Disc-shaped cutter and method of manufacturing the same

Abstract

A disc-shaped cutter or a manufacturing method thereof, the disc-shaped cutter including a disc-shaped base metal having a single-blade-shaped tip end portion connected by a flat surface of a side contacting other cutters used in pairs and an inclined surface inclined with respect to the flat surface, and a clad layer cladding the flat surface of the disc-shaped base metal, the disc-shaped cutter having a nose point constituted by the clad layer, of two surfaces formed by the clad layer constituting the nose point, one surface is inclined at an acute angle with respect to the flat surface of the disc-shaped base metal, and the other surface is connected with the exposed inclined surface of the disc-shaped base metal, an angle α of an angle formed by the flat surface and the inclined surface in the disc-shaped base metal and an angle β of an angle formed by the two surfaces formed by the clad layer constituting the nose point satisfy a relationship of α < β.

Description

Technical Field

[0001] This invention relates to a disc-shaped cutting tool and its manufacturing method. Background Technology

[0002] A method for cutting strip-shaped objects using a pair of disc-shaped cutters consisting of a lower cutter and an upper cutter.

[0003] As a disc-shaped cutting tool, for example, a disc-shaped cutting tool with a coating layer on the surface of the base metal having a hardness higher than that of the base metal is used.

[0004] As a disc-shaped cutting tool having a coating layer on the surface of a base metal, for example, those disclosed in Japanese Patent Application Publication No. 2012-11475... Figure 1 Japanese Patent Application Publication No. 2016-190497 Figure 2 Grade A. Summary of the Invention

[0005] The technical problem that the invention aims to solve

[0006] When cutting, a disc-shaped cutting tool with a cladding layer on the surface of a base metal requires a non-notched tip. However, manufacturing a disc-shaped cutting tool with a non-notched tip is not easy due to the difference in hardness between the base metal and the cladding layer.

[0007] Here, "disc-shaped cutting tool without a notch at the tip" refers to a disc-shaped cutting tool without a concave portion at the tip that is more than 10 μm wide.

[0008] Therefore, the problem to be solved by one embodiment of the present invention is accomplished in view of the above circumstances, and its object is to provide a disc-shaped cutting tool with no notch at the tip and which is easy to manufacture.

[0009] Furthermore, another embodiment of the present invention aims to solve the problem of providing a method for manufacturing the above-described disc-shaped cutting tool.

[0010] Means for solving technical problems

[0011] The solutions to the above problems include the following implementation methods.

[0012] <1> A disc-shaped cutting tool, used in pairs with other cutting tools, wherein,

[0013] The aforementioned disc-shaped cutting tool comprises: a disc-shaped base metal having a single-edged tip formed by a plane on one side in contact with the other cutting tools and an inclined surface inclined relative to that plane; and a cladding layer covering the aforementioned plane of the disc-shaped base metal.

[0014] The aforementioned disc-shaped cutting tool has a cutting tip formed by the aforementioned coating layer.

[0015] Of the two surfaces formed by the coating layer constituting the aforementioned blade tip, one surface is inclined at an acute angle relative to the plane of the aforementioned disk-shaped base metal, and the other surface is connected to the exposed inclined surface of the aforementioned disk-shaped base metal.

[0016] The angle α between the plane and the inclined surface in the aforementioned disk-shaped base metal and the angle β between the two surfaces formed by the coating layer constituting the aforementioned blade tip satisfy the relationship α < β.

[0017] <2> According to the disc-shaped cutting tool described in <1>, wherein,

[0018] The angles α and β satisfy the relationship α+1°≤β≤α+10°.

[0019] <3> The disc-shaped cutting tool according to <1> or <2>, wherein,

[0020] The angle α mentioned above is 10° to 110°.

[0021] <4> The disc-shaped cutting tool according to any one of <1> to <3>, wherein,

[0022] The hardness of the aforementioned coating layer is 1.5 to 5 times that of the aforementioned disc-shaped base metal.

[0023] <5> A method for manufacturing a disc-shaped cutting tool, which is the method for manufacturing a disc-shaped cutting tool as described in any one of <1> to <4>, wherein,

[0024] In the above-described method for manufacturing a disc-shaped cutting tool, a workpiece is used, comprising: a disc-shaped base metal having a front end formed by a plane including a side that contacts the other cutting tool; and a cladding layer covering the entire front end of the disc-shaped base metal.

[0025] The manufacturing method of the above-mentioned disc-shaped cutting tool includes:

[0026] In the first grinding process, the workpiece is ground to expose a portion of the disc-shaped base metal within the workpiece, forming an inclined surface on which the exposed disc-shaped base metal is located in the disc-shaped cutting tool, and the angle α is adjusted.

[0027] In the second grinding process, the workpiece after the first grinding process is ground to form a cutting tip composed of the coating layer in the disc-shaped tool, and the angle β is adjusted.

[0028] <6> According to the manufacturing method of the disc-shaped cutting tool described in <5>, wherein,

[0029] The grinding is performed by reverse milling using a cup-shaped grinding wheel, and the angle θ between the forward direction of the cup-shaped grinding wheel and the rotation direction of the workpiece being ground is 30° to 150°.

[0030] Invention Effects

[0031] According to one embodiment of the present invention, a disc-shaped cutting tool with no notch at the tip and easy to manufacture can be provided.

[0032] Furthermore, according to another embodiment of the present invention, a method for manufacturing the above-described disc-shaped cutting tool can be provided. Attached Figure Description

[0033] Figure 1 This is a cross-sectional schematic diagram showing an example of the front end of a disc-shaped cutter according to one embodiment.

[0034] Figure 2 This is a cross-sectional schematic diagram showing another example of the front end of a disc-shaped cutter according to one embodiment.

[0035] Figure 3 This is a cross-sectional schematic diagram illustrating the first grinding step of a method for manufacturing a disc-shaped cutting tool according to an embodiment.

[0036] Figure 4 This is a cross-sectional schematic diagram illustrating the second grinding step of a method for manufacturing a disc-shaped cutting tool according to one embodiment.

[0037] Figure 5 This is a cross-sectional schematic diagram illustrating the third grinding step of a method for manufacturing a disc-shaped cutting tool according to one embodiment.

[0038] Figure 6 This is a schematic diagram illustrating an example of grinding used in a method for manufacturing a disc-shaped cutting tool according to one embodiment.

