EP3135434B1 - Method for producing a multi-dimensional scalable tool - Google Patents
Method for producing a multi-dimensional scalable tool Download PDFInfo
- Publication number
- EP3135434B1 EP3135434B1 EP16185598.6A EP16185598A EP3135434B1 EP 3135434 B1 EP3135434 B1 EP 3135434B1 EP 16185598 A EP16185598 A EP 16185598A EP 3135434 B1 EP3135434 B1 EP 3135434B1
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- European Patent Office
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- recesses
- layer
- particles
- primary
- abrasive
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- 238000004519 manufacturing process Methods 0.000 title claims description 11
- 239000002245 particle Substances 0.000 claims description 87
- 239000000463 material Substances 0.000 claims description 35
- 238000000034 method Methods 0.000 claims description 27
- 238000007650 screen-printing Methods 0.000 claims description 16
- 239000011230 binding agent Substances 0.000 claims description 15
- 238000007639 printing Methods 0.000 claims description 12
- 238000010438 heat treatment Methods 0.000 claims description 9
- 238000005245 sintering Methods 0.000 claims description 6
- 244000007853 Sarothamnus scoparius Species 0.000 claims description 4
- 229910003460 diamond Inorganic materials 0.000 claims description 4
- 239000010432 diamond Substances 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 238000001513 hot isostatic pressing Methods 0.000 claims description 2
- 238000007731 hot pressing Methods 0.000 claims description 2
- 150000004767 nitrides Chemical class 0.000 claims description 2
- 238000005219 brazing Methods 0.000 claims 1
- 239000010410 layer Substances 0.000 description 85
- 238000005520 cutting process Methods 0.000 description 16
- 230000000694 effects Effects 0.000 description 8
- 239000002356 single layer Substances 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 239000011324 bead Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000010354 integration Effects 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 2
- 239000003082 abrasive agent Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000003750 conditioning effect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 235000021384 green leafy vegetables Nutrition 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 229920005596 polymer binder Polymers 0.000 description 1
- 239000002491 polymer binding agent Substances 0.000 description 1
- 239000012254 powdered material Substances 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
- B24D11/001—Manufacture of flexible abrasive materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
- B24D11/04—Zonally-graded surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
- B24D5/02—Wheels in one piece
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
- B24D5/14—Zonally-graded wheels; Composite wheels comprising different abrasives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D7/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor
- B24D7/02—Wheels in one piece
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D7/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor
- B24D7/14—Zonally-graded wheels; Composite wheels comprising different abrasives
Definitions
- WO 2013/142988 A1 discloses an abrasive article and also a method for its manufacture.
- the WO 2013/142988 A1 discloses a method for producing a multi-layer tool in which a green part is produced by producing a primary layer provided with recesses from a primary material provided with an organic binder system and subsequently introducing particles with an abrasive effect into the recesses and then a cover layer made from the the primary material provided with the organic binder system is applied to fix the abrasive particles in the recesses, with the tool being obtained by a final heat treatment of the green part.
- the present invention is therefore based on the object of proposing a method for producing a tool that avoids the disadvantages mentioned, with which particles with an abrasive effect can therefore be easily arranged at defined positions of the tool.
- the abrasive particles can be introduced in a targeted manner in the primary layer and thus in the finished tool.
- the spatial positions of the recesses and thus also of the abrasive particles or cutting particles subsequently introduced into them are therefore fixed and precisely defined.
- Stencil printing can cause these to have an abrasive effect Particles can continue to be introduced and positioned easily and quickly.
- the final covering layer finally fixes the cutting particles.
- the final heat treatment drives out the organic binder system, which preferably contains polymer binders and additives, and the primary material remains and forms the tool.
- At least one subsequent layer is applied to the layer provided with the abrasive particles in an intermediate step.
- the gaps are usually spatially offset from the gaps in the primary layer or an adjacent layer, so that the gaps in the layer already applied with the abrasive particles contained therein are also filled with the primary material provided with the binder system.
- a stencil is used for stencil printing, which has a maximum thickness of 30 percent of the maximum diameter of the abrasive particles, in order to be able to carry out the stencil printing reliably.
- the recesses 2 which can also be referred to as cavities, cavities or channels, have a width of between 40 ⁇ m and 3 mm and are at the same distance from one another.
- all the recesses 2 in the primary layer 1 are the same, that is to say they have an identical width and an identical depth.
- the designs shown have a square opening, so their maximum width is equal to their maximum length. In further exemplary embodiments, however, the opening can of course also have other shapes, for example round, or the recesses 2 can also all have different dimensions. Provision can also be made for identical recesses 2 to be provided in the primary layer 1 in a periodically repeating manner. Likewise, the distances between the individual recesses 2 can be of different sizes.
- FIG 2 shows in one figure 1
- abrasive particles 3 made of diamond or cutting particles are introduced into the recesses 2.
