particle size D1 is 1.6 μm.
If it is smaller than this, the sharpness is poor, so that the work is damaged or the processing accuracy is deteriorated. on the other hand,
Peripheral layer 9 or abrasive grain layer main body 2 used for rough machining of work
The average particle diameter D2 of the rough processing abrasive particles dispersed in 1 is 50 μm
If it is larger than the above, large chipping, cracks, and the like are likely to occur in the work, and a large load is applied to the subsequent finishing of the cut surface by the inner peripheral layer 8 or the side surface abrasive grain layer 23. If the average particle size D2 is smaller than 5 μm,
Since the sharpness is poor, it damages the work and reduces the processing accuracy. For this reason, in the cutting wheel according to the present invention, the average grain size D1 of the finishing abrasive grains is within the range of 25 μm to 1.6 μm, and the average grain size D2 of the roughening grains is within the range of 50 μm to 5 μm. It is preferable to set the inside.
【００３９】また、外周層９または砥粒層本体２２に分
散される超砥粒の平均粒径Ｄ２が、内周層８または側面
砥粒層２３に分散される超砥粒の平均粒径Ｄ１の１．３
倍よりも小さいと、これらの粒径の差が小さくなりすぎ
て、内周層８と外周層９との間、または砥粒層本体２２
と側面砥粒層２３との間で分散される超砥粒の粒径を変
えたことによる効果が小さくなってしまう。一方、平均
粒径Ｄ２が平均粒径Ｄ１の３倍よりも大きいと、ワーク
にクラックやチッピングが発生し、その後の内周層８や
側面砥粒層２３による切削によってもクラックやチッピ
ングが除去できなくなってしまう。このため、外周層９
または砥粒層本体２２に分散される超砥粒の平均粒径Ｄ
２は、内周層８または側面砥粒層２３に分散される超砥
粒の平均粒径Ｄ１の１．３倍〜３倍の範囲内とすること
が好ましい。The average particle diameter D2 of the superabrasive particles dispersed in the outer peripheral layer 9 or the abrasive grain layer body 22 is the average particle diameter D1 of the superabrasive particles dispersed in the inner peripheral layer 8 or the side surface abrasive grain layer 23. Of 1.3
If it is less than double, the difference in particle size between them becomes too small, and it is between the inner peripheral layer 8 and the outer peripheral layer 9 or the abrasive grain layer main body 22.
The effect of changing the particle size of the superabrasive particles dispersed between the side surface abrasive grain layer 23 and the side abrasive grain layer 23 becomes small. On the other hand, when the average particle diameter D2 is larger than three times the average particle diameter D1, cracks and chippings occur in the work, and the cracks and chippings can be removed by subsequent cutting with the inner peripheral layer 8 and the side surface abrasive grain layer 23. It's gone. Therefore, the outer peripheral layer 9
Alternatively, the average particle diameter D of the superabrasive grains dispersed in the abrasive grain layer body 22
2 is preferably in the range of 1.3 to 3 times the average particle diameter D1 of the superabrasive grains dispersed in the inner peripheral layer 8 or the side surface abrasive grain layer 23.
【００４０】また、上記各実施の形態では、砥粒層３の
内周層８や砥粒層本体２２を、超砥粒が分散されたメタ
ル焼結体によって構成し、外周層９や側面砥粒層２３
を、超砥粒が分散された状態で形成される金属層または
合金層をめっき処理によって形成した例を示したが、こ
れに限られることなく、内周層８や砥粒層本体２２をめ
っき処理によって形成してもよく、また外周層９や側面
砥粒層２３をメタル焼結体やレジン焼結体によって構成
してもよい。Further, in each of the above-mentioned embodiments, the inner peripheral layer 8 of the abrasive grain layer 3 and the main body 22 of the abrasive grain layer are made of a metal sintered body in which superabrasive grains are dispersed, and the outer peripheral layer 9 and the side surface abrasive. Grain layer 23
Although the example in which the metal layer or the alloy layer formed in the state where the superabrasive grains are dispersed is formed by the plating treatment is not limited to this, the inner peripheral layer 8 and the abrasive grain layer main body 22 are plated. Alternatively, the outer peripheral layer 9 and the side surface abrasive grain layer 23 may be formed of a metal sintered body or a resin sintered body.
【００４１】[0041]
【実施例】次に、本発明の切断用ホイール（以下本発明
とする）と、性能の比較のために本発明において砥粒層
３を単層構造とした切断用ホイール（以下、比較例とす
る）とを用意し、これら切断用ホイールのそれぞれにつ
いて、ワークの切削試験を行い、ワークの切断面の状態
の比較と、その寿命とを比較した。EXAMPLES Next, a cutting wheel of the present invention (hereinafter referred to as the present invention) and a cutting wheel having a single layer structure of the abrasive grain layer 3 in the present invention for comparison of performance (hereinafter referred to as Comparative Example and The cutting test of the work was performed for each of these cutting wheels, and the state of the cut surface of the work was compared with the life thereof.
