Ultra-thin cutting blade and preparation method thereof

Abstract

The present application relates to the field of material processing, and in particular to an ultra-thin cutting blade and a preparation method thereof. An ultra-thin cutting blade comprises the following components in percentage by mass: 10-25% diamond abrasive, 65-80% metal binder, and 10-20% ceramic whisker phase; the cutting blade is prepared by mixing diamond abrasive and metal binder and then impregnating the mixture in a sol-gel solution formed by raw materials of the ceramic whisker phase, and then undergoing calcination, sintering, and thinning; the ultra-thin cutting blade has a thickness of 0.1-1mm and a bending strength of 800-1500MPa; its preparation method comprises the steps of mixing; sol-gel; impregnation, calcination, pressing, sintering, and thinning-grinding. The ultra-thin cutting blade prepared in the present application has a thickness of 0.1-1mm, a bending strength of 800-1500MPa, and a service life of up to 3000-3800m, solving the technical problems of reduced strength of the cutting blade due to reduced thickness and easy deformation and wrinkling.

Description

Technical Field

[0001] The present application relates to the field of material processing, and in particular to an ultra-thin cutting blade and a preparation method thereof. Background Art

[0002] Microelectronic packaging is trending towards thinner and smaller components. As chip density increases, the width of the cut streets reserved for wafer dicing is shrinking, reducing chip thickness. Dicing blades are widely used in wafer dicing, a critical step in the process. However, as blade thickness decreases, blade strength decreases, leading to significant blade warping. This complicates wafer dicing.

[0003] Currently, dicing blades are made of metal or resin bonds. Due to their plasticity, dicing blades are prone to deformation and wrinkling. Furthermore, as the thickness of the dicing blade decreases, its strength also decreases, leading to severe warping of the dicing blade. This makes wafer dicing more difficult. Summary of the Invention

[0004] In order to solve the technical problems of reduced strength, easy deformation and wrinkling of cutting blades due to reduced thickness, the present application provides an ultra-thin cutting blade and a preparation method thereof.

[0005] In the first aspect, the present application provides the following technical solutions:

[0006] An ultra-thin cutting blade comprises the following components by mass percentage: 10-25% diamond abrasive, 65-80% metal binder, and 10-20% ceramic whisker phase; the cutting blade is prepared by mixing the diamond abrasive and the metal binder, impregnating the mixture in a sol-gel solution formed from raw materials of the ceramic whisker phase, and then calcining, sintering, and thinning the mixture;

[0007] The thickness of the ultra-thin cutting blade is 0.1-1mm and the bending strength is 800-1500MPa.

[0008] By the above technical scheme, the addition of metal binder can make the cutting blade tissue density, good self-sharpening, extend the wear resistance of diamond tools, and improve the cutting blade sharpness. After adding ceramic whisker phase inside the cutting blade, the plasticity of diamond and metal binder is reduced, its rigidity is improved, and the possibility of its deformation is reduced. Compared with traditional metal or resin binder, the thickness of the cutting blade is reduced and the deformation phenomenon is significantly improved. The ceramic whisker phase strengthens the strength of the cutting blade, improves the warping of the cutting blade and extends its life and sharpness. And when the cutting blade of the present application is prepared, after the diamond abrasive is mixed with the metal binder and immersed in the sol-gel solution formed by the ceramic whisker phase raw material, a layer of ceramic whisker phase film can be formed on the metal binder surface, and then calcined and sintered, so that the above raw materials are mixed and alloyed. After the thickness of the cutting product obtained is thinned, the thickness is 0.1-1mm, and its bending strength can reach 800-1500MPa, which greatly enhances the bending strength of the cutting blade, and the life span reaches 3000-3800m. A more preferred thickness is 0.3-1 mm, which has excellent bending strength and longer service life. When the thickness is less than 0.3 mm, the service life is reduced.

[0009] Preferably, the metal binder comprises the following components in mass percentage: 10-20% Fe powder, 20-30% CuSn10 pre-alloyed powder, 10-20% Co powder, 5-15% Ni powder, 20-30% Cu powder, and 10-20% FeNi30 pre-alloyed powder.

[0010] Through the above technical solution, after adding reduced iron powder to the diamond cutting blade, the alloying degree of the diamond cutting product body can be improved, the sintered body structure is uniform, the holding force of the diamond is improved, the structure is dense, and the self-sharpening property is good. It can not only extend the wear resistance of the diamond cutting blade, but also improve the sharpness. Moreover, the moderate etching of diamond by the Fe powder during the sintering process can increase the bonding force between the binder and the diamond, and ultimately the bending strength and service life of the cutting blade are better.