- the abrasive particles 3 are triangular in cross section in the illustrated embodiment, but can also have any other shape.
- the recesses 2 have a depth that corresponds to just 75 percent of a maximum diameter of the abrasive particles 3 .
- the abrasive particles 3 therefore protrude from the recesses 2 as soon as they have been introduced. In further exemplary embodiments, however, there can also be a flush termination of the abrasively acting particles 3 with an opening in the recesses 2 .
- all abrasive particles 3 used for the primary layer 1 are identical, but identical particles 3 can also be used for just one layer or different particles 3 can be used independently of the layer. Only the abrasive particles 3 are introduced into the recesses 2 by dry squeegeeing, with exactly one of the abrasive particles 3 fitting in one of the recesses 2 and further additives being unnecessary.
- a subsequent layer 7 or, if this layer to be applied is the final layer, a top layer on the abrasive particles 3 introduced into the primary layer 1 is in figure 3 in a figure 1 corresponding schematic sectional view shown.
- the subsequent layer 7 is in turn applied from the primary material in powder or paste form and provided with the organic binder system through the screen 8 with an integrated layout, the integrated layout 9 closing the screen 8 at the positions of the abrasive particles 3 . If the cover layer is applied as the last layer to be applied, the gaps 2 in the layer immediately below are only filled, but no new gaps 2 are formed.
- the particles 3 with an abrasive effect are embedded in the primary material and at the same time new recesses 2 are defined and formed by the shaded areas when the subsequent layer 7 is applied.
- the subsequent layer 7 or cover layer is directly attached to the filled primary layer 1, the gaps in the primary layer 1 are thus closed by the application of the subsequent layer 7 or the cover layer and the abrasive particles 3 are embedded and fixed in the primary layer.
- the green part produced in this way from the primary material made of metal or a metal alloy applied in layers and the abrasive particles 3 is sintered, pressure sintered, free sintered, hot pressed, hot isostatic pressed or soldered as a final heat treatment solidified, the organic binder system expelled and the multi-layer tool, in the illustrated embodiment an abrasive segment, completed.
- the entire tool shown has a length of 300 mm.
- Cutting tools produced with the method described can be designed very freely and definably. In addition to free forms, channels, cavities or cavities can be created. This free design is also an integration of z. B. cooling channels, guide grooves, support or integration structures possible during component development.
- By changing the print layout, in particular by changing a used Template during the layered construction of the abrasive particles 3, an adjustable offset of the abrasive particles 3 between the individual layers or plies can be implemented. This ensures that particles 3 with an abrasive effect are always available in the finished cutting tool along a wear axis.
- process-related structural adjustments can also be implemented in the form of guide holes and/or beads, which ensure that different layers overlap during the heat treatment.
- the particles 3 with an abrasive effect can have an adapted and narrow powder distribution curve and be smaller than a maximum diameter of a stencil opening.
- By changing the template layout it is also possible to use different abrasive substances, ie different materials for the abrasively acting particles 3, within the defined, three-dimensionally arranged particle positions.
- a local concentration or a gradation of the particles 3 with an abrasive action within the cutting tool is made possible by the change in printing screen or stencil layout described.
- these concentration islands are offset from one another by exactly 90°, but the concentration islands of the primary layer 1 are each offset by 45° in relation to the concentration islands of the subsequent layer 7 .
- both the particle concentration and the particle positions between the individual layers can be varied and a gradation in the direction of construction can be achieved.
- the top layer 6 is typically also applied to the subsequent layer 7 .
- a layer system with introduced abrasive bodies 3 can of course also have any other shape, in particular spherical or cylindrical, with the individual layers 1 or 7 being round, oval or elliptical in their basic shape.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Polishing Bodies And Polishing Tools (AREA)
Description
Die vorliegende Erfindung betrifft ein Verfahren zum Herstellen eines mehrdimensional skalierbaren Werkzeugs.The present invention relates to a method for producing a multidimensionally scalable tool.
In verschiedenen Industriegebieten werden abrasive Werkzeug eingesetzt, die über eine definierte Anordnung von Schneidpartikeln verfügen. Neben Problemen hinsichtlich eines Werkzeuglebensdauerzyklus stehen hier vor allem im Bereich von Feinschnittanwendungen abrasive Werkzeuge mit geordneten Schneidpartikeln im Vordergrund. Eine Serienfertigung derartiger Werkzeuge mittels bekannter Herstellungsverfahren ist jedoch aufwändig bzw. mit hohen Produktionskosten verbunden. Zudem unterliegen aktuelle Lösungen geometrischen Einschränkungen.Abrasive tools that have a defined arrangement of cutting particles are used in various industrial areas. In addition to problems with regard to a tool life cycle, abrasive tools with ordered cutting particles are in the foreground here, especially in the area of fine blanking applications. However, mass production of such tools using known manufacturing processes is complex and associated with high production costs. In addition, current solutions are subject to geometric limitations.