【００４２】〔第一実施例〕本実施例では、本発明の切
断用ホイールとして、第一の実施の形態で示すように、
砥粒層３を、内周層８と外周層９とによって構成したも
のを用いている（以下、この切断用ホイールを本発明１
とする）。本発明１及び比較例１、２は、いずれも台金
２として、内径４０ｍｍ、外径６５ｍｍ、幅１２ｍｍの
Ｓ４５Ｃ材を用いている。本発明１は、この台金２の外
周に、砥粒層３を構成する内周層８を形成している。内
周層８を形成した時点での砥粒層３の外径は７４．７ｍ
ｍとした。ここでは、内周層８は、Ｃｕ−Ｓｎ系のメタ
ル焼結体原料中に平均粒径４．５μｍのダイヤモンド粒
を２５ｖｏｌ％の割合で分散したものを焼結してなる構
成としている。そして、この内周層８の外周面に、外径
が７５ｍｍとなるように、平均粒径８．２μｍのダイヤ
モンド粒を分散した金属結合相をめっき処理によって形
成し、外周層９とした。すなわち、外周層９の厚みは
０．１５ｍｍである。ここで、外周層９を形成するめっ
き処理では、めっき液としてスルファミン酸Ｎｉ液を用
い、３Ａの電流で５時間のダイヤモンド分散めっき処理
を行った。さらに、型彫り放電加工機やワイヤー放電加
工機によって砥粒層３に凹部６を形成して、台金２の軸
線Ｏ方向に離間される５つのフランジ状凸部７を形成し
た。ここで、フランジ状凸部７の幅は、０．２ｍｍとし
た。First Embodiment In this embodiment, as the cutting wheel of the present invention, as shown in the first embodiment,
The abrasive grain layer 3 is composed of an inner peripheral layer 8 and an outer peripheral layer 9 (hereinafter, this cutting wheel is referred to as the present invention 1
And). In the present invention 1 and the comparative examples 1 and 2, as the base metal 2, S45C material having an inner diameter of 40 mm, an outer diameter of 65 mm and a width of 12 mm is used. In the present invention 1, the inner peripheral layer 8 forming the abrasive grain layer 3 is formed on the outer periphery of the base metal 2. The outer diameter of the abrasive grain layer 3 at the time of forming the inner peripheral layer 8 is 74.7 m
m. Here, the inner peripheral layer 8 has a structure in which diamond particles having an average particle diameter of 4.5 μm are dispersed at a rate of 25 vol% in a Cu—Sn-based metal sintered body raw material and sintered. Then, on the outer peripheral surface of the inner peripheral layer 8, a metal binding phase in which diamond particles having an average particle diameter of 8.2 μm were dispersed was formed by plating so that the outer diameter was 75 mm, and the outer peripheral layer 9 was obtained. That is, the thickness of the outer peripheral layer 9 is 0.15 mm. Here, in the plating process for forming the outer peripheral layer 9, a Ni sulfamate solution was used as a plating solution, and a diamond dispersion plating process was performed at a current of 3 A for 5 hours. Further, the recesses 6 were formed in the abrasive grain layer 3 by a die-sinking electric discharge machine or a wire electric discharge machine to form five flange-shaped projections 7 spaced apart in the direction of the axis O of the base metal 2. Here, the width of the flange-shaped convex portion 7 was 0.2 mm.
【００４３】また、比較例１として、台金２の表面に、
本発明１における内周層８の形成方法と同じ方法によっ
て、平均粒径８．２μｍのダイヤモンド粒を２５ｖｏｌ
％の割合で分散してなる砥粒層を形成した。ここで、こ
の砥粒層の外径は、本発明１の外径と同じく７５ｍｍと
した。さらに、本発明と同様に、型彫り放電加工機、ワ
イヤー放電加工機によって砥粒層に凹部を形成して、台
金２の軸線Ｏ方向に離間される５つのフランジ状凸部を
形成した。ここで、フランジ状凸部の幅は、０．２ｍｍ
とした。Further, as Comparative Example 1, on the surface of the base metal 2,
By the same method as the method for forming the inner peripheral layer 8 in the present invention 1, 25 vol.
% To form an abrasive grain layer. Here, the outer diameter of the abrasive grain layer was set to 75 mm, which is the same as the outer diameter of the first embodiment. Further, similarly to the present invention, recesses were formed in the abrasive grain layer by a die-sinking electric discharge machine or a wire electric discharge machine to form five flange-shaped convex portions that were separated in the direction of the axis O of the base metal 2. Here, the width of the flange-shaped convex portion is 0.2 mm
And
【００４４】一方、比較例２として、台金２の表面に、
本発明１における内周層８の形成方法と同じ方法によっ
て、平均粒径４．５μｍのダイヤモンド粒を２５ｖｏｌ
％の割合で分散してなる砥粒層を形成した。ここで、こ
の砥粒層の外径は、本発明１の外径と同じく７５ｍｍと
した。さらに本発明１と同様に、型彫り放電加工機、ワ
イヤー放電加工機によって砥粒層に凹部を形成して、台
金２の軸線Ｏ方向に離間される５つのフランジ状凸部を
形成した。ここで、フランジ状凸部の幅は、０．２ｍｍ
とした。On the other hand, as Comparative Example 2, on the surface of the base metal 2,
By the same method as the method for forming the inner peripheral layer 8 in the present invention 1, 25 vol.
