A diamond tool and a method of manufacturing the same

Abstract

The present application provides a kind of diamond tool and its manufacturing method, diamond tool includes tool body and the diamond working layer attached to tool body, diamond working layer includes: metal flake layer, brazing layer and multiple diamonds, the diamond is diamond with magnetically permeable plating layer, multiple the diamond is sequentially arranged by magnetic field guidance, metal flake layer has good flexibility and hardness is lower than 120HB, still has good flexibility after high-temperature brazing, so diamond tool has good mechanical properties in actual grinding process, effectively improves the service life of diamond tool. Diamond particles are highly ordered, so that they have uniform diamond exposure height, so that the working surface of the diamond tool has higher flatness, which is more conducive to improving the actual grinding effect of the diamond tool.

Description

Technical Field

[0001] This invention patent relates to the field of superhard material products technology, specifically to the manufacturing tools and processes for preparing high-efficiency and stable irregular grinding and polishing products for processing materials such as stone, semiconductors, and sapphire using brazing diamond technology. Background Technology

[0002] Brazed diamond tools are widely used in stone cutting, glass panel chamfering, wafer polishing and thinning, and sapphire grinding and finishing due to their high processing efficiency. However, they are limited to rough machining due to their short lifespan, unstable diamond holding properties, and wide range of sizes.

[0003] In order to produce efficient and stable brazed diamond tools, the diamond particles must be arranged in a highly ordered manner to have a uniform diamond exposure height and stable holding performance, resulting in better stability during processing. This is the ultimate mission of brazed diamond tools.

[0004] The processing of most materials is not limited to planar processing, but also includes the processing of irregular shapes, such as chamfering, edge trimming, inner arc contours, and other curved surfaces. This necessitates the introduction of appropriate precision grinding tools for curved surfaces to better complete these processing steps. Therefore, the development of efficient and stable irregular-shaped ordered brazing diamond tools is urgently needed. Summary of the Invention

[0005] In order to overcome the shortcomings and deficiencies of the existing technology, the purpose of this invention is to provide diamond tools and a method for manufacturing the same.

[0006] The objective of this invention is achieved through the following technical solution:

[0007] This invention provides a diamond tool, comprising a tool body and a diamond working layer attached to the tool body. The diamond working layer comprises a metal sheet layer, a brazing layer, and a plurality of diamonds. The metal sheet layer includes a first surface and a second surface. The first surface is used for brazing with the brazing layer, and the second surface is used for attachment to the tool body. The diamonds are diamonds with a magnetically conductive coating. The plurality of diamonds are arranged in an orderly manner guided by a magnetic field. The diamonds are connected and fixed to the first surface of the metal sheet layer via the brazing layer, and at least a portion of each diamond protrudes from the brazing layer and is exposed.

[0008] Furthermore, the brazing layer is obtained by heat curing of brazing paste. The diamonds arranged in an orderly manner are transferred into the brazing paste. After the brazing paste is heat-cured, the diamonds are connected and fixed to the first surface of the metal sheet through the brazing layer, and at least a portion of them protrude from the brazing layer and are exposed.

[0009] Furthermore, the metal used for the magnetic coating of the diamond is selected from copper-based, nickel-based, tungsten-based, or iron-based metals, and the metal of the magnetic coating increases the weight of the diamond by 20% to 150%.

[0010] Furthermore, the metal sheet layer has a hardness of less than 120 HB and is flexible.

[0011] Furthermore, the metal sheet layer is an elemental metal such as iron, copper, molybdenum, aluminum, nickel, or chromium, or an alloy based on at least one of these metals.

[0012] Another aspect of the present invention provides a method for manufacturing a diamond working layer, the diamond working layer being used to attach to a diamond tool, characterized in that: the method for manufacturing the diamond working layer includes the following steps: S1. applying a magnetically conductive plating to the diamond and providing a metal sheet layer; S2. arranging the diamonds in an orderly manner; S3. brazing the orderly arranged diamonds onto the metal sheet layer and ensuring that at least a portion of the diamonds protrudes from the brazing layer and is exposed.