Dies bedeutet zum Beispiel, dass Lösungskonzepte in ihren minimal möglichen Positionierungsmaßen für Abrasivstoffe aufgrund von Verfahrensgrenzen beschränkt sind. Weiterhin kann keine reproduzierbare und wiederholt definiert vorgegebene Schneidpartikelüberlappung generiert werden, die eine Schneideffizienz derartiger Werkzeuge erhöht.This means, for example, that solution concepts are limited in their minimum possible positioning dimensions for abrasive materials due to process limitations. Furthermore, no reproducible and repeatedly defined predetermined cutting particle overlap are generated, which increases the cutting efficiency of such tools.
So offenbart beispielsweise die Druckschrift
So sind aus
Ein Verfahren zum Schärfen eines Schneidelements geht aus
Der vorliegenden Erfindung liegt daher die Aufgabe zugrunde, ein Verfahren zum Herstellen eines Werkzeugs vorzuschlagen, das die genannten Nachteile vermeidet, mit dem also abrasiv wirkende Partikel an definierten Positionen des Werkzeugs einfach angeordnet werden können.The present invention is therefore based on the object of proposing a method for producing a tool that avoids the disadvantages mentioned, with which particles with an abrasive effect can therefore be easily arranged at defined positions of the tool.
Diese Aufgabe wird erfindungsgemäß gelöst durch ein Verfahren nach Anspruch 1. Vorteilhafte Ausgestaltungen und Weiterbildungen sind in den abhängigen Ansprüchen beschrieben.This object is achieved according to the invention by a method according to
Bei einem Verfahren zum Herstellen eines mehrschichtigen Werkzeugs wird ein Grünteil hergestellt, indem zunächst durch Siebdruck eine mit Aussparungen versehene Primärschicht aus einem mit einem organischen Bindemittelsystem versehenen Primärwerkstoff hergestellt wird und nachfolgend durch Schablonendruck in die Aussparungen abrasiv wirkende Partikel eingebracht werden. Dann wird durch Siebdruck eine Deckschicht des mit dem organischen Bindemittelsystem versehenen Primärwerkstoffs zum Fixieren der abrasiv wirkenden Partikel in den Aussparungen aufgebracht. Das Werkzeug wird schließlich durch eine abschließende Wärmebehandlung des Grünzeugs erhalten.In a method for producing a multi-layer tool, a green part is produced in that a primary layer provided with recesses is first produced by screen printing from a primary material provided with an organic binder system and abrasive particles are subsequently introduced into the recesses by stencil printing. A cover layer of the primary material provided with the organic binder system is then applied by screen printing in order to fix the abrasive particles in the recesses. The tool is finally obtained by a final heat treatment of the greens.
Durch das Verwenden von Siebdruck zum Definieren und Herstellen der Aussparungen können die abrasiv wirkenden Partikel gezielt in der Primärschicht und somit in dem fertigen Werkzeug eingebracht werden. Die räumlichen Positionen der Aussparungen und damit auch der nachfolgend in diese eingebrachten abrasiv wirkenden Partikel oder Schneidpartikel sind daher festgelegt und genau definiert. Durch Schablonendruck können diese abrasiv wirkenden Partikel weiterhin einfach und schnell eingebracht sowie positioniert werden. Die abschließende Deckschicht fixiert die Schneidpartikel schließlich. Durch die abschließende Wärmebehandlung wird das organische Bindemittelsystem, das vorzugsweise Polymerbinder und Additive aufweist, ausgetrieben und der Primärwerkstoff verbleibt und formt das Werkzeug.By using screen printing to define and produce the recesses, the abrasive particles can be introduced in a targeted manner in the primary layer and thus in the finished tool. The spatial positions of the recesses and thus also of the abrasive particles or cutting particles subsequently introduced into them are therefore fixed and precisely defined. Stencil printing can cause these to have an abrasive effect Particles can continue to be introduced and positioned easily and quickly. The final covering layer finally fixes the cutting particles. The final heat treatment drives out the organic binder system, which preferably contains polymer binders and additives, and the primary material remains and forms the tool.
Unter Siebdruck soll hierbei ein Verfahren verstanden werden, bei dem der aufzubringende Primärwerkstoff samt des beigemischten organischen Bindemittelsystems durch ein feinmaschiges Sieb gedruckt wird. Hierzu liegt der Primärwerkstoff und das dem Primärwerkstoff beigefügte organische Bindemittelsystem vorzugsweise in Form einer Druckpaste vor. Das Sieb selbst weist typischerweise an nicht zu bedruckenden Stellen ein abschattendes Strukturlayout als Beschichtung auf. Schablonendruck soll demgegenüber ein Verfahren bezeichnen, bei dem lediglich eine Schablone verwendet wird, also kein Sieb zum Einsatz kommt.Screen printing is to be understood as meaning a process in which the primary material to be applied, together with the added organic binder system, is printed through a fine-meshed screen. For this purpose, the primary material and the organic binder system added to the primary material are preferably in the form of a printing paste. The screen itself typically has a shading structure layout as a coating in areas that are not to be printed. Stencil printing, on the other hand, is intended to describe a process in which only a stencil is used, i.e. no screen is used.
