Method for manufacturing a diamond tool

Abstract

To provide a diamond tool combined with a processing apparatus to process a workpiece.SOLUTION: A diamond tool comprises: a shank having a through hole through which grinding powder generated in processing the workpiece by the processing apparatus is discharged outside; a segment bonded to an end portion of the shank to contact and process the workpiece; and an abrasion preventing part disposed on a surface of an adjacent portion in an outer surface of the shank adjacent to the through hole so as to prevent abrasion of the outer surface during the processing of the workpiece.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Embodiments of the present invention relate to diamond tools and methods for manufacturing the same. More specifically, embodiments of the present invention relate to a diamond tool capable of performing a machining process such as cutting or drilling on a workpiece, and a method for manufacturing a diamond tool for manufacturing the diamond tool.

Background Art

[0002] A diamond tool includes a shank (corresponding to the main body) and a plurality of segments arranged at an end of the shank. Diamond particles are distributed on the surface of the segment. Therefore, by using the diamond tool, an operator can perform cutting, polishing, or drilling operations on a workpiece.

[0003] The segment is configured to include a bond made of metal powder and a cutting material in which industrial diamonds for performing direct cutting are distributed. The diamond tool can be classified into a saw blade type diamond tool and a core bit type diamond tool according to the forms of the shank and the segment.

[0004] The saw blade type diamond tool includes a disk-shaped metal shank and a plurality of segments (Tips) attached to a peripheral portion of the shank. The saw blade type diamond tool can be used for cutting a workpiece.

[0005] The core bit type diamond tool includes a plurality of segments (Tips) fixed to a cylindrical metal shank. The core bit type diamond tool can be used for a drilling operation to form a hole in a workpiece.

[0006] At this time, in the segment, since diamond particles are distributed among the metal powders (bond metals), the diamond particles distributed in each segment perform cutting / grinding.

[0007] To fabricate such a cutting / grinding segment, generally, the powder metallurgy method is used. Specifically, after forming a mixture of metal powder in powder form and diamond crystals, the mixture is formed into a segment shape. By heating the formed body at a high temperature, a cutting / grinding segment having a dense structure is formed by sintering or hot pressing.

[0008] After that, the cutting / grinding segment is joined to the shank. Examples of such joining processes include a laser welding process, a brazing process using silver solder, a diffusion bonding process by sintering, and the like.

[0009] By subjecting the product formed by such a joining process to a dressing process in which the surface of the segment is polished with a grindstone or the like so that diamond is exposed to the outside, the diamond tool can be finally manufactured so that the initial cutting is performed smoothly.

Prior Art Documents

Patent Documents

[0010]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0011] However, the manufacturing method of such tools requires complex processes such as sintering necessary for the production of cutting / polishing segments. In order to fix the cutting / polishing segments to the tool body, joining processes such as welding, brazing, or electroplating are required, so there are problems that many processes and a lot of equipment are required for the production of cutting / polishing tools, and a lot of labor is needed.

[0012] On the other hand, the thinner the shank included in the diamond tool, the more advantageous it is for the cutting process. However, conversely, there may be a problem that the durability deteriorates. Therefore, there is a need for a diamond tool that can ensure excellent durability despite the shank having a relatively thin thickness.

[0013] Furthermore, when the chips generated during the processing of the diamond tool on the workpiece are not easily discharged, there may be a problem that the wear of the shank progresses rapidly. The present invention has been devised to solve the above-described problems of the prior art. An embodiment of the present invention aims to provide a diamond tool having a shank with excellent durability and facilitating chip discharge.

[0014] Another object of an embodiment of the present invention is to provide a method for manufacturing a diamond tool having a shank capable of ensuring excellent durability by relatively simple processes.

Means for Solving the Problems

[0015] To achieve the above object of the present invention, according to an embodiment of the present invention, there is provided a diamond tool coupled to a processing device for processing a workpiece. The diamond tool includes a shank having a through hole provided to discharge chips generated when the processing device processes the workpiece to the outside, a segment attached to an end of the shank to contact and process the workpiece, and a wear suppression portion provided on a surface of an adjacent portion adjacent to the through hole on an outer surface of the shank to suppress wear of the outer surface when processing the workpiece.