[0039] Figure 7 This is a schematic diagram illustrating the "forward direction of the cup-shaped grinding wheel", the "rotation direction of the workpiece being ground", and the "angle θ between the forward direction of the cup-shaped grinding wheel and the rotation direction of the workpiece being ground" in a method for manufacturing a disc-shaped cutting tool according to an embodiment.

[0040] Figure 8 This is a schematic diagram showing the positional relationship between the workpiece being ground and the annular edge of the cup-shaped grinding wheel during the first grinding process.

[0041] Figure 9 This is a schematic diagram showing the positional relationship between the workpiece being ground and the annular edge of the cup-shaped grinding wheel during the second grinding process. Detailed Implementation

[0042] The following describes embodiments of a disc-shaped cutting tool and its manufacturing method. However, the present invention is not limited to any of the following embodiments, and appropriate modifications can be made to implement it within the scope of the objectives of the present invention.

[0043] In this invention, the numerical range represented by “~” refers to the range encompassed by taking the values ​​recorded before and after “~” as the minimum and maximum values, respectively.

[0044] In the numerical ranges described in stages in this invention, the upper or lower limit value described in a certain numerical range can be replaced with the upper or lower limit value of other numerical ranges described in stages. Furthermore, the upper or lower limit value described in a certain numerical range in this invention can also be replaced with the values ​​shown in the embodiments.

[0045] The elements in the various figures shown in this invention are not necessarily at an exact scale; the focus is on clearly illustrating the principles of the invention, and there are also parts that are emphasized.

[0046] Furthermore, in each of the accompanying drawings, the same symbols are used to mark the constituent elements with the same function, and repeated descriptions are omitted.

[0047] In this invention, a combination of two or more preferred methods or solutions constitutes a more preferred method or solution.

[0048] Disc-shaped cutting tools

[0049] As already described, when manufacturing a disc-shaped cutting tool with a cladding layer on the surface of the base metal that is harder than the base metal, it is not easy to produce a product with a notch-free cutting tip due to the hardness difference between the base metal and the cladding layer. For example, in various prior art documents describing conventional disc-shaped cutting tools, the figures show disc-shaped cutting tools with a base metal and a cladding layer and a notch-free cutting tip, but grinding such a notch-free disc-shaped cutting tool is not easy.

[0050] The inventors conducted in-depth research on disc-shaped cutting tools with a coating layer on the surface of a single-edged base metal and found that by exposing the outer side (sloping face) of the base metal and forming the shape of the cutting tip by the coating layer, and by making the angle of the cutting tip formed by the coating layer greater than the angle of the front end of the base metal, the disc-shaped cutting tool according to this embodiment was completed.

[0051] The disc-shaped cutting tool involved in this embodiment is a disc-shaped cutting tool used in pairs with other cutting tools. The disc-shaped cutting tool includes: a disc-shaped base metal, a single-edged tip formed by connecting a plane on one side that contacts the other cutting tool and an inclined surface that is inclined relative to the plane; and a cladding layer covering the plane of the disc-shaped base metal. The disc-shaped cutting tool has a cutting tip formed by the cladding layer. Of the two surfaces formed by the cladding layer constituting the cutting tip, one surface is inclined at an acute angle relative to the plane of the disc-shaped base metal, and the other surface is connected to the exposed inclined surface of the disc-shaped base metal. The angle α between the plane and the inclined surface in the disc-shaped base metal and the angle β between the two surfaces formed by the cladding layer constituting the cutting tip satisfy the relationship α < β.

[0052] The disc-shaped tool involved in this embodiment is a disc-shaped tool used in pairs with other tools (preferably disc-shaped tools) as described above.

[0053] Here, the "plane" in the disc-shaped base metal refers to the plane that contacts the "other cutting tool" used in pairs with the disc-shaped cutting tool according to this embodiment. As described above, since the plane in the disc-shaped base metal is covered by a cladding layer, in the disc-shaped cutting tool according to this embodiment, the surface of this cladding layer becomes the surface that contacts the "other cutting tool" (also referred to as the ventral surface, ventral surface, etc.). In other words, in the disc-shaped cutting tool according to this embodiment, the plane of the disc-shaped base metal and the surface of the cladding layer covering the plane are also surfaces configured to face the "other cutting tool (specifically, the cutting face of the other cutting tool)".

[0054] Furthermore, the "single-edged tip" can be an acute angle (e.g., see reference). Figure 1 or Figure 2 The front end of the disc-shaped base metal 10 shown may also have an arc that allows the angle α to be determined by the method described later. That is, the "single-edged front end" may have a chamfer that allows the angle α to be determined by the method described later.

[0055] The disc-shaped tool involved in this embodiment is a disc-shaped tool with no notch at the tip (hereinafter also simply referred to as "without notch") and is easy to manufacture.

[0056] Furthermore, in the disc-shaped cutting tool according to this embodiment, the inclined surface of the disc-shaped base metal is exposed, and this exposed surface is connected to the surface formed by the coating layer constituting the cutting tip. By having this structure, for example, it has the advantage that even when the cutting tip of the disc-shaped cutting tool becomes dull and needs to be re-grinded, the grinding conditions used to expose the inclined surface of the disc-shaped base metal during the manufacture of the disc-shaped cutting tool can be directly applied.

[0057] (The relationship between α and β)

[0058] In the disc-shaped cutting tool of this embodiment, the angle α between the plane and the inclined surface of the disc-shaped base metal and the angle β between the two surfaces formed by the coating layer constituting the cutting tip satisfy the relationship α < β.

[0059] From the perspective of designing a disc-shaped tool that is not easily damaged and a sharp blade tip, it is preferable to satisfy the relationship α+1°≤β≤α+10°, more preferably to satisfy the relationship α+2°≤β≤α+8°, and even more preferably to satisfy the relationship α+3°≤β≤α+7°.

[0060] (Methods for measuring angles α and β)

[0061] Angles α and β are determined as follows.

[0062] Angle β is measured from the tip side of the disc-shaped tool using either a non-contact measurement method, such as a laser microscope, or a contact measurement method, such as a surface roughness meter.