% To form an abrasive grain layer. Here, the outer diameter of the abrasive grain layer was set to 75 mm, which is the same as the outer diameter of the first embodiment. Further, as in the case of the first aspect of the present invention, recesses were formed in the abrasive grain layer by a die-sinking electric discharge machine or a wire electric discharge machine to form five flange-shaped convex portions that were separated in the direction of the axis O of the base metal 2. Here, the width of the flange-shaped convex portion is 0.2 mm
And
【００４５】これら本発明１、比較例１、２のそれぞれ
について、以下の切削試験を行った。ここでは、ワーク
として、縦５０ｍｍ、横５０ｍｍ、厚さ１．０ｍｍのＡ
ｌ2Ｏ3−ＴｉＣ（アルミナ−チタンカーバイド）を用い
た。このワークは、図８に示すように、上面に複数本の
溝１６ａが切削方向に並行に形成される櫛歯状冶具１６
に対してワックスを用いて固定している。以下に、この
切削試験の切削条件を示す。これら切断用ホイールが装
着される切断機として、不二越社製マイクログラインダ
ーを用い、切断用ホイールの回転数は９０００回転／ｍ
ｉｎ、送り速度は１００ｍｍ／ｍｉｎ、切り込み量は
１．５ｍｍ（フルカット）とし、切削方向はダウンカッ
トとし、クーラントとして、エマルジョンタイプの水溶
性クーラントを１．５Ｌ／ｍｉｎ供給した。この切削試
験の結果を、以下の表１に示す。The following cutting test was performed on each of the present invention 1 and Comparative Examples 1 and 2. Here, as the work, A with a length of 50 mm, a width of 50 mm, and a thickness of 1.0 mm is used.
I 2 O 3 -TiC (alumina-titanium carbide) was used. As shown in FIG. 8, this work has a comb-tooth-shaped jig 16 in which a plurality of grooves 16a are formed on the upper surface in parallel to the cutting direction.
Is fixed using wax. The cutting conditions of this cutting test are shown below. As a cutting machine on which these cutting wheels are mounted, a Fujikoshi Micro Grinder is used, and the rotation speed of the cutting wheels is 9000 rpm.
In, feed rate was 100 mm / min, depth of cut was 1.5 mm (full cut), cutting direction was down cut, and emulsion type water-soluble coolant was supplied at 1.5 L / min as the coolant. The results of this cutting test are shown in Table 1 below.
【００４６】[0046]
【表１】 [Table 1]
【００４７】表１に示すように、切断面の表面粗さＲ
ａ、及びチッピングの大きさについては、本発明１と比
較例２とが同程度となっており、比較例１のみが、切断
面の表面粗さＲａ及びチッピング量が大きくなってい
る。これは、比較例１では、全ての切削を、平均粒径の
大きい砥粒によって行っているために、ワークにチッピ
ングやクラック等が発生しやすくなっていると思われ
る。As shown in Table 1, the surface roughness R of the cut surface
Regarding a and the magnitude of chipping, the present invention 1 and the comparative example 2 have the same degree, and only the comparative example 1 has a large surface roughness Ra and a chipping amount of the cut surface. This is because, in Comparative Example 1, all the cutting is performed with the abrasive grains having a large average grain size, so that chipping and cracks are likely to occur in the work.
【００４８】一方、切断用ホイールの寿命については、
本発明１と比較例１とが１０００ライン以上の切断が可
能であるが、比較例２は、３８０ラインで磨耗量が大き
くなりすぎてワークの切断が不能となってしまった。こ
れは、比較例２では、全ての切削を、平均粒径の小さい
砥粒によって行っているために、切断用ホイールの切れ
味が不良となっているためと思われる。On the other hand, regarding the life of the cutting wheel,
Inventive Example 1 and Comparative Example 1 were able to cut 1000 lines or more, but in Comparative Example 2, the wear amount was too large at 380 lines and the work could not be cut. This is considered to be because, in Comparative Example 2, all the cutting was performed with the abrasive grains having a small average particle diameter, and thus the cutting wheel had poor sharpness.