[0016] In one embodiment of the present invention, the shank has a cylindrical shape in which a plurality of the through holes are formed at intervals along the circumference. The segment is attached to an end of the cylindrical shank. The wear suppression portion is formed between the adjacent through holes.

[0017] In one embodiment of the present invention, the shank has a disk shape. A plurality of slots are formed in the shank at intervals along the circumferential direction of the shank and are each connected to the through hole. The segment is attached to a peripheral portion of the disk-shaped shank. The wear suppression portion includes a first laser welding portion formed along the circumferential direction.

[0018] Here, the wear suppression portion may further include a second laser welding portion formed at a central portion of the shank and a plurality of third laser welding portions arranged between the first laser welding portion and the second laser welding portion.

[0019] Also, the wear suppression portion may have the same height as or a lower height than the segment with respect to the outer surface of the shank. In one embodiment of the present invention, the wear suppression portion has a hardness in the range of 50 to 120 HRB.

[0020] According to an embodiment of the present invention, there is provided a method for manufacturing a diamond tool coupled to a processing apparatus for processing a workpiece. The method for manufacturing a diamond tool includes forming a shank having a through-hole provided to discharge chips generated when processing the workpiece to the outside. The method for manufacturing a diamond tool forms segments that contact and process the workpiece, and then joins the segments to the shank. Subsequently, the method for manufacturing a diamond tool forms a wear suppression portion on a surface adjacent to the through-hole on the outer surface of the shank to suppress wear of the outer surface when processing the workpiece.

[0021] In one embodiment of the present invention, the step of forming the wear suppression portion may include performing a laser printing process of injecting cutting material particles and metal powder having a specific gravity greater than that of the cutting material particles while irradiating laser light on the outer surface of the shank.

[0022] Here, the laser printing process may use a laser printing apparatus including a laser generation unit, a transfer unit for moving the laser generation unit, and a cutting material particle supply unit.

[0023] Further, the laser generation unit may have a transfer speed of 500 to 2,000 mm / min, a laser pitch of 0.1 to 2.0 mm, and a power of 200 to 2,000 W.

Effects of the Invention

[0024] As described above, the diamond tool according to the present invention includes a wear suppression portion arranged between through-holes on the outer surface of the shank. Accordingly, not only can chips be easily discharged from the through-holes, but it is possible to implement a diamond tool having a shank with excellent durability.

[0025] Furthermore, according to an embodiment of the present invention, by forming a wear suppression portion through a relatively simple laser printing process, it is possible to manufacture a diamond tool having a shank capable of easily ensuring excellent durability.

Brief Description of the Drawings

[0026]

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Modes for Carrying Out the Invention

[0027] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention should not be construed as being limited to the embodiments described below, and can be embodied in many other various forms. The following embodiments are provided not so much to completely complete the present invention, but rather to fully convey the scope of the present invention to those skilled in the art in the technical field of the present invention.

[0028] When an element of an embodiment of the present invention is described as being disposed on or connected to another element, the element can be directly disposed on or connected to the other element, and it is also possible for other elements to be interposed therebetween. In contrast, when an element is described as being directly disposed on or connected to another element, there are no further elements present therebetween. To describe various items, such as various elements, components, regions, layers, and / or parts, terms such as first, second, third, etc. can be used, but the above items are not limited by these terms.

[0029] The technical terms used in the embodiments of the present invention are used only for the purpose of explaining specific embodiments and are not for limiting the present invention. Also, unless otherwise specifically limited, all terms with technical and scientific terms have the same meaning that can be understood by those skilled in the art having ordinary knowledge in the technical field of the present invention. The above terms, which are the same as those defined in a normal dictionary, are construed to have a meaning consistent with their meaning from the context of the related art and the description of the present invention, and are not construed ideally or excessively in terms of external intuition unless clearly limited.