[0013] Furthermore, the magnetic coating of diamond in step S1 includes:

[0014] Prepare the plating solution and determine the weight gain ratio of diamond particles;

[0015] The prepared plating solution and diamond particles are added to a container. A suitable metal rod is selected as the anode, and a cathode wire is placed inside the diamond particles to conduct electricity in order to prepare the diamond with the desired magnetic coating.

[0016] Furthermore, the metal sheet layer provided in step S1 is: a metal sheet layer with a hardness of less than 120HB and with flexibility is selected, wherein the metal sheet layer is an elemental metal such as iron, copper, molybdenum, aluminum, nickel or chromium or an alloy based on at least one of these metals.

[0017] Furthermore, before step S2 arranges the diamonds in an orderly manner, step S20 is included: pre-planning the working area of ​​the diamonds on the metal sheet layer.

[0018] Furthermore, step S20, which involves pre-planning the working area of ​​the diamond on the metal sheet, further includes: verifying the three-dimensional dimensions of the working part of the attached diamond tool, decomposing the approximate planar shape corresponding to the surface of the working part, and then designing the orderly distribution of magnetic points to complete the planning of the working area of ​​the diamond on the metal sheet.

[0019] Furthermore, step S20, which involves pre-planning the working area of ​​diamond on the metal sheet, also includes: preparing an ordered magnetic plate based on the design of ordered magnetic dots.

[0020] Furthermore, in step S3, the diamond being brazed and fixed onto the metal sheet layer also includes: preparing brazing paste, applying the brazing paste to the metal sheet layer, and, after being guided by a magnetic field, arranging the diamonds in an orderly manner on an ordered magnetic plate according to an ordered distribution of magnetic dots, bonding the brazing paste-coated metal sheet layer with the diamonds, and allowing the brazing paste to be heated and cured, so that at least a portion of the diamond protrudes from the brazing layer and is exposed.

[0021] Furthermore, in step S3, the ordered magnetic plate is an ordered magnetic ceramic plate, and the brazing paste is directly heated and cured on the magnetic ceramic plate.

[0022] Furthermore, the preparation of brazing paste in step S3, which involves applying the brazing paste to the metal sheet layer, includes: uniformly mixing organic binder and NiCrSiB powder at a mass ratio of 1:1 to 1:25, pouring the mixed paste onto the metal sheet, and smoothing the paste on the metal sheet into a thin layer with a thickness of 0.01-0.1 mm.

[0023] Furthermore, in step S3, the orderly arranged diamonds are brazed and fixed onto the metal sheet layer, wherein the brazing temperature is between 960 and 1040°C, and the holding time is between 1 and 15 minutes.

[0024] Furthermore, step S3, in which the orderly arranged diamonds are brazed and fixed onto the metal sheet layer, also includes pressing the fired metal sheet to correct the deformation of the metal sheet layer during the firing process.

[0025] Another aspect of the present invention provides a method for manufacturing a diamond tool, comprising a method for manufacturing a diamond working layer as described above, and attaching the manufactured diamond working layer to a tool body.

[0026] Furthermore, the diamond working layer is attached to the tool body by adhesive hot pressing. The adhesive hot pressing includes applying glue and hot pressing. The diamond working layer is cut, a bonding organic adhesive is scraped onto the back of the diamond working layer, and the diamond working layer is pressed onto the tool body by a press and heated to solidify it. Then the diamond tool with the attached diamond working layer is trimmed.

