Cutting blade and method for manufacturing the same

Abstract

To provide a cutting blade which can improve blade rigidity while satisfactorily maintaining sharpness of a cutting edge part, and a method for manufacturing the same.SOLUTION: A cutting blade comprises: a bond phase 1 which is a discoidal around a central axis O, on an outer peripheral part of which a cutting edge part 11 is located; a plurality of abrasive grains which are dispersed at least in the cutting edge part 11; and a plurality of bond reinforcement parts 3 which are held by the bond phase 1, and have a Young's modulus higher than that of the bond phase 1. The bond phase 1 has the cutting edge part 11, and a blade main body part 12 which is positioned on a radial inner side with respect to the cutting edge part 11, and the plurality of bond reinforcement parts 3 are located on the blade main body part 12.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a cutting blade and a manufacturing method thereof, and more particularly to a cutting blade used in technical fields that require cutting or other division of pre-sintered green sheets, such as MLCCs (multilayer ceramic capacitors), the electronic material manufacturing field that uses a manufacturing method for division by cutting, and technical fields where cutting speeds are particularly high and straightness is easily hindered, and a manufacturing method thereof. [Background technology]

[0002] BACKGROUND ART Conventionally, thin cutting blades are known that are used to cut green sheets (so-called green ceramics) such as MLCCs. For example, the high-rigidity cutting blade described in Patent Document 1 is an all-blade type in which the entire blade, including the outer periphery (cutting edge), is constructed as a sintered body using cemented carbide, cermet, or high-hardness intermetallic compound as the bond material and one or both of diamond and cBN as the abrasive grains. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2003-326466 Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, although the rigidity of the blade as a whole is increased, the bond phase is made of cemented carbide or the like, so the cutting edge is also hard, making it difficult for the abrasive grains to sharpen themselves. This makes it easy for the blade to lose its sharpness, hindering straight cutting.

[0005] An object of the present invention is to provide a cutting blade that can increase blade rigidity while maintaining good sharpness of the cutting edge portion, and a method for manufacturing the same. [Means for solving the problem]

[0006] One embodiment of the cutting blade of the present invention is disc-shaped centered on a central axis, and comprises a bond phase having a cutting edge portion arranged on its outer periphery, a plurality of abrasive grains dispersed in at least the cutting edge portion, and a plurality of bond reinforcement portions held in the bond phase and having a higher Young's modulus than the bond phase, wherein the bond phase has the cutting edge portion and a blade main body portion located radially inward of the cutting edge portion, and the plurality of bond reinforcement portions are arranged in the blade main body portion, the bond reinforcement portions extend in one direction when viewed from the axial direction, and the bond reinforcement portions have a plurality of granular bodies arranged in the one direction. Another aspect of the present invention is a cutting blade comprising: a bond phase having a disk shape centered on a central axis and a cutting edge portion disposed on an outer periphery thereof; a plurality of abrasive grains dispersed at least in the cutting edge portion; and a plurality of bond reinforcement portions held in the bond phase and having a higher Young's modulus than the bond phase, wherein the thickness of the cutting blade is 50 μm or more and 250 μm or less; the bond phase has the cutting edge portion and a blade main body portion located radially inward of the cutting edge portion; and the plurality of bond reinforcement portions are disposed in the blade main body portion, and the plurality of bond reinforcement portions are disposed at intervals from one another in the circumferential direction. The bond reinforcement portion has a recess recessed from an outer surface of the bond reinforcement portion, and the recess recessed from a side surface of the outer surface of the bond reinforcement portion facing a circumferential direction. .

[0007] According to the present invention, a bond reinforcement portion having a higher Young's modulus than the bond phase is disposed in the blade body of the bond phase. This increases the rigidity of the blade body, and also improves the blade rigidity of the entire cutting blade. In this invention, the strength of the bond phase is increased by the bond reinforcement portion, rather than increasing the hardness of the material that constitutes the bond phase itself, so that the effect of favorably self-sharpening the abrasive grains in the cutting edge portion, i.e., the self-sharpening effect, can be favorably maintained.