[0011] CuSn10 pre-alloyed powder, because Sn is a low-melting-point metal, first has the effect of reducing the sintering temperature of the matrix. At the same time, adding CuSn10 to the cutting blade matrix can form a hard and brittle phase to increase the hardness of the matrix and improve the sharpness of the cutting blade. In addition, tin is an element that reduces the surface tension of the liquid alloy and has the effect of reducing the wetting angle of the liquid alloy on the diamond. It is an element that improves the wetting of the bonding metal on the diamond, can lower the melting point of the alloy, and improve the press formability. Therefore, although copper has almost no wetting effect on diamond, the alloy of Sn and copper can significantly improve its wettability on diamond.

[0012] Cobalt can form carbide (Co2C) with diamond under certain conditions. Cobalt can reduce the internal interface tension between cobalt and diamond and increase the holding force on diamond.

[0013] Nickel has excellent ductility, toughness and oxidation resistance, and is infinitely miscible with copper. It can strengthen the matrix alloy, inhibit the loss of low-melting-point metals, and increase toughness and wear resistance. After adding nickel to the matrix, it has good sintering properties.

[0014] Cu, adding copper to the matrix can lower the sintering temperature of the matrix, improve the formability and sinterability and compatibility with other elements, which is beneficial to alloying during the matrix sintering process.

[0015] FeNi30 pre-alloyed powder, adding alloy powder to the matrix is ​​beneficial to the rapid alloying during the matrix sintering process and improves the holding force of diamond.

[0016] The metal binder obtained by using the alloy elements of the above components has good sintering properties when combined with the ceramic whisker phase and diamond, and the cutting blade finally obtained has a better degree of alloying and more excellent bending strength.

[0017] Preferably, the diamond abrasive has a particle size of 5-20 μm; the metal binder has a particle size of 3-30 μm; the ceramic whisker phase has a diameter of 10-50 μm and a length of 0.05-0.1 mm.

[0018] The above technical solution further limits the particle size of diamond abrasives, metal binders, and ceramic whiskers. For the same diamond concentration, coarser particle size means fewer diamond particles per unit volume. Under the same conditions, the impact force on each diamond is greater, causing the diamond to break, impacting the saw blade's cutting efficiency. If the diamond is too fine, the diamond's edge is low and cannot be fully exposed. At the same time, if the impact force is too low, the diamond cannot be micro-fragmented, resulting in rounding, which also affects cutting efficiency.

[0019] Preferably, the ceramic whisker phase is ceramic glass fiber, and the thickness of the ceramic glass fiber coating on the ultra-thin cutting disc is 0.05-0.1 μm.

[0020] Through the above technical solution, the ceramic whisker phase is ceramic glass fiber, which can increase the brittleness of the metal binder and increase the self-sharpening property of the metal binder grinding wheel. In addition, the sol-gel method is used in this application to prepare the ceramic whisker phase on the surface of the metal powder, which is beneficial to improve the dispersion of the metal ceramic whisker phase, so that the ceramic whisker phase is evenly distributed on the cutting blade, and the bending strength of the cutting blade is higher, especially the ultra-thin cutting blade has excellent bending strength and will not warp or deform.

[0021] In a second aspect, the present application provides a method for preparing an ultra-thin cutting sheet, which adopts the following technical solution:

[0022] A method for preparing an ultra-thin cutting sheet comprises the following steps:

[0023] Step 1) batching and mixing: diamond and metal binder are prepared in proportion and mixed evenly to obtain a diamond-metal mixture;

[0024] Step 2), sol-gel: adding anhydrous ethanol to tetraethyl orthosilicate and stirring to mix uniformly, adding acid to adjust the pH to 3-5, adding acetylacetone and polyvinyl alcohol and stirring until clear to obtain liquid A; dissolving aluminum nitrate nonahydrate, boric acid, and sodium nitrate in a mixed solution of deionized water and anhydrous ethanol and stirring to obtain liquid B; adding liquid B dropwise to liquid A in a certain proportion and mixing to obtain a sol-gel solution;

[0025] Step 3) Impregnation: The diamond-metal mixture is transferred to a tank containing anhydrous ethanol, the sol-gel solution is added to the tank, and the mixture is sealed and ball milled;

[0026] Step 4), calcining: spray drying the mixture obtained in step 3), and calcining the dried powder;

[0027] Step 5), pressing: the powder obtained in step 4) is pressed by hydraulic pressure and steel film charging to obtain a green compact;

[0028] Step 6), sintering: hot pressing and sintering the compact obtained in step 5), and naturally cooling to obtain a cutting piece;

[0029] Step 7), thinning and grinding: the cutting blade obtained in step 6) is subjected to thinning and grinding treatment in sequence to obtain an ultra-thin cutting blade.