[0027] The technical solution provided by this invention has the following technical effects:

[0028] 1. The diamond is bonded and fixed to the metal sheet layer via a brazing layer, which is formed by the heat curing of brazing paste. This allows the diamond to adhere firmly to the metal sheet layer, resulting in better holding force of the diamond tool on the diamond abrasive grains. Furthermore, the brazing method ensures that at least a portion of the diamond protrudes beyond the brazing layer and is exposed. Compared to attaching the diamond to the metal sheet layer via electroplating, this method reduces metal contamination of the exposed diamond portion caused by electroplating, thus improving the actual grinding performance of the diamond tool.

[0029] 2. The magnetic coating metal of the diamond not only gives the diamond a certain degree of magnetism, but also provides thermal protection for the diamond during the brazing process, reducing the decrease in diamond strength caused by thermal damage and effectively extending the service life of diamond tools.

[0030] 3. The metal sheet layer of diamond tools has good flexibility and a hardness of less than 120HB. It still has good flexibility after high-temperature brazing. Therefore, diamond tools have good mechanical properties in actual grinding process, which effectively improves the service life of diamond tools.

[0031] 4. By using an ordered magnetic ceramic plate to define the adsorption area, one diamond is adsorbed by one magnetic point, which makes the diamond particles highly ordered and gives them a uniform diamond exposure height. This results in a smoother working surface for the diamond tool and improves the actual grinding effect of the diamond tool. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the stone inner edge grinding milling cutter in Example 1;

[0033] Figure 2 This is a magnified view of the diamond abrasive particles after the metal sheet layer with diamond abrasive particles is adhered to the substrate in Example 1.

[0034] Figure 3 This is a schematic diagram of the structural design of the metal sheet layer of the CMP trimmer in Example 2;

[0035] Figure 4 This is a schematic diagram of the drill bit substrate for Example 3;

[0036] Figure 5 This is a diagram of the diamond particle adsorption area in the top cutting edge distribution area of ​​the down-the-hole drill bit in Example 3;

[0037] Figure 6 This is a diagram of the diamond particle adsorption area in the side cutting edge distribution area of ​​the down-the-hole drill bit in Example 3. Detailed Implementation

[0038] To further illustrate the various embodiments, the present invention provides accompanying drawings. These drawings are part of the disclosure of the present invention, primarily used to illustrate the embodiments and to explain the operating principles of the embodiments in conjunction with the relevant descriptions in the specification. With reference to these drawings, those skilled in the art should be able to understand other possible implementations and the advantages of the present invention. Components in the drawings are not drawn to scale, and similar component symbols are generally used to represent similar components.

[0039] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments.

[0040] This invention provides a diamond tool, including a diamond working layer 100 and a tool body 19. The diamond working layer 100 is attached to the tool body 19. The diamond working layer 100 includes a metal sheet layer 103, a brazing layer 102, and a plurality of diamonds 101. The metal sheet layer 103 includes a first surface and a second surface. The first surface is used for brazing with the brazing layer 102, and the second surface is used for attaching with the tool body 19. The diamonds 101 are diamonds with a magnetically conductive coating. The plurality of diamonds 101 are arranged in an orderly manner guided by a magnetic field. The diamonds 101 are connected and fixed to the first surface of the metal sheet layer 103 via the brazing layer 102, and at least a portion of the diamonds 101 protrudes from the brazing layer 102 and is exposed.

[0041] The brazing layer 102 is formed by brazing a plurality of diamonds 101 to the metal sheet layer 103. The brazing methods include, but are not limited to, resistance brazing and furnace brazing. Preferably, the brazing layer 102 is obtained by heat curing brazing paste. The orderly arranged diamonds 101 are transferred into the brazing paste. After the brazing paste is heat-cured, the diamonds 101 are connected and fixed to the first surface of the metal sheet layer 103 via the brazing layer 102, and at least a portion of them protrude from the brazing layer 102 and are exposed.

[0042] The diamonds 101 are pre-distributed in the solder paste, and after being guided by a magnetic field, they are arranged in an orderly manner within the solder paste. In this embodiment, the adsorption area is defined by a magnetic ceramic plate, and one diamond is adsorbed by one magnetic point, thereby achieving the orderly arrangement of the diamonds 101.

