WO2007060984A1 - Resin-bonded superabrasive wheel and process for producing the same - Google Patents

Abstract

A resin-bonded superabrasive wheel which has high bonding strength between the core and the superabrasive layer. The resin-bonded superabrasive wheel comprises a core (3) and a superabrasive layer (1) bonded thereto, wherein the core (3) has been bonded to the superabrasive layer (1) through a copper layer at the interface between these, the copper layer being one formed by thermal spraying.

Description

 Specification

 Resin bonded superabrasive wheel and method of manufacturing the same

 Technical field

 The present invention relates to a resin-bonded superabrasive wheel having a strong bonding force between a base metal and an abrasive grain layer and

, And its manufacturing method.

 Background art

 In a resin-bonded superabrasive wheel, as a method of bonding a base and an abrasive layer, a method of compression molding inside a mold while making the raw material powder adhere to a copper base metal is manufactured. Conventional power is also adopted as one of the methods.

 [0003] The reason why this method is adopted is that it is a manufacturing method in which the bonding strength between resin and copper is relatively high and the stability of adhesive strength is also high. In particular, the bonding strength between polyimide resin and copper is remarkably high, and has been applied mainly to the manufacture of semiconductor substrates.

 According to a general theory, it can be said that the bonding mechanism between polyimide resin and copper is based on the anchor effect and intermolecular force, but in particular, recently, as a reason for polyimide resin to be strongly bonded to copper, It is clear that it is due to the chemical reaction between metal and polyimide resin. Also, in general, it is difficult to maintain a perfect cleaning surface on a metal surface, and hydroxyl groups and the like are formed on the metal surface unless treated in a special environment such as vacuum. Copper is similar to iron-based materials in that hydroxyl groups are present on the surface, although the rate of oxidation is slower.

 [0005] A polyimide resin used as a binder for a resin-bonded super-granular wheel is partially commercially available in which the imidization reaction is completely completed, but in many cases the imidization reaction proceeds completely. It is a state and contains a precursor. A carboxyl group is present in the precursor, and it is considered that bonding strength is generated by bonding with a hydroxyl group on the metal surface. Therefore, it is possible to achieve very strong bonding by heating and compression molding the raw material powders of the granule layer with the polyimide resin as a binder using a copper base metal in close contact with each other in a mold. Conceivable.

However, since the yield point of copper is low, there is a problem that the copper base metal is distorted in the compression molding process. The subject arose. If the base metal is distorted, it will be difficult to finish the shape in the post-process, and it will be necessary to restrict the shape that can be manufactured. Also, even if the distortion is small, copper is a ductile material, so it is not an efficient manufacturing method that makes removal very difficult. Also force, thermal expansion coefficient of copper is ^{16 X 10- 6 ZK: ~ 18} X 10- 6 is a ZK, of iron or steel ^{10 X 10- 6 ΖΚ: ~ 12} X

^10-6 thermal expansion coefficient of the high tool abrasive layer as compared to Zetakappa is not lower than 10 X 10- ⁶ Ζκ below and iron and steel. Therefore, tensile stress is generated as a residual stress in the adhesive layer when it is cooled after the heat forming, but the residual stress is higher particularly when copper is used as the base metal than when it is iron or steel. An increase in residual stress is one of the factors causing a decrease in adhesive strength.

 On the other hand, a method of applying copper plating to a base metal of high rigidity and ferrous material has already been proposed.

. According to this method, a high bonding strength can be obtained between the copper and the resin of the granule layer, similarly to using a copper base.

 (For example, see Japanese Patent Application Laid-Open No. 5-293763 (Patent Document 1))

 In addition, since the yield point of the base metal is high, no distortion occurs and removal processing becomes easy. Therefore, restrictions on the shape of the wheel base and the size of the wheel are much less than in the case of the copper base.

 Other than the above, as a method of using a material having a high yield point for the base metal, a soft metal such as copper is thickly sprayed on the metal base metal to form a porous stress relaxation layer, and a metal bond is formed. Methods for manufacturing wheels have also been proposed. In order to obtain a porous layer by thermal spraying, it is necessary to melt only the surface of the raw material particles to be jetted and keep the inside unmelted. It is the powder flame spray process that is capable of this.