[0030] Through the above technical solution, ethyl silicate forms a sol under the catalytic action of a strong acid, and aluminum nitrate nonahydrate, boric acid, and sodium nitrate are added and mixed evenly; the sol is mixed with a diamond-metal mixture in a ball mill, fully dispersed and spray-dried, and then calcined. After calcination, the sol is pressed into a compact, hot-pressed and sintered to obtain a cutting blade, which is then thinned and ground to obtain an ultra-thin cutting blade.

[0031] Preferably, in step 4), the calcination is performed in stages. Under an inert atmosphere, the heating rate is 10-15°C / min, the first stage is heated to 100-150°C and kept warm for 15-30 minutes, the second stage is heated to 250-350°C and kept warm for 10-15 minutes, and the third stage is heated to 450-550°C and calcined for 1.5-2 hours.

[0032] Through the above technical solution, calcination is carried out under an inert atmosphere to prevent the reducing metal therein from being oxidized. At the same time, staged calcination is adopted to dehydrate the silicic acid in the powder to form silicon dioxide, and the aluminum nitrate nonahydrate is dehydrated to form aluminum oxide.

[0033] Preferably, in step 5), the molding pressure is 100-500 kgf / cm 2, the size of the pressed green sheet is 1.1-1.3 times of the final height.

[0034] Through the above technical solution, the hydraulic pressure and the size of the compact are limited. If the pressure is too small, the compact cannot be formed.

[0035] Preferably, in step 6), the heating rate is 10-15°C / min, the heating steps are 120, 300, 500, 700, and 900°C, each step is kept for 3-5 minutes, and the sintering is performed at 800-900°C for 1-1.5 hours.

[0036] Through the above technical solution, a temperature step method is adopted to avoid the generation of green material in the compact, and to avoid cracking and becoming waste due to uneven temperature. At the same time, hot pressing and sintering alloy the metal binder, diamond and ceramic glass fiber, thereby enhancing the bending strength and life of the diamond ultra-thin cutting blade.

[0037] In summary, this application has at least one or more of the following beneficial effects:

[0038] 1. The present application adopts the addition of metal binder to make the cutting blade tissue dense, self-sharpening, extend the wear resistance of diamond tools, and improve the sharpness of the cutting blade. After adding ceramic whisker phase inside the cutting blade, the plasticity of diamond and metal binder is reduced, its rigidity is increased, the possibility of its deformation is reduced, the bending strength of the cutting blade is significantly enhanced, the warping of the cutting blade is improved, and its life and sharpness are extended.

[0039] 2. When preparing the cutting blade of the present application, the diamond abrasive is mixed with the metal binder and then immersed in a sol-gel solution formed by the ceramic whisker phase raw material. In this way, a ceramic whisker phase film can be formed on the surface of the metal binder. The mixture is then calcined and sintered to alloy the above raw materials. After the thickness of the cutting product is thinned, it has a thickness of 0.1-1mm and a bending strength of 800-1500MPa, which greatly enhances the bending strength of the cutting blade. At the same time, the service life reaches 3000-3800m, with excellent performance.

[0040] 3. The combination of various raw materials in the metal binder of the present application, especially the Sn in the CuSn10 pre-alloyed powder is a low-melting-point metal, which reduces the sintering temperature of the matrix. At the same time, the addition of CuSn10 to the cutting blade matrix can form a hard-brittle phase to increase the hardness of the matrix and improve the sharpness of the cutting blade. In addition, tin improves the wetting of the bonding metal to the diamond. The metal binder obtained by using the alloying elements of the above components has good sintering properties when combined with the ceramic whisker phase and diamond, and the cutting blade finally obtained has a better degree of alloying and has more excellent bending strength.