[0043] The metal sheet layer 103 is fixedly connected to the tool body 19, for example, by means of an adhesive 18. The diamond 101 is fixedly connected to the metal sheet layer 103 after brazing. The diamond 101 is a diamond with a magnetically conductive coating. The coating metal can be copper-based, nickel-based, tungsten-based, or iron-based. This coating increases the weight of the diamond by 20% to 150%, and while maintaining a certain magnetic property, it also provides thermal protection during brazing to reduce the strength loss caused by thermal damage. The metal sheet layer 103 has good flexibility and a hardness below 120 HB, retaining good flexibility even after high-temperature brazing. The metal sheet layer 103 can be an elemental metal such as iron, copper, molybdenum, aluminum, nickel, or chromium, or an alloy of at least one of these metals. The tool body 19 can be irregularly shaped. The irregular tool body 19 may include internal circle machining type, external circle machining type, arc edge machining type, internal and external truncated cone machining type and slotted type, etc., and has multiple machining feasibility.

[0044] The present invention also provides a method for fabricating a diamond working layer and further manufacturing a diamond tool, the manufacturing method comprising the following steps: S1. applying a magnetically conductive plating to the diamond and providing a metal sheet layer; S2. arranging the diamonds in an orderly manner; S3. brazing the orderly arranged diamonds onto the metal sheet layer, with at least a portion of the diamonds protruding from the brazing layer and exposed; S4. hot-pressing the diamond working layer obtained in the preceding steps to the tool body for bonding.

[0045] The magnetic coating process for diamond in step S1 includes the preparation of the plating solution and the determination of the weight gain of the diamond particles. The prepared plating solution and diamond particles are added to a container, a suitable metal rod is selected as the anode, and a cathode wire is placed inside the diamond particles to conduct electricity to prepare the diamond with the desired magnetic coating layer. The weight gain ratio is determined by continuously weighing a certain number of diamond particles, thereby determining the outer diameter of the diamond particles.

[0046] Before arranging the diamonds in an orderly manner in step S2, step S20 is included: a step of pre-planning the sorting of the working area of ​​the diamonds on the metal sheet layer. Preferably, this includes: verifying the three-dimensional dimensions of the working part of the attached diamond tool, decomposing the approximate planar shape corresponding to the surface of the working part, and then designing the orderly distribution of magnetic points to complete the sorting of the working area of ​​the diamonds on the metal sheet layer. Preferably, this also includes: preparing an ordered magnetic plate according to the design of the orderly distribution of magnetic points.

[0047] Step S3, which involves brazing the diamond onto the metal sheet layer, further includes: preparing brazing paste; applying the brazing paste to the metal sheet layer; arranging the diamonds in an orderly manner on an ordered magnetic plate after being guided by a magnetic field; bonding the brazing paste-coated metal sheet layer with the diamonds; and allowing the brazing paste to cure under heat, so that at least a portion of the diamond protrudes from the brazing layer and is exposed. Preferably, the ordered magnetic plate is an ordered magnetic ceramic plate, and the brazing paste is directly cured by heat on the magnetic ceramic plate.

[0048] Preferably, the preparation of brazing paste in step S3 includes: uniformly mixing a certain mass of organic binder and NiCrSiB powder at a mass ratio of 1:1 to 1:25. This mass ratio depends on the particle size of the diamond particles and the required cutting edge height. For diamond particles with fine particle size and high cutting edge height requirements, a thinner solder paste can be prepared. The mixed solder paste is poured onto an ultra-thin metal sheet, which is then placed on a flat test bench with a 0.01-0.1 mm thick pad on both sides. The solder paste is then smoothed using a scraper, and the thickness of the solder paste is the thickness of the pad.