Es kann vorgesehen sein, dass die abrasiv wirkenden Partikel durch Rakeln in die Aussparungen aufgebracht bzw. eingebracht werden. Dies erlaubt eine schnelle und sichere Verarbeitung der abrasiv wirkenden Partikel. Vorzugsweise erfolgt das Rakeln mit einer Schieberakel oder einer Besenrakel. Ebenso wird typischerweise auch der mit dem organischen Bindemittelsystem versehene Primärwerkstoff beim Siebdruck durch Rakeln bearbeitet und aufgebracht bzw. eingebracht.Provision can be made for the abrasive particles to be applied or introduced into the recesses by squeegeeing. This allows the abrasive particles to be processed quickly and safely. Squeegeeing is preferably carried out with a sliding squeegee or a broom squeegee. Likewise, the primary material provided with the organic binder system is typically also processed and applied or introduced by squeegeeing during screen printing.
Typischerweise wird vor dem Aufbringen der Deckschicht in einem Zwischenschritt mindestens eine Folgeschicht auf die mit den abrasiv wirkenden Partikeln versehene Schicht aufgebracht. Bei dieser Folgeschicht sind die Aussparungen üblicherweise räumlich versetzt zu den Aussparungen der Primärschicht oder einer benachbarten Schicht angeordnet, so dass auch die Aussparungen der bereits aufgebrachten Schicht mit den darin enthaltenen abrasiv wirkenden Partikeln mit dem mit dem Bindemittelsystem versehenen Primärwerkstoff gefüllt werden. Dies erlaubt es, in dreidimensionalem Siebdruck in ihrer Raumstruktur optimierte abrasive Werkzeuge mit engen Positionierungsmaßen herzustellen, wobei die Positionen im dreidimensionalen Bauteilraum nahezu frei definierbar sind. Es lässt sich hiermit eine höhere Konzentration von abrasiv wirkenden Partikeln erreichen und auch räumlich lokale Konzentrationen oder Konzentrationsgradienten der abrasiv wirkenden Partikel generieren. Durch ein Wiederholen der beschriebenen Schritte lässt sich somit ein mehrdimensionales Schneidwerkzeug herstellen.Typically, before the top layer is applied, at least one subsequent layer is applied to the layer provided with the abrasive particles in an intermediate step. In this subsequent layer, the gaps are usually spatially offset from the gaps in the primary layer or an adjacent layer, so that the gaps in the layer already applied with the abrasive particles contained therein are also filled with the primary material provided with the binder system. This allows the three-dimensional screen printing to produce abrasive tools with an optimized three-dimensional structure with tight positioning dimensions, with the positions in the three-dimensional component space being almost freely definable. It is hereby possible to achieve a higher concentration of abrasive particles and also spatially local concentrations or generate concentration gradients of the abrasive particles. A multi-dimensional cutting tool can thus be produced by repeating the steps described.
Zudem kann vorgesehen sein, integrierte, frei gestaltbare Führungskanäle und bzw. oder Kühlkanäle durch das beschriebene Verfahren einzubringen oder Haltestrukturen und bzw. oder Fixierungsstrukturen innerhalb oder an dem Werkzeug vorzusehen. Durch die verschiedenen Siebdruckschritte mit jeweils einstellbaren Eigenschaften der herzustellenden Schicht können nahezu beliebige Strukturen in dem Werkzeug realisiert werden.In addition, it can be provided that integrated, freely configurable guide channels and/or cooling channels are introduced using the method described, or that retaining structures and/or fixing structures are provided inside or on the tool. Due to the various screen printing steps, each with adjustable properties of the layer to be produced, almost any structure can be realized in the tool.
Die Aussparungen können einen Durchmesser zwischen 40 µm und 3 mm, vorzugsweise zwischen 50 µm und 2,5 mm, besonders vorzugsweise zwischen 100 µm und 1 mm ausgebildet sein, um typische abrasiv wirkende Partikel aufnehmen zu können. Das durch das Verfahren hergestellte mehrschichtige Werkzeug weist typischerweise eine Länge, Breite und bzw. oder Tiefe von zwischen 3 mm und 300 mm, vorzugsweise zwischen 10 mm und 250 mm, besonders vorzugsweise zwischen 50 mm und 100 mm auf.The recesses can have a diameter of between 40 μm and 3 mm, preferably between 50 μm and 2.5 mm, particularly preferably between 100 μm and 1 mm, in order to be able to accommodate typical abrasive particles. The multilayer tool produced by the method typically has a length, width and/or depth of between 3 mm and 300 mm, preferably between 10 mm and 250 mm, particularly preferably between 50 mm and 100 mm.
