Super hard alloy baseplate outer circumference cutting blade and manufacturing method thereof

Abstract

The disclosed cemented carbide base outer blade cutting wheel comprises a base in the form of an annular thin disc of cemented carbide, and a blade section on the outer periphery of the base. The blade section contains: diamond and/or CBN abrasive grains pre-coated with a magnetic material; a metal or alloy bond formed by electroplating or electroless plating for bonding abrasive grains together and to the base; a resin infiltrated between abrasive grains and between abrasive grains and the base, said resin being a thermoplastic resin having a melting point of up to 350° C. or a thermoset resin obtained by curing a liquid thermosetting resin composition having a curing temperature of up to 350° C. The method for manufacturing said outer blade cutting wheel is also disclosed.

1 . An outer blade cutting wheel comprising a base in the form of an annular thin disc of cemented carbide having a Young's modulus of 450 to 700 GPa, having an outer diameter of 80 to 200 mm defining an outer periphery, an inner diameter of 30 to 80 mm and a thickness of 0.1 to 1.0 mm, and a blade section on the outer periphery of the base,
 said blade section comprising   diamond and/or CBN abrasive grains pre-coated with a magnetic material,   a metal or alloy bond formed by electroplating or electroless plating for bonding abrasive grains together and to the base, and   a resin infiltrated between abrasive grains and between abrasive grains and the base, said resin being a thermoplastic resin having a melting point of up to 350° C. or a thermoset resin obtained by curing a liquid thermosetting resin composition having a curing temperature of up to 350° C.   
     
     
         2 . The cutting wheel of  claim 1  wherein the resin is at least one member selected from the group consisting of acrylic resins, epoxy resins, phenolic resins, polyamide resins, polyimide resins, and modified resins of the foregoing. 
     
     
         3 . The cutting wheel of  claim 1  wherein the resin has a Poisson's ratio between 0.3 and 0.48. 
     
     
         4 . The cutting wheel of  claim 1  wherein said base has a saturation magnetization of at least 40 kA/m (0.05 T). 
     
     
         5 . The cutting wheel of  claim 1  wherein said abrasive grains have an average grain size of 10 to 300 μm. 
     
     
         6 . The cutting wheel of  claim 1  wherein said abrasive grains have a mass magnetic susceptibility χg of at least 0.2. 
     
     
         7 . A method for manufacturing an outer blade cutting wheel comprising the steps of:
 providing a base in the form of an annular thin disc of cemented carbide having a Young's modulus of 450 to 700 GPa, having an outer diameter of 80 to 200 mm defining an outer periphery, an inner diameter of 30 to 80 mm, and a thickness of 0.1 to 1.0 mm,   providing diamond and/or CBN abrasive grains pre-coated with a magnetic material,   placing a permanent magnet near the outer periphery of the base so that the magnetic field produced by the permanent magnet may act to magnetically attract and hold the coated abrasive grains close to the outer periphery of the base,   electroplating or electroless plating a metal or alloy on the base outer periphery and the coated abrasive grains being magnetically attracted and held, for bonding the abrasive grains together and to the base to fixedly secure the abrasive grains to the base outer periphery to form a blade section, and   letting a thermoplastic resin having a melting point of up to 350° C. infiltrate into any voids between abrasive grains and between abrasive grains and the base or letting a liquid thermosetting resin composition having a curing temperature of up to 350° C. infiltrate into any voids between abrasive grains and between abrasive grains and the base and cure thereat.   
     
     
         8 . The method of  claim 7  wherein the resin is at least one member selected from the group consisting of acrylic resins, epoxy resins, phenolic resins, polyamide resins, polyimide resins, and modified resins of the foregoing. 
     
     
         9 . The method of  claim 7  wherein the infiltrating resin has a Poisson's ratio between 0.3 and 0.48. 
     
     
         10 . The method of  claim 7  wherein said base has a saturation magnetization of at least 40 kA/m (0.05 T). 
     
     
         11 . The method of  claim 7  wherein said abrasive grains have an average grain size of 10 to 300 μm. 
     
     
         12 . The method of  claim 7  wherein said abrasive grains have a mass magnetic susceptibility χg of at least 0.2. 
     
     
         13 . The method of  claim 7  wherein the permanent magnet produces a magnetic field of at least 8 kA/m within a space extending a distance of 10 mm or less from the base outer periphery.