Method for preventing adhesion of diamond grinding head to metal plating layer of ceramic filter

Abstract

The application provides a method for preventing adhesion of a diamond grinding head to a ceramic filter metal coating. In the application, a diamond grinding head abrasive cutter is used to perform dry grinding processing on the surface metal coating of a ceramic filter. During processing, sufficient solid powder dust remover is injected between the grinding head and the processing area to prevent the metal coating chips from adhering to the gaps between the abrasive grains of the grinding head, thereby ensuring that the grinding head remains sharp at all times and better processes the metal coating, thereby improving the service life of the diamond abrasive cutter and the processing efficiency, quality and reliability of the ceramic filter.

Description

Technical Field

[0001] This invention relates to the field of ceramic filter metal coating production and processing technology, and more specifically, to a method for removing anti-adhesion coatings from ceramic filters using a diamond grinding head. Background Technology

[0002] With the rapid development of the information age, miniaturization, lightweighting, and low cost have become the future development trends of filters. Ceramic filters typically use ceramic materials with high dielectric constants and low losses, such as aluminum oxide (Al2O3) and strontium titanate (SrTiO3). Ceramic filters made from these materials are suitable for high-frequency applications, especially in 5G, wireless communication equipment, radar systems, and medical instruments, for filtering out interference signals and selecting signals in specific frequency bands.

[0003] In the process of metallizing the surface of ceramic filters, it is necessary to locally engrave the port excitation pattern and coupling window pattern on the surface of the metallized layer after metallization of the ceramic surface. Currently, commonly used methods for removing silver from dielectric ceramic surfaces include laser engraving and milling with diamond abrasive tools. However, laser engraving requires bombarding the surface of the sintered dielectric waveguide filter with a combination of high-power engraving layers and low-power cleaning layers to locally engrave and remove silver. This laser-bombardment method causes significant thermal damage to the sintered dielectric ceramic surface, easily leading to surface cracks and affecting the reliability of the dielectric waveguide filter. Furthermore, carbide residues remain at the edges of the engraved and removed dielectric ceramic surface, significantly impacting the highly sensitive coupling window. Since various filtering parameters need to be tested simultaneously during the processing of ceramic filters, coolant cannot be used during the process to avoid thermal damage. While the process of removing local silver layers by milling with a diamond grinding head results in less thermal damage to the surface of the ceramic filter, the metallized coating is mostly composed of highly ductile metals. Metal debris generated during the process can clog the tool surface, leading to a decrease in surface quality and a shortened tool life due to clogging.

[0004] In view of this, the applicant hereby submits this application after studying the existing technology. Summary of the Invention

[0005] This invention provides a method for preventing adhesion of metal coatings on ceramic filters by grinding with a diamond grinding head, aiming to improve at least one of the above-mentioned technical problems.

[0006] To solve the above-mentioned technical problems, this invention provides a method for preventing the adhesion of metal coatings on ceramic filters using a diamond grinding head, comprising the following steps: Step S00: Installing the diamond grinding head and the ceramic filter to be processed at the output end of a machine tool and below the output end of the machine tool, respectively; Step S10: Adding a solid powder chip remover to the processing area of ​​the ceramic filter; Step S20: Presetting the process control toolpath parameters for the machine tool; Step S30: Receiving the process control toolpath parameters from the machine tool, and processing the ductile metal coating on the surface of the ceramic filter according to the cleaning layer and the process control toolpath parameters, removing the ductile metal coating from the surface of the ceramic filter; Step 40: Using a high-pressure air gun to blow away the solid powder chip remover and the coating chips. During the processing of the metal coating by the diamond grinding head, the solid powder chip remover fills the grinding head, thereby causing the metal adhesion layer adhering to the abrasive grains on the surface of the grinding head and the chip space between the abrasive grains to fall off in time through friction, extrusion, and other actions, keeping the grinding head sharp, removing chips, and causing the chips to fall off.

[0007] As a further optimization, step S10 also includes step S11, where: when the processing area of ​​the ceramic filter is the bottom of a blind hole or the upper surface of the workpiece, the solid powder chip remover is directly added to the entire surface of the processing area; when the processing location is the sidewall of the blind hole or the side surface of the workpiece, the solid powder chip remover is continuously injected into the entire surface of the processing area at a low flow rate. That is, the chip remover is injected into the processing area in advance or continuously during grinding, so as to effectively and promptly enter the contact interface between the grinding head and the workpiece, and remove adhering metal chips in a timely manner.

[0008] As a further optimization, a powder storage tank is also included, which is positioned above the processing area of ​​the ceramic filter; during operation, the diamond grinding head passes through the powder storage tank to process the surface of the ceramic filter. This ensures a sufficient supply of solid powder shaving agent, guaranteeing that the grinding head remains sharp at all times.

