Electrodeposition tool and method for manufacturing an electrodeposition tool

Abstract

An electrodeposition tool has a base, a plurality of spherical superabrasive grains fixed to the base, and a plating layer formed on the base and embedding the plurality of spherical superabrasive grains, the plurality of spherical superabrasive grains having a flat surface formed by polishing, a ratio of a height to a width of a portion of the plurality of spherical superabrasive grains other than the flat surface being 0.90 or more, and a circularity of the portion of the plurality of spherical superabrasive grains other than the flat surface being 0.95 or more. A method of manufacturing the electrodeposition tool includes a disposing step of disposing the plurality of spherical superabrasive grains having a ratio of a height to a width of 0.90 or more and a circularity of 0.95 or more on the base, and a fixing step of forming the plating layer on the base and embedding the plurality of spherical superabrasive grains in the plating layer.

Description

Technical Field

[0001] This disclosure relates to electrodeposition tools and methods for manufacturing electrodeposition tools. Background Technology

[0002] Previously, a rotary dresser with a plurality of abrasive grains embedded on the outer circumferential surface of a cylindrical shape was known (see, for example, Patent Document 1). Such a rotary dresser requires high shape accuracy. However, if ordinary abrasive grains are directly fixed to a substrate (iron core), deviations in the size and crystal shape of the abrasive grains will cause deviations in the height of the abrasive grains relative to the substrate, making it difficult to manufacture a high-precision rotary dresser. Therefore, a reverse method similar to the manufacturing method of a single-layer abrasive wheel described in Patent Document 2 has been used to manufacture rotary dressers. In this reverse method, abrasive grains are fixed to the inner circumferential surface of a cylindrical master mold using electroforming, the substrate is fixed to the center of the master mold with the abrasive grains fixed, a low-melting-point metal is injected between the master mold and the substrate, and the master mold is removed after the low-melting-point metal has solidified. This produces a rotary dresser with uniform abrasive grain height. Then, a flat surface is formed at the tip of the abrasive grains by grinding, thereby manufacturing a high-precision shaped rotary dresser.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2016-078158; Patent document 2: Japanese Patent No. 6193645. Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] Traditional inversion methods require the use of a master mold, which must eventually be removed, resulting in high material costs and numerous manufacturing steps. Furthermore, the electroforming process to fix the abrasive grains onto the inner circumference of the master mold takes a long time, thus requiring significant materials and time to manufacture high-precision rotary dressers.

[0008] However, in electrodeposition tools such as rotary dressers and electrodeposition reamers, there are tools that utilize grinding to form flat surfaces at the tips of multiple abrasive grains. In such electrodeposition tools, if deviations in the size and crystal shape of the abrasive grains cause deviations in the height of the abrasive grains relative to the substrate, the size of the flat surfaces of the multiple abrasive grains will also vary. As a result, machining accuracy, such as grinding, decreases, and chip flow deteriorates, making chip clogging more likely.

[0009] Therefore, the objective of this disclosure is to provide an electrodeposition tool that can improve machining accuracy and suppress chip clogging, and a method for manufacturing the electrodeposition tool.

[0010] Technical means to solve the problem

[0011] [1] The electrodeposition tool disclosed herein comprises: a substrate; a plurality of spherical abrasive grains fixed to the substrate; and a coating formed on the substrate and in which the plurality of spherical abrasive grains are embedded, the plurality of spherical abrasive grains having a flat surface formed by grinding, the aspect ratio of the portion of the plurality of spherical abrasive grains other than the flat surface being 0.90 or more, and the roundness of the portion of the plurality of spherical abrasive grains other than the flat surface being 0.95 or more.

[0012] In this electrodeposition tool, a plurality of spherical abrasive grains are embedded in a coating formed on a substrate. The aspect ratio of the portion of the plurality of spherical abrasive grains excluding the flat surface is 0.90 or higher, and the roundness of the portion of the plurality of spherical abrasive grains excluding the flat surface is 0.95 or higher. Therefore, the deviation in the size of the flat surface among the plurality of spherical abrasive grains can be reduced. As a result, machining accuracy can be improved and chip clogging can be suppressed.