 (For example, see JP-A-2-256466 (Patent Document 2))

As described above, in a resin-bonded super-granular wheel, a method of firmly bonding by interposing a copper layer at the interface between a metallic base metal having a relatively high yield point of an iron-based material etc. and an abrasive grain layer. It is conceivable to form a copper layer by plating. However, in the method using plating, it is possible to obtain a uniform copper layer on a flat surface without unevenness. If the artifice surface used for force processing has a shape with projections and depressions, the plating thickness It is likely that non-uniformities will occur, making it difficult to control the film thickness. On the other hand, in the case of metal bond wheels, a method of forming by powder flame spraying can be considered, but thermal spraying was applied to resin bond wheels. The invention does not exist so far. Moreover, in powder flame spraying, it is advantageous to obtain a thick porous layer Even if the position and angle of the nozzle are precisely controlled using a robot arm, it is difficult to obtain a thin layer with a uniform thickness. Because of this, resin bond wheels are not suitable for the purpose of enhancing the bonding strength between the base metal and the particle layer.

 Patent Document 1: Japanese Patent Application Laid-Open No. 5-293763

 Patent Document 2: Japanese Patent Application Laid-Open No. Hei 2-256466

 Disclosure of the invention

 Problem that invention tries to solve

 [0009] When the copper layer is too thick, the strength of the joint becomes dependent on the breaking strength of copper, leading to a reduction in the joint strength. Therefore, it is necessary to control the thickness so as not to create a thicker area than necessary. However, if the thickness of the copper layer to be formed is uneven, if the conditions for forming the copper layer are set based on the maximum thickness, the copper layer is formed, which is not only a very thin portion. There is a risk that an insulting area will occur.

 The problem to be solved by the present invention is to make the thickness of the copper layer, which is the key to the bonding strength between the base metal and the abrasive grain layer, uniform and to increase the bonding strength between the base metal and the abrasive grain layer. is there.

 Means to solve the problem

 [0011] A first feature of the resin-bonded ultra-granulated wheel of the present invention is a resin-bonded ultra-fine particle, in which a metal coating is formed on the surface of a base metal by thermal spraying and a super-granular layer is bonded to the surface of the metal film. A grit wheel wherein the metal coating is copper. The surface roughness of the copper layer formed in this manner does not depend on the surface roughness of the base metal, and the surface roughness is 1 / z mRa or more. Also by setting the conditions appropriately, it is possible to form a film with uniform surface roughness and uniform thickness. The present invention differs from the method proposed in Patent Document 1 in that the copper layer is formed by thermal spraying. Further, the present invention is an invention relating to a resin bonded wheel, and the function of the copper layer and the bonding mechanism are completely different from those related to the metal bond of Patent Document 2.

The second feature is that arc spraying is used, and the rotation speed of the base metal is 20 Zmin or more and 6 OOZ min or less, the feed speed of the nozzle is 300 mm Zmin or more and 1 OOO mm Zmin or less, and the spraying distance is 80 mm or more 150 mm or less, wire feed speed is 0.8 mZ min or more and 2. 4 mm or less, wire diameter is 1. O mm or more and 1.6 mm or less, and voltage between wires is The current is set to 40A or more and 80A or less by setting 30V or more and 50V or less. The structure of the copper layer is preferably denser than porous. Therefore, as the method of thermal spraying, arc thermal spraying should be used rather than powder flame spraying. The arc spraying method is a method also used for coating on metal surfaces, and since it melts to the inside of the raw material particles to be jetted, the structure of the film becomes dense, and a uniform copper layer is obtained without increasing the film thickness. You can get The number of revolutions of the base metal is more preferably 20 Zmin or more and 550 Zmin or less, and more preferably 50 Zmin or more and 550 Zmin or less. The feed rate of nos and nore is more preferably 350 mmZ min or more and 100 mm or less and more preferably 350 mm Zmin or more and 950 mm Zmin or less. The spraying distance is more preferably 90 mm or more and 150 mm or less, still more preferably 90 mm or more and 140 mm or less. The wire feeding speed is more preferably 0.9 mZmin or more and 2.4 mZmin or less, and still more preferably 0.9 mZ min or more and 2.2 mZ min or less. The wire diameter is more preferably 1.1 mm or more and 1.6 mm or less, still more preferably 1.1 or more and 1.5 or less. The voltage between the wires is more preferably 35V or more and 50V or less. The current is more preferably 40A or more and 70A or less.