[0049] Preferably, in step S3, the orderly arranged diamonds are brazed and fixed onto the metal sheet layer, wherein the brazing temperature is between 960 and 1040°C, and the holding time is between 1 and 15 minutes.

[0050] Preferably, step S3, which involves brazing the orderly arranged diamonds onto the metal sheet layer, further includes pressing the fired metal sheet to correct the deformation of the metal sheet layer during the firing process.

[0051] In step S4, the bonding and hot pressing of the diamond working layer obtained in the previous step with the tool body includes applying adhesive and hot pressing. The metal sheet layer is cut into a specific shape, a bonding organic adhesive is scraped onto the back of the diamond working layer, the diamond working layer is pressed onto the tool body using a press and heated to solidify it, and then the diamond tool with the attached diamond working layer is trimmed.

[0052] The following are the specific implementation methods.

[0053] Example 1

[0054] (1) Preparation of magnetically coated diamond

[0055] Add 150g of 40 / 45-sized diamond particles to the plating solution, place an iron-copper based anode, and embed the cathode wire into the diamond particles. Connect the circuit for electroplating. After 15 hours, remove the diamond particles, weigh a certain number of them, and calculate that the weight gain of the diamond particles is 40% of their original weight. This completes the preparation of the magnetically coated diamond. If the weight gain of the diamond particles does not reach the target value, continue electroplating for a period of time and weigh the diamond particles again using the above method until the target weight gain is reached.

[0056] (2) Design of orderly arrangement of diamonds

[0057] See Figure 1-2 The stone internal edge grinding milling cutter body 19 is taken, and the specifications of the stone internal edge grinding milling cutter base body are φ10mm / 4mm*6mm, with a top surface 14, a side surface 15, and a bottom surface 16. A φ10mm / 4mm ring pattern (corresponding to the top surface 14), a φ10mm / 5mm ring pattern (corresponding to the bottom surface 16), and a 32mm*6mm rectangular pattern (corresponding to the side surface 15) are designed with diamonds distributed in an orderly manner. The adsorption area is defined using a point-magnetic ceramic plate, and one diamond is adsorbed by one magnetic point. The diamonds are arranged according to the set pattern.

[0058] (3) Application of solder paste

[0059] Take 10g of self-adhesive, 0.5mL of thinner and 40g of 300-mesh NiCrSiB powder, add them to a container and mix them evenly. Then take 3 ultra-thin metal sheets, roughen their surfaces and stick them on a flat operating test table. Then stick 10mm wide and 0.1mm thick stickers on both sides of the ultra-thin metal sheets. Transfer the solder paste onto the ultra-thin metal sheets and use a scraper to smooth the solder paste, so that the thickness of the solder paste is uniformly controlled at 0.1mm.

[0060] (4) Preparation of metal thin film layers

[0061] A thin metal sheet with solder paste evenly applied is placed on a magnetic ceramic plate with the solder paste side facing up, so that the diamond particles adhere to the solder paste. After compaction, it is heated for 10 minutes to solidify the solder paste. The thin metal sheet is then removed and cut into φ10mm / 4mm ring patterns 11, φ10mm / 5mm ring patterns 12, and 32mm*6mm rectangular patterns 13 according to the orderly distribution of diamond areas. These correspond to the top surface 14, bottom surface 16, and side surface 15 of the stone inner edge grinding milling cutter substrate, respectively.

[0062] (5) Firing of metal sheet layers

[0063] Place the metal sheet in a vacuum brazing furnace, set the brazing temperature to 1030℃ and the holding time to 15 minutes. Once the furnace temperature drops below 100℃, open the furnace door and remove the fired metal sheet. Use a flat press to flatten the transition layer.

[0064] (6) Hot pressing of the metal sheet layer to the tool body

[0065] A layer of thermosetting resin adhesive is coated on the back of the metal sheet, and the metal sheet is bonded to the inner edge grinding milling cutter substrate of the stone. Then, it is placed in a mold and pressurized and heated to make it completely dry and solidified, and then demolded.