[0041] 4. The ceramic whisker phase in the present application is ceramic glass fiber, and its preparation method uses ethyl silicate to form a sol under the catalytic action of a strong acid, and at the same time adds aluminum nitrate nonahydrate, boric acid, and sodium nitrate, and mixes evenly to obtain a sol-gel solution. The diamond-metal mixture is then immersed in the sol-gel solution and ball-milled, calcined, and hot-pressed to obtain a cutting blade. The ceramic whisker phase is prepared on the surface of the metal powder by the sol-gel method, which is beneficial to improving the dispersibility of the metal ceramic whisker phase, so that the ceramic whisker phase is evenly distributed on the cutting blade, and the bending strength of the cutting blade is higher, especially the ultra-thin cutting blade has excellent bending strength and will not warp or deform.

[0042] 5. The method of the present application preferably adopts a temperature step method to avoid the generation of raw materials in the pressed green body and to avoid cracking and waste caused by uneven temperature. At the same time, hot pressing and sintering alloy the metal binder, diamond and ceramic glass fiber, thereby enhancing the bending strength and life of the diamond ultra-thin cutting blade. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 This is a diagram of the ultra-thin cutting blade prepared in Example 1 of the present application. DETAILED DESCRIPTION

[0044] As the thickness of the cutting blade decreases, the bending strength decreases, and the cutting blade warps severely, which brings great trouble to wafer cutting. Moreover, since it is easy to deform, when the thickness of the cutting blade is too small, double-end thinning is used, and the cutting blade is difficult to fix. After the applicant added ceramic glass fiber inside it, its plasticity was reduced and its brittleness was increased, reducing the probability of its deformation; adding suitable metal binders and proportions can improve the bending strength of the cutting blade, and the service life is greatly improved. It is on this basis that the applicant prepared an ultra-thin cutting blade. In this application, a sol-gel method is used to prepare a composite material of a ceramic whisker phase coated with a diamond-metal binder, which improves the bending strength of the cutting blade, improves the warping of the ultra-thin cutting blade, and extends its life and sharpness. In addition, the technical solution provided by this application can also prepare ultra-thin cutting blades with a thickness of 0.1 mm, and the cutting blade prepared in this application can be thinned on one side, fixed in one direction, and then thinned on the other side using a grinding wheel, which will not affect the fixation of the cutting blade.

[0045] The following examples further illustrate the present application in detail. It is particularly noted that if no specific conditions are specified in the following examples, the reactions were carried out according to conventional conditions or the conditions recommended by the manufacturer. Unless otherwise specified, the raw materials used in the following examples can be obtained from ordinary commercial sources, and the following mass percentages are all mass percentages.

[0046] In the following examples, the diamond abrasive particle size is 5-20 μm; the metal binder particle size is 3-30 μm; and the ceramic whisker phase formed after sol-gel, impregnation, and calcination has a diameter of 10-50 μm and a length of 0.05-0.1 mm.

[0047] Preparation Example

[0048] Preparation Example 1

[0049] The preparation method of the sol-gel solution specifically comprises the following steps:

[0050] Step 1) 1.2 kg of orthosilicate was added to 12 kg of anhydrous ethanol and stirred to mix evenly, nitric acid was added to adjust the pH to 4, 0.3 L of acetylacetone and 0.3 L of polyvinyl alcohol were added and stirred until clear to obtain solution A;

[0051] Step 2) Dissolve 2.6 kg of aluminum nitrate nonahydrate, 5 kg of boric acid, and 1.2 kg of sodium nitrate in a mixed solution of 24 kg of deionized water and 12 kg of anhydrous ethanol, and stir to obtain Solution B;

[0052] Step 3) Liquid B is added dropwise to liquid A and mixed evenly to obtain one sol-gel solution.

[0053] Example

[0054] Example 1

[0055] The method for preparing an ultra-thin cutting sheet provided in Example 1 specifically comprises the following steps:

[0056] Step 1), batching and mixing: 10 kg of diamond abrasive and 80 kg of metal binder are prepared in proportion and mixed evenly to obtain a diamond-metal mixture; wherein the metal binder is composed of 20% Fe powder, 30% CuSn10 pre-alloyed powder, 15% Co powder, 5% Ni powder, 20% Cu powder, and 10% FeNi30 pre-alloyed powder;

[0057] Step 2), sol-gel: prepare 1 part of sol-gel solution according to Preparation Example 1;

[0058] Step 3) Impregnation: Transfer the diamond-metal mixture into a polytetrafluoroethylene tank containing 10 kg of anhydrous ethanol, add the sol-gel solution into the tank, seal it, and perform ball milling on the mixture;