 The third feature is that the thickness of the metal film is 5 μm or more and 1 mm or less. This is a condition for obtaining strength as a joint. If the thickness of the copper layer exceeds 1 mm, the strength of the copper material will be low, which may cause plastic deformation of the joint, which may reduce the accuracy of the outer circumference of the wheel. There is a risk that the grain layer may peel off. On the other hand, if the distance is 5 m or less, there is a risk that unsprayed portions may occur due to nonuniform film thickness that can not be suppressed under the spraying conditions. Preferably, the force is 500 / z m, more preferably 10 μm to 100 μm.

 [0014] A fourth feature is that the binder of the superabrasive layer is a polyimide resin. If a polyimide resin containing a precursor is used, it is preferred that the copper layer be in the oxidized state, rather than having to be a non-acidic surface, but formed by thermal spraying. If the precursor is not contained, it may be treated in a reducing atmosphere.

A fifth feature is that the material of the base metal is iron-based material, titanium alloy, duralmin. Iron-based materials, titanium alloys and duralumin can form abrasive grain layers with high yield points at high pressure. In view of the yield point and Young's modulus of the material, preferably, iron-based material, titanium alloy It is better to use. Further, it is more preferable to use an iron-based material from the viewpoint of bonding between the material to be sprayed and the base metal. However, when thermally spraying on a titanium alloy, a nickel layer should be provided on the surface of the base metal in advance, and copper should be sprayed on the nickel surface.

 The resin-bonded ultra-granulated wheel according to the present invention is provided with a base metal, a metal coating formed on the surface of the base metal by thermal spraying, a surface of the metal coating, and a resin bond and a super-granule. And the metal film includes copper and copper oxide.

[0017] In the resin-bonded superabrasive grain wheel configured as described above, the metal coating is formed by the thermal spraying treatment, so that the metal coating having a smooth surface can be formed even if there are irregularities on the surface of the base metal.

 Preferably, the resin bond contains a polyimide resin.

 Preferably, the base metal contains cemented carbide.

[0019] Preferably, the polyimide resin constituting the resin bond has oxygen, which can form a coordinate bond, for example, an ether bond.

Preferably, the X-ray diffraction intensity of the (111) plane of copper oxide, Cu 0 (111), and the X-ray of the (111) plane of copper.

 2

 Diffraction intensity ratio Cu O (l l l

 2) Z {Cu (l l l) + Cu 2 O (l l l)} is not less than 0.15 and not more than 0.25.

 2

 It is.

 According to one aspect of the present invention, there is provided a method of manufacturing a resin-bonded ultra-granulated wheel comprising the steps of: forming a metal film having a surface by thermal spraying on a surface of a base metal; and resin bonding the surface of the metal film. And a step of forming a superabrasive grain layer including

 [0022] Preferably, the step of forming the metal film includes forming the metal film by thermal spraying in an inert gas. The method for producing a resin-bonded superabrasive wheel preferably further comprises the step of heat treating the metal coating after forming the metal coating and before forming the superabrasive layer.

 Preferably, the base metal includes a cemented carbide.

 Preferably, the thickness of the base metal is lmm or less.

According to another aspect of the present invention, there is provided a method of manufacturing a resin-bonded ultra-granulated wheel, comprising: covering the upper and lower surfaces of a base metal having a disk-like upper surface, lower surface and outer peripheral surface with a jig; A metal coating containing copper and copper oxide is exposed by thermal spraying on the exposed outer peripheral surface. Forming a film; and forming a superabrasive layer including resin bond and superabrasive particles so as to be in contact with the metal film.

Brief description of the drawings

 FIG. 1 is a perspective view including a partial cross section of a resin-bonded ultra-granulated wheel according to Embodiment 1 of the present invention.

 FIG. 2 is a view showing a cross section of a joint portion of a resin-bonded super-granular wheel according to Embodiment 1 of the present invention.

 FIG. 3 is a perspective view for illustrating a first step of the method for producing a resin-bonded ultra-granulated wheel according to Embodiment 1 of the present invention.