【００４９】〔第二実施例〕本実施例では、本発明の切
断用ホイールを、第二の実施の形態で示すように、砥粒
層３を、砥粒層本体２２と側面砥粒層２３とによって構
成したものを用いている（以下、この切断用ホイールを
本発明２とする）。本発明２及び比較例３、４は、いず
れも台金２として、内径４０ｍｍ、外径８０ｍｍ、幅１
５ｍｍのＳ４５Ｃ材を用いている。本発明２では、この
台金２の外周に、砥粒層３を構成する砥粒層本体２２を
形成し、その外径を９０ｍｍとした。ここでは、砥粒層
本体２２は、Ｃｕ−Ｓｎ系のメタル焼結体原料中に平均
粒径１１．５μｍのダイヤモンド粒を２５ｖｏｌ％の割
合で分散したものを焼結してなる構成としている。そし
て、この砥粒層本体２２の外周に、型彫り放電加工機や
ワイヤー放電加工機によって凹部６を形成して、台金２
の軸線Ｏ方向に離間される７つのフランジ状凸部７を形
成した。ここで、フランジ状凸部７の幅は０．１ｍｍ、
フランジ状凸部７間の間隔は１ｍｍとした。さらに、こ
の砥粒層本体２２の外周に、平均粒径７．２μｍのダイ
ヤモンド粒を分散した金属結合相をめっき処理によって
形成し、砥粒層本体２２の外周を露出させる処理を経
て、フランジ状凸部７の側面に側面砥粒層２３を形成し
た。これにより、フランジ状凸部７の幅と側面砥粒層２
３の厚みとの合計（すなわち刃厚）は０．１３ｍｍとし
た。ここで、外周層９を形成するめっき処理では、めっ
き液としてスルファミン酸Ｎｉ液を用い、２Ａの電流で
１時間のダイヤモンド分散めっき処理を行った。[Second Embodiment] In this embodiment, as shown in the second embodiment of the cutting wheel of the present invention, the abrasive grain layer 3, the abrasive grain layer main body 22 and the side surface abrasive grain layer 23 are used. The cutting wheel is referred to as Invention 2 hereinafter. In the present invention 2 and the comparative examples 3 and 4, the base metal 2 is 40 mm in inner diameter, 80 mm in outer diameter, and 1 in width.
A 5 mm S45C material is used. In the second aspect of the present invention, the abrasive grain layer main body 22 constituting the abrasive grain layer 3 is formed on the outer periphery of the base metal 2 and the outer diameter thereof is set to 90 mm. Here, the abrasive grain layer main body 22 is configured by sintering diamond-based metal sintered body raw material in which diamond grains having an average grain size of 11.5 μm are dispersed at a rate of 25 vol%. Then, the recess 6 is formed on the outer periphery of the abrasive grain layer body 22 by a die-sinking electric discharge machine or a wire electric discharge machine, and the base metal 2
The seven flange-shaped protrusions 7 are formed so as to be separated from each other in the direction of the axis O. Here, the width of the flange-shaped convex portion 7 is 0.1 mm,
The distance between the flange-shaped convex portions 7 was 1 mm. Further, a metal-bonded phase in which diamond particles having an average particle size of 7.2 μm are dispersed is formed on the outer periphery of the abrasive grain layer body 22 by a plating process, and the outer periphery of the abrasive grain layer body 22 is exposed to form a flange shape. The side surface abrasive grain layer 23 was formed on the side surface of the convex portion 7. Thereby, the width of the flange-shaped convex portion 7 and the side surface abrasive grain layer 2
The total thickness of 3 (that is, blade thickness) was 0.13 mm. Here, in the plating process for forming the outer peripheral layer 9, a Ni sulfamate solution was used as a plating solution, and a diamond dispersion plating process was performed at a current of 2 A for 1 hour.
【００５０】また、比較例３として、台金２の表面に、
本発明２における砥粒層本体２２の形成方法と同じ方法
によって、平均粒径１１．５μｍのダイヤモンド粒を２
５ｖｏｌ％の割合で分散してなる砥粒層を形成した。こ
こで、この砥粒層の外径は、本発明２の外径と同じく９
０ｍｍとした。さらに、本発明２と同様に、型彫り放電
加工機、ワイヤー放電加工機によって砥粒層に凹部を形
成して、台金２の軸線Ｏ方向に離間される７つのフラン
ジ状凸部を形成した。ここで、フランジ状凸部の幅は
０．１ｍｍ、フランジ状凸部間の間隔は１ｍｍとした。As Comparative Example 3, on the surface of the base metal 2,
By the same method as the method for forming the abrasive grain layer main body 22 in the second aspect of the present invention, diamond grains having an average grain size of 11.5 μm are formed into
An abrasive grain layer formed by being dispersed at a ratio of 5 vol% was formed. Here, the outer diameter of this abrasive grain layer is the same as the outer diameter of the second aspect of the present invention.
It was set to 0 mm. Further, as in the case of the second aspect of the invention, recesses were formed in the abrasive grain layer by a die-sinking electric discharge machine or a wire electric discharge machine to form seven flange-shaped convex portions that were separated in the axis O direction of the base metal 2. . Here, the width of the flange-shaped protrusions was 0.1 mm, and the interval between the flange-shaped protrusions was 1 mm.
【００５１】一方、比較例４として、台金２の表面に、
本発明２における砥粒層本体２２の形成方法と同じ方法
によって、平均粒径７．２μｍのダイヤモンド粒を２５
ｖｏｌ％の割合で分散してなる砥粒層を形成した。ここ
で、この砥粒層の外径は、本発明２の外径と同じく９０
ｍｍとした。さらに本発明２と同様に、型彫り放電加工
機、ワイヤー放電加工機によって砥粒層に凹部を形成し
て、台金２の軸線Ｏ方向に離間される５つのフランジ状
凸部を形成した。ここで、フランジ状凸部の幅は０．１
ｍｍ、フランジ状凸部間の間隔は１ｍｍとした。On the other hand, as Comparative Example 4, on the surface of the base metal 2,
By the same method as the method for forming the abrasive grain layer main body 22 in the second aspect of the invention, 25 diamond grains having an average grain size of 7.2 μm are formed.