[0030] Embodiments of the present invention are described with reference to schematic illustrations of ideal embodiments of the present invention. Accordingly, changes from the shapes of the above illustrations, such as changes in manufacturing methods and / or tolerances, are reasonably predictable. Therefore, embodiments of the present invention are not described as being limited to the specific shapes of the regions illustrated, but have deviations in shape. The elements depicted in the drawings are generally schematic, and these shapes are not for explaining the exact shapes of the elements, nor for limiting the scope of the present invention.

[0031] Figure 1 is a perspective view for explaining a diamond tool according to an embodiment of the present invention. Figure 2 is a cross-sectional view for explaining the diamond tool of Figure 1. Referring to FIGS. 1 and 2, a diamond tool 50 according to an embodiment of the present invention is used for machining a workpiece by being coupled to a machining apparatus. Such a machining apparatus can be used for surface polishing or hole machining depending on the shape of the diamond tool 50.

[0032] The diamond tool 50 is provided with a coupling portion 51 so as to be coupled to a machining apparatus such as a core drill or a hole cutter. The diamond tool 50 includes a shank 52 having a coupling portion 51 for being coupled to the machining apparatus at one end, a segment 54, and an abrasion suppression portion 59.

[0033] The other end of the shank 52 is formed in a cylindrical shape. A hollow 58 is formed in the shank 52. At this time, the shank 52 can be selected and used in various sizes according to the workpiece to be machined or the perforation shape. A through hole 53 is formed at the other end of the shank 52. The through hole 53 penetrates in the axial direction of the rotational axis of the cylindrical shank 52.

[0034] The through hole 53 functions as a discharge port so that chips generated when the machining apparatus machines the workpiece are discharged to the outside. Also, the through hole 53 can be provided as a cooling space so as to cool the heat generated during the driving of the machining apparatus. Further, the through hole 53 can provide flexibility to the shank 52 against the cutting load applied during the driving of the machining apparatus.

[0035] The segments 54 are provided at predetermined intervals around the other end of the shank 52. The tip of the segment 54 directly contacts the workpiece to polish or cut the workpiece. At this time, when the shank 52 rotates at high speed by the machining apparatus, the segment 54 can polish the surface of the workpiece or form a hole in the workpiece.

[0036] The wear suppression portion 59 is formed on the surface of an adjacent portion adjacent to the through hole 53 on the outer surface of the shank 52. For example, the wear suppression portion 59 can be arranged between adjacent through holes 53.

[0037] The wear suppression portion 59 can be formed using cutting material particles containing diamond and metal powder as raw materials. The wear suppression portion 59 is formed by a laser printing process using a laser having a wavelength band that transmits the diamond and melts the metal powder.

[0038] The wear suppression portion 59 can suppress wear on the outer surface of the shank 52 when machining a workpiece. During machining of the workpiece, the wear suppression portion 59 can facilitate the entry of the diamond tool 50 and more precisely maintain the machining dimensions by additionally machining the outer peripheral surface of the hole.

[0039] On the other hand, the core bit type diamond tool 50 can suppress wear of the shank 52 by including the wear suppression portion 59. Further, the wear suppression portion 59 can suppress pinching of the tool during drilling of the workpiece, increase the strength of the shank 52, and shorten the machining time.

[0040] Referring further to FIGS. 1 and 2, the shank 52 is cylindrical, and a plurality of the through holes 53 are formed at intervals along the circumference of the shank 52. At this time, the segment 54 is attached to the other end of the cylindrical shank 52.

[0041] On the other hand, the wear suppression portion 59 can be formed between the through holes 53. As a result, since the core bit type diamond tool 50 includes the wear suppression portion 59 formed between the through holes 53, the chips generated by the segment 54 and the wear suppression portion 59 during machining can be discharged to the outside through the through holes 53. Therefore, surface damage to the shank 52 caused by residual chips can be suppressed.

[0042] In one embodiment of the present invention, the wear suppression portion 59 may have a hardness in the range of 50 to 120 HRB (one of the Rockwell hardnesses). For example, when the metal powder is cobalt (Co), the wear suppression portion 59 has a hardness in the range of 85 to 110 HRB. When the metal powder is iron (Fe), the wear suppression portion 59 has a hardness in the range of 50 to 80 HRB. On the other hand, when the metal powder is tungsten (W), the wear suppression portion 59 has a hardness in the range of 110 to 120 HRB.