[0008] Therefore, according to the present invention, the blade rigidity is increased while maintaining good sharpness of the cutting edge, and straightness during cutting is stably ensured. This stably improves cutting accuracy. Various materials can be used for the bond phase, such as conventional plated phases, metal bond phases, resin bond phases, and vitrified bond phases. For example, compared to using expensive cemented carbide or the like as the bond phase material to increase the rigidity of the bond phase, the present invention allows cutting blades to be manufactured more inexpensively. In the above cutting blade, the bond reinforcement portion extends in one direction when viewed from the axial direction, and the bond reinforcement portion has a plurality of granular bodies arranged in the one direction. In this way, a bond reinforcement portion can be provided on the blade body by using a plurality of granular bodies arranged in one direction, and in this case, the degree of freedom in the shape of the bond reinforcement portion is increased. In the above cutting blade, the bond reinforcement portion has a recess recessed from the outer surface of the bond reinforcement portion. In this case, during the manufacturing of the cutting blade, a part of the bond phase enters the recess of the bond reinforcement part. In other words, a part of the bond phase is disposed in the recess. This provides an anchor effect, increasing the holding power of the bond reinforcement part. The bond reinforcement part is firmly integrated with the bond phase, and can be prevented from falling off the bond phase.

[0009] In the above cutting blade, it is preferable that the bond reinforcement portion extends in one direction when viewed from the axial direction, and that the radial position of one end of the bond reinforcement portion is different from the radial position of the other end of the bond reinforcement portion.

[0010] In this case, the bond reinforcement portion extends along the radial direction, or extends in the circumferential direction as it moves in the radial direction. This makes it easier to equalize the strength of the bond phase at each radial position, and stably increases the rigidity of the bond phase at each radial position. The increased strength of the bond phase along the radial direction makes it more stable to cut straight.

[0011] In the cutting blade, the bond reinforcement portions are preferably arranged at positions rotationally symmetrical to one another about the central axis.

[0012] In this case, the rigidity of the bond phase in the circumferential direction is equalized, and straightness during cutting is more stably ensured.

[0013] In the cutting blade, the bond reinforcement portion is preferably exposed on a plate surface facing the axial direction of the bond phase.

[0014] For example, compared to when the bond reinforcement portion is not exposed from the plate surface facing the axial direction of the bond phase, the above-described configuration of the present invention can increase the ratio of the axial dimension of the bond reinforcement portion to the axial dimension (thickness dimension) of the bond phase. In other words, the axial dimension of the bond reinforcement portion can be ensured to be large. Therefore, the blade rigidity can be more stably increased.

[0017] In the above cutting blade, the bond reinforcement portion preferably has a rough surface portion on the outer surface of the bond reinforcement portion, the roughness of which is set to a predetermined value or more.

[0018] In this case, during the manufacturing of the cutting blade, the bond phase adheres to the rough surface of the bond reinforcement portion, ensuring a large contact area between the bond reinforcement portion and the bond phase. This increases the holding force of the bond reinforcement portion relative to the bond phase. The bond reinforcement portion is firmly integrated with the bond phase, preventing it from falling off the bond phase.

[0019] In the cutting blade, the bond reinforcement portion may have a rod shape extending in one direction when viewed in the axial direction.

[0020] In this case, the bond reinforcement portions are easily arranged on the blade body during manufacturing of the cutting blade, making it easier to handle. Also, there is less variation in the function (action) of each bond reinforcement portion. Therefore, the effects of the present invention are more likely to be stabilized.

[0023] In the above cutting blade, the blade body portion is a main body exposed portion disposed on an outer periphery of the blade main body; and a portion of the blade main body other than the outer periphery. The bond reinforcement portion has a portion of the blade body other than the outer periphery; It is preferable that the insulating film is disposed across the main body exposed portion.

[0025] In the cutting blade, the bond reinforcement portion may be made of ceramics.