[0013] [2] The electrodeposition tool disclosed herein comprises: a substrate; a plurality of spherical abrasive grains fixed to the substrate; and a coating formed on the substrate and in which the plurality of spherical abrasive grains are embedded, wherein the aspect ratio of the plurality of spherical abrasive grains is 0.90 or more, and the roundness of the plurality of spherical abrasive grains is 0.95 or more.

[0014] In this electrodeposition tool, a plurality of spherical abrasive grains are embedded in a coating formed on a substrate. The aspect ratio of the plurality of spherical abrasive grains is 0.90, and the roundness of the plurality of spherical abrasive grains is 0.95 or higher. Therefore, when the plurality of spherical abrasive grains are ground to form a flat surface on the plurality of spherical abrasive grains, the size deviation of the flat surface among the plurality of spherical abrasive grains can be reduced. As a result, machining accuracy can be improved and chip clogging can be suppressed.

[0015] [3] In the electrodeposition tool described in [1] or [2], the plurality of spherical abrasive grains may not have planar crystal faces. In this electrodeposition tool, since the plurality of spherical abrasive grains do not have planar crystal faces, the height deviation of the plurality of spherical abrasive grains relative to the substrate can be further reduced when the plurality of spherical abrasive grains are arranged on the substrate during manufacturing.

[0016] [4] In any one of [1] to [3], the plurality of spherical abrasive grains can also be bonded to the substrate using an adhesive. In this electrodeposition tool, since the plurality of spherical abrasive grains are bonded to the substrate using an adhesive, during manufacturing, the plurality of spherical abrasive grains can be temporarily fixed to the substrate using an adhesive before a coating is formed on the substrate. Therefore, the electrodeposition tool can be easily manufactured.

[0017] [5] In any one of [1] to [4], the plurality of spherical abrasive grains can also be arranged regularly. In this electrodeposition tool, since the plurality of spherical abrasive grains are arranged regularly, the sharpness and machining accuracy can be improved.

[0018] The electrodeposition tool described in any one of [6] [1] to [5] may also be a rotary dresser. Even if the electrodeposition tool is a rotary dresser, the same effect as described above can be obtained.

[0019] The electrodeposition tool described in any one of [7] [1] to [5] may also be an electrodeposition reamer. Even if the electrodeposition tool is an electrodeposition reamer, the same effect as described above can be obtained.

[0020] [8] The method for manufacturing an electrodeposition tool disclosed herein includes: a configuration step in which a plurality of spherical abrasive grains with an aspect ratio of 0.90 or higher and a roundness of 0.95 or higher are configured on a substrate; and a bonding step in which a coating is formed on a substrate and the plurality of spherical abrasive grains are embedded in the coating.

[0021] In this method for manufacturing an electrodeposition tool, a plurality of spherical abrasive grains with an aspect ratio of 0.90 or higher and a roundness of 0.95 or higher are arranged on a substrate. A coating is formed on the substrate, and the plurality of spherical abrasive grains are embedded in the coating. This allows the plurality of spherical abrasive grains to be fixed to the substrate, and reduces the height deviation of the plurality of spherical abrasive grains relative to the substrate. Therefore, when grinding the plurality of spherical abrasive grains to form a flat surface on the plurality of spherical abrasive grains, the size deviation of the flat surface among the plurality of spherical abrasive grains can be reduced. As a result, machining accuracy can be improved and chip clogging can be suppressed.

[0022] [9] In the method for manufacturing the electrodeposition tool described in [8], the plurality of spherical abrasive grains may not have planar crystal faces. In this method for manufacturing the electrodeposition tool, since the plurality of spherical abrasive grains do not have planar crystal faces, the height deviation of the plurality of spherical abrasive grains relative to the substrate when the plurality of spherical abrasive grains are disposed on the substrate can be further reduced.

[0023]

[10] In the manufacturing method of the electrodeposition tool described in [8] or [9], during the preparation step, a plurality of spherical abrasive grains may be bonded to the substrate using an adhesive. In this manufacturing method of the electrodeposition tool, since a plurality of spherical abrasive grains are bonded to the substrate using an adhesive, the plurality of spherical abrasive grains can be temporarily fixed to the substrate using an adhesive before a coating is formed on the substrate. Therefore, the electrodeposition tool can be easily manufactured.