Alternativ oder zusätzlich kann eine Tiefe der Aussparungen von mindestens 75 Prozent bis maximal 100 Prozent eines maximalen Durchmessers der abrasiv wirkenden Partikel eingehalten werden, so dass die abrasiv wirkenden Partikel entweder gerade in den Aussparungen verschwinden oder ein Stück weit herausragen. Die geometrischen Eigenschaften der Aussparungen, insbesondere deren Durchmesser und Tiefe, können identisch bei allen Aussparungen sein. Es kann alternativ aber auch vorgesehen sein, dass die Aussparungen unterschiedlich geformt sind und bzw. oder unterschiedliche Eigenschaften aufweisen. Schließlich kann auch vorgesehen sein, dass innerhalb einer einzelnen Schicht die Aussparungen identisch ausgeführt sind, eine benachbarte Schicht jedoch Aussparungen mit unterschiedlichen Abmessungen und Formen aufweist.Alternatively or additionally, a depth of the recesses of at least 75 percent to a maximum of 100 percent of a maximum diameter of the abrasive particles can be maintained, so that the abrasive particles either just disappear into the recesses or protrude a little. The geometric properties of the recesses, in particular their diameter and depth, can be identical for all recesses. Alternatively, however, it can also be provided that the recesses are shaped differently and/or have different properties. Finally, it can also be provided that the cutouts are identical within a single layer, but that an adjacent layer has cutouts with different dimensions and shapes.
Die Aussparungen können Öffnungen aufweisen, die kreisförmig, dreieckig, rechteckig, vieleckig, oval oder freigeschwungen ausgeführt sind. Dementsprechend können auch die abrasiv wirkenden Partikel unterschiedlich geformt sein und jeweils unterschiedliche Größen aufweisen. Es kann aber auch vorgesehen sein, dass alle abrasiv wirkenden Partikel, die in das Grünteil, das auch als Grünling bezeichnet wird, eingebracht werden, gleiche Abmessungen und eine identische Form aufweisen. Es ist aber natürlich auch möglich, dass alle in einer einzelnen Schicht eingebrachten abrasiv wirkenden Partikel identisch sind, allerdings die abrasiv wirkenden Partikel verschiedener Schichten unterschiedlich ausgestaltet sind.The recesses can have openings that are circular, triangular, rectangular, polygonal, oval or freely curved. Accordingly, the abrasive particles can also be shaped differently and each have different sizes. But it can also be provided that all abrasive particles that are introduced into the green part, which is also referred to as a green body, have the same dimensions and an identical shape. However, it is of course also possible for all particles with an abrasive action introduced into a single layer to be identical, although the particles with an abrasive action in different layers are designed differently.
Typischerweise wird für den Schablonendruck eine Schablone verwendet, die eine Dicke von maximal 30 Prozent des maximalen Durchmessers der abrasiv wirkenden Partikel aufweist, um den Schablonendruck zuverlässig durchführen zu können.Typically, a stencil is used for stencil printing, which has a maximum thickness of 30 percent of the maximum diameter of the abrasive particles, in order to be able to carry out the stencil printing reliably.
Die abrasiv wirkenden Partikel können aus Diamant und bzw. oder aus einem Hartstoff, vorzugsweise einem Nitridwerkstoff, einem Oxidwerkstoff oder einem Karbidwerkstoff, besonders vorzugsweise aus Siliziumkarbid oder Wolframkarbid, ausgebildet werden. Es können alle verwendeten abrasiv wirkenden Partikel aus einem identischen Werkstoff ausgebildet sein, es können aber auch jeweils verschiedene Werkstoffe verwendet werden. Außerdem ist es möglich, dass alle in einer einzelnen Schicht eingebrachten abrasiv wirkenden Partikel aus dem gleichen Werkstoff sind. Die abrasiv wirkenden Partikel können alle eine identische Form aufweisen, es können aber auch unterschiedlich geformte Partikel zum Einsatz kommen.The abrasive particles can be formed from diamond and/or from a hard material, preferably a nitride material, an oxide material or a carbide material, particularly preferably silicon carbide or tungsten carbide. All of the abrasive particles used can be made of an identical material, but different materials can also be used in each case. In addition, it is possible that all particles with an abrasive effect that are introduced into a single layer are made of the same material. The abrasive particles can all have an identical shape, but differently shaped particles can also be used.
Der Primärwerkstoff kann aus Metall ausgebildet sein, wobei für die abschließende Wärmebehandlung in diesem Fall typischerweise Sintern, Drucksintern, freies Sintern, Heißpressen, heißisostatisches Pressen und bzw. oder Löten eingesetzt wird.The primary material can be made of metal, in which case sintering, pressure sintering, free sintering, hot pressing, hot isostatic pressing and/or soldering are typically used for the final heat treatment.