 FIG. 4 is a perspective view showing a second step of the method for producing a resin-bonded super-granular wheel according to Embodiment 1 of the present invention.

 FIG. 5 is a perspective view showing a third step of the method of manufacturing a resin-bonded ultra-granulated wheel according to Embodiment 1 of the present invention.

 FIG. 6 is a perspective view including a partial cross section shown to explain a fourth step of the method of manufacturing a resin-bonded super-granular wheel according to Embodiment 1 of the present invention.

 FIG. 7 is a perspective view showing a fifth step of the method of manufacturing a resin-bonded ultra-granulated wheel according to Embodiment 1 of the present invention.

 FIG. 8 is a perspective view showing a first step of a method of manufacturing a resin-bonded super-granular wheel according to Embodiment 2 of the present invention.

 FIG. 9 is a perspective view showing a second step of the method of manufacturing a resin-bonded super-granular wheel according to Embodiment 2 of the present invention.

 FIG. 10 is a perspective view showing a third step of the method of manufacturing a resin-bonded super-granular wheel according to Embodiment 2 of the present invention.

 FIG. 11 is a perspective view showing a fourth step of the method of manufacturing a resin-bonded super-granular wheel according to Embodiment 2 of the present invention.

 FIG. 12 is a perspective view showing a fifth step of the method of manufacturing a resin-bonded super-granular wheel according to Embodiment 2 of the present invention.

13] It is a perspective view showing an internal structure in FIG. FIG. 14 is a perspective view showing a first step of a method of manufacturing a resin-bonded super-granular wheel according to a comparative example.

 FIG. 15 is a perspective view showing a second step of the method of manufacturing the resin-bonded super-granular wheel according to the comparative example.

 FIG. 16 is a perspective view showing a third step of the method of manufacturing the resin-bonded super-granular wheel according to the comparative example.

 FIG. 17 is a graph showing X-ray diffraction patterns of the product of the present invention and the comparative product.

 FIG. 18 is a graph showing the concentration of copper oxide in the metal film according to the present invention.

 FIG. 19 is a cross-sectional view showing the structure of a superabrasive grain layer.

 Explanation of sign

 [0026] 1 Ultra-granular layer, 2 metal film, 3 base metal, 31 upper surface, 32 lower surface, 33 outer peripheral surface, 38 penetration holes, 100 resin-bonded ultra-granular wheel.

 BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following embodiments, the same or corresponding portions are denoted by the same reference characters, and description thereof will not be repeated. Moreover, it is also possible to combine each embodiment.

Embodiment 1

 FIG. 1 is a perspective view including a partial cross section of a resin-bonded ultra-granulated wheel according to Embodiment 1 of the present invention. Referring to FIG. 1, the disc-shaped resin-bonded super-granular wheel 100 is a disc-shaped base metal 3 having a through hole 38 formed in the center and a metal formed on the outer peripheral surface 33 of the base metal 3. A coating 2 and a superabrasive layer 1 formed on the surface of the metal coating 2 are provided. The base metal can be made of, for example, an alloy containing iron. Furthermore, base metal 3 is made of tungsten carbide, cemented carbide with a main component of Boid, and so on! When cemented carbide is used, the resin-bonded super-granular wheel 100 after use can be recycled.

The metal film 2 is provided on the outer peripheral surface 33 of the base metal 3 by thermal spraying. The metal film 2 contains copper as a main component, and a portion of the copper further contains oxidized copper. The metal film 2 may be pure copper without containing copper oxide. Also, metal coating 2 is a base metal on the inner circumference 3 Since it is a member for bonding with the superabrasive layer 1 on the outer peripheral side, the adhesion between the superabrasive layer 1 and the base metal 3 is good, and if it is a material, the metal coating 2 is It can be included in the constituent copper.

 Superabrasive layer 1 has a configuration in which superabrasive grains are held by resin bonding. Diamond or cubic boron nitride (cBN) can be used as the superabrasive. The super-granular layer 1 is provided on the outer peripheral surface 21 of the metal film 2. The thickness of the base metal 3 (the distance from the upper surface 31 to the lower surface 32) tl is not particularly limited, but may be 1 mm or less! /.