[0059] Step 4), calcination: spray drying the mixture obtained in step 3), and calcining the dried powder under an argon atmosphere at a heating rate of 15°C / min, heating to 120°C for 15 minutes in the first stage, heating to 300°C for 10 minutes in the second stage, and heating to 500°C for 2 hours in the third stage. After calcination, the amount of ceramic whiskers is 10 kg;

[0060] Step 5) Pressing: The powder obtained in step 4) is pressed by hydraulic pressure and steel film charging to obtain a green compact. The forming pressure is 400 kgf / cm 2 , the green compact size is 1.3 times the final height;

[0061] Step 6) Sintering: The compact obtained in step 5) was hot-pressed and sintered in a vacuum hot-press sintering machine at a heating rate of 15°C / min. The heating steps were 120°C, 300°C, 500°C, 700°C, and 900°C, with each step held for 5 minutes. The compact was sintered at 900°C for 1.5 hours and then naturally cooled to obtain a cut disc.

[0062] Step 7), thinning-grinding: the cutting piece obtained in step 6) is thinned by thinning equipment in sequence, and trimmed by cylindrical grinder and electric spark wire equipment to obtain an ultra-thin cutting piece with a thickness of 0.15 mm. Figure 1 shown.

[0063] Example 2

[0064] The method for preparing an ultra-thin cutting sheet provided in Example 2 specifically comprises the following steps:

[0065] Step 1), batching and mixing: 25 kg of diamond abrasive and 65 kg of metal binder are prepared in proportion and mixed uniformly to obtain a diamond-metal mixture; wherein the metal binder is composed of 20% Fe powder, 25% CuSn10 pre-alloyed powder, 20% Co powder, 5% Ni powder, 25% Cu powder, and 10% FeNi30 pre-alloyed powder;

[0066] Step 2), sol-gel: prepare 1 part of sol-gel solution according to Preparation Example 1;

[0067] Step 3) Impregnation: Transfer the diamond-metal mixture into a polytetrafluoroethylene tank containing 10 kg of anhydrous ethanol, add the sol-gel solution into the tank, seal it, and perform ball milling on the mixture;

[0068] Step 4), calcination: spray-dry the mixture obtained in step 3), and calcine the dried powder under an argon atmosphere at a heating rate of 10°C / min, heating to 120°C for 30 minutes in the first stage, heating to 250°C for 15 minutes in the second stage, and heating to 450°C for 1.5 hours in the third stage;

[0069] Step 5) Pressing: The powder obtained in step 4) is pressed by hydraulic pressure and steel film charging to obtain a green compact, and the forming pressure is 100 kgf / cm 2 , the green compact size is 1.1 times the final height;

[0070] Step 6) Sintering: The compact obtained in step 5) is hot-pressed and sintered in a vacuum hot-press sintering machine at a heating rate of 10°C / min. The heating steps are 120°C, 300°C, 500°C, 700°C, and 900°C, with each step held for 3 minutes. The compact is sintered at 900°C for 1 hour and then cooled naturally to obtain a cut disc.

[0071] Step 7), thinning-grinding: the cutting disc obtained in step 6) is sequentially thinned by a thinning device, and trimmed on a cylindrical grinder and an electric spark wire discharge device to obtain an ultra-thin cutting disc with a thickness of 0.25 mm.

[0072] Example 3

[0073] The method for preparing an ultra-thin cutting sheet provided in Example 3 specifically comprises the following steps:

[0074] Step 1), batching and mixing: 15 kg of diamond abrasive and 65 kg of metal binder are prepared in proportion and mixed uniformly to obtain a diamond-metal mixture; wherein the metal binder is composed of 15% Fe powder, 20% CuSn10 pre-alloyed powder, 10% Co powder, 15% Ni powder, 25% Cu powder, and 15% FeNi30 pre-alloyed powder;

[0075] Step 2), sol-gel: prepare 2 portions of sol-gel solution according to Preparation Example 1;

[0076] Step 3) Impregnation: Transfer the diamond-metal mixture into a polytetrafluoroethylene tank containing 10 kg of anhydrous ethanol, add the sol-gel solution into the tank, seal it, and perform ball milling on the mixture;

[0077] Step 4), calcination: spray drying the mixture obtained in step 3), and calcining the dried powder under an argon atmosphere at a heating rate of 15°C / min. The first stage is heated to 120°C and kept warm for 15 minutes, the second stage is heated to 300°C and kept warm for 10 minutes, and the third stage is heated to 500°C and calcined for 2 hours. After calcination, the ceramic whisker weight is 20 kg;

[0078] Step 5) Pressing: The powder obtained in step 4) is pressed by hydraulic pressure and steel film charging to obtain a green compact. The forming pressure is 400 kgf / cm 2 , the green compact size is 1.3 times the final height;

[0079] Step 6) Sintering: The compact obtained in step 5) was hot-pressed and sintered in a vacuum hot-press sintering machine at a heating rate of 15°C / min. The heating steps were 120°C, 300°C, 500°C, 700°C, and 900°C, with each step held for 5 minutes. The compact was sintered at 900°C for 1.5 hours and then naturally cooled to obtain a cut disc.