[0063] Since angle α cannot be directly measured from a disc-shaped tool, it is measured as follows. First, a coating layer formed on a plane other than the tool tip (e.g., Figure 1 This is equivalent to the cladding layer 20A. Figure 2 Assuming the thickness of the cladding layer (equivalent to 20B) is uniform and its surface is parallel to the plane, the angle between the surface of this cladding layer and the exposed inclined surface of the disk-shaped base metal is measured using a laser microscope or surface roughness meter, and the obtained value is taken as angle α. Therefore, angle α is set as the angle from a position 5 μm away from the tip of the tool.

[0064] Furthermore, the accuracy of the coating thickness used to determine angle α is approximately 0.01 μm or less in the aforementioned measurement area, and therefore can serve as the aforementioned premise.

[0065] Here, as a laser microscope, for example, the KEYENCE CORPORATION VK-9500 can be used. And as a surface roughness meter, the Tokyo Seimitsu Co., Ltd. SURFCOM FLEX-50A can be used.

[0066] The disc-shaped cutting tools described in Japanese Patent Application Publication Nos. 2012-11475 and 2016-190497 are all scribing wheels. When cutting the workpiece, no other cutting tools are used with the scribing wheel. Therefore, the disc-shaped base metal in the disc-shaped cutting tools described in Japanese Patent Application Publication Nos. 2012-11475 and 2016-190497 does not have a flat surface on the side that contacts other cutting tools, and is different from the disc-shaped cutting tool involved in this embodiment. Furthermore, the disc-shaped cutting tools described in Japanese Patent Application Publication Nos. 2012-11475 and 2016-190497 also do not have an area where the disc-shaped base metal is exposed, which is also different from the disc-shaped cutting tool involved in this embodiment.

[0067] The disc-shaped cutting tool described in this embodiment will now be explained.

[0068] First, referring to the accompanying drawings, the layer structure and shape of the disc-shaped tool involved in this embodiment will be described. (The material used herein...) Figure 1 and Figure 2 This is a schematic cross-sectional view used to illustrate the layer structure and shape of the disc-shaped tool involved in this embodiment.

[0069] like Figure 1 As shown, the front end of the disc-shaped cutting tool 100A has: a disc-shaped base metal 10, having a single-edged front end formed by a plane 12 and an inclined surface 14 inclined relative to the plane 12; and a cladding layer 20A, covering the plane 12 of the disc-shaped base metal 10.

[0070] Then, the blade tip 30A is formed from the coating layer 20A.

[0071] Furthermore, of the two surfaces 22A and 24A formed by the cladding layer 20A constituting the blade tip 30A, one surface 22A is inclined at an acute angle relative to the plane 12 of the disk-shaped base metal 10, and the other surface 24A is connected to the exposed inclined surface 14 of the disk-shaped base metal 10. In particular, in Figure 1 In this structure, the surface 24A formed by the cladding layer 20A and the exposed inclined surface 14 of the disk-shaped base metal 10 form the same plane. That is, the angle between the surface 24A and the inclined surface 14 is 180°.

[0072] And, as Figure 1 As shown, the angle α between the plane 12 and the inclined surface 14 of the disk-shaped base metal 10 and the angle β between the two surfaces 22A and 24A formed by the cladding layer 20A constituting the tip 30A satisfy the relationship α < β.

[0073] In this invention, "of the two surfaces formed by the coating layer constituting the blade tip, one surface is inclined at an acute angle relative to the plane of the disk-shaped base metal" means, as... Figure 1 As shown, the surface 22A formed by the cladding layer is inclined at an acute angle relative to the plane 12 of the disk-shaped base metal 10 toward the blade tip 30A. Therefore, the angle formed by the intersection of the extension of the plane 12 and the surface 22A is an acute angle.

[0074] Furthermore, in this invention, as Figure 1 As shown, "α" is the angle between plane 12 and inclined surface 14 that is inclined relative to plane 12, representing the apex angle of the single-edged front end of the disk-shaped base metal 10.

[0075] Furthermore, in this invention, such as Figure 1 As shown, "β" is the angle formed by the two surfaces 22A and 24A of the coating layer 20A that constitutes the blade tip 30A, representing the blade tip angle of the blade tip formed by the coating layer.

[0076] And, as Figure 2 As shown, the front end of the disc-shaped cutting tool 100B has: a disc-shaped base metal 10, having a single-edged front end formed by a plane 12 and an inclined surface 14 inclined relative to the plane 12; and a cladding layer 20B, covering the plane 12 of the disc-shaped base metal 10.

[0077] Then, the blade tip 30B is formed from the coating layer 20B.

[0078] Furthermore, of the two surfaces 22B and 24B formed by the cladding layer 20B constituting the blade tip 30B, one surface 22B is inclined at an acute angle relative to the plane 12 of the disk-shaped base metal 10, and the other surface 24B is connected to the exposed inclined surface 14 of the disk-shaped base metal 10. Figure 2 In, with Figure 1 Unlike other surfaces, the surface 24B formed by the cladding layer 20B and the exposed inclined surface 14 of the disk-shaped base metal 10 do not form the same plane. Here, the angle (specifically, the interior angle) between the surface 24B and the inclined surface 14 is less than 180°.

[0079] and, Figure 2 In the disc-shaped cutting tool 100B shown, the angle α between the plane 12 and the inclined surface 14 of the disc-shaped base metal 10 and the angle β between the two surfaces 22B and 24B formed by the cladding layer 20B constituting the cutting tip 30B also satisfy the relationship α < β.

[0080] exist Figure 2 In the case of the disc-shaped cutter 100B shown, the angle (i.e., interior angle) between the surface 24B and the inclined surface 14 is preferably 120° to 150°.

[0081] Next, the disc-shaped base metal and the cladding layer constituting the disc-shaped cutting tool according to this embodiment will be described.

[0082] (Disc-shaped base metal)

[0083] There are no particular limitations on the disc-shaped base metal constituting the disc-shaped cutting tool according to this embodiment, as long as it is a disc-shaped base metal having a single-edged tip formed by a plane and an inclined surface inclined relative to such a plane.

[0084] Materials that can serve as a disc-shaped base metal include metals or metal compounds. Specifically, materials that can serve as a disc-shaped base metal include high-speed tool steel (also known as high-speed steel), alloy tool steel, cemented carbide, ceramics, etc.

[0085] There are no particular restrictions on the size of the disc-shaped base metal; it can be determined based on the intended use, the type of material being cut, and the available space within the equipment.