 Next, a method of manufacturing the resin-bonded super-granulated wheel shown in FIGS. 1 and 2 will be described. FIGS. 3 to 7 are diagrams for explaining the method of manufacturing the super-granulated wheel according to the first embodiment of the present invention. First, prepare base metal 3 with reference to FIG. The base metal 3 is disk-shaped, and has a through hole 38 at its center.

 Referring to FIG. 4, jigs 51 and 52 are attached to the upper and lower surfaces of base metal 3. The jigs 51 and 52 cover the upper and lower surfaces. The area of the jigs 51 and 52 is equal to the area of the upper and lower surfaces. The outer peripheral surface which is the side surface is exposed.

 Referring to FIG. 5, shaft 53 is inserted into through hole 38, and shaft 53 is rotated in the direction indicated by arrow R. Referring to FIG. As a result, the base metal 3 engaged with the shaft 53 and the jigs 51 and 52 also rotate in the direction indicated by the arrow R. At this time, copper is injected from the nozzle 54 toward the outer peripheral surface 33. A metal coating is formed on the outer peripheral surface 33 by the thermal spraying process.

 Referring to FIG. 6, after forming the metal film 2, the base metal 3 is fixed with the molds 61, 62, 63, 64. In this state, super granules and a resin bond are disposed to be in contact with the outer peripheral surface 21 of the metal film 2, and a pressure is applied to the super-abrasive layer 1 by using a mold 65.

 Referring to FIG. 7, resin-bonded super-granular wheel 100 having super-granular layer 1 provided on the outer periphery is completed by removing molds 61-65.

 Second Embodiment

A resin-bonded super-granular wheel according to Embodiment 2 of the present invention will be described with reference to FIGS. 8 to 13. Referring to FIG. 8, base metal 3 according to the second embodiment has a flange portion 35. The flange portion 35 is a portion having an outer diameter larger than other portions, and a metal film is formed on the outer peripheral surface 33 of the flange portion 35. Referring to FIG. 9, base metal 3 is fitted to jigs 51, 52 and shaft 53. The outer peripheral surface 33 of the flange portion 35 of the base metal 3 is exposed to the outside. In this state, metal is sprayed from the nozzle 54 on the outer peripheral surface 33 while rotating the base metal 3.

 Referring to FIG. 10, metal coating 2 is formed on the surface of outer peripheral surface 33 as a result of the thermal spraying process.

 Referring to FIG. 11, the base metal 3 on which the metal film 2 is formed is fixed in the molds 61, 62, 64, 65.

 Referring to FIG. 12 and FIG. 13, the inside of the mold is filled with super granules and a resin bond, and these are solidified to form the super-abrasive layer 1. That is, resin-bonded super-granular wheel 100 according to Embodiments 1 and 2 has base 3 having outer peripheral surface 33 and outer peripheral surface 21 formed on outer peripheral surface 33 of base 3 by thermal spraying. A metal coating 2 and a superabrasive layer 1 provided on an outer peripheral surface 21 of the metal coating 2 and including a resin bond and a superabrasive are provided. The metal film 2 contains copper and copper oxide.

 The resin bond may contain polyimide resin. The copper oxide may be localized near the interface between the metal coating 2 and the superabrasive grain layer 1. The base metal 3 may contain cemented carbide. The molecules that make up the resin bond may contain oxygen as a constituent.

 The method of manufacturing resin-bonded ultra-granulated wheel 100 according to the present invention comprises the steps of forming metal coating 2 having outer peripheral surface 21 by thermal spraying on outer peripheral surface 33 of base metal 3; And forming a superabrasive layer 1 including resin bonds and superabrasive grains on the outer peripheral surface 21. The step of forming the metal coating 2 includes forming the metal coating 2 by thermal spraying in an inert gas such as nitrogen or argon, and after the metal coating 2 is formed, the superabrasive grain layer 1 is formed. The method may further include the step of oxidizing the surface of the metal film 2 by heat treatment before the metal film 2. The thickness of the base metal 3 is preferably lmm or less!