Ein mehrschichtiges Werkzeug mit abrasiv wirkenden Partikeln wird vorzugsweise mit dem beschriebenen Verfahren hergestellt. Typischerweise ist dieses Werkzeug eine abrasive Schleifscheibe, ein abrasives Sägeblatt, eine abrasive Schneidperle für ein Sägeseil oder eine abrasive Bohrkrone.A multi-layered tool with abrasive particles is preferably produced using the method described. Typically, this tool is an abrasive grinding wheel, an abrasive saw blade, an abrasive cutting bead for a saw wire, or an abrasive drill bit.
Ausführungsbeispiele der Erfindung sind in den Zeichnungen dargestellt und werden nachfolgend anhand der
Es zeigen:
- Fig. 1
- eine schematische Schnittansicht einer Primärschicht mit eingebrachten Aussparungen;
- Fig. 2
- eine
Fig. 1 entsprechende Ansicht eines Schablonendrucks von abrasiv wirkenden Partikeln; - Fig. 3
- eine
Fig. 1 entsprechende Ansicht von eingebetteten abrasiv wirkenden Partikeln; - Fig. 4
- eine
Fig. 1 entsprechende Ansicht eines Aufbringens einer weiteren Schicht abrasiv wirkender Partikel; - Fig. 5
- eine perspektivische Ansicht eines ringförmigen Werkzeugs mit zwei Schichten und
- Fig. 6
eine Figur 5 entsprechende perspektivische Ansicht eines Quaders mit zwei Schichten und in die Schichten eingebrachten abrasiv wirkenden Partikeln.
- 1
- a schematic sectional view of a primary layer with recesses introduced;
- 2
- one
1 Corresponding view of a stencil print of abrasive particles; - 3
- one
1 Corresponding view of embedded abrasive particles; - 4
- one
1 corresponding view of an application of a further layer of abrasive particles; - figure 5
- a perspective view of an annular tool with two layers and
- 6
- one
figure 5 Corresponding perspective view of a cuboid with two layers and abrasive particles introduced into the layers.
In
Die Aussparungen 2, die auch als Hohlräume, Kavitäten oder Kanäle bezeichnet werden können, haben eine Breite zwischen 40 µm und 3 mm und einen jeweils gleich großen Abstand zueinander. In dem dargestellten Ausführungsbeispiel sind alle Aussparungen 2 der Primärschicht 1 gleich ausgeführt, weisen also eine identische Breite und eine identische Tiefe auf. Die dargestellten Ausführungen haben eine quadratische Öffnung, ihre maximale Breite ist also auch gleich ihrer maximalen Länge. In weiteren Ausführungsbeispielen kann die Öffnung aber natürlich auch andere Formen aufweisen, beispielsweise rund, oder die Aussparungen 2 können auch alle jeweils unterschiedliche Abmessungen aufweisen. Es kann auch vorgesehen sein, dass sich periodisch wiederholend in der Primärschicht 1 identische Aussparungen 2 vorgesehen sind. Ebenso können die Abstände zwischen den einzelnen Aussparungen 2 unterschiedlich groß sein.The
In weiteren Ausführungsbeispielen können die abrasiv wirkenden Partikel 3 auch aus Siliziumkarbid oder Wolframkarbid ausgebildet sein. Außerdem können die abrasiv wirkenden Partikel 3 auch nicht alle aus einem einzigen Werkstoff sein, sondern es kann auch eine Mischung aus abrasiv wirkenden Partikeln 3 unterschiedlicher Werkstoffe vorliegen.In further exemplary embodiments, the
Die abrasiv wirkenden Partikel 3 werden durch einen Schablonendruck in die Aussparungen 2 eingebracht. Hierzu wird eine Schablone 4 über der Primärschicht 1 platziert und durch ein Schieberakel 5 werden die abrasiv wirkenden Partikel 3 durch Öffnungen der Schablone 4 geführt. Eine maximale Partikelgröße ist hierbei kleiner oder gleich einer minimalen Schablonenöffnung, d. h. die Öffnungen der Schablone 4 können alle gleich sein, aber auch unterschiedliche Formen oder Abmessungen aufweisen. Statt des Schieberakels 5 kann auch ein Besenrakel, vorzugsweise ein Mehrstufen- und bzw. oder Mehrzonenbesenrakel verwendet werden. Die Schablone 4 weist eine Dicke von maximal 30 Prozent des maximalen Durchmessers der abrasiv wirkenden Partikel 3 auf. In dem dargestellten Ausführungsbeispiel sind alle für die Primärschicht 1 verwendeten abrasiv wirkenden Partikel 3 identisch, es können aber auch nur für eine Schicht identische Partikel 3 verwendet werden oder voneinander verschiedene Partikel 3 unabhängig von der Schicht zum Einsatz kommen. Durch Trockenrakeln werden somit nur die abrasiv wirkenden Partikel 3 in die Aussparungen 2 eingebracht, wobei in einer der Aussparungen 2 genau eines der abrasiv wirkenden Partikel 3 passt und auf weitere Zusatzstoffe verzichtet werden kann.The
Das Aufbringen einer Folgeschicht 7 bzw., falls diese aufzubringende Schicht die finale Schicht ist, einer Deckschicht auf die in die Primärschicht 1 eingebrachten abrasiv wirkenden Partikel 3 ist in