[0024]

[11] The method for manufacturing an electrodeposition tool according to any one of [8] to

[10] may further include a grinding process, which grinds a plurality of spherical abrasive grains and forms a flat surface at the top of the plurality of spherical abrasive grains. In this method for manufacturing an electrodeposition tool, since the plurality of spherical abrasive grains are ground and a flat surface is formed at the top of the plurality of spherical abrasive grains, it is possible to manufacture an electrodeposition tool in which the height of the plurality of spherical abrasive grains relative to the substrate is uniform with high precision.

[0025] Invention Effects

[0026] According to this disclosure, machining accuracy can be improved and chip clogging can be suppressed. Attached Figure Description

[0027] Figure 1 This is a schematic cross-sectional view showing the electrodeposition tool of this embodiment.

[0028] Figure 2 It is Figure 1 A partially enlarged schematic cross-sectional view of the electrodeposition tool shown.

[0029] Figure 3 This is a schematic diagram illustrating an example of a regular arrangement of a plurality of spherical abrasive grains.

[0030] Figure 4 This is a schematic cross-sectional view illustrating the manufacturing method of the electrodeposition tool according to this embodiment.

[0031] Figure 5 This is a schematic cross-sectional view illustrating the manufacturing method of the electrodeposition tool according to this embodiment.

[0032] Figure 6 This is a schematic cross-sectional view illustrating the manufacturing method of the electrodeposition tool according to this embodiment.

[0033] Figure 7 This is a schematic cross-sectional view illustrating the manufacturing method of the electrodeposition tool according to this embodiment.

[0034] Figure 8 It is a schematic cross-sectional view showing the flow of chips.

[0035] Figure 9 This is a schematic cross-sectional view of a modified electrodeposition tool.

[0036] Figure 10 It is Figure 9 A partially enlarged schematic cross-sectional view of the electrodeposition tool shown.

[0037] Figure 11 It is a graph representing the measurement results of thrust load.

[0038] Figure 12 This is a graph showing the measurement results of the roundness of the hole in the workpiece.

[0039] Figure 13 This is a graph showing the measurement results of the inner diameter of the workpiece hole. Detailed Implementation

[0040] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Furthermore, the same or equivalent elements in the following description will be labeled with the same reference numerals, and repeated descriptions will be omitted.

[0041] This embodiment describes the application of the electrodeposition tool disclosed herein to a rotary dresser. Figure 1 This is a schematic cross-sectional view showing the electrodeposition tool of this embodiment. Figure 2 It is Figure 1 A partially enlarged schematic cross-sectional view of the electrodeposition tool shown. (See attached image.) Figure 1 and Figure 2 As shown, the electrodeposition tool 1 in this embodiment is a rotary dresser. The electrodeposition tool 1 is also called a shaping rotary dresser and is formed in a generally cylindrical shape. The electrodeposition tool 1 has: a substrate 2; a plurality of spherical abrasive grains 3 fixed to the substrate 2; an adhesive 4 for bonding the plurality of spherical abrasive grains 3 to the substrate 2; and a coating 5 formed on the substrate 2 and in which the plurality of spherical abrasive grains 3 are embedded.

[0042] The substrate 2 is formed in a generally cylindrical shape. The substrate 2 has a surface 21 on which a plurality of spherical abrasive grains 3 are attached. The surface 21 is at least a portion of the outer peripheral surface of the substrate 2. An annular recess extending along the entire circumference of the substrate 2 is formed on the surface 21.

[0043] A plurality of spherical abrasive particles 3 are fixed to the surface 21 of the substrate 2. Each of the plurality of spherical abrasive particles 3 (hereinafter also simply referred to as "spherical abrasive particles 3") is a spherical abrasive particle. The abrasive particles are, for example, diamond abrasive particles, CBN abrasive particles, etc. The spherical abrasive particles are abrasive particles that do not have planar crystal planes. The spherical abrasive particles 3 can be perfectly spherical or non-spherical, such as ellipsoidal. In addition, abrasive particles coated with metal or the like can also be used as spherical abrasive particles 3.