 The resin-bonded super-granular wheel is manufactured in the disk shape by covering the upper surface 31 and the lower surface 32 of the base metal 3 having the upper surface 31, the lower surface 32 and the outer peripheral surface 33 with jigs 51 and 52. And forming a metal film 2 containing copper and copper oxide on the exposed outer peripheral surface 33 by thermal spraying, and a resin bond and a superabrasive particle so as to be in contact with the metal film 2. And the step of forming the abrasive grain layer 1.

[0043] In order to form the metal coating 2 by thermal spraying, the metal coating 2 is formed only where necessary. It is possible. Therefore, the outer peripheral surface 33 can be cleaned and reused after the base metal 3 is used, and the life of the base metal can be improved.

Comparative Example

 The method of manufacturing the super-granular wheel according to the comparative example will be described with reference to FIGS. In the comparative example, as shown in FIGS. 14 and 15, the mask 112 is formed on the upper surface 31 and the lower surface 32.

 Referring to FIG. 16, the base metal 3 on which the mask 112 is formed is immersed in the plating solution 113, and the base metal 3 is rotated using the shaft 114. Thereby, a metal film is formed on the base metal 3.

 In the formation of the metal film using such adhesion, there is a problem that it takes time to form the mask 112.

 Example 1

 [0047] Using a 140 mm diameter base for carbon steel for machine structure, a copper layer with a thickness of 20 to 30 / ιπ was formed on the outer peripheral surface by arc spraying. The surface roughness of the copper layer at this time was 4.3 μm Ra ̃4., As a result of measurement using a surface roughness meter surfcoml 400 manufactured by Tokyo Seimitsu Co., Ltd. A resin-bonded superabrasive wheel was manufactured using powder raw material of polyimide resin as a binder. The spraying conditions are as shown in Table 1. Insert the base metal on the bottom plate of the mold, place the core of the same diameter as the base metal on the base metal, fill the gap between the outer frame and the core with the raw material powder of the granule layer, and insert the punch. The load was also increased at low pressure. After that, a predetermined pressure was applied from above the punch, and while maintaining the pressure, the room temperature force was also heated to 400 ° C. for about 30 minutes, and then it was gradually cooled.

 Example 2

 A resin-bonded super-granular wheel was produced in the same manner as in Example 1.

 However, as a result of measuring the surface roughness of the base metal, it was 6 μmRa to 7 μmRa. Example 3

 A resin-bonded super-granular wheel was produced in the same manner as in Example 1.

 However, as a result of measuring the surface roughness of the base metal, it was 1.3 mRa to 1.6 mRa.

[Table 1] Base rotation speed 200 / min

 Nozzle feed speed 900 mm / m i n

 Spray distance 120 mm

 Voltage 45 V

 Current 50 A

 Wire feed speed 1.5 m / m i n

 Wire diameter: 1.2 mm Comparative example 1

 A resin-bonded super-granular wheel was produced in the same manner as in Example 1 using a copper base metal.

 However, the abrasive layer was bonded directly to the base metal without forming a copper layer by arc spraying.

 Comparative example 2

 A base of carbon steel for machine structural use was plated with copper at a thickness of 10 m, and a resin-bonded super-granular wheel was manufactured in the same manner as in Example 1.

 Comparative example 3

 In the method of manufacturing the resin-bonded wheel of Example 1, only the ring-shaped abrasive particle layer is formed without incorporating the base metal in the mold, and the aluminum base metal separately manufactured is used for conventional V, The epoxy resin adhesive was used to bond.

 Sixteen slots were provided at circumferentially equidistant positions in the particle layer portion of the resin-bonded super-granulated wheel manufactured as described above to form 16 segments. The joint strength was measured by pressing the head of a universal tester from the side of each segment and performing a compressive shear test. The bonding strength was calculated by averaging 16 values for each wheel.

 The results are shown in Table 2. Example 1 had higher strength than Comparative Examples 1 and 3. Moreover, although Example 2 and Example 3 are a result in case the surface roughness of a copper layer differs a little, the result which has sufficient intensity | strength was obtained. On the other hand, in Comparative Example 2, the strength was lower than in Examples 1 to 3, in which the copper layer was formed by plating instead of thermal spraying.