[0009] As a further optimization, in step S20, the process control toolpath parameters are those for spiral wall-mounted dry grinding without coolant, replacing milling. Since the ceramic filter requires testing various filtering parameters during machining, dry grinding, which cannot use coolant, is employed during the machining process; furthermore, it has high precision requirements, and the process method of replacing milling with grinding ensures that the machining quality meets the standards.

[0010] As a further optimization, ceramic filters include ceramic dielectric resonant filters, ceramic dielectric filters, surface acoustic wave filters, bulk acoustic wave filters, and LTCC filters, etc.

[0011] As a further optimization, the highly malleable metal coating may include silver, copper, gold, tungsten, etc.

[0012] As a further optimization, the diamond grinding head is a grinding head made of diamond abrasive grains, and the manufacturing process includes brazing, sintering, electroplating, etc. The diamond abrasive grains may be untreated or have undergone metallization treatment such as metal plating.

[0013] As a further optimization, the material of the solid powder chip remover can be wear-resistant hard particle powders such as alumina, calcium oxide, calcium carbonate, boron carbide, sodium chloride, silicon carbide, and boron nitride, with a particle size of 20-50% of the average abrasive edge height on the grinding head surface.

[0014] As a further optimization, the particle size of the solid powder chip remover is smaller than the abrasive particle size of the diamond abrasive tool.

[0015] By adopting the above technical solution, the present invention can achieve the following technical effects:

[0016] This application provides a method for preventing the adhesion of metal coatings on ceramic filters when using diamond grinding heads. The method involves dry grinding with diamond abrasive tools ("grinding instead of milling") to remove the ductile metal coatings from ceramic filters, resulting in finer chips that detach from the gaps between the diamond abrasive grains and prevent cutting blockage. Different injection methods are selected based on the processing area to appropriately place solid powder chip remover in the processing area, ensuring the chip remover functions effectively during diamond grinding, maintaining sharpness between the abrasive grains, and guaranteeing processing results. Furthermore, a powder storage tank is used to pre-fill the chip remover, ensuring sufficient chip remover during processing and guaranteeing processing quality. This method prevents chip clogging of the diamond abrasive tools, thereby improving the service life of the diamond abrasive tools and the processing efficiency and reliability of the ceramic filters. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the process of an anti-adhesion method for removing metal coatings from ceramic filters using a diamond grinding head, according to the present invention.

[0019] Figure 2 This is a schematic diagram of the processing effect of a diamond grinding head method for removing metal coatings from ceramic filters without the addition of a solid powder shaving agent, according to the present invention.

[0020] Figure 3 yes Figure 2 Enlarged view of point A in the middle;

[0021] Figure 4 This is a schematic diagram illustrating the processing effect of adding a solid powder shaving agent to a method for preventing adhesion of the metal coating of a ceramic filter using a diamond grinding head according to the present invention.

[0022] Figure 5 yes Figure 3 Enlarged view of point B in the middle;

[0023] Figure 6 This is an image showing the actual processing effect of the grinding head part of the diamond grinding head method for removing the metal coating of ceramic filters without the addition of solid powder chip remover, according to the present invention.

[0024] Figure 7 This is an image showing the actual effect of adding a solid powder chip remover to the grinding head area in a method for preventing adhesion of the metal coating of a ceramic filter using a diamond grinding head according to the present invention.

[0025] In the diagram: 1. Diamond grinding head; 2. Solid powder chip remover; 3. Powder storage tank; 4. Ceramic filter; 5. Diamond abrasive grains; 6. Tool holder; 7. Metal coating. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0027] See Figure 1This invention provides a method for preventing the adhesion of metal coatings on ceramic filters when using a diamond grinding head, comprising the following steps: Step S00: The diamond grinding head and the ceramic filter 4 to be processed are respectively installed at the output end of a machine tool and below the output end of the machine tool. In a preferred embodiment, the machine tool is a high-speed CNC milling machine. In this embodiment, the diamond grinding head is a grinding head made of diamond abrasive grains, which, together with the tool holder 6, forms a diamond grinding head tool 1. The diamond grinding head tool 1 is clamped onto the machine tool spindle, and a special fixture is used to clamp the ceramic filter 4 onto the machine tool's worktable to maintain stability.

[0028] Step S10: Add solid powder chip remover 2 to the processing area of ​​the ceramic filter 4; see [link / reference] Figure 2-7 In a preferred embodiment of this application, by adding solid powder chip remover 2 during processing, the solid powder chip remover 2 can squeeze out and cut off the metal coating debris in the abrasive grain gaps on the surface of the diamond grinding head, so that it can be discharged from the abrasive grain gaps of the diamond grinding head, which greatly reduces the problem of chip adhesion and clogging.