[0043] FIG. 3 is a plan view for explaining a diamond tool according to an embodiment of the present invention. FIG. 4 is a cross-sectional view for explaining the diamond tool of FIG. 3. Referring to FIGS. 3 and 4, a diamond tool 100 according to an embodiment of the present invention includes a shank 110, a segment 120, and a wear suppression portion 130. The diamond tool 100 may be of a saw blade type. The diamond tool 100 may be used to cut a part of a workpiece.

[0044] The shank 110 has a disk shape. A plurality of through holes 115 are arranged along the circumferential direction in the shank 110. A plurality of slots 116 are formed at intervals from each other along the circumferential direction of the shank 110. The slots 116 are each connected to the through holes 115.

[0045] On the other hand, the segment 120 is attached to the peripheral portion of the shank 110 having the disk shape. The wear suppression portion 130 is formed on the side portion of the shank 110. The wear suppression portion 130 includes a first laser welding portion formed along the circumferential direction of the shank 110.

[0046] The saw blade type diamond tool 100 is provided with a wear suppression portion 130, thereby suppressing wear of the shank 110. In particular, the wear suppression portion 130 can supplement the rigidity of the shank 110 and reduce the cutting load on the side portion of the shank 110. Further, the wear suppression portion 130 can reduce the heat generation phenomenon generated during cutting and shorten the processing time of the workpiece.

[0047] The wear suppression portion 130 may be at the same height as or lower than the segment 120 with reference to the outer surface of the shank 110. Thereby, when the wear suppression portion 130 contacts the workpiece in a state where the segment 120 has processed the workpiece first, it is possible to effectively suppress wear of the shank 110.

[0048] FIG. 5 is a front view for explaining another example of the shank and the wear suppression portion included in FIG. 3. Referring to FIG. 5, the wear suppression portion 230 may include a first laser welding portion 231, a second laser welding portion 232 formed at the central portion of the shank 210, and a plurality of third laser welding portions 233 arranged between the first laser welding portion 231 and the second laser welding portion 232.

[0049] The second laser welding portion 232 may be in a donut shape. On the other hand, the third laser welding portion 233 may be in a semi-circular shape. Since the second laser welding portion 232 and the third laser welding portion 233 are formed on the outer surface of the shank 210, wear of the shank 210 can be additionally suppressed.

[0050] Hereinafter, the manufacturing process and the operation of the diamond tool according to the present invention described above will be described. FIG. 6 is a flowchart for explaining a method of manufacturing a diamond tool according to an embodiment of the present invention.

[0051] FIG. 7 is a schematic diagram for explaining a process for forming a wear suppression portion. Referring to FIGS. 6 and 7, the shank 110 is formed (S110). On the other hand, the segment 120 provided around the shank 110 is separately formed (S120). At this time, the segment 120 is formed by a sintering process in which a cutting material containing diamond abrasive grains and a binder which is a metal powder is mixed and molded and then sintered.

[0052] Thereafter, the segment 120 is joined to the shank 110 (S130). In order to join the segment 120 to the end of the shank 110, laser welding, brazing using silver brazing, or diffusion bonding by sintering, etc. can be used. Thus, since the segment 120 has excellent bonding strength to the shank 110, peeling of the segment 120 from the shank 110 can be suppressed.

[0053] Subsequently, an abrasion suppression portion 130 is formed on the outer peripheral surface of the shank 110 (S140). The abrasion suppression portion 130 can be formed as follows. First, a laser printing process is provided in which while irradiating the surface of the shank 110 with laser light using a heating device 21 provided adjacent to the shank 110, cutting material particles and metal powder having a specific gravity greater than that of the cutting material particles are injected. By the laser printing process, a welded layer is formed by welding the metal powder onto the surface of the shank 110. At this time, the cutting material particles distributed inside the welded layer are included. The first welded layer in which the cutting material particles and the metal particles thus formed are welded is formed as the abrasion suppression portion 130.

[0054] On the other hand, the cutting material particles supplied from the cutting material particle supply portion and the metal powder are mixed in the mixing portion 23 and then injected from the nozzle 24. At this time, the injection amounts of the cutting material particles and the metal powder supplied to the mixing portion 23 can be individually controlled.