[0026] In this case, the Young's modulus of the bond reinforcement portion can be more stably increased than the Young's modulus of the bond phase.

[0027] In the cutting blade, the bond reinforcement portion may be made of diamond.

[0028] In this case, the Young's modulus of the bond reinforcement portion can be more stably increased than the Young's modulus of the bond phase.

[0029] In the cutting blade, the bond phase may be a plating phase, and the bond reinforcement portion may be made of a non-conductive material.

[0030] In this case, the bond phase that holds the bond reinforcement portion is made of a plating phase, so deformation due to thermal shrinkage during blade manufacturing is suppressed compared to, for example, a resin bond phase that requires hot pressing during blade manufacturing, making it easier to manufacture a cutting blade. Furthermore, since the bond reinforcement portion is non-conductive, plating adhesion to the bond reinforcement portion is suppressed when the bond phase is produced by electrolytic plating, which makes it possible to appropriately reduce the lapping process performed after the plating process.

[0031] In the above cutting blade, the bond reinforcement portion may be made of a cemented carbide alloy.

[0032] In this case, the Young's modulus of the bond reinforcement portion can be more stably increased than the Young's modulus of the bond phase.

[0033] In the above cutting blade, the bond phase may be any one of a resin bond phase, a metal bond phase, and a vitrified bond phase.

[0034] In this case, the cutting blade of the present invention can be easily used appropriately and suitably in accordance with various requirements for the cutting blade.

[0035] Another aspect of the present invention is a method for manufacturing the above-mentioned cutting blade, comprising a bond reinforcement positioning step for positioning and fixing the bond reinforcement to a base metal, and a plating step for immersing the bond reinforcement and the base metal in a plating bath to precipitate the bond phase on the base metal.

[0036] In this case, cutting blades according to the present invention, in which the bond phase is made of a plated phase, i.e., electroformed blades, can be stably manufactured.

[0037] Another aspect of the present invention is a method for manufacturing the above-mentioned cutting blade, comprising a bond reinforcement positioning process for positioning and fixing the bond reinforcement to a base metal; a preliminary plating process for immersing the bond reinforcement and the base metal in a first plating bath to precipitate a preliminary plating phase made of a material different from the bond phase on the base metal; a plating process for immersing the bond reinforcement, the base metal, and the preliminary plating phase in a second plating bath different from the first plating bath to precipitate the bond phase on the preliminary plating phase; and a preliminary plating removal process for removing the preliminary plating phase from a laminate of the bond phase and the preliminary plating phase.

[0038] In this case, cutting blades of the present invention, i.e., electroformed blades, in which the bond phase is composed of a plated phase, can be stably manufactured. Furthermore, since only the pre-plated phase can be removed from the laminate of the bond phase and the pre-plated phase by, for example, dissolution, the effects of external loads and thermal loads on the manufactured cutting blade can be more easily suppressed than when the pre-plated phase is removed by, for example, lapping.

[0039] Another aspect of the present invention is a method for manufacturing the above-mentioned cutting blade, comprising: a bond reinforcement positioning step for positioning and fixing the bond reinforcement to a base metal; a blade body plating step for immersing the bond reinforcement and the base metal in a plating bath to precipitate the blade body on the base metal; and a cutting edge plating step for rotating the blade body and the bond reinforcement that have been peeled off from the base metal in a plating bath, while precipitating the cutting edge that protrudes radially outward from the outer periphery and extends circumferentially on the outer periphery of the blade body.

[0040] In this case, cutting blades of the present invention, i.e., electroformed blades, in which the bond phase is composed of a plating phase, can be stably manufactured. Furthermore, it is possible to change the type of plating bath between the blade body and the cutting edge of the bond phase. For example, the plating material, the size of the abrasive grains contained, the type of filler, etc. can be appropriately set for the blade body and the cutting edge, respectively, making it possible to add various functions to the cutting blade.