[0066] (7) Dressing of the inner edge grinding cutter for stone

[0067] Place the stone inner edge grinding milling cutter on the grinding machine to trim and remove excess edges and corners. Then place it in the sandblasting machine for sandblasting for 30 minutes. After taking it out, place it in the ultrasonic cleaning machine for cleaning, then take it out and dry it before sealing and packaging it.

[0068] Example 2

[0069] (1) Preparation of magnetically coated diamond

[0070] Add 150g of 80 / 100 size diamond particles to the plating solution, place an iron-copper based anode, embed the cathode wire into the diamond particles, connect the circuit for electroplating, and remove the diamond particles after 15 hours. Weigh a certain number of diamond particles and calculate that the weight gain of the diamond particles is 18% of their original weight. This completes the preparation of magnetically coated diamond. If the weight gain of the diamond particles does not reach the target value, continue electroplating for a period of time and weigh the diamond particles again using the above method until the target weight gain is reached.

[0071] (2) Design of orderly arrangement of diamonds

[0072] Take the CMP dresser substrate (where CMP is short for Chemical Mechanical Polishing), such as... Figure 2 As shown, the dimensions are φ100mm*0.2mm. A φ100mm circular pattern with diamonds distributed in an orderly manner is designed. The circle is divided into 8 equal irregular spiral regions with a maximum spacing of 2mm, with the center as the base point. The diamond adsorption area 21 is defined by a point magnetic ceramic plate. One diamond can be adsorbed by one magnetic point. The diamonds are arranged according to the set pattern.

[0073] (3) Application of solder paste

[0074] Take 10g of self-adhesive, 0.5mL of thinner and 40g of 300-mesh NiCrSiB powder, add them to a container and mix them evenly. Then take an ultra-thin metal sheet, roughen its surface and stick it on a flat operating test table. Then stick 10mm wide and 0.1mm thick stickers on both sides of the ultra-thin metal sheet. Transfer the solder paste onto the ultra-thin metal sheet and use a scraper to smooth the solder paste, so that the thickness of the solder paste is uniformly controlled at 0.1mm.

[0075] (4) Preparation of metal thin film layers

[0076] A thin metal sheet with solder paste evenly applied is placed on a magnetic ceramic plate with the solder paste side facing up, so that the diamond particles adhere to the solder paste. After compaction, it is heated for 10 minutes to solidify the solder paste. The thin metal sheet is then removed and cut into a specific shape according to the orderly distribution of diamond areas.

[0077] (5) Firing of metal sheet layers

[0078] Place the metal sheet in a vacuum brazing furnace, set the brazing temperature to 1020℃ and the holding time to 8 minutes. Once the furnace temperature drops below 100℃, open the furnace door and remove the fired metal sheet. Use a flat press to flatten the transition layer.

[0079] (6) Hot pressing of the metal sheet layer to the tool body

[0080] A thermosetting resin adhesive is coated on the back of the metal sheet layer, and the metal sheet layer is bonded to the CMP dresser substrate. Then, it is placed in a mold and pressurized and heated to make it completely dry and solidified, and then demolded.

[0081] (7) Dressing of the inner edge grinding cutter for stone

[0082] Place the CMP dresser on the grinding machine to dress it, removing excess edges and corners. Then place it in the sandblasting machine for sandblasting for 30 minutes. After removing it, place it in the ultrasonic cleaning machine for cleaning, then remove it and dry it before sealing and packaging it.

[0083] Example 3

[0084] (1) Preparation of magnetically coated diamond

[0085] Add 150g of 45 / 50 sized diamond particles to the plating solution, place an iron-copper based anode, embed a wire into the diamond particles, connect the circuit for electroplating, and remove the diamond particles after 15 hours. Weigh a certain number of diamond particles and calculate that the weight gain of the diamond particles is 25% of their original weight. This completes the preparation of the magnetically coated diamond. If the weight gain of the diamond particles does not reach the target value, continue electroplating for a period of time and weigh the diamond particles again using the above method until the target weight gain is reached.