[0055] The above-mentioned metal powder can use ordinary metal powder. As an example, it may contain one or more metals selected from non-ferrous metal groups including Co, Ni, etc. As another example, it may contain an alloy powder (pre-alloyed_powder) containing one or more metals selected from the above-mentioned metal groups. Further, the cutting material particles may contain diamond particles. As an example, the diamond particles can have the most excellent hardness.

[0056] In addition, the heating device 21 can be composed of a laser generating device that emits a laser in a wavelength band that can penetrate diamond, which is a cutting material particle. As such a laser device, any one of a CO2 laser device, an Nd-YAG laser device, a fiber laser device, a diode laser device, and a disk laser device can be used.

[0057] And since diamond particles are vulnerable to heat, it is desirable that the output of the heating device 21 be adjusted so that the temperature of the molten pool in which the metal powder is melted does not exceed a preset temperature.

[0058] Figure 8 is a schematic diagram for explaining another example of the process for forming the wear suppression part. Referring to FIGS. 6 and 8, the cutting material particles supplied from the cutting material particle supply part 23a and the metal powder supplied from the metal powder supply part 23b are individually sprayed toward the shank 110. At this time, the heating device 21 can be a laser generating device (21) that emits a laser in a wavelength band that can penetrate diamond, which is a cutting material particle.

[0059] The laser generating device (21) used in the laser printing process can have a transfer speed of 500 to 2,000 mm / min, a laser pitch of 0.1 to 2.0 mm, and a power of 200 to 2,000 W.

[0060] Referring to FIGS. 6 and 8, a non-contact temperature sensor (not shown) for measuring the temperature of the molten pool may be provided. When the temperature of the molten pool sensed by the temperature sensor exceeds the set temperature, the control unit (not shown) lowers the output of the heating device. Conversely, when the temperature of the molten pool is lower than the set temperature range, the output of the heating device can be increased so that the welding layer is effectively formed.

[0061] In particular, in the case of a conventional welding process, there is a problem that deformation of the shank occurs due to heat treatment. On the other hand, in the case of a conventional electroplating process, not only is the process complicated, but there is also a problem that the gripping force on the diamond is relatively low.

[0062] Compared with these, the laser printing process has a relatively simple process, and not only can the process conditions be easily changed by modifying the detailed content of the program, but also it is easy in terms of process automation.

[0063] As described above, the diamond tool according to the present invention has been described with reference to the illustrated drawings. However, the present invention is not limited by the above-described embodiments and drawings, and it goes without saying that various modifications and variations can be made within the scope of the claims by those having ordinary knowledge in the technical field to which the present invention belongs.

Explanation of Reference Numerals

[0064] 50, 100... diamond tools. 51... joint part. 52, 110... shanks.

[0065] 54, 120... segments. 59, 130... wear suppression parts.

Claims

1. forming a shank having a through hole provided for discharging chips generated when machining a workpiece to the outside; forming a segment for contacting and machining the workpiece; joining the segment to the shank; forming a wear suppressing portion having a hardness in the range of 50 to 120 HRB on a surface of the outer surface of the shank adjacent to the through hole, the wear suppressing portion suppressing wear of the outer surface when the workpiece is machined; It is equipped with The step of forming the wear suppressing portion includes performing a laser printing process of individually spraying cutting material particles and metal powder onto the outer surface of the shank while irradiating a laser beam onto the outer surface of the shank, the metal powder having a higher specific gravity than the cutting material particles and including at least one of cobalt, iron, and tungsten, The laser printing process includes: The present invention is characterized in that a laser printing device is used, the laser printing device including a laser generating unit, a transport unit for moving the laser generating unit, a metal particle supply unit for supplying the metal powder, and a cutting material particle supply unit for supplying the cutting material particles. A method for manufacturing diamond tools.

2. The laser generating unit has a transport speed of 500 to 2,000 mm / min, a laser pitch of 0.1 to 2.0 mm, and a power of 200 to 2,000 W. A method for manufacturing a diamond tool according to claim 1.

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