[0041] Another aspect of the present invention is a method for manufacturing the above-mentioned cutting blade, comprising a bond reinforcement portion positioning step of positioning and fixing the bond reinforcement portion within a mold, a compression molding step of filling the mold with a mixed powder containing raw material powder of the bond phase and compressing it to form a disk-shaped blade molded body, and a sintering step of sintering the blade molded body.

[0042] In this case, cutting blades of the present invention having bond phases made of various materials other than the plating phase can be stably manufactured. Specifically, this manufacturing method can suitably manufacture, for example, resin blades whose bond phase is a resin bond phase, metal blades whose bond phase is a metal bond phase, and vitrified blades whose bond phase is a vitrified bond phase. [Effects of the Invention]

[0043] According to the cutting blade and the manufacturing method thereof of one aspect of the present invention, it is possible to increase the rigidity of the blade while maintaining good sharpness of the cutting edge portion. [Brief explanation of the drawings]

[0044] [Figure 1] FIG. 1 is a plan view showing a cutting blade according to a first embodiment. [Figure 2] FIG. 2 is a cross-sectional view showing the cutting blade of the first embodiment. [Figure 3] FIG. 3 is a flowchart illustrating a method for manufacturing the cutting blade of the first embodiment. [Figure 4] FIG. 4 is a perspective view illustrating a part (bond reinforcement portion fabrication step) of the manufacturing method of the cutting blade of the first embodiment. [Figure 5] FIG. 5 is a plan view showing the bond reinforcement portion of the first embodiment. [Figure 6] FIG. 6 is a cross-sectional view illustrating a part (bond reinforcement portion positioning step) of the manufacturing method of the cutting blade of the first embodiment. [Figure 7] FIG. 7 is a plan view illustrating a part (bond reinforcement portion positioning step) of the manufacturing method of the cutting blade of the first embodiment. [Figure 8] FIG. 8 is a cross-sectional view illustrating a part (plating step) of the method for manufacturing the cutting blade of the first embodiment. [Figure 9] FIG. 9 is a plan view illustrating a part (plating step) of the method for manufacturing the cutting blade of the first embodiment. [Figure 10] FIG. 10 is a flowchart illustrating a method for manufacturing the cutting blade according to the second embodiment. [Figure 11] FIG. 11 is a partial cross-sectional view illustrating a part (plating step) of the method for manufacturing the cutting blade of the second embodiment. [Figure 12] FIG. 12 is a cross-sectional view illustrating a part (plating step) of the method for manufacturing the cutting blade according to the third embodiment. [Figure 13] FIG. 13 is an enlarged cross-sectional view of a part of FIG. [Figure 14] FIG. 14 is a plan view showing a cutting blade according to the fourth embodiment. [Figure 15] FIG. 15 is a cross-sectional view illustrating a part (bond reinforcement portion positioning step) of the manufacturing method of the cutting blade of the fourth embodiment. [Figure 16] FIG. 16 is a plan view illustrating a part (bond reinforcement portion positioning step) of the manufacturing method of the cutting blade of the fourth embodiment. [Figure 17] FIG. 17 is a cross-sectional view illustrating a part (plating step) of the method for manufacturing the cutting blade according to the fourth embodiment. [Figure 18] FIG. 18 is an enlarged cross-sectional view of a part of FIG. [Figure 19] FIG. 19 is a plan view showing a cutting blade according to the fifth embodiment. [Figure 20] FIG. 20 is a plan view illustrating a part (bond reinforcement portion positioning step) of the manufacturing method of the cutting blade of the fifth embodiment. [Figure 21] FIG. 21 is a plan view illustrating a part (bond reinforcement portion positioning step) of the manufacturing method of the cutting blade of the sixth embodiment. [Figure 22] FIG. 22 is a plan view showing a cutting blade according to the seventh embodiment. [Figure 23] FIG. 23 is a flowchart illustrating a method for manufacturing the cutting blade of the seventh embodiment. [Figure 24] FIG. 24 is a cross-sectional view illustrating a part (cutting edge portion plating step) of the method for manufacturing the cutting blade of the seventh embodiment. [Figure 25] FIG. 25 is a flowchart illustrating a method for manufacturing the cutting blade of the eighth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0045] First Embodiment A cutting blade 10 according to a first embodiment of the present invention and a method for manufacturing the same will be described with reference to Figures 1 to 9 and 11. In the drawings of each embodiment, the thickness of the cutting blade may be shown to be greater than it actually is in order to clearly illustrate the characteristic parts of the cutting blade.