[0044] The spherical abrasive grains 3 have a flat surface 31 formed by grinding. The flat surface 31 is formed at the top of the spherical abrasive grains 3. The height of the plurality of spherical abrasive grains 3 relative to the substrate 2 is uniformly controlled with high precision through their respective flat surfaces 31. The flat surface 31 is a flat surface along the surface 21 of the substrate 2, but it is not necessarily a plane.

[0045] The aspect ratio of the portion of the spherical abrasive grain 3 excluding the flat surface 31 is 0.90 or higher, preferably 0.91 or higher, and more preferably 0.92 or higher. Furthermore, the roundness of the portion of the spherical abrasive grain 3 excluding the flat surface 31 is 0.95 or higher, preferably 0.96 or higher, and more preferably 0.97 or higher. That is, the spherical abrasive grain 3 is formed by grinding spherical abrasive grains with an aspect ratio of 0.90 or higher, preferably 0.91 or higher, more preferably 0.92 or higher, and a roundness of 0.95 or higher, preferably 0.96 or higher, and more preferably 0.97 or higher, and forming a flat surface 31 at its tip. The aspect ratio is the ratio of the length of the major axis to the length of the minor axis. Circularity refers to the ratio obtained by dividing the circumference of a circle with the same area as a spherical abrasive grain by the circumference of an image of the actual spherical abrasive grain. For example, the circularity is measured by using the Malvern Morphologi G3S fully automated image-based particle size distribution measurement device according to the image-based particle size (particle size)-shape analysis method based on JIS Z 8827.

[0046] Spherical abrasive particles 3 with such aspect ratio and roundness can be selected by screening using a plurality of sieves with different mesh sizes (pore diameters). The particle size distribution of the plurality of spherical abrasive particles 3 is not particularly limited; for example, the value of D90-D10 can be 70 μm or less, preferably 60 μm or less, and more preferably 50 μm or less.

[0047] The spherical abrasive particles 3 are embedded in the coating layer 5 formed on the surface 21 of the substrate 2 while being bonded (temporarily fixed) to the surface 21 of the substrate 2 using the adhesive 4, thereby fixing them to the surface 21 of the substrate 2. The tip of the spherical abrasive particle 3, including the flat surface 31, protrudes from the coating layer 5.

[0048] The adhesive 4 can be applied in a dotted pattern on the substrate 2. Since the spherical abrasive particles 3 are positioned at the locations of the adhesive 4, by applying the adhesive 4 in a dotted pattern at predetermined locations on the substrate 2, it is possible to arrange a plurality of spherical abrasive particles 3 at predetermined locations. "Dotted" refers to a small area, such as an area corresponding to one or two spherical abrasive particles 3.

[0049] The plurality of spherical abrasive particles 3 can also be irregularly arranged, but a regular arrangement is preferred. The plurality of spherical abrasive particles 3 can be regularly arranged by applying the adhesive 4 in a dotted pattern at regular locations on the substrate 2. There are no particular limitations on the regular arrangement; for example, such as... Figure 3 As shown, it can be an arrangement of multiple columns tilted relative to the rotation direction D of the electrodeposition tool 1. Figure 3 This is a schematic diagram illustrating an example of a regular arrangement of a plurality of spherical abrasive grains.

[0050] There are no particular limitations on adhesive 4; for example, it can be epoxy resin or acrylic resin.

[0051] There are no particular limitations on coating 5; for example, it can be a nickel coating.

[0052] Next, refer to Figures 4-7 The manufacturing method of electrodeposition tools is explained. Figures 4-7 This is a schematic cross-sectional view illustrating the manufacturing method of the electrodeposition tool according to this embodiment.

[0053] First, a substrate 2 and a plurality of spherical abrasive grains 32 are prepared. Each of the plurality of spherical abrasive grains 32 (hereinafter also simply referred to as "spherical abrasive grains 32") is a spherical abrasive grain before the grinding process of spherical abrasive grains 3. Therefore, the flat surface 31 of spherical abrasive grains 3 is not formed on the spherical abrasive grains 32. Like spherical abrasive grains 3, spherical abrasive grains 32 do not have planar crystal planes. The aspect ratio of spherical abrasive grains 32 is 0.90 or more, preferably 0.91 or more, and more preferably 0.92 or more. In addition, the spherical abrasive grains 32 have a roundness of 0.95 or more, preferably 0.96 or more, and more preferably 0.97 or more.