An abrasive grain layer dispersed at a vol% ratio was formed. Here, the outer diameter of this abrasive grain layer is the same as the outer diameter of the second aspect of the present invention.
mm. Further, similarly to the second aspect of the present invention, recesses were formed in the abrasive grain layer by a die-sinking electric discharge machine or a wire electric discharge machine to form five flange-shaped convex portions that were separated in the direction of the axis O of the base metal 2. Here, the width of the flange-shaped convex portion is 0.1
mm, and the distance between the flange-shaped convex portions was 1 mm.
【００５２】これら本発明２、比較例３、４のそれぞれ
について、以下の切削試験を行った。ここでは、ワーク
として、縦８０ｍｍ、横８０ｍｍ、厚さ５．０ｍｍのフ
ェライトを用た。このワークは、クランプを用いて作業
台に固定している。この切削試験では、このワークに対
して溝入れ加工を行い、５００ライン切断後の刃部の形
状から、これら切断用ホイールの寿命を評価した。以下
に、この切削試験の切削条件を示す。これら切断用ホイ
ールが装着される切断機として、不二越社製マイクログ
ラインダーを用い、切断用ホイールの回転数は６０００
回転／ｍｉｎ、送り速度は６００ｍｍ／ｍｉｎ、切り込
み量は３ｍｍとし、切削方向はダウンカットとし、クー
ラントとして、エマルジョンタイプの水溶性クーラント
を１．５Ｌ／ｍｉｎ供給した。この切削試験の結果を、
以下の表２に示す。The following cutting test was performed on each of the present invention 2 and Comparative Examples 3 and 4. Here, as the work, a ferrite having a length of 80 mm, a width of 80 mm, and a thickness of 5.0 mm was used. This work is fixed to the workbench using a clamp. In this cutting test, grooving was performed on this work, and the life of these cutting wheels was evaluated from the shape of the blade after cutting 500 lines. The cutting conditions of this cutting test are shown below. As a cutting machine to which these cutting wheels are attached, a micro grinder manufactured by Fujikoshi Co., Ltd. is used, and the rotation speed of the cutting wheels is 6000.
The rotation / min, the feed rate was 600 mm / min, the depth of cut was 3 mm, the cutting direction was downcut, and an emulsion-type water-soluble coolant was supplied at 1.5 L / min as the coolant. The result of this cutting test
The results are shown in Table 2 below.
【００５３】[0053]
【表２】 [Table 2]
【００５４】表２に示すように、ワークに生じたチッピ
ングの大きさについては、本発明２と比較例４とが同程
度となっており、比較例３のみが、チッピング量が大き
くなっている。これは、比較例３では、全ての切削を、
平均粒径の大きい砥粒によって行っているために、ワー
クにチッピングやクラック等が発生しやすくなっている
と思われる。As shown in Table 2, with respect to the size of the chipping generated on the work, the present invention 2 and the comparative example 4 have the same degree, and only the comparative example 3 has a large chipping amount. . This is because in Comparative Example 3, all cutting was
It is considered that chipping and cracks are likely to occur in the work because the abrasive grains having a large average particle size are used.
【００５５】一方、ワークのカーフ幅（すなわち切断
幅）は、本発明２と比較例３とが同程度となっており、
比較例４のみが、カーフ幅が大きくなっている。これ
は、比較例４では、全ての切削を、平均粒径の小さい砥
粒によって行っているために、切れ味が不良となってい
るためと思われる。On the other hand, the kerf width (that is, the cutting width) of the work is almost the same in the invention 2 and the comparative example 3,
Only the comparative example 4 has a large kerf width. This is considered to be because the sharpness is poor in Comparative Example 4 because all the cutting is performed with the abrasive grains having a small average grain size.
【００５６】さらに、これら本発明２、比較例３、４に
ついて、５００ライン切断後の刃部の形状を比較した。
ここでは、これら切断用ホイールの刃部において、刃部
の先端からＲ形状となっている範囲を比較した。表２に
示すように、比較例３では刃部の先端から０．１０ｍｍ
の範囲がＲ形状となっているのに対して、比較例４では
刃部の先端から０．１５ｍｍの範囲がＲ形状となってお
り、比較例３に比べて比較例４では刃部の磨耗が進行し
ていることがわかる。一方、本発明２では、範囲は０．
０５ｍｍと、比較例３よりもさらに磨耗が抑えられてお
り、切削性能が維持されていることがわかる。Further, with respect to the present invention 2 and comparative examples 3 and 4, the shapes of the blade portions after cutting 500 lines were compared.
Here, in the blade portions of these cutting wheels, the range of the R shape from the tip of the blade portion was compared. As shown in Table 2, in Comparative Example 3, 0.10 mm from the tip of the blade
In comparison example 4, the range of 0.15 mm from the tip of the blade has an R shape, while in comparison example 3, compared to comparison example 3, in comparison example 4, wear of the blade part You can see that is progressing. On the other hand, in the present invention 2, the range is 0.
It is 05 mm, which indicates that the wear is further suppressed as compared with Comparative Example 3, and the cutting performance is maintained.