[0046] The cutting blade 10 of this embodiment is suitable for use in technical fields that require cutting and other individualization of pre-sintered green sheets (so-called raw ceramics) such as MLCCs (multilayer ceramic capacitors), the electronic material manufacturing field that uses a cutting-to-single method, and technical fields where cutting speeds are particularly fast and straightness is easily hindered.

[0047] 1 and 2, the cutting blade 10 is disc-shaped and centered on a central axis O, and includes a bond phase 1 having a cutting edge portion 11 arranged on the outer periphery thereof, a plurality of abrasive grains 2 (see FIG. 11), and a plurality of bond reinforcement portions 3. Although not specifically shown, the cutting blade 10 may also include a plurality of fillers. Fillers are used as appropriate for purposes such as increasing blade rigidity or improving sliding properties with the material to be cut.

[0048] In this embodiment, the direction in which the central axis O of the bond phase 1 extends is called the axial direction (blade axial direction). The axial direction corresponds to the thickness direction of the cutting blade 10. Therefore, the axial direction can also be called the thickness direction. The direction perpendicular to the central axis O is called the radial direction (blade radial direction). Within the radial direction, the direction approaching the central axis O is called the radially inner direction, and the direction away from the central axis O is called the radially outer direction. The direction of rotation around the central axis O is called the circumferential direction (blade circumferential direction).

[0049] The cutting blade 10 of this embodiment is disk-shaped, specifically an annular plate-shaped. That is, the "disk-shaped" in this embodiment includes an annular plate-shaped disk having a hole in the center. This cutting blade 10 is a so-called washer-type cutting blade. The axial dimension, i.e., thickness dimension, of the cutting blade 10 is, for example, 50 μm or more and 250 μm or less. The outer diameter dimension of the cutting blade 10 is, for example, 52 mm or more and 75 mm or less. The inner diameter dimension of the cutting blade 10 is, for example, 40 mm.

[0050] The cutting blade 10 is detachably attached to the main shaft of a cutting device (dicer) (not shown) using a circular plate-shaped flange F. The cutting blade 10 is rotated in the circumferential direction about a central axis O by the main shaft of the cutting device and moved in the radial direction relative to the material to be cut, such as an MLCC green sheet (not shown), with the cutting edge portion 11 protruding radially outward from the flange F cutting into the material to cut it. In this embodiment, "cutting" includes not only dividing the material to be cut, but also groove processing in the material to be cut, etc.

[0051] The bond phase 1 of this embodiment is a plating phase. That is, the bond phase 1 is a metallic bonding phase. The bond phase 1 is made of a metal containing, for example, Ni as a main component.

[0052] The bond phase 1 has a cutting edge portion 11 , a blade body portion 12 , and an attachment hole 13 . The cutting edge portion 11 constitutes the outer periphery of the bond phase 1. The cutting edge portion 11 is in the shape of a circular ring centered on the central axis O. The cutting edge portion 11 includes outer periphery edge portions of a pair of plate surfaces 1a, 1a facing the axial direction of the bond phase 1, an outer periphery surface 1b facing radially outward of the bond phase 1, and a pair of ridge portions, i.e., edges, connecting the outer periphery edge portions and the outer periphery surface 1b. For example, the radial dimension of the cutting edge portion 11 is, for example, 1 mm or more and 3 mm or less.

[0053] The blade body 12 is a portion of the bond phase 1 that is located radially inward of the cutting edge portion 11. The blade body 12 is annular and has a circular plate shape centered on the central axis O. In this embodiment, the blade body 12 is disposed over the entire portion of the bond