[0054] Next, as Figure 4 As shown, adhesive 4 is applied to surface 21 of substrate 2. Then, as... Figure 5 As shown, a plurality of spherical abrasive particles 32 are disposed on the surface 21 of the substrate 2 (disposition step). Then, using an adhesive 4 coated on the surface 21 of the substrate 2, the plurality of spherical abrasive particles 32 are bonded to the surface 21 of the substrate 2. Thus, the plurality of spherical abrasive particles 32 are disposed on the surface 21 of the substrate 2 in a temporarily fixed state.

[0055] Here, the aspect ratio of the spherical abrasive particles 32 is 0.90 or higher, preferably 0.91 or higher, more preferably 0.92 or higher, and the roundness of the spherical abrasive particles 32 is 0.95 or higher, preferably 0.96 or higher, more preferably 0.97 or higher. Therefore, by distributing a plurality of spherical abrasive particles 32 on the surface 21 of the substrate 2, regardless of the orientation (orientation) of the plurality of spherical abrasive particles 32 relative to the surface 21 of the substrate 2, the height deviation of the plurality of spherical abrasive particles 32 relative to the surface 21 of the substrate 2 is reduced.

[0056] Next, as Figure 6 As shown, a coating 5 is formed on the surface 21 of the substrate 2, and a plurality of spherical abrasive particles 32 are embedded in the coating 5 (adhesion process). The coating 5 can be formed, for example, by electroplating.

[0057] Next, as Figure 7As shown, the spherical abrasive grains 32 are ground to form a flat surface 31 at the tip of the spherical abrasive grains 32 (grinding process). The grinding of a plurality of spherical abrasive grains 32 can be performed, for example, by grinding with a diamond grinding wheel. Thus, the spherical abrasive grains 32 become spherical abrasive grains 3 with a flat surface 31 formed at the tip, thereby manufacturing an electrodeposition tool 1 with a plurality of spherical abrasive grains 3 fixed on the surface 21 of the substrate 2.

[0058] Here, refer to Figure 8 The flow of chips is explained. Figure 8 This is a schematic cross-sectional view showing the flow of chips. For example... Figure 8 As shown, when machining is performed using the electrodeposition tool 1 of this embodiment, chips are generated. These chips flow along the outer peripheral surface of the spherical abrasive grains 3 to the side opposite to the rotation direction D of the electrodeposition tool 1. At this time, since the aspect ratio and roundness of the portions of the plurality of spherical abrasive grains 3, excluding the flat surface 31, are within the above-mentioned range, the chips are not easily retained on the outer peripheral surface of the spherical abrasive grains 3.

[0059] As explained above, in the electrodeposition tool 1 of this embodiment, a plurality of spherical abrasive grains 3 are embedded in a plating layer 5 formed on a substrate 2. The aspect ratio of the portion of the plurality of spherical abrasive grains 3 excluding the flat surface 31 is 0.90 or more, preferably 0.91 or more, more preferably 0.92 or more, and the roundness of the portion of the plurality of spherical abrasive grains 3 excluding the flat surface 31 is 0.95 or more, preferably 0.96 or more, more preferably 0.97 or more. Therefore, the deviation in the size of the flat surface 31 of the plurality of spherical abrasive grains 3 can be reduced. As a result, machining accuracy can be improved and chip clogging can be suppressed. Thus, since chip clogging is suppressed, sharpness and machining accuracy can be maintained for a long time.

[0060] Furthermore, in this electrodeposition tool 1, during manufacturing, even without using a master mold for the reverse process, a plurality of spherical abrasive grains 32 can be fixed to the surface 21 of the substrate 2, and the height deviation of the plurality of spherical abrasive grains 32 relative to the surface 21 of the substrate 2 can be reduced. Therefore, the manufacturing process can be simplified, and the material cost of the master mold can be reduced. In addition, since the plurality of spherical abrasive grains 32 can be fixed without electroforming, the production cycle can be shortened. Moreover, since the plurality of spherical abrasive grains 3 are fixed to the surface 21 of the substrate 2 by embedding the plurality of spherical abrasive grains 3 into the coating 5, the substrate 2 can be reused by removing the coating 5. Therefore, the environmental impact can also be reduced.