[0086] (2) Design of orderly arrangement of diamonds

[0087] Take a down-the-hole drill bit base with a size of φ100mm. The down-the-hole drill bit base has a top cutting edge feeding area 31 and a side cutting edge feeding area 32, such as... Figure 4 As shown. The design includes 30mm*314mm rectangular patterns 34 and 30mm*345mm rectangular patterns 35 (rectangular patterns 34 and 35 correspond to the side cutting edge fabric application area 32) and a φ112mm / 100mm annular pattern 33 (corresponding to the top cutting edge fabric application area 31) with diamonds distributed in an orderly manner, as shown. Figure 4-6 As shown, the adsorption area is defined by using a magnetic ceramic plate, and one diamond can be adsorbed by one magnetic point, arranged according to the set pattern.

[0088] (3) Application of solder paste

[0089] Take 10g of self-adhesive, 0.5mL of thinner and 40g of 300-mesh NiCrSiB powder, add them to a container and mix them evenly. Then take 3 ultra-thin metal sheets 36, roughen their surfaces and attach them to a flat operating test table. Then attach 10mm wide and 0.1mm thick stickers to both sides of the ultra-thin metal sheets 36. Transfer the solder paste onto the ultra-thin metal sheets 36 and use a scraper to smooth the solder paste, so that the thickness of the solder paste is uniformly controlled at 0.1mm.

[0090] (4) Preparation of metal thin film layers

[0091] A metal sheet 36 with solder paste evenly applied is placed on a magnetic ceramic plate with the solder paste side facing up, so that the diamond particles adhere to the solder paste. After compaction, it is heated for 10 minutes to solidify the solder paste. The metal sheet 36 is then removed and cut into 30mm*314mm rectangular patterns 34, 30mm*345mm rectangular patterns 35, and φ112mm / 100mm annular patterns 33 according to the orderly distribution of diamond areas.

[0092] (5) Firing of metal sheet layers

[0093] Place the metal sheet in a vacuum brazing furnace, set the brazing temperature to 1020℃ and the holding time to 8 minutes. Once the furnace temperature drops below 100℃, open the furnace door and remove the fired metal sheet. Use a flat press to flatten the transition layer.

[0094] (6) Hot pressing of the metal sheet layer to the tool body

[0095] A layer of thermosetting resin is coated on the back of the metal sheet, which is then bonded to the down-the-hole drill bit substrate. The substrate is then placed in a mold and subjected to pressure and heating to allow it to dry and solidify completely before demolding.

[0096] (7) Dressing of down-the-hole drill bits

[0097] The down-the-hole drill bit is placed on a grinding machine for trimming to remove excess edges and corners. Then it is placed in a sandblasting machine for sandblasting for 30 minutes. After that, it is placed in an ultrasonic cleaner for cleaning, then removed and dried, and finally sealed and packaged.