[0086] For example, the outer diameter of the disc-shaped base metal can be 30mm to 300mm, but from the viewpoints of ease of changing disc-shaped tools and operability during regrinding, it is preferable to be 80mm to 160mm.

[0087] When a disc-shaped base metal has a through hole, that is, when a ring-shaped base metal has a through hole, its inner diameter (i.e., the diameter of the through hole) can be, for example, 20 mm to 200 mm.

[0088] The thickness of the disc-shaped base metal, specifically excluding the thickness of the single-edged tip region, can be 0.3 mm to 3 mm, taking into account the strength, dimensional accuracy, and suitable weight for operation of the disc-shaped cutting tool.

[0089] In a disc-shaped base metal, the angle α between the plane and the inclined surface that is inclined relative to the plane can be determined based on the type of object being cut, the ease of manufacturing, and the ease with which dust is generated from the cut surface.

[0090] For example, the angle α can be 10° to 110°, preferably 20° to 100°, and more preferably 30° to 95°.

[0091] (Covering layer)

[0092] There are no particular limitations on the coating layer constituting the disc-shaped cutting tool involved in this embodiment, as long as the coating layer is higher than the disc-shaped base metal.

[0093] Materials that can be used as coating layers include diamond carbon (DLC), titanium nitride (TiN), titanium carbonitride (TiCN), and aluminum chromium nitride (AlCrN).

[0094] From the viewpoint of improving cutting performance and obtaining a disc-shaped cutting tool without notches, the hardness of the coating layer relative to the hardness of the disc-shaped base metal is preferably 1.2 to 8 times, more preferably 1.5 to 5 times, and even more preferably 2 to 5 times.

[0095] Here, the hardness of the coating layer and the disk-shaped base metal is determined by the following method.

[0096] The hardness of the coating layer and the disk-shaped base metal is expressed by Vickers hardness.

[0097] The Vickers hardness of the coating layer and the disk-shaped base metal was determined by the method described in JIS Z 2244:2009. Specifically, the Vickers hardness of the coating layer and the disk-shaped base metal was determined, for example, using a Vickers hardness tester HV-100 from Mitutoyo Corporation.

[0098] As a method for forming the coating layer, physical vapor deposition (PVD) or chemical vapor deposition (CVD) methods such as sputtering, vacuum evaporation, ion beam evaporation, molecular beam evaporation, and ion electroplating are applicable.

[0099] From the viewpoint of improving the strength of the disc-shaped cutting tool, the thickness of the cladding layer formed on the plane of the disc-shaped base metal (excluding the cutting tip) is preferably 0.5 μm to 10 μm, and more preferably 1 μm to 6 μm.

[0100] The thickness of the aforementioned coating layer was determined by the following method.

[0101] The object to be coated, namely a disc-shaped base metal, and a partially masked test sample (specifically, a test sample made from the same raw material as the disc-shaped base metal) are placed in the same apparatus, and a coating layer is formed on both the disc-shaped base metal and the test sample. Then, in the test sample with the coating layer formed, the height difference caused by whether or not it is masked is taken as the thickness of the coating layer, and measured using a laser microscope or a stylus roughness gauge.

[0102] Furthermore, the thickness of the aforementioned coating layer can be partially removed by laser processing, grinding, etc., to expose the disc-shaped base metal. The height difference between the exposed disc-shaped base metal and the remaining coating layer is taken as the thickness of the coating layer, and it can be measured by laser microscope or scanning electron microscope (SEM).

[0103] <Manufacturing Method of Disc-shaped Cutting Tools>

[0104] The method for manufacturing a disc-shaped cutting tool according to this embodiment is the same as the method described above. In this method, a workpiece is used, comprising: a disc-shaped base metal having a front end portion formed by a plane including a side that contacts the other cutting tool (i.e., other cutting tools used in pairs with the disc-shaped cutting tool according to this embodiment); and a covering layer covering the entire front end portion of the disc-shaped base metal.

[0105] And includes:

[0106] In the first grinding process, the workpiece is ground to expose a portion of the disc-shaped base metal within the workpiece, forming an inclined surface on which the exposed disc-shaped base metal is located in the disc-shaped cutting tool, and the angle α is adjusted.

[0107] In the second grinding process, the workpiece after the first grinding process is ground to form a cutting tip composed of the coating layer in the disc-shaped tool, and the angle β is adjusted.

[0108] Hereinafter, with reference to the accompanying drawings, the manufacturing method of the disc-shaped cutting tool according to this embodiment will be described.

[0109] like Figure 3 As shown, a workpiece 110a to be ground is prepared, comprising: a disc-shaped base metal 40 having a front end portion (here, a single-bladed front end portion) formed by including a plane; and cladding layers 52 and 54 covering the entire front end portion of the disc-shaped base metal 40.

[0110] First, such as Figure 3 As shown, the workpiece 110a is ground from the inclined surface side of the disc-shaped base metal 40 (first grinding step). That is, in the first grinding step, the cladding layer 54 is ground from the inclined surface side of the disc-shaped base metal 40, exposing a portion of the disc-shaped base metal 40. Here, as... Figure 3 As shown, the workpiece 110a is ground in the direction of the arrow during the first grinding process. While the "exposed inclined surface of the disc-shaped base metal" in the disc-shaped tool of this embodiment is formed by the grinding, the angle α can be adjusted.

[0111] The workpiece 110b, which is obtained by the first grinding process, has its inclined surface exposed on the disc-shaped base metal 40.

[0112] Next, as Figure 4 The workpiece 110b after the first grinding step is ground from the planar side of the disc-shaped base metal 40 as shown (second grinding step). That is, in the second grinding step, the cladding layer 52 is ground from the planar side of the disc-shaped base metal 40, and the shape of the cutting tip is determined. Here, as shown... Figure 4As shown, the workpiece 110b is ground in the direction of the arrow during the second grinding process. Through this grinding, the "tool tip made of a coating layer" in the disc-shaped tool according to this embodiment, as described above, is formed, and the angle β can be adjusted.

[0113] The shape of the cutting tip of the workpiece 110b is adjusted through the second grinding process, and the angle β is adjusted to obtain the desired result. Figure 1 The disc-shaped cutting tool 100A shown in this embodiment is an example of this method.