[0061] Furthermore, in this electrodeposition tool 1, since the plurality of spherical abrasive grains 3 do not have planar crystal planes, the height deviation of the plurality of spherical abrasive grains 32 when they are disposed on the surface 21 of the substrate 2 can be further reduced during manufacturing.

[0062] Furthermore, in this electrodeposition tool 1, since a plurality of spherical abrasive particles 3 are bonded to the surface 21 of the substrate 2 using an adhesive 4, during manufacturing, the plurality of spherical abrasive particles 32 can be temporarily fixed on the surface 21 of the substrate 2 using the adhesive 4 before the plating layer 5 is formed on the surface 21 of the substrate 2. Therefore, the electrodeposition tool 1 can be easily manufactured.

[0063] In the manufacturing method of the electrodeposition tool according to this embodiment, a plurality of spherical abrasive grains 32 with an aspect ratio of 0.90 or higher, preferably 0.91 or higher, more preferably 0.92 or higher, and a roundness of 0.95 or higher, preferably 0.96 or higher, more preferably 0.97 or higher are disposed on the surface 21 of the substrate 2, and a coating layer 5 is formed on the surface 21 of the substrate 2, embedding the plurality of spherical abrasive grains 32 into the coating layer 5. Therefore, the plurality of spherical abrasive grains 32 can be fixed to the surface 21 of the substrate 2, and the height deviation of the plurality of spherical abrasive grains 32 relative to the surface 21 of the substrate 2 can be reduced. Therefore, the size deviation of the flat surface 31 of the plurality of spherical abrasive grains 3 can be reduced. As a result, the machining accuracy can be improved and chip clogging can be suppressed. In this way, by suppressing chip clogging, sharpness and machining accuracy can be maintained for a long time.

[0064] Furthermore, this method for manufacturing electrodeposition tools simplifies the manufacturing process and reduces the material cost of the master mold. Additionally, since a plurality of spherical abrasive grains 32 can be fixed without electroforming, the production cycle can be shortened. Moreover, since the plurality of spherical abrasive grains 32 are fixed to the surface 21 of the substrate 2 by embedding them into the coating 5, the substrate 2 can be reused by removing the coating 5. Therefore, the environmental impact can also be reduced.

[0065] Furthermore, in the manufacturing method of this electrodeposition tool, since the plurality of spherical abrasive grains 32 do not have planar crystal planes, the height deviation of the plurality of spherical abrasive grains 32 relative to the surface 21 of the substrate 2 when the plurality of spherical abrasive grains 32 are disposed on the surface 21 of the substrate 2 can be further reduced.

[0066] Furthermore, in this method for manufacturing the electrodeposition tool, since a plurality of spherical abrasive particles 32 are bonded to the surface 21 of the substrate 2 using an adhesive 4, the plurality of spherical abrasive particles 32 can be temporarily fixed to the surface 21 of the substrate 2 using the adhesive 4 before the plating layer 5 is formed on the surface 21 of the substrate 2. Therefore, the electrodeposition tool 1 can be easily manufactured.

[0067] Furthermore, in the manufacturing method of this electrodeposition tool, since a flat surface 31 is formed at the top of the plurality of spherical abrasive grains 32 by grinding, it is possible to manufacture an electrodeposition tool 1 in which the height of the plurality of spherical abrasive grains 3 relative to the surface 21 of the substrate 2 is uniform with high precision.

[0068] This disclosure is not limited to the above-described embodiments, and appropriate modifications can be made without departing from the spirit of this disclosure.