[0098] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. A method for manufacturing a diamond working layer, wherein the diamond working layer is used for attachment to a diamond tool, characterized in that: The method for manufacturing the diamond working layer includes the following steps: S1. applying magnetic plating to the diamond and providing a metal sheet layer; S2. arranging the diamonds in an orderly manner; S3. brazing the orderly arranged diamonds onto the metal sheet layer and ensuring that at least a portion of the diamonds protrudes from the brazing layer and is exposed. The magnetic coating process for diamond in step S1 includes: Prepare the plating solution and determine the weight gain ratio of diamond particles; Add the prepared plating solution and diamond particles to a container, select a suitable metal rod as the anode, place the cathode wire inside the diamond particles and pass an electric current to prepare the diamond with the desired magnetic coating. Before step S2, which arranges the diamonds in an orderly manner, step S20 is also included: pre-planning the sorting of the working area of ​​the diamonds on the metal sheet, including: verifying the three-dimensional dimensions of the working part of the attached diamond tool, decomposing the planar graphic corresponding to the surface of the working part, and then designing the orderly distribution of magnetic points to complete the sorting of the working area of ​​the diamonds on the metal sheet; and preparing an ordered magnetic plate according to the design of the orderly distribution of magnetic points. The step S3, in which the diamond is brazed and fixed onto the metal sheet layer, further includes: preparing brazing paste, applying the brazing paste to the metal sheet layer, and, after being guided by a magnetic field, arranging the diamonds in an orderly manner on an ordered magnetic plate according to an ordered distribution of magnetic dots, bonding the brazing paste-coated metal sheet layer with the diamonds, and allowing the brazing paste to cure under heat, so that at least a portion of the diamond protrudes from the brazing layer and is exposed; the ordered magnetic plate in step S3 is an ordered magnetic ceramic plate, and the brazing paste is directly cured by heat on the magnetic ceramic plate.

2. The method for manufacturing a diamond working layer according to claim 1, characterized in that: The preparation of brazing paste in step S3, which involves applying the brazing paste to a metal sheet, includes: taking an organic binder and NiCrSiB powder at a mass ratio of 1:1 to 1:25 and mixing them evenly; pouring the mixed paste onto the metal sheet; and smoothing the paste on the metal sheet into a thin layer with a thickness of 0.01-0.1 mm.

3. The method for manufacturing the diamond working layer according to claim 1, characterized in that: In step S3, the orderly arranged diamonds are brazed and fixed onto the metal sheet layer, wherein the brazing temperature is between 960 and 1040°C and the holding time is between 1 and 15 minutes; the fired metal sheet is pressed to correct the deformation of the metal sheet layer during the firing process.

4. A method for manufacturing a diamond tool, comprising the method for manufacturing a diamond working layer as described in any one of claims 1-3, and attaching the manufactured diamond working layer to a tool body; wherein the diamond working layer is attached to the tool body by adhesive hot pressing, the adhesive hot pressing comprising applying adhesive and hot pressing, the diamond working layer is cut, a bonding organic adhesive is applied to the back of the diamond working layer, the diamond working layer is pressed onto the tool body using a press and heated to solidify it, and then the diamond tool with the attached diamond working layer is trimmed.

5. A diamond tool, comprising a tool body and a diamond working layer attached to the tool body, characterized in that: The diamond working layer is manufactured using the manufacturing method of the diamond working layer as described in any one of claims 1-3; the diamond working layer includes: a metal sheet layer, a brazing layer, and a plurality of diamonds, the metal sheet layer includes a first surface and a second surface, the first surface is used for brazing with the brazing layer, the second surface is used for attaching with the tool body, the diamonds are diamonds with a magnetically conductive coating, the plurality of diamonds are arranged in an orderly manner guided by a magnetic field, the diamonds are connected and fixed to the first surface of the metal sheet layer via the brazing layer, and at least a portion of the diamonds protrudes from the brazing layer and is exposed.

6. The diamond tool according to claim 5, characterized in that: The brazing layer is obtained by heating and curing brazing paste. The diamonds arranged in an orderly manner are transferred into the brazing paste. After the brazing paste is heated and cured, the diamonds are connected and fixed to the first surface of the metal sheet through the brazing layer, and at least a portion of them protrude from the brazing layer and are exposed.

7. The diamond tool according to claim 5, characterized in that: The metal used for the magnetic coating of the diamond is selected from copper-based, nickel-based, tungsten-based, or iron-based metals, and the metal of the magnetic coating increases the weight of the diamond by 20% to 150%; or the metal sheet layer is an elemental metal of iron, copper, molybdenum, aluminum, nickel, or chromium, or an alloy of at least one of these metals; or the metal sheet layer has a hardness of less than 120 HB and is flexible.

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