[0080] Step 7), thinning-grinding: the cutting disc obtained in step 6) is sequentially thinned by a thinning device, and trimmed on a cylindrical grinder and an electric spark wire discharge device to obtain an ultra-thin cutting disc with a thickness of 0.3 mm.

[0081] Example 4

[0082] The difference between the method for preparing an ultra-thin cutting blade provided in Example 4 and Example 1 is that in Example 4, the metal binder is composed of 10% Fe powder, 10% CuSn10 pre-alloyed powder, 20% Co powder, 10% Ni powder, 30% Cu powder, and 15% FeNi30 pre-alloyed powder.

[0083] Example 5

[0084] The difference between the method for preparing an ultra-thin cutting blade provided in Example 5 and that in Example 1 is that in Example 5, Co powder and Ni powder are replaced by Fe powder in equal amounts.

[0085] Example 6

[0086] The difference between the method for preparing an ultra-thin cutting blade provided in Example 6 and Example 1 is that in Example 6, the CuSn10 pre-alloyed powder is replaced by Cu powder in equal amounts.

[0087] Example 7

[0088] The difference between the method for preparing an ultra-thin cutting blade provided in Example 7 and Example 1 is that in Example 7, one-step temperature rise sintering is adopted, the pressed blank is hot pressed and sintered in a vacuum hot pressing sintering machine, the heating rate is 15°C / min, sintered at 900°C for 1.5h, and naturally cooled to obtain the cutting blade.

[0089] Comparative Example

[0090] Comparative Example 1

[0091] The difference between the method for preparing an ultra-thin cutting sheet provided in Comparative Example 1 and that in Example 1 is that, in Comparative Example 1, the method specifically includes the following steps:

[0092] Step 1), batching and mixing: 25 kg of diamond abrasive and 65 kg of metal binder are prepared in proportion and mixed uniformly to obtain a diamond-metal mixture; wherein the metal binder is composed of 20% Fe powder, 30% CuSn10 pre-alloyed powder, 15% Co powder, 5% Ni powder, 20% Cu powder, and 10% FeNi30 pre-alloyed powder;

[0093] Step 2) Pressing: The diamond-metal mixture obtained in step 1) is pressed by hydraulic pressure and steel film charging to obtain a compact. The forming pressure is 100 kgf / cm 2 , the green compact size is 1.1 times the final height;

[0094] Step 3) Sintering: The compact obtained in step 2) was hot-pressed and sintered in a vacuum hot-press sintering machine at a heating rate of 10°C / min. The heating steps were 120°C, 300°C, 500°C, 700°C, and 900°C, with each step held for 3 minutes. The final step was sintered at 900°C for 1 hour. The resulting cut piece was then cooled naturally to obtain a cut piece.

[0095] Step 4), thinning-grinding: the cutting blade obtained in step 4) is sequentially thinned by a thinning device, and trimmed on a cylindrical grinder and an electric spark wire discharge device to obtain an ultra-thin cutting blade.

[0096] Comparative Example 2

[0097] The method for preparing an ultra-thin cutting sheet provided in Comparative Example 2 differs from that in Example 1 in that the method specifically includes the following steps:

[0098] Step 1), batching and mixing: 10 kg of diamond abrasive and 80 kg of metal binder are prepared in proportion and mixed evenly to obtain a diamond-metal mixture; wherein the metal binder is composed of 20% Fe powder, 30% CuSn10 pre-alloyed powder, 15% Co powder, 5% Ni powder, 20% Cu powder, and 10% FeNi30 pre-alloyed powder;

[0099] Step 2), calcination: take 2kg of commercially available glass fiber and 8kg of commercially available ceramic fiber, mix them, and calcine them under argon atmosphere at a heating rate of 15°C / min. The first stage is heated to 120°C and kept warm for 15 minutes, the second stage is heated to 300°C and kept warm for 10 minutes, and the third stage is heated to 500°C and calcined for 2 hours;

[0100] Step 3) mixing: mixing the calcined glass fiber and ceramic fiber with the diamond-metal mixture in step 1) in a mixer for 1 hour to obtain a premix;

[0101] Step 4) Pressing: the same as in Example 1;

[0102] Step 5) sintering: the same operation as in Example 1;

[0103] Step 6) Thinning and grinding: the operation is the same as that in Example 1.