[0029] Step S20: Preset the process control toolpath parameters for the machine tool;

[0030] Step S30: The high-speed CNC milling machine receives the process control toolpath parameters. The diamond grinding head processes the ductile metal coating 7 on the surface of the ceramic filter 4 according to the cleaning layer and the process control toolpath parameters, removing the ductile metal coating 7 from the surface of the ceramic filter 4. Preferably, the process control toolpath parameters mainly include: spindle speed, feed rate, entry angle, and transverse toolpath spacing. The spindle speed is set in the range of 0-100000 r / min, the feed rate is set in the range of 0-1000 mm / min, and a helical entry angle of 0 to 5 degrees is used. The transverse toolpath spacing is related to the tool diameter, so the overlap rate is used as the setting standard, and the overlap rate is set to any value between 25% and 99%. Under the premise of following the above parameter settings, the parameters of the process control toolpath are determined by the toolpath path of the cleaning layer.

[0031] Furthermore, in a preferred embodiment of this application, the spindle speed is 30,000 r / min, the feed rate is 90 mm / min, and a helical cutting method with a cutting angle of 0.1° is used, with a path spacing overlap rate of 90% for inward helical grinding of the bottom surface. The parameter settings of this embodiment enable the high-speed CNC engraving and milling machine to complete the machining steps with high efficiency, and the overall effect of the resulting product is also better after processing by this method.

[0032] Step 40: Finally, after completing the above steps to remove the ductile metal coating 7 from the surface of the ceramic filter 4, use a high-pressure air gun to blow away the solid powder chip remover and coating chips.

[0033] In a preferred embodiment, step S10 further includes step S11: when the processing area of ​​the ceramic filter 4 is the bottom of a blind hole or the upper surface of the workpiece, the solid powder chip remover 2 is directly added to the entire surface of the processing area; when the processing location is the side wall of the blind hole or the side surface of the workpiece, the solid powder chip remover 2 is continuously injected into the entire surface of the processing area at a small flow rate. By adding the solid powder chip remover 2 to the processing area in advance and continuously adding it, the diamond grinding head can always have sufficient solid powder chip remover 2 to interact with the grinding head during operation, thereby enabling the grinding head to always maintain a sharp state during operation.

[0034] In a preferred embodiment, a powder storage tank 3 is also included, which is disposed above the processing area of ​​the ceramic filter 4. During operation, the diamond grinding head passes through the powder storage tank 3 to process the surface of the ceramic filter 4. The processing area is located at the center of the powder storage tank 3, and the through hole in the center of the powder storage tank 3 also guides the solid powder shaving agent 2. The powder storage tank 3 can be installed on the ceramic filter 4 or on the diamond grinding head, so that it generates a slight vibration effect with the output when working, thereby guiding the powder into the processing area. This further ensures a sufficient supply of shaving agent, ensuring that the diamond grinding head always has sufficient solid powder shaving agent 2 to interact with it during operation, thus allowing the grinding head to maintain a sharp edge throughout its operation.

[0035] In a preferred embodiment, the process control toolpath parameters in step S20 are those for "grinding instead of milling"—a coolant-free spiral-type wall-mounted dry grinding process. The use of this coolant-free spiral-type wall-mounted dry grinding toolpath is necessary because the ceramic filter requires testing various filtering parameters during machining, necessitating the use of dry grinding without coolant. Furthermore, given the high precision requirements, replacing milling with grinding ensures that the machining quality meets the standards.

[0036] In a preferred embodiment, the ceramic filter 4 includes a ceramic dielectric resonant filter, a ceramic dielectric filter, a surface acoustic wave filter, a bulk acoustic wave filter, and an LTCC filter, etc.

[0037] In a preferred embodiment, the ductile metal coating 7 may be a silver coating, a copper coating, a gold coating, a tungsten coating, etc.

[0038] In a preferred embodiment, the diamond grinding head is a grinding head made of diamond abrasive grains, and the manufacturing process includes brazing, sintering, electroplating, etc. The diamond abrasive grains may be untreated or have undergone metallization treatment such as metal plating.

[0039] In a preferred embodiment, the solid powder shaving agent 2 can be made of wear-resistant hard particle powders such as alumina, calcium oxide, calcium carbonate, boron carbide, sodium chloride, silicon carbide, and boron nitride, with a particle size of 20-50% of the average abrasive edge height on the grinding head surface.

[0040] In a preferred embodiment, the particle size of the solid powder chip remover 2 is smaller than the abrasive particle size of the diamond abrasive tool.