[0114] Furthermore, after the first grinding step or the second grinding step, the coating layer in the workpiece can be ground, and the angle β can be adjusted (third grinding step). From the viewpoint of preventing tool tip notching and breakage, the third grinding step is preferably performed after the first grinding step and before the second grinding step.

[0115] When a third grinding step is performed after the first grinding step, the coating layer 52 of the workpiece 110b after the first grinding step is ground (an example of the third grinding step). That is, according to an example of the third grinding step, the coating layer 52 of the workpiece 110b can be ground and the shape of the cutting tip can be adjusted.

[0116] Here, as Figure 5 As shown, the workpiece 110c is ground in the direction of the arrow during the third grinding process. This grinding adjusts the shape of the "tool tip composed of the coating layer" and simultaneously adjusts the angle β. Furthermore, Figure 5 The example shown is when a third grinding process is performed on a workpiece 110c obtained by sequentially performing a first grinding process and a second grinding process. The case of performing a third grinding process on a workpiece 110b after the first grinding process is also similar. Figure 5 Similarly, the workpiece 110b to be ground can be ground in the direction of the arrow.

[0117] Thus, the method for manufacturing the disc-shaped cutting tool according to this embodiment can achieve the desired result by including a third grinding step. Figure 2 The disc-shaped cutting tool 100B shown in this embodiment is an example of this embodiment.

[0118] (The object being ground)

[0119] The workpiece to be ground comprises: a disk-shaped base metal having a front end portion formed including a plane; and a cladding layer covering the entire front end portion of the disk-shaped base metal.

[0120] The workpiece to be ground can be any workpiece that can be ground into the disc-shaped tool involved in this embodiment through grinding.

[0121] The disc-shaped base metal in the workpiece being ground is the same as the disc-shaped base metal in the disc-shaped cutting tool according to this embodiment. However, since the angle α is adjusted in the first grinding process, the apex angle of the disc-shaped base metal in the workpiece being ground is not particularly limited as long as the front end of the disc-shaped base metal is formed by including a plane, and can be greater than the angle α.

[0122] Furthermore, the material of the coating layer in the workpiece being ground is the same as that in the disc-shaped cutting tool according to this embodiment. However, since the shape and angle β of the cutting tip are adjusted through the first to third grinding processes, it is desirable that the coating layer in the workpiece being ground is thicker than that in the disc-shaped cutting tool according to this embodiment.

[0123] (Grinding method)

[0124] In the method for manufacturing a disc-shaped tool according to this embodiment, from the viewpoint of manufacturing a disc-shaped tool without notches and from the viewpoint of performing precision grinding, it is preferable to use a cup-shaped grinding wheel for grinding.

[0125] Here, the cup-shaped grinding wheel is a cup-shaped grinding wheel whose opening is formed by an annular rim. The central portion of the annular rim (also simply referred to as the "annular portion") functions as the grinding wheel in the width direction. During grinding, it is preferable that the central portion of the annular portion in the width direction, that is, about 1 / 2 to 2 / 3 of the width of the annular portion, contacts the workpiece being ground.

[0126] When using a cup-shaped grinding wheel for grinding, for example, as Figure 6 As shown, grinding is performed by rotating the workpiece 110 fixed to the rotary drive shaft 120 in the direction of arrow x, and by bringing the cup-shaped grinding wheel 130 rotating in the direction of arrow y into contact with the front end of the rotating workpiece 110.

[0127] From the viewpoint of manufacturing a disc-shaped tool without notches, it is preferable to perform grinding using a cup-shaped grinding wheel by reverse milling.

[0128] In this invention, grinding using a cup-shaped grinding wheel via conventional milling refers to grinding from the outside of the workpiece towards the tool tip using the cup-shaped grinding wheel. For details regarding grinding using a cup-shaped grinding wheel via conventional milling, please refer to the usage... Figure 8 Instructions and usage of the first grinding process Figure 9 The description of the second grinding process is provided in the column.

[0129] In the method for manufacturing a disc-shaped tool according to this embodiment, as described above, grinding is performed by reverse milling using a cup-shaped grinding wheel. Furthermore, it is preferable that the angle θ between the forward direction of the cup-shaped grinding wheel and the rotation direction of the workpiece being ground is 30° to 150°.

[0130] Here, use Figure 7 The following are explanations of "the forward direction of the cup-shaped grinding wheel", "the rotation direction of the workpiece being ground", and "the angle θ between the forward direction of the cup-shaped grinding wheel and the rotation direction of the workpiece being ground". Figure 7 This is a schematic diagram illustrating the positional relationship between the workpiece and the annular edge of the cup-shaped grinding wheel during grinding. Figure 7 This is a schematic diagram showing the position of the cup-shaped grinding wheel when viewed from the side of the workpiece being ground, with the rotation direction of the wheel known (i.e., the rotation direction of the annular rim of the cup-shaped grinding wheel).

[0131] exist Figure 7 In this context, the arrow y1 pointing in the direction of rotation along the annular edge 132 of the cup-shaped grinding wheel is defined as the "forward direction of the cup-shaped grinding wheel" by the contact points p1 and p2 between the two ends of the workpiece 110 in the thickness direction and the annular edge 132 of the cup-shaped grinding wheel. Furthermore, in... Figure 7 In this context, the rotation direction of the workpiece 110 at contact points p1 and p2, i.e., the direction of arrow x1, is defined as the aforementioned "rotation direction of the workpiece". Therefore, as... Figure 7 The angle θ formed by the direction of arrow x1 and the direction of arrow y1 is called the angle θ between the forward direction of the cup-shaped grinding wheel and the rotation direction of the workpiece being ground.

[0132] From the viewpoint of manufacturing a disc-shaped tool without a notch, the aforementioned angle θ is preferably 30° to 150°, and more preferably 30° to 90°.

[0133] The angle θ can be adjusted by setting the position of the cup-shaped grinding wheel and the position of the workpiece being ground.

[0134] -Specific plan for the first grinding process-

[0135] use Figure 8 The specific plan for the first grinding process is explained here. Figure 8 This is a schematic diagram showing the positional relationship between the workpiece being ground and the annular edge of the cup-shaped grinding wheel during the first grinding process.