【００５７】以上の各切削試験の結果から、本発明にか
かる切断用ホイールは、切断面の状態を良好にしてワー
クの切断が可能であり、また長寿命であることがわか
る。From the results of the above cutting tests, it is understood that the cutting wheel according to the present invention is capable of cutting the work by improving the condition of the cutting surface and has a long life.
【００５８】[0058]
【発明の効果】以上説明したように、本発明にかかる切
断用ホイールによれば、ワークの切削に作用する複数の
フランジ状凸部が、台金に設けられる砥粒層に一体的に
形成されているので、フランジ状凸部の位置精度を高精
度とすることができ、また、使用を続けることによるフ
ランジ状凸部の位置のずれが生じない。このため、本発
明にかかる切断用ホイールでは、ワークの加工精度を良
好にすることができる。As described above, according to the cutting wheel of the present invention, the plurality of flange-shaped convex portions that act on the cutting of the work are integrally formed on the abrasive grain layer provided on the base metal. Therefore, the positional accuracy of the flange-shaped convex portion can be made highly accurate, and the positional deviation of the flange-shaped convex portion due to continued use does not occur. Therefore, the cutting wheel according to the present invention can improve the processing accuracy of the work.
【００５９】また、本発明にかかる切断用ホイールにお
いて、砥粒層を、台金上に形成される内周層と、内周層
上に形成されてこの内周層に分散される砥粒よりも平均
粒径の大きい砥粒が分散されてなる外周層とを有し、凹
部の深さＧは外周層の厚みＴを超える深さとされ、各フ
ランジ状凸部において、内周層は、外周層よりも前記軸
線方向の両側に張り出している構成とすることで、ワー
クの切削に供されるフランジ状凸部のうち、重切削を強
いられる外周部（特に外周部の中央部）に、粗い砥粒が
用いられる外周層が形成されているので切れ味が確保さ
れる。そして、内周層は、外周層よりも前記軸線方向の
両側に張り出しているので、外周層による切断面は、よ
り細かい砥粒が用いられる内周層によって仕上げ切削さ
れる。すなわち、この切断用ホイールによれば、一度の
切削加工で粗加工と仕上げ加工との両方を行うことがで
き、効率的にワークの加工を行うことができる。In the cutting wheel according to the present invention, the abrasive grain layer is composed of an inner peripheral layer formed on the base metal and abrasive grains formed on the inner peripheral layer and dispersed in the inner peripheral layer. Also has an outer peripheral layer in which abrasive grains having a large average particle size are dispersed, and the depth G of the concave portion is a depth exceeding the thickness T of the outer peripheral layer, and in each flange-shaped convex portion, the inner peripheral layer is the outer peripheral layer. By being configured to project to both sides in the axial direction rather than the layer, the flange-shaped convex portion used for cutting the workpiece has a rough outer peripheral portion (particularly the central portion of the outer peripheral portion) that is subjected to heavy cutting. Since the outer peripheral layer using the abrasive grains is formed, sharpness is secured. Since the inner peripheral layer projects to both sides in the axial direction more than the outer peripheral layer, the cut surface of the outer peripheral layer is finish-cut by the inner peripheral layer using finer abrasive grains. That is, according to this cutting wheel, both rough machining and finish machining can be performed by one cutting process, and the workpiece can be efficiently processed.
【００６０】また、本発明にかかる切断用ホイールにお
いて、砥粒層を、前記凹部及び前記フランジ状凸部が形
成されて粗加工用砥粒が分散される砥粒層本体と、砥粒
層本体のフランジ状凸部の側面に設けられて粗加工用砥
粒よりも平均粒径の小さい仕上げ用砥粒が分散される側
面砥粒層とを有している構成とすることで、ワークの切
削に供されるフランジ状凸部のうち、重切削を強いられ
る外周部の中央部には、平均粒径の大きい粗加工用砥粒
が分散された砥粒層本体が露出しているので、切れ味が
確保される。そして、フランジ状凸部の側面には、より
平均粒径の小さい仕上げ用砥粒が分散された側面砥粒層
が形成されているので、ワークの切断面が側面砥粒層に
よって仕上げ切削される。すなわち、この切断用ホイー
ルにおいても、一度の切削加工でワークに粗加工と仕上
げ加工との両方が施される。Further, in the cutting wheel according to the present invention, an abrasive grain layer is provided with an abrasive grain layer main body in which the concave portions and the flange-shaped convex portions are formed and in which roughening abrasive grains are dispersed, and an abrasive grain layer main body. By cutting the work by having a side surface abrasive grain layer provided on the side surface of the flange-shaped convex portion and in which finishing abrasive grains having an average particle size smaller than that of the roughening abrasive grains are dispersed. Of the flange-shaped convex portion provided for, the central portion of the outer peripheral portion where heavy cutting is forced, the abrasive grain layer main body in which the roughening abrasive grains with a large average grain diameter are dispersed is exposed, so the sharpness Is secured. Then, since the side surface abrasive grain layer in which the finishing abrasive grains having a smaller average particle size are dispersed is formed on the side surface of the flange-shaped convex portion, the cut surface of the workpiece is finish cut by the side surface abrasive grain layer. . That is, also in this cutting wheel, the workpiece is subjected to both roughing and finishing by one cutting.