Das so hergestellte Grünteil aus dem in Schichten aufgetragenen Primärwerkstoff aus Metall oder einer Metalllegierung und den abrasiv wirkenden Partikeln 3 wird durch Sintern, Drucksintern, freies Sintern, Heißpressen, heißisostatisches Pressen bzw. Löten als abschließende Wärmebehandlung verfestigt, das organische Bindemittelsystem ausgetrieben und das mehrschichtige Werkzeug, im dargestellten Ausführungsbeispiel ein abrasives Segment, fertiggestellt. Das gesamte dargestellte Werkzeug weist eine Länge von 300 mm auf.The green part produced in this way from the primary material made of metal or a metal alloy applied in layers and the
Mit dem beschriebenen dreidimensionalen Siebdruck können sowohl dünne Wandstrukturen als auch kleine Lochdurchmesser der Aussparungen 2 mit entsprechenden pulverförmigen Werkstoffen generiert werden. Mit dem dreidimensionalen Siebdruckverfahren und der Kombination mit dem Schablonendruckverfahren ist es möglich, neben dem Strukturaufbau auch eine gezielte und definiert reproduzierbare Füllung von Hohlstrukturen bzw. Aussparungen 2 zu erzeugen. Dabei werden wie beschrieben die abrasiv wirkenden Partikel 3 mit definiertem Formlayout durch die positionierte Schablone 4 in die bereits vorher gedruckten Kanäle, Hohlräume bzw. Aussparungen 2 eingebracht. Im Anschluss an eine Lage dieser Schneidpartikel bzw. abrasiv wirkenden Partikel 3 kann die aktuelle Struktur unverändert weitergedruckt werden oder durch Layoutänderung bzw. durch ein Deckellayout mit der Deckschicht 6 geschlossen werden.With the three-dimensional screen printing described, both thin wall structures and small hole diameters of the
Mit dem beschriebenen Verfahren hergestellte Schneidwerkzeuge können sehr frei und definierbar gestaltet werden. Neben Freiformen können vor allem Kanäle, Hohlräume oder Kavitäten erzeugt werden. Durch diese freie Gestaltung ist auch eine Integration von z. B. Kühlkanälen, Führungsnuten, Stütz- oder Einbindungsstrukturen während der Bauteilentstehung möglich. Durch einen Wechsel des Drucklayouts, insbesondere durch Wechsel einer verwendeten Schablone, während des schichtweisen Aufbaus der abrasiv wirkenden Partikel 3 wird ein einstellbarer Versatz der abrasiv wirkenden Partikel 3 zwischen den einzelnen Schichten bzw. Lagen umsetzbar. Dies stellt sicher, dass in dem fertiggestellten Schneidwerkzeug entlang einer Verschleißachse jederzeit abrasiv wirkende Partikel 3 zur Verfügung stehen.Cutting tools produced with the method described can be designed very freely and definably. In addition to free forms, channels, cavities or cavities can be created. This free design is also an integration of z. B. cooling channels, guide grooves, support or integration structures possible during component development. By changing the print layout, in particular by changing a used Template, during the layered construction of the
Außerdem können auch verfahrensbedingte Strukturanpassungen in Form von Führungslöchern und bzw. oder -sicken umgesetzt werden, die ein Überschneiden verschiedener Schichten während der Wärmebehandlung sicherstellen. Die abrasiv wirkenden Partikel 3 können eine angepasste und enge Pulververteilungskurve aufweisen und kleiner als ein maximaler Durchmesser einer Schablonenöffnung sein. Durch einen Schablonenlayoutwechsel ist es weiterhin möglich, innerhalb der definiert dreidimensional geordneten Partikelpositionen verschiedene Abrasivstoffe, also verschiedene Werkstoffe für die abrasiv wirkenden Partikel 3 einzusetzen. Weiterhin wird durch den beschriebenen Drucksieb- bzw. Schablonenlayoutwechsel eine lokale Konzentration oder eine Gradierung der abrasiv wirkenden Partikel 3 innerhalb des Schneidwerkzeugs ermöglicht.In addition, process-related structural adjustments can also be implemented in the form of guide holes and/or beads, which ensure that different layers overlap during the heat treatment. The
In
Diese Konzentrationsinseln sind in jeder der Schichten 1 und 7 gerade um 90° zueinander versetzt, die Konzentrationsinseln der Primärschicht 1 sind jedoch jeweils um 45° gegenüber den Konzentrationsinseln der Folgeschicht 7 versetzt. Durch den Layoutwechsel kann sowohl die Partikelkonzentration als auch die Partikelpositionen zwischen den einzelnen Schichten variiert und eine Gradierung in Baurichtung erreicht werden. Auf die Folgeschicht 7 wird typischerweise noch die Deckschicht 6 aufgebracht.In each of the
Neben den in den
Claims (9)
- A method of manufacturing a multilayer tool in which a green part is produced byproducing a primary layer (1) provided with recesses (2) by screen printing from a primary material provided with an organic binder system, and subsequentlyintroducing abrasively acting particles (3) into the recesses (2) by stencil printing, and thereafterapplying a cover layer (6) of the primary material provided with the organic binder system for fixing the abrasively acting particles (3) in the recesses (2) by screen printing, whereinthe tool is obtained by a final heat treatment of the green part.