[Table 2] Bonding strength kgf / rmi ²

 Example 14.0

 Example 2 3.9

 Example 3 3.5

 Comparative Example 1 2. 7

 Comparative Example 2 2. 7

 Comparative example 3 2.5

(Verification of Samples of Example 1 and Comparative Example 2)

 The distribution ratio of copper to copper oxide in the metal coatings produced in Example 1 and Comparative Example 2 was examined using X-ray diffraction. The results are shown in FIG.

As shown in FIG. 17, in the sample of Example 1 formed by thermal spraying, Cu and Cu

 It can be seen that O exists and contains copper oxide.

 2

 On the other hand, in the plated product (Comparative Example 2), copper oxide is included!

 Next, the concentration of copper oxide in the metal film manufactured in Example 1 was examined in detail. FIG. 18 is a graph showing the distribution of copper oxide in the metal film 2. Referring to FIG. 18, it can be seen that the concentration of copper oxide increases at the interface between the metal coating 2 and the superabrasive grain layer 1, and copper oxide is unevenly distributed at the interface.

 Furthermore, the configuration in the superabrasive layer 1 was examined. The results are shown in FIG. As shown in FIG. 19, it was confirmed that super-granule 1001 was bonded by resin bond 1002.

 The resin bond 1002 can contain metal powder, carbide or nitride hard particles, solid lubricant particles, and the like as filler in addition to granules such as diamond and CBN.

 Examples of metal powder include Cu, Ag, Sn, Ni, Au and the like. Particularly preferred from the viewpoint of cost and effect are Cu, Ag or their alloys. Or you may mix and add two or more kinds of metal powder.

 Examples of hard particles of carbide or nitride include SiC, Si N, Cr 2 O, Al 2 O, SiO 2 and the like.

3 4 2 3 2 3 2 force is also selected One or more kinds of hard particle force It may be contained in the resin bond as a further filler. By containing such hard particles, the abrasion resistance of the resin bond is enhanced, and the effect of prolonging the life of the superabrasive wheel can be obtained. [0065] As a further filler, solid lubricant particles may be contained in the resin bond. Examples of solid lubricants of this type include fluorine-containing resins such as polytetrafluoroethylene, hBN, calcium fluoride, graphite, MoS and the like. Such solid lubricant particles

 2

 By adding one or more of the above, the effect of reducing the friction between the particle layer and the work material and reducing the grinding resistance can be obtained.

 Example 4

 Samples 1 to 8 were produced by arc spraying according to the production method of Example 1. For samples 1 to 8, (111) of Cu 2 O in the sample under the following measurement device and measurement conditions

 2

 The ratio of the plane to the (111) plane of Cu was investigated by X-ray diffraction.

Measuring Device

 Rint-1500 (made by RIGAKU)

 Measurement condition

 Use X-ray: Cu- α α (with monochromator)

 Excitation conditions: 50kV, 200mA

 Optical system: Focusing method

 Slit system: DS1 °

 RS 0.15 mm

 SS 1 °

 Running speed: 6 / min

 Step width: 0.20 °

 Measurement mode: θ-2 Θ 3⁄4

 The results are shown in Table 3.

[Table 3] Cu ₂ 0 (11) Cu (111) Cu ₂ 0 (11) /

 Sample No.

(Integrated intensity) (Integrated intensity) {Gu ₂ 0 (11 l) + Cu (11 l) l ratio

 1 281 102 1149225 0.197

2 244213 953971 0.204

Three 248183 1042261 0.192

4 221693 845997 0.208

5 199101 928923 0.177

6 229 214 986069 0.189

7 242764 1026982 0.191

8 220236 937613 0.190 Average value--0.194 Standard deviation (1σ)--0.01

From Table 3, the ratio of CuO (lll) Z {Cu (lll) + CuO (lll)} is 0 · 15 or more and 0.25 or more.

 twenty two

 It is important to be able to obtain desirable characteristics if it is below.

 Industrial applicability

As described above, the resin-bonded ultra-granulated wheel of the present invention can achieve stable and extremely high bonding strength as compared to the conventional method of forming a copper layer by plating, so it has a long life and a high efficiency. It exerts an excellent effect that a high performance resin bonded superabrasive wheel can be obtained. In particular, resin-bonded superabrasive wheels using polyimide resin exhibit outstanding high performance and long life, so they can be expected to contribute significantly to the industry where grinding is required. .