[0136] like Figure 8 As shown, it is preferable to use a method having, as Figure 3 The workpiece 110a, with the structure and shape shown, rotates in the direction of arrow x, causing the annular rim 132 of the cup-shaped grinding wheel to rotate in the direction of arrow y to perform grinding in the first grinding process. Figure 8 As shown, grinding is performed by rotating the cup-shaped grinding wheel from the edge 112a of the workpiece 110a to the right by rotating it in the direction of arrow x along the workpiece 110a and in the direction of arrow y along the annular edge 132 of the cup-shaped grinding wheel. That is, as... Figure 8As shown, the grinding of the coating layer 54 of the workpiece 110a in the first grinding process is performed by reverse milling.

[0137] In addition, such as Figure 8 As shown, grinding of the workpiece 110a by reverse milling is preferably performed when the angle θ between the forward direction of the cup-shaped grinding wheel and the rotation direction of the workpiece being ground is between 30° and 150°.

[0138] -Specific plan for the second grinding process-

[0139] use Figure 9 The specific plan for the second grinding process is explained here. Figure 9 This is a schematic diagram showing the positional relationship between the workpiece being ground and the annular edge of the cup-shaped grinding wheel during the second grinding process.

[0140] like Figure 9 As shown, it is preferable to use a method having, as Figure 4 The workpiece 110b, with the structure and shape shown, rotates in the direction of arrow x, causing the annular edge 132 of the cup-shaped grinding wheel to rotate in the direction of arrow y to perform grinding in the second grinding process. Figure 9 As shown, grinding is performed by rotating the cup-shaped grinding wheel from the edge 112b of the workpiece 110b to the left by rotating it in the direction of arrow x along the workpiece 110b and in the direction of arrow y along the annular edge 132 of the cup-shaped grinding wheel. That is, as... Figure 9 As shown, the coating layer 52 of the workpiece 110b is ground by reverse milling.

[0141] In addition, such as Figure 9 As shown, grinding of the workpiece 110b by reverse milling is preferably performed when the angle θ between the forward direction of the cup-shaped grinding wheel and the rotation direction of the workpiece being ground is between 30° and 150°.

[0142] (Cup-shaped grinding wheel)

[0143] There are no particular limitations on the cup-shaped grinding wheel used in the manufacturing method of the disc-shaped tool according to this embodiment, as long as it can perform the first grinding step and the second grinding step.

[0144] As the cup-shaped grinding wheel used in the first grinding process, since the grinding amount is large, it is preferable to use a cup-shaped grinding wheel with an abrasive grain size of 2μm to 80μm (preferably 3μm to 30μm, more preferably 5μm to 10μm).

[0145] Furthermore, the abrasive grains used in the cup-shaped grinding wheel in the first grinding process can be determined based on the material being ground, and examples include diamond and cubic boron nitride.

[0146] Furthermore, the width of the annular rim of the cup-shaped grinding wheel used in the first grinding process is preferably 0.5 mm to 20 mm (preferably 5 mm to 10 mm).

[0147] As for the cup-shaped grinding wheel used in the second grinding process, since precision grinding is required, it is preferable to use a cup-shaped grinding wheel with an abrasive grain size of 0.5μm to 10μm (preferably 0.75μm to 8μm, more preferably 1μm to 3μm).

[0148] Furthermore, the abrasive grains used in the cup-shaped grinding wheel in the second grinding process can be determined based on the material being ground, and examples include diamond and cubic boron nitride.

[0149] Furthermore, the width of the annular rim of the cup-shaped grinding wheel used in the second grinding process is preferably 2 mm to 15 mm (preferably 5 mm to 10 mm).

[0150] (Grinding conditions)

[0151] The grinding conditions in the first, second, and third grinding processes are not particularly restricted as long as the target grinding is performed and the desired angles α and β can be obtained.

[0152] To obtain the desired angles α and β, simply adjust the type of cup-shaped grinding wheel, the circumferential speed of the cup-shaped grinding wheel, the circumferential speed of the workpiece being ground, the cutting amount, the grinding time, the grinding amount, and the number of cutting operations.

[0153] The circumferential speed of the cup-shaped grinding wheel, the circumferential speed of the workpiece, the cutting amount, the grinding time, the grinding amount, and the number of cutting operations (amount to be ground / load amount) can be selected from the ranges shown below, for example.

[0154] • Circumferential speed of cup-shaped grinding wheel: 200m / min~2000m / min

[0155] • Circumferential speed of the workpiece being ground: 10 m / min ~ 500 m / min

[0156] • Cutting depth: 0.5μm / cut to 5μm / cut

[0157] Grinding time: 1s~60s

[0158] • Grinding depth (amount to be ground): 1μm~100μm

[0159] • Number of cutting operations: the above amount to be ground / the above amount of cutting.

[0160] (Grinding device)

[0161] As for the grinding apparatus applicable to the manufacturing method of the disc-shaped cutting tool involved in this embodiment, there are no particular limitations as long as it is an apparatus capable of performing the first grinding step, the second grinding step, and the third grinding step (for example, an apparatus that includes: a shaft that fixes and rotates the workpiece being ground and a drive member that rotates it; a drive member that rotates the cup-shaped grinding wheel; a moving member that moves the cup-shaped grinding wheel; a member that moves the workpiece being ground; and a means for applying grinding fluid to the grinding section, etc.).

[0162] <Applications (usage methods), cutting device and cutting method>

[0163] The disc-shaped cutter described in this embodiment is applicable in combination with other cutters and can cut the object to be cut. In this case, the disc-shaped cutter described in this embodiment and other cutters are configured such that their respective cutting surfaces (i.e., the sides of the cutting tips) face each other and slide in contact to cut the object.

[0164] Other cutting tools used in combination (i.e., other cutting tools used in pair with the disc-shaped cutting tool described in this embodiment) are not particularly limited as long as they are disc-shaped cutting tools and can be combined with the disc-shaped cutting tool described in this embodiment to cut the workpiece. Specifically, as other cutting tools, for example, disc-shaped cutting tools made of cemented carbide and whose deflection accuracy of the outer periphery and sides during rotation is adjusted to approximately 50 μm or less are preferred. Furthermore, the cutting tips of other cutting tools may be chamfered. Alternatively, the disc-shaped cutting tool described in this embodiment can be used as another cutting tool.