- The method according to claim 1, characterized in that the abrasively acting particles (3) are introduced into the recesses (2) by doctoring, preferably by doctoring with a slide doctor blade (5) or a broom doctor blade.
- The method according to claim 1 or claim 2, characterized in that, before the application of the cover layer (6), at least one subsequent layer (7) is applied to the layer provided with the abrasively acting particles (3), in which the recesses (2) are arranged spatially offset with respect to the recesses (2) of the primary layer (1).
- The method according to one of the preceding claims, characterized in that the recesses (2) are formed with a diameter between 40 µm and 3 mm, preferably between 50 µm and 2.5 mm, particularly preferably between 100 µm and 1 mm.
- The method according to one of the preceding claims, characterized in that a depth of the recesses (2) of at least 75 percent to at most 100 percent of a maximum diameter of the abrasively acting particles (3) is maintained.
- The method according to one of the preceding claims, characterized in that a stencil (4) is used for the stencil printing, which has a thickness of at most 30 percent of the maximum diameter of the abrasively acting particles (3).
- The method according to one of the preceding claims, characterized in that the abrasively acting particles (3) are formed from diamond and/or a hard material, preferably a carbide material, a nitride material or an oxide material.
- The method according to one of the preceding claims, characterized in that the primary material is formed from metal, and sintering, pressure sintering, free sintering, hot pressing, hot isostatic pressing and/or brazing is used for the final heat treatment.
- The method according to one of the preceding claims, characterized in that the recesses (2) have openings which are circular, triangular, rectangular, polygonal, oval or free-curved.
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DE102015216538.8A DE102015216538B3 (en) | 2015-08-28 | 2015-08-28 | Method for producing a multidimensionally scalable tool |
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EP3135434B1 true EP3135434B1 (en) | 2022-10-12 |
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EP (1) | EP3135434B1 (en) |
DE (1) | DE102015216538B3 (en) |
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DK180350B1 (en) * | 2019-09-18 | 2021-01-22 | Flex Trim As | GRINDING ELEMENT FOR USE IN ROTARY GRINDING OR GRINDING TOOLS |
DE102019127341A1 (en) * | 2019-10-10 | 2021-04-15 | Schmitz-Metallographie GmbH | Method of manufacturing an abrasive unit |
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US7124753B2 (en) * | 1997-04-04 | 2006-10-24 | Chien-Min Sung | Brazed diamond tools and methods for making the same |
US6755720B1 (en) * | 1999-07-15 | 2004-06-29 | Noritake Co., Limited | Vitrified bond tool and method of manufacturing the same |
KR100572669B1 (en) * | 2004-02-09 | 2006-04-24 | 신한다이아몬드공업 주식회사 | Cutting tools with multi layers of abrasive grain and method for fabricating the same |
KR20080063588A (en) * | 2007-01-02 | 2008-07-07 | 신한다이아몬드공업 주식회사 | Diamond tool and method of the same |
TW201012596A (en) * | 2008-08-14 | 2010-04-01 | jian-min Song | Self-sharpening grits and associated methods |
US20110081848A1 (en) * | 2009-10-05 | 2011-04-07 | Chia-Pei Chen | Grinding tool and method of manufacturing the grinding tool |
DE102009053570B4 (en) * | 2009-10-19 | 2014-09-11 | Dr. Fritsch Sondermaschinen Gmbh | Cold press and process for the production of green compacts |
CA2773197A1 (en) * | 2012-03-27 | 2013-09-27 | Yundong Li | Electroplated super abrasive tools with the abrasive particles chemically bonded and deliberately placed, and methods for making the same |
US9254548B2 (en) * | 2012-04-25 | 2016-02-09 | Taiwan Semiconductor Manufacturing Co., Ltd. | Method of forming diamond conditioners for CMP process |
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DE102015216538B3 (en) | 2016-10-13 |
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