Claims

The scope of the claims  [1] The surface (33) of the base metal (3) is provided with a metal coating (2) by thermal spraying treatment, and the metal coating  A resin-bonded super-granular wheel (100) in which a super-granular layer (1) is bonded to the surface (21) of (2),  The resin-bonded superabrasive wheel, wherein the metal coating (2) is copper. [2] The thermal spraying process is arc thermal spraying,  Set the rotation speed of the base metal to 20 Zmin or more and 600 Zmin or less,  Set the feed speed of the nozzle to 300mmZmin or more and lOOOmmZmin or less  Spraying distance is 80mm or more and 150mm or less,  Wire feed speed is 0.8 mZ min or more 2. Within 4 mm,  The diameter of the wire is 1. Omm or more and 1.6 mm or less,  Make the voltage between wires 30V or more and 50V or less,  The resin bonded wheel according to claim 1, wherein the current is set to 40A or more and 80A or less. [3] The resin-bonded ultra-granulated wheel according to claim 1, wherein the thickness of the metal film (2) is 5 m or more and 1 mm or less. [4] The resin-bonded ultragranular wheel according to claim 1, wherein the binder of the ultragranular layer (1) is a polyimide resin.  [5] The resin-bonded super-granulated wheel according to claim 1, wherein the material of the base metal (3) is iron-based material, titanium alloy, duralmin. [6] preparing a base metal (3) having a surface (33),  A method for producing a resin-bonded superabrasive wheel, comprising the step of forming a copper film (2) having a thickness of 5 μm or more and 1 mm or less by thermal spraying on the surface (33) of a base metal (3). [7] The method for producing a resin-bonded super-granular wheel according to claim 6, wherein the thermal spraying process according to claim 2 is used. [8] base metal (3) with surface (33),  A metal coating (2) having a surface (21) formed on the surface (33) of the base metal (3) by thermal spraying treatment; It is provided on the surface (21) of the metal coating (2), and resin bond (1002) and super-granular (1001) A resin-bonded super-granulated wheel comprising a superabrasive layer (1) and a metal coating (2) containing copper and copper oxide.  [9] The resin-bonded super-granular wheel according to claim 8, wherein the resin bond (1002) contains a polyimide resin.  [10] The resin-bonded ultragranulated wheel according to claim 8, wherein the base metal (3) contains a cemented carbide. [11] The polyimide resin constituting the resin bond (1002) contains oxygen as a component The resin-bonded super-granular wheel according to claim 8. [12] X-ray diffraction intensity of the (111) plane of the copper oxide CuO (l l l) X-ray diffraction of the (111) plane of the copper  2  The ratio of bending strength Cu O (l l l) Z {Cu (l l l) + Cu O (l l l)} is not less than 0.15 and not more than 0.25.  twenty two  The resin-bonded super-granular wheel according to claim 8. [13] a step of forming a metal coating (2) having a surface (21) on the surface (33) of the base metal (3) by thermal spraying;  Forming a superabrasive layer (1) including a resin bond (1002) and super granules (1001) on the surface (21) of the metal coating (2), producing a resin-bonded superabrasive wheel Method. [14] The step of forming the metal coating (2) includes forming the metal coating (2) by thermal spraying in an inert gas, and the method of producing a resin-bonded superabrasive wheel includes the step of forming the metal coating (2) The resin-bonded superabrasive grain wheel according to claim 13, further comprising the step of subjecting the metal coat (2) to heat treatment after forming the coat (2) and before forming the superabrasive layer (1). Production method.  [15] The method for producing a resin-bonded ultragranulated wheel according to claim 13, wherein the base metal (3) contains a cemented carbide.  [16] The method for producing a resin-bonded super-granular wheel according to claim 13, wherein the thickness of the base metal (3) is 1 mm or less. [17] Cover the upper surface (31) and lower surface (32) of the base metal (3) having the upper surface (31), lower surface (32) and outer peripheral surface (33) in the disk shape with jigs (51, 52) Exposing the surface (33) and forming a metal coating (2) containing copper and copper oxide on the exposed outer peripheral surface (33) by thermal spray treatment and contacting the metal coating (2) Includes resin bond (1002) and super-granule (1001) And (e) forming a superabrasive layer (1).