[0165] Specifically, it is preferable that the disc-shaped cutter involved in this embodiment is used in a pair with other cutters for slitting. More specifically, the disc-shaped cutter involved in this embodiment is preferably a disc-shaped cutter suitable for a Goebel-type slitting machine or a slitting machine with multiple blades. When the disc-shaped cutter involved in this embodiment is applied to a Goebel-type slitting machine or a slitting machine with multiple blades, it may be used only for the upper blade, only for the lower blade, or both.

[0166] As a method and apparatus for cutting an object by combining the disc-shaped cutter involved in this embodiment with other cutters, for example, the method and apparatus for cutting an object described in Japanese Patent Application Publication No. 2001-315089 can be applied.

[0167] Example

[0168] The present invention will be described in more detail below with examples. The materials, quantities, proportions, and details of each process shown in the following examples can be appropriately modified without departing from the spirit of the invention. Therefore, the scope of the present invention is not limited to the specific examples shown below.

[0169] <Preparation of the workpiece>

[0170] Prepared as Figure 3 The workpiece 110a shown is a cemented carbide (FW35, KYOCERA Corporation, hardness: 1550HV) disk-shaped base metal with an outer diameter of 100mm, an inner diameter of 80mm, a thickness of 1mm, and a single-edged tip with a 30° apex angle including a plane. A TiCN layer with a thickness of 3μm (hardness: 3500HV) is formed on the entire surface of this base metal. This workpiece is used for grinding.

[0171] [Example 1]

[0172] <First Grinding Process>

[0173] like Figure 8 As shown, a cup-shaped grinding wheel with a gauge of #1000 (diameter) is used. ), for diameter The first grinding process was performed by adjusting the contact angle of the cup-shaped grinding wheel (i.e., the angle of the rotation axis of the cup-shaped grinding wheel) with the angle α being 30° on the workpiece being ground.

[0174] At this point, grinding is performed by reverse milling, and other grinding conditions are as follows.

[0175] • Circumferential speed of the cup-shaped grinding wheel: 1200 m / min

[0176] • Circumferential speed of the workpiece being ground: 100 m / min

[0177] • Cutting depth: 2μm / cut

[0178] Grinding time: 20 seconds x 20 times

[0179] • The angle θ between the forward direction of the cup-shaped grinding wheel and the rotation direction of the workpiece being ground is 75°.

[0180] Through this first grinding process, a portion of the disc-shaped base metal in the workpiece is exposed, forming an inclined surface of the disc-shaped base metal, and the angle α is set to 30°.

[0181] <Second Grinding Process>

[0182] Next, as Figure 9 As shown, a cup-shaped grinding wheel with a gauge of #6000 (diameter) is used. The second grinding process was performed on the workpiece after the first grinding process by adjusting the contact angle of the cup-shaped grinding wheel (i.e., the angle of the rotation axis of the cup-shaped grinding wheel) to an angle β of 35°.

[0183] At this point, grinding is performed by reverse milling, and other grinding conditions are as follows.

[0184] • Circumferential speed of the cup-shaped grinding wheel: 100 m / min

[0185] • Circumferential speed of the workpiece being ground: 100 m / min

[0186] • Cutting depth: 0.5μm

[0187] Grinding time: 2 seconds x 3 times

[0188] • The angle θ between the forward direction of the cup-shaped grinding wheel and the rotation direction of the workpiece being ground is 75°.

[0189] Through this second grinding process, a tool tip consisting of a coating layer is formed, and the angle β is set to 35°.

[0190] The above process yields a disc-shaped cutting tool with a TiCN-based cutting tip, α = 30° and β = 35°.

[0191] [Example 2]

[0192] In the second grinding process, the contact angle of the cup-shaped grinding wheel relative to the workpiece (i.e., the angle of the rotation axis of the cup-shaped grinding wheel) was adjusted. Otherwise, in the same manner as in Example 1, a disc-shaped tool with a TiCN-based cutting tip and α of 30° and β of 32° was obtained.

[0193] [Examples 3-7]

[0194] In the first and second grinding processes, the contact angle of the cup-shaped grinding wheel relative to the workpiece (i.e., the angle of the rotation axis of the cup-shaped grinding wheel) and the angle of the rotation axis of the grinding wheel are appropriately changed. Otherwise, a disc-shaped tool with a TiCN-based cutting tip and the values ​​of α and β described in Table 1 are obtained in the same manner as in Example 1.

[0195] [Example 8]

[0196] After performing the first grinding process with an angle α of 30°, the third grinding process is performed as described below. Then, the contact angle of the cup-shaped grinding wheel (i.e., the angle of the rotation axis of the cup-shaped grinding wheel) is adjusted to an angle β of 38° and the second grinding process is performed. Otherwise, a disc-shaped tool with a TiCN-based cutting tip and α of 30° and β of 38° is obtained in the same manner as in Example 1.

[0197] In the third grinding process, such as Figure 8 As shown, a cup-shaped grinding wheel with a gauge of #6000 (diameter) is used. The contact angle of the cup-shaped grinding wheel (i.e., the angle of the rotation axis of the cup-shaped grinding wheel) was adjusted to 35° for the workpiece after the first grinding process and then ground.

[0198] At this point, grinding is performed by reverse milling, and other grinding conditions are as follows.

[0199] • Circumferential speed of the cup-shaped grinding wheel: 100 m / min

[0200] • Circumferential speed of the workpiece being ground: 100 m / min

[0201] • Cutting depth: 0.5μm

[0202] Grinding time: 2 seconds x 10 times

[0203] • The angle θ between the forward direction of the cup-shaped grinding wheel and the rotation direction of the workpiece being ground is 75°.

[0204] [Comparative Examples 1-3]

[0205] The second grinding process was not performed. Otherwise, disc-shaped cutting tools with the values ​​of α and β recorded in Table 1 were obtained in the same manner as in Examples 1, 3 or 4.

[0206] [Evaluation of the gap]

[0207] The tips of the disc-shaped cutting tools obtained in each example were observed using an optical microscope. If the tip of the disc-shaped cutting tool had a concave portion with a width of 10 μm or more, it was evaluated as "C: Has a notch". Furthermore, even if the tip of the disc-shaped cutting tool had a concave portion, as long as its width was 5 μm or more and less than 10 μm, it was evaluated as "B: Has a fine notch". Even if the tip of the disc-shaped cutting tool did not have a concave portion, or even if the tip had a concave portion, as long as its width was less than 5 μm, it was evaluated as "A: Has no notch".