[0104] Comparative Example 3

[0105] The method for preparing an ultrathin cutting blade provided in Comparative Example 3 differs from that in Comparative Example 2 in that, in Comparative Example 3, step 2) is mixing, wherein 2 kg of commercially available glass fiber and 8 kg of commercially available ceramic fiber are mixed with the diamond-metal mixture in step 1) in a mixer for 1 hour to obtain a premix;

[0106] Then, step 3) calcination is performed, wherein the premix is ​​calcined in an argon atmosphere at a heating rate of 15°C / min, with the first stage being heated to 120°C and kept warm for 15 minutes, the second stage being heated to 300°C and kept warm for 10 minutes, and the third stage being heated to 500°C and calcined for 2 hours;

[0107] Then carry out step 4) and other steps, the same as Comparative Example 2.

[0108] Performance Testing

[0109] The ultra-thin cutting blades obtained in Examples 1-7 of the present application and Comparative Examples 1-4 were tested for bending strength and service life performance. The bending strength was tested using the three-point bending strength performance test of GB / T6569-2006 standard. The service life detection method is as follows: the ultra-thin cutting blade is installed on the cutting machine, and the cutting performance test is performed using single crystal silicon. The rotation speed of the ultra-thin cutting blade is 1000 rpm / min, and the feed speed of the single crystal silicon is 1.5 mm / min.

[0110] The performance tests of the embodiments and comparative examples are shown in Table 1 below.

[0111] Table 1

[0112]

[0113] The ultra-thin cutting blades prepared by the ultra-thin cutting blade preparation method provided in Examples 1-7 have a thickness of 0.1-1 mm and a corresponding bending strength of 800-1500 MPa. At the same time, they are not prone to deformation and wrinkling during the preparation process, and have excellent bending strength while thinning the cutting blade.

[0114] In Example 5, iron powder replaced Co powder and Ni powder in equal amounts. When the thickness was 0.1-1 mm, the bending strength was significantly weakened. This shows that Co powder can reduce the internal interfacial tension between cobalt and diamond and increase the holding force on diamond; Ni has very good ductility, toughness and oxidation resistance, is infinitely miscible with copper, can strengthen the matrix alloy, inhibit the loss of low-melting-point metals, and increase toughness and wear resistance.

[0115] In Example 6, the CuSn10 pre-alloyed powder in the cutting blade raw material is replaced with Cu powder in equal amounts. When the tin element is not added, it has a certain effect on the element's wetting, and the bending strength of the cutting blade is also significantly reduced. When the sintering is carried out in one step in Example 7, its bending strength is also reduced, and its service life is also significantly reduced. Multi-step sintering plays an important role in element alloying.

[0116] Comparative Example 1 provides a method for preparing an ultra-thin cutting blade. The cutting blade is prepared without adding ceramic glass fiber to the raw materials. It can be observed that when it is cut to 1400 mm, it has obvious curling and deformation, cannot be used any further, and has a short lifespan. This shows that after adding ceramic glass fiber to diamond, the glass phase is increased, the rigidity is enhanced, and the metal plasticity of the diamond is reduced. It is better fixed in the thinning and grinding equipment and is not prone to deformation and wrinkling.

[0117] In Comparative Example 2, the specially prepared ceramic whiskers were replaced with commercially available glass fibers and ceramic fibers in equal amounts, and the mixture was first calcined and then physically mixed. It can be seen that the flexural strength and service life were greatly reduced, similar to those without the addition of ceramic whiskers. In Comparative Example 3, the specially prepared ceramic whiskers were also replaced with commercially available glass fibers and ceramic fibers in equal amounts, and the mixture was first mixed with raw materials such as diamond and then calcined. The flexural strength and service life were also greatly reduced, similar to those in Comparative Example 1. In this application, the diamond-metal binder was immersed in a sol-gel solution and then calcined. The sol-gel method was used to prepare a composite material of a ceramic whisker phase coated with a diamond-metal binder, thereby significantly improving the flexural strength and service life of the cutting blade obtained.