[0069] For example, in the above embodiment, a grinding process was described to form a flat surface at the tips of a plurality of spherical abrasive grains, but this grinding process may also be omitted. In this case, the electrodeposition tool is an electrodeposition tool in which a plurality of spherical abrasive grains without flat surfaces at their tips are fixed to a substrate, and the aspect ratio and sphericality of these plurality of spherical abrasive grains are the same as those of the portion of the plurality of spherical abrasive grains excluding the flat surfaces described in the above embodiment. Furthermore, if the electrodeposition tool is manufactured without a grinding process, a grinding process may be performed on the manufactured electrodeposition tool to form a flat surface at the tips of the plurality of spherical abrasive grains.

[0070] Furthermore, in the above embodiment, the method of forming the substrate into a generally cylindrical shape and forming an annular recess on the surface 21 of the substrate has been described. However, the shape of the substrate is not particularly limited, and various shapes can be adopted depending on the application, etc.

[0071] Furthermore, in the above embodiments, the electrodeposition tool is described as a rotary dresser, but the electrodeposition tool of this disclosure may also be an electrodeposition tool other than a rotary dresser such as an electrodeposition reamer.

[0072] Figure 9 This is a schematic cross-sectional view of a modified electrodeposition tool. Figure 10 It is Figure 9 A partially enlarged schematic cross-sectional view of the electrodeposition tool shown. (See attached image.) Figure 9 and Figure 10 As shown, the electrodeposition tool 1A in the modified example is an electrodeposition reamer. The electrodeposition tool 1A is an electrodeposition reamer for honing and is formed in the shape of a cylindrical rod. The electrodeposition tool 1A has: a substrate 2A; a plurality of spherical abrasive grains 3 fixed to the substrate 2A; an adhesive 4 for bonding the plurality of spherical abrasive grains 3 to the substrate 2A; and a plating layer 5 formed on the substrate 2A and in which the plurality of spherical abrasive grains 3 are embedded.

[0073] The substrate 2A is formed in the shape of a cylindrical rod. The substrate 2A has a surface 21A on which a plurality of spherical abrasive particles 3A are attached. That is, the plurality of spherical abrasive particles 3A are attached to the surface 21A of the substrate 2A. The surface 21A is at least a portion of the outer peripheral surface of the substrate 2.

[0074] Example

[0075] Next, embodiments of the present disclosure will be described. However, the present disclosure is not limited to the embodiments described below.

[0076] (Example 1)

[0077] A particle size of [missing information] was bonded to the surface of a cylindrical rod-shaped matrix. A plurality of spherical diamond abrasive grains with a 60 / 80 aspect ratio, an aspect ratio of 0.93, and a roundness of 0.99 were formed. Next, an electroplating process was used to form a coating on the upper surface of a substrate, embedding the plurality of spherical diamond abrasive grains within the coating. Then, the spherical diamond abrasive grains were ground using a diamond grinding wheel, resulting in a flat surface at the tip of each spherical diamond abrasive grain. This yielded the electrodeposited reamer of Example 1.

[0078] The electrodeposited reamer of Example 1 was used to finish a hole formed in a cast iron (FC250) workpiece. During the finishing process, the spindle speed was set to 477.5 rev / min, the peripheral speed to 30 m / min, the feed rate to 95.5 mm / min, the feed per revolution to 0.2 mm / rev, and the machining allowance to be set to... 0.030 [mm], set the processing quantity (number of holes) to 10 consecutive holes.

[0079] Then, the sharpness, roundness of the workpiece hole, and inner diameter of the workpiece hole were measured. Sharpness was evaluated using the maximum thrust load. The roundness of the workpiece hole was taken as the average of the roundness at every 13.5 mm depth. The inner diameter of the workpiece hole was taken as the average of the inner diameter at every 11 mm depth. The thrust load measurement results are shown in... Figure 11 The measurement results of the roundness of the workpiece hole are shown in Figure 12 The measurement results of the inner diameter of the workpiece hole are shown in Figure 13 .

[0080] (Comparative Example 1)

[0081] Use granularity as A plurality of polyhedral diamond abrasive grains of 60 / 80 were used instead of a plurality of spherical diamond abrasive grains. Under the same conditions as in Example 1, the electrodeposited reamer of Comparative Example 1 was obtained. Then, as in Example 1, the sharpness, roundness of the workpiece hole, and inner diameter of the workpiece hole were measured. The results of the thrust load measurement are shown in… Figure 11The measurement results of the roundness of the workpiece hole are shown in Figure 12 The measurement results of the inner diameter of the workpiece hole are shown in Figure 13 .