[0041] See Figures 2 to 7 In one implementation method, from Figure 2 As can be seen, diamond abrasive grains 5 are fixed to the surface of the tool holder 6 by diamond adhesive to form a diamond grinding head tool 1, which processes the metal coating 7 on the surface of the ceramic filter 4. Figure 3 As can be seen, the gaps between the diamond abrasive grains are blocked by debris from the coated metal. Figure 6 This is a magnified view of the actual object without the addition of solid powder chip remover; it is clear that the surface of the grinding head is severely clogged. Furthermore, based on... Figures 4-7 After adding solid powder chip remover 2, the gaps between the abrasive grains on the surface of the diamond grinding head become noticeably clearer and more distinct. Figure 5 The gaps between the medium diamond abrasive grains are mainly a mixture of coated metal debris and solid powder chip remover. At this point, the debris will not stubbornly adhere, which can ensure the processing quality and the service life of the grinding head.

[0042] In summary, the anti-adhesion and clogging processing method for removing the metal coating of a ceramic filter using a diamond grinding head provided by this invention uses a solid powder chip remover 2 and a diamond abrasive tool 1 to remove the metal coating 7 of the ceramic filter 4. This prevents thermal damage during laser engraving and prevents the diamond abrasive tool 1 from being clogged by ductile metal coating debris, thus reducing its service life and improving workpiece processing quality, efficiency, and overall reliability of the ceramic filter 4. Finally, by adding the solid powder chip remover 2, the solid powder chip remover 2 squeezes out and cuts the metal coating debris, allowing it to exit through the gaps in the diamond abrasive grains, greatly reducing the problem of chip adhesion and clogging.

[0043] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the invention by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A method for preventing adhesion of metal coatings on ceramic filters by grinding with a diamond grinding head, characterized in that, It includes the following steps: Step S00: Install the diamond grinding head and the ceramic filter to be processed at the output end of the machine tool and below the output end of the machine tool, respectively; Step S10: Add solid powder chip remover to the processing area of ​​the ceramic filter; Step S20: Preset the process control toolpath parameters for the machine tool; Step S30: The machine tool receives the process control toolpath parameters, and the diamond grinding head processes and removes the ductile metal coating on the surface of the ceramic filter according to the cleaning layer and the process control toolpath parameters. Step 40: Use a high-pressure air gun to blow away the solid powder chip remover and coating chips; Step S10 further includes step S11, where: when the processing area of ​​the ceramic filter is the bottom of a blind hole or the upper surface of the workpiece, a solid powder chip remover is directly added to the entire surface of the processing area; when the processing location is the side wall of a blind hole or the side surface of the workpiece, a solid powder chip remover is continuously injected into the entire surface of the processing area at a small flow rate.

2. The method for preventing adhesion of metal coatings on ceramic filters by grinding with a diamond grinding head according to claim 1, characterized in that... It also includes a powder storage tank, which is disposed above the processing area of ​​the ceramic filter; when in operation, the diamond grinding head passes through the powder storage tank to process the surface of the ceramic filter.

3. The method for preventing adhesion of metal coatings on ceramic filters by grinding with a diamond grinding head according to claim 1, characterized in that... In step S20, the process control toolpath parameters are the toolpath parameters for spiral wall-mounted dry grinding without cooling liquid, which replaces milling.

4. The method for preventing adhesion of metal coatings on ceramic filters by grinding with a diamond grinding head according to claim 1, characterized in that... Ceramic filters include ceramic dielectric filters, surface acoustic wave filters, bulk acoustic wave filters, and LTCC filters.

5. A method for preventing adhesion of metal coatings on ceramic filters using a diamond grinding head according to claim 1, characterized in that... The highly malleable metal coating includes at least one of silver, copper, gold, and tungsten coatings.

6. The method for preventing adhesion of metal coatings on ceramic filters by grinding with a diamond grinding head according to claim 1, characterized in that... The diamond grinding head is a grinding head made of diamond abrasive grains, and the manufacturing process includes brazing, sintering and electroplating.

7. The method for preventing adhesion of metal coatings on ceramic filters by grinding with a diamond grinding head according to claim 1, characterized in that... The solid powder chip remover is made of at least one of the following: alumina, calcium oxide, calcium carbonate, boron carbide, sodium chloride, silicon carbide, and boron nitride wear-resistant hard particle powders, with a particle size of 20-50% of the average abrasive edge height on the grinding head surface.

8. A method for preventing adhesion of metal coatings on ceramic filters using a diamond grinding head according to claim 7, characterized in that... The particle size of solid powder chip remover is smaller than that of diamond abrasive tools.

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