[0118] In addition, one side of the 0.2 mm thick cutting blade obtained in Example 1 was fixed, and the other side was thinned by a grinding wheel to obtain a 0.1 mm thick cutting blade. The compressive strength and service life of the blade were tested. The compressive strength reached 1256 MPa and the cutting length was 2840 mm. Obviously, the method in the present application can produce an ultra-thin cutting blade with a thickness of 0.1 mm. Although its service life is relatively reduced, it still has excellent bending strength and service life compared with the comparative example.

[0119] This specific embodiment is merely an explanation of the present application and is not a limitation of the present application. After reading this specification, those skilled in the art may make non-creative modifications to the present embodiment as needed, but as long as they are within the scope of the claims of the present application, they are protected by the patent law.

Claims

1. An ultra-thin cutting blade, characterized in that: The cutting blade comprises the following components by mass percentage: 10-25% diamond abrasive, 65-80% metal binder, and 10-20% ceramic whisker phase; the cutting blade is prepared by mixing the diamond abrasive and the metal binder, dipping the mixture into a sol-gel solution formed by raw materials of the ceramic whisker phase, and then calcining, sintering, and thinning the mixture; The thickness of the ultra-thin cutting blade is 0.1-1mm, and the bending strength is 800-1500MPa; The metal binder comprises the following components in percentage by mass: 10-20% Fe powder, 20-30% CuSn10 pre-alloyed powder, 10-20% Co powder, 5-15% Ni powder, 20-30% Cu powder, and 10-20% FeNi30 pre-alloyed powder.

2. The ultra-thin cutting blade according to claim 1, characterized in that: The diamond abrasive has a particle size of 5-20 μm; the metal binder has a particle size of 3-30 μm; the ceramic whisker has a diameter of 10-50 μm and a length of 0.05-0.1 mm.

3. The ultra-thin cutting blade according to claim 1, characterized in that: The ceramic whisker phase is ceramic glass fiber, and the thickness of the ceramic glass fiber coating on the ultra-thin cutting piece is 0.05-0.1 μm.

4. A method for preparing an ultra-thin cutting blade according to any one of claims 1 to 3, comprising the following steps: Step 1) batching and mixing: prepare diamond and metal binder in proportion and mix them evenly to obtain a diamond-metal mixture; Step 2), Sol-Gel: Add anhydrous ethanol to tetraethyl orthosilicate and stir to mix evenly, add acid to adjust the pH to 3-5, add acetylacetone and polyvinyl alcohol and stir until clear to obtain Solution A; Dissolve aluminum nitrate nonahydrate, boric acid, and sodium nitrate in a mixed solution of deionized water and anhydrous ethanol and stir to obtain Solution B; Add Solution B dropwise to Solution A in proportion and mix evenly to obtain a sol-gel solution; Step 3), impregnation: transfer the diamond-metal mixture into a tank containing anhydrous ethanol, add the sol-gel solution into the tank, seal it and perform ball milling; Step 4), calcination: spray drying the mixture obtained in step 3), and calcining the dried powder; Step 5), pressing: the powder obtained in step 4) is pressed by hydraulic pressure and steel film charging to obtain a green compact; Step 6), sintering: hot pressing and sintering the compact obtained in step 5), and naturally cooling to obtain a cutting piece; Step 7), thinning-grinding: the cutting blade obtained in step 6) is subjected to thinning and trimming treatment in sequence to obtain an ultra-thin cutting blade.

5. The method for preparing an ultra-thin cutting blade according to claim 4, characterized in that: In step 4), the calcination is performed in stages. Under an inert atmosphere, the heating rate is 10-15°C / min, the first stage is heated to 100-150°C and kept warm for 15-30 minutes, the second stage is heated to 250-350°C and kept warm for 10-15 minutes, and the third stage is heated to 450-550°C and calcined for 1.5-2 hours.

6. The method for preparing an ultra-thin cutting blade according to claim 4, wherein: In step 5), the molding pressure is 100-500 kgf / cm 2 , the size of the pressed green sheet is 1.1-1.3 times of the final height.

7. The method for preparing an ultra-thin cutting sheet according to claim 5, wherein: In step 6), the heating rate is 10-15°C / min, the heating steps are 120, 300, 500, 700, and 900°C, each temperature step is kept for 3-5 minutes, and the sintering time is 800-900°C for 1-1.5 hours.

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