[0082] (evaluate)

[0083] like Figure 11 As shown, for the electrodeposition reamer of Comparative Example 1, the thrust load is greater than 40 [N] when machining the third workpiece, but for the electrodeposition reamer of Example 1, the thrust load is less than 35 [N] when machining all workpieces.

[0084] like Figure 12 As shown, for the electrodeposited reamer of Comparative Example 1, the roundness of the workpiece hole changed significantly after the seventh workpiece, while for the electrodeposited reamer of Example 1, the roundness of the workpiece hole did not change significantly until after the tenth workpiece.

[0085] like Figure 13 As shown, for the electrodeposited reamer of Comparative Example 1, the inner diameter of the workpiece hole varies significantly between workpieces, but for the electrodeposited reamer of Example 1, the inner diameter of the workpiece hole does not vary significantly between workpieces.

[0086] These results show that, compared with the electrodeposited reamer of Comparative Example 1, the electrodeposited reamer of Example 1 is less likely to have chips stuck on the outer peripheral surface of the spherical diamond abrasive grains, thereby suppressing chip clogging. As a result, even in ten processing cycles, it can maintain sharpness and processing accuracy.

[0087] Explanation of reference numerals in the attached figures

[0088] 1: Electrodeposition tool (rotary dresser); 2: Substrate; 21: Surface; 3: Spherical abrasive grains; 31: Flat surface; 32: Spherical abrasive grains; 4: Adhesive; 5: Coating; 1A: Electrodeposition tool (electrodeposition reamer); 2A: Substrate; 21A: Surface; D: Rotation direction.

Claims

1. An electrodeposition tool, wherein, It has: a matrix; A plurality of spherical ultra-abrasive particles are fixed to the matrix; as well as A coating is formed on the substrate and contains the plurality of spherical abrasive particles. The plurality of spherical abrasive particles have flat surfaces formed by grinding. The aspect ratio of the portion of the plurality of spherical abrasive grains, excluding the flat surface, is 0.90 or higher. The roundness of the portion of the plurality of spherical abrasive grains other than the flat surface is 0.95 or higher.

2. An electrodeposition tool, wherein, It has: a matrix; A plurality of spherical ultra-abrasive particles are fixed to the matrix; as well as A coating is formed on the substrate and contains the plurality of spherical abrasive particles. The aspect ratio of the plurality of spherical abrasive particles is greater than 0.

90. The roundness of the plurality of spherical abrasive particles is greater than 0.

95.

3. The electrodeposition tool according to claim 1 or 2, wherein, The plurality of spherical ultra-abrasive grains do not have planar crystal faces.

4. The electrodeposition tool according to claim 1 or 2, wherein, The plurality of spherical abrasive particles are bonded to the substrate using an adhesive.

5. The electrodeposition tool according to claim 1 or 2, wherein, The plurality of spherical abrasive particles are arranged regularly.

6. The electrodeposition tool according to claim 1 or 2, wherein, The electrodeposition tool is a rotary dresser.

7. The electrodeposition tool according to claim 1 or 2, wherein, The electrodeposition tool is an electrodeposition reamer.

8. A method for manufacturing an electrodeposition tool, in, Includes: a configuration process, which configures a plurality of spherical abrasive particles with an aspect ratio of 0.90 or higher and a roundness of 0.95 or higher on a substrate; as well as A bonding process, wherein a coating is formed on the substrate, and the plurality of spherical abrasive particles are embedded in the coating.

9. The method for manufacturing an electrodeposition tool according to claim 8, wherein, The plurality of spherical abrasive grains disposed on the substrate do not have planar crystal faces.

10. The method for manufacturing an electrodeposition tool according to claim 8 or 9, wherein, In the configuration process, the plurality of spherical abrasive particles are bonded to the substrate using an adhesive.

11. The method for manufacturing an electrodeposition tool according to claim 8 or 9, wherein, It also includes a grinding process, in which the plurality of spherical abrasive grains are ground and a flat surface is formed at the top of the plurality of spherical abrasive grains.

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