Saw blade and method for multiple sawing of rare earth magnet

Abstract

A multiple blade assembly comprising a plurality of spaced apart saw blades mounted on a rotating shaft is used for sawing a rare earth magnet block into multiple pieces by rotating the plurality of saw blades. The saw blade comprises a core in the form of a thin doughnut disk and a peripheral cutting part on an outer peripheral rim of the core. The cutting part is made of a composition comprising an abrasive, a resin binder, and a lubricant.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This non-provisional application claims priority under 35 U.S.C. §119(a) on Patent Application No. 2011-259157 filed in Japan on Nov. 28, 2011, the entire contents of which are hereby incorporated by reference.TECHNICAL FIELD[0002]This invention generally relates to a method for sawing a magnet block into multiple pieces. More particularly, it relates to a saw blade for use in sawing a rare earth magnet block into multiple pieces.BACKGROUND ART[0003]Systems for manufacturing commercial products of rare earth magnet include a single part system wherein a part of substantially the same shape as the product is produced at the stage of press molding, and a multiple part system wherein once a large block is molded, it is divided into a plurality of parts by machining. The single part system includes press molding, sintering or heat treating, and finishing steps. A molded part, a sintered or heat treated part, and a finished part (or product) ar...

AI Technical Summary

Benefits of technology

[0018]The saw blades in the form of a resinoid wheel are used in multiple sawing of a rare earth magnet block into multiple pieces. As compared with the prior art, the saw blade reduces the cutting resistance, improves the sawing accuracy, and ensures sawing at a high accuracy and high speed even if the saw blade is thinner than the conventional blades. The blade is of great worth in the industry.

Problems solved by technology

However, when it is desired to manufacture parts of small size or parts having a reduced thickness in magnetization direction, the sequence of press molding and sintering is difficult to form sintered parts of normal shape, leading to a lowering of manufacturing yield, and at worst, such parts cannot be formed.

The sawing technology using ID blades is low in productivity because of a single blade cutting mode.

However, in an attempt to saw a hard material such as rare earth magnet by a thin OD blade, the prior art core of alloy tool steel is short in mechanical strength and becomes deformed or bowed during sawing operation, losing dimensional accuracy.

However, if a high frictional resistance is exerted between the cutting part and the magnet during sawing of the magnet, high accuracy machining is not expected.

Then, even if the cemented carbide core is used, chipping and / or bowing can occur, adversely affecting the machined state.

However, since the space between the saw blade and the workpiece or rare earth magnet is extremely narrow, it is difficult to effectively supply the coolant between the saw blade and the magnet.

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