[0208] The results are shown in Table 1.

[0209] [Evaluation of sharpness (smoothness of the blade tip)]

[0210] For each of the obtained disc-shaped cutting tools, the shape was measured from the front end of the blade tip using a laser microscope, and the radius R was calculated by treating the front end shape as an approximate circle. Blade tips with a radius R of 1 μm or more in the front end shape were rated as "C: No sharpness", blade tips with a radius R of 0.5 μm or more but less than 1 μm in the front end shape were rated as "B: Sharpness", and blade tips with a radius R of less than 0.5 μm in the front end shape were rated as "A: Good sharpness".

[0211] The results are shown in Table 1.

[0212] [Cutting Test]

[0213] The disc-shaped cutter obtained in the example and the following cutting combination were used to conduct a cutting test.

[0214] As the cutting tool, the disc-shaped tool (with a tip angle of α = 90° and β = 95°) obtained in Example 4 was used.

[0215] As the material to be cut, a 50μm thick PET film (manufactured by Toyobo Co., Ltd., COSMOSHINE (registered trademark) A4300) was used.

[0216] The disc-shaped cutter obtained in the embodiment was used as the upper cutter, combined with the lower cutter, and the workpiece was continuously cut up to 10,000 μm. At this time, the upper and lower cutters were configured such that the coating layers of the cutter tips were in sliding contact with each other, with an engagement amount of 0.8 mm. The presence or absence of notches on the cutter tip of the subsequent disc-shaped cutter was evaluated in the same manner as the "notch evaluation" described above.

[0217] [Table 1]

[0218]

[0219] As shown in Table 1, the disc-shaped tool in the embodiment that satisfies α < β has no notches.

[0220] On the other hand, a notch was observed in the disc-shaped cutting tool of the comparative example where α = β.

[0221] Therefore, it can be seen that the disc-shaped tool in the embodiment that satisfies α < β has no notches and is easy to manufacture.

[0222] Furthermore, as in Comparative Example 1, when manufacturing a disc-shaped tool with α = β = 30°, in order to eliminate the notch at the tool tip, a fine and long grinding method is considered, for example, using a #6000 grinding wheel, setting the cutting depth to 0.5 μm, and setting the grinding time to about 1 hour. However, this method has extremely poor productivity. Therefore, it can be said that it is difficult to manufacture a disc-shaped tool with α = β = 30° without a notch.

[0223] Symbol Explanation

[0224] 10-Disc-shaped base metal; 12-Flat surface; 14-Inclined surface; 20A, 20B-Clad layer; 22A, 22B-Surface formed by cladding layer; 24A, 24B-Surface formed by cladding layer; 30A, 30B-Tool tip; 40-Disc-shaped base metal; 52, 54-Clad layer; 100A, 100B-Disc-shaped tool; 110a, 110b, 110c, 110-Workpiece to be ground; 112a, 112b-Edge; 120-Shaft; 130-Cup-shaped grinding wheel; 132-Annular edge. p1, p2 - the contact points between the two ends of the workpiece in the thickness direction and the annular edge of the cup-shaped grinding wheel; x - the rotation direction of the workpiece; x1 - the rotation direction of the workpiece at the intersection of the two ends of the workpiece in the thickness direction and the annular edge of the cup-shaped grinding wheel; y - the rotation direction of the cup-shaped grinding wheel; y1 - the direction passing through the intersection of the two ends of the workpiece in the thickness direction and the annular edge of the cup-shaped grinding wheel, and along the rotation direction of the annular edge of the cup-shaped grinding wheel; θ - the angle between the forward direction of the cup-shaped grinding wheel and the aforementioned rotation direction of the workpiece.

[0225] All disclosures of Japanese Patent Application No. 2021-018378, filed on February 8, 2021, are incorporated herein by reference. All documents, patent applications, and technical standards described in this specification are incorporated herein by reference to the same extent as those specifically and separately described therein.

Claims

1. A disc-shaped cutting tool, used in pairs with other cutting tools, wherein, The disc-shaped cutting tool comprises: a disc-shaped base metal having a single-edged tip formed by a plane on one side in contact with the other cutting tool and an inclined surface inclined relative to that plane; and a cladding layer covering the plane of the disc-shaped base metal. The disc-shaped cutting tool has a cutting tip formed by the coating layer. Of the two surfaces formed by the coating layer constituting the blade tip, one surface is inclined at an acute angle relative to the plane of the disk-shaped base metal, and the other surface is connected to the exposed inclined surface of the disk-shaped base metal. The angle α between the plane and the inclined surface in the disc-shaped base metal and the angle β between the two surfaces formed by the coating layer constituting the blade tip satisfy the relationship α < β.

2. The disc-shaped cutting tool according to claim 1, wherein, The angles α and β satisfy the relationship α+1°≤β≤α+10°.

3. The disc-shaped cutting tool according to claim 1 or 2, wherein, The angle α is 10° to 110°.

4. The disc-shaped cutting tool according to claim 1 or 2, wherein, The hardness of the coating layer is 1.5 to 5 times that of the disk-shaped base metal.

5. A method for manufacturing a disc-shaped cutting tool, comprising the method for manufacturing a disc-shaped cutting tool according to any one of claims 1 to 4, wherein, In the method for manufacturing the disc-shaped cutting tool, a workpiece is used, which comprises: a disc-shaped base metal having a front end formed by a plane including a side that contacts the other cutting tool; and a cladding layer that covers the entire front end portion of the disk-shaped base metal. The method for manufacturing the disc-shaped cutting tool includes: In the first grinding process, the workpiece is ground to expose a portion of the disc-shaped base metal in the workpiece, forming an inclined surface for exposing the disc-shaped base metal in the disc-shaped cutting tool, and the angle α is adjusted. as well as The second grinding step grinds the workpiece after the first grinding step, forming a cutting tip composed of the coating layer in the disc-shaped tool, and adjusting the angle β.

6. The method for manufacturing a disc-shaped cutting tool according to claim 5, wherein, The grinding is performed by reverse milling using a cup-shaped grinding wheel, and the angle θ between the forward direction of the cup-shaped grinding wheel and the rotation direction of the workpiece being ground is 30° to 150°.

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