【図１】 本発明の第一の実施の形態にかかる切断用ホ
イールを示す図であって、（ａ）は平面図、（ｂ）は
（ａ）のＡ−Ａ矢視断面図である。1A and 1B are diagrams showing a cutting wheel according to a first embodiment of the present invention, in which FIG. 1A is a plan view and FIG. 1B is a sectional view taken along the line AA of FIG.
【図２】 本発明の第一の実施の形態にかかる切断用ホ
イールを製造する工程を示す図である。FIG. 2 is a diagram showing a process of manufacturing the cutting wheel according to the first embodiment of the present invention.
【図３】 本発明の第一の実施形態にかかる切断用ホイ
ールによるワークの切断の様子を概略的に示す図であ
る。FIG. 3 is a diagram schematically showing how a work is cut by the cutting wheel according to the first embodiment of the present invention.
【図４】 本発明の一実施の形態にかかる切断用ホイー
ルのフランジ状凸部の形状の他の例を示す断面図であ
る。FIG. 4 is a cross-sectional view showing another example of the shape of the flange-shaped convex portion of the cutting wheel according to the embodiment of the present invention.
【図５】 本発明の第二の実施の形態にかかる切断用ホ
イールを示す断面図である。FIG. 5 is a sectional view showing a cutting wheel according to a second embodiment of the present invention.
【図６】 本発明の第二の実施の形態にかかる切断用ホ
イールの製造工程を概略的に示す図である。FIG. 6 is a diagram schematically showing a manufacturing process of a cutting wheel according to a second embodiment of the present invention.
【図７】 本発明の第二の実施の形態にかかる切断用ホ
イールによるワークの切断の様子を概略的に示す図であ
る。FIG. 7 is a diagram schematically showing how a work is cut by a cutting wheel according to a second embodiment of the present invention.
【図８】 本発明にかかる切断用ホイールと比較例の切
断用ホイールの切削試験の様子を示す斜視図である。FIG. 8 is a perspective view showing a state of a cutting test of a cutting wheel according to the present invention and a cutting wheel of a comparative example.
１、２１ 切断用ホイール ２ 台金 ３ 砥粒層 ６ 凹部 ７ フランジ状凸部 ８ 内周層 ９ 外周層 ２２ 砥粒層本体 ２３ 側面砥粒層 Ｇ 凹部の深さ Ｏ 台金の軸線 Ｔ 外周層の厚み 1,21 Cutting wheel 2 units 3 Abrasive layer 6 Recess 7 Flange-shaped projection 8 Inner peripheral layer 9 outer peripheral layer 22 abrasive grain layer main body 23 Side Abrasive Grain Layer G Depth of Recess O Base metal axis T Peripheral layer thickness
───────────────────────────────────────────────────── フロントページの続き Ｆターム(参考） 3C058 AA03 AA09 CB01 CB03 DA02 DA16 3C063 AA02 AB03 BA24 BA35 BB02 BB07 BC02 BG07 CC02 CC12 EE10 EE23 EE31 FF23 ─────────────────────────────────────────────────── ─── Continued front page F-term (reference) 3C058 AA03 AA09 CB01 CB03 DA02 DA16 3C063 AA02 AB03 BA24 BA35 BB02 BB07 BC02 BG07 CC02 CC12 EE10 EE23 EE31 FF23
Claims (7)
属結合相中に分散配置してなる砥粒層が全周にわたって
形成される切断用ホイールであって、 前記砥粒層には、周面全周にわたる凹部と、該凹部によ
って前記台金の軸線方向に隔てられて外周部がワークの
切削に供される複数のフランジ状凸部とが形成されてい
ることを特徴とする切断用ホイール。1. A cutting wheel in which an abrasive grain layer formed by dispersing abrasive grains in a metal-bonded phase is formed around the outer periphery of a base metal having a cylindrical shape, the abrasive grain layer being formed on the abrasive grain layer. Is characterized in that a concave portion is formed over the entire circumference and a plurality of flange-shaped convex portions, which are separated by the concave portion in the axial direction of the base metal and whose outer peripheral portion is used for cutting a work, are formed. Cutting wheel.
仕上げ用砥粒が分散される内周層と、該内周層上に形成
されて前記仕上げ用砥粒よりも平均粒径の大きい粗加工
用砥粒が分散される外周層とを有し、 前記凹部の深さＧは前記外周層の厚みＴを超える深さと
され、 前記各フランジ状凸部において、前記内周層は、前記外
周層よりも前記軸線方向の両側に張り出していることを
特徴とする請求項１記載の切断用ホイール。2. The abrasive grain layer is formed on the base metal and has an inner peripheral layer in which finishing abrasive grains are dispersed, and an average grain that is formed on the inner peripheral layer and is larger than the finishing abrasive grains. An outer peripheral layer in which coarse-grained abrasive grains having a large diameter are dispersed, and a depth G of the concave portion is a depth exceeding a thickness T of the outer peripheral layer, and in each of the flange-shaped convex portions, the inner peripheral layer is formed. 2. The cutting wheel according to claim 1, wherein the cutting wheel projects from both sides of the outer peripheral layer in the axial direction.
凸部が形成されて粗加工用砥粒が分散される砥粒層本体
と、 該砥粒層本体の前記フランジ状凸部の側面に設けられて
前記粗加工用砥粒よりも平均粒径の小さい仕上げ用砥粒
が分散される側面砥粒層とを有していることを特徴とす
る請求項１記載の切断用ホイール。3. The abrasive grain layer has an abrasive grain layer body in which the recesses and flange-shaped protrusions are formed and in which abrasive grains for rough machining are dispersed, and a side surface of the flange-shaped protrusion of the abrasive grain layer body. 2. The cutting wheel according to claim 1, further comprising a side surface abrasive grain layer which is provided on the side surface and in which finishing abrasive grains having an average particle diameter smaller than that of the roughening abrasive grains are dispersed.
μｍ〜１．６μｍの範囲内とされ、 前記粗加工用砥粒の平均粒径Ｄ２は、５０μｍ〜５μｍ
の範囲内とされていることを特徴とする請求項２または
３に記載の切断用ホイール。4. The average grain size D1 of the finishing abrasive grains is 25.
The average particle diameter D2 of the roughening abrasive grains is 50 μm to 5 μm.
The cutting wheel according to claim 2 or 3, wherein the cutting wheel is in the range.
記仕上げ用砥粒の平均粒径Ｄ１の１．３倍〜３倍の範囲
内とされていることを特徴とする請求項２から４のいず
れかに記載の切断用ホイール。5. The average particle diameter D2 of the rough-polishing abrasive grains is in the range of 1.3 times to 3 times the average particle diameter D1 of the finishing abrasive grains. The cutting wheel according to any one of 2 to 4.
法であって、 前記台金の外周に、前記内周層を形成する内周層形成工
程と、 該内周層の外周に前記外周層を形成する外周層形成工程
と、 これら内周層、外周層に整形を施して、これら内周層、
外周層の周面全周にわたる前記凹部と、該凹部によって
前記台金の軸線方向に隔てられる複数の前記フランジ状
凸部とを形成する砥粒層整形工程とを有していることを
特徴とする切断用ホイールの製造方法。6. The method of manufacturing a cutting wheel according to claim 2, wherein an inner peripheral layer forming step of forming the inner peripheral layer on the outer periphery of the base metal, and the outer periphery on the outer periphery of the inner peripheral layer. An outer peripheral layer forming step of forming a layer, and shaping the inner peripheral layer and the outer peripheral layer to form the inner peripheral layer,
An abrasive grain layer shaping step of forming the concave portion over the entire circumference of the outer peripheral layer and the plurality of flange-shaped convex portions separated by the concave portion in the axial direction of the base metal, Method for manufacturing cutting wheel.
法であって、 前記台金の外周に、前記砥粒層本体を形成する砥粒層本
体形成工程と、 該砥粒層本体に整形を施して、該砥粒層本体の周面全周
にわたる凹部と、該凹部によって前記台金の軸線方向に
隔てられる複数のフランジ状凸部とを形成する砥粒層本
体整形工程と、 該砥粒層本体の前記フランジ状凸部の側面に、前記側面
砥粒層を形成する側面砥粒層形成工程とを有しているこ
とを特徴とする切断用ホイールの製造方法。7. The method of manufacturing a cutting wheel according to claim 3, wherein an abrasive grain layer main body forming step of forming the abrasive grain layer main body on an outer periphery of the base metal, and shaping the abrasive grain layer main body. An abrasive grain layer body shaping step of forming a concave portion over the entire circumferential surface of the abrasive grain layer main body and a plurality of flange-shaped convex portions separated by the concave portion in the axial direction of the base metal; And a side surface abrasive grain layer forming step of forming the side surface abrasive grain layer on a side surface of the flange-shaped convex portion of the grain layer main body.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002106784A JP4236859B2 (en) | 2002-03-06 | 2002-04-09 | Cutting wheel and manufacturing method thereof |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002-61117 | 2002-03-06 | ||
| JP2002061117 | 2002-03-06 | ||
| JP2002106784A JP4236859B2 (en) | 2002-03-06 | 2002-04-09 | Cutting wheel and manufacturing method thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2003326464A true JP2003326464A (en) | 2003-11-18 |
| JP4236859B2 JP4236859B2 (en) | 2009-03-11 |
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ID=29713813
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2002106784A Expired - Fee Related JP4236859B2 (en) | 2002-03-06 | 2002-04-09 | Cutting wheel and manufacturing method thereof |
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| Country | Link |
|---|---|
| JP (1) | JP4236859B2 (en) |
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| JP2007021589A (en) * | 2005-07-12 | 2007-02-01 | Toyota Motor Corp | Polishing method and polishing member |
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| JP2006082197A (en) * | 2004-09-17 | 2006-03-30 | Toyoda Mach Works Ltd | Grinding wheel |
| JP2007021589A (en) * | 2005-07-12 | 2007-02-01 | Toyota Motor Corp | Polishing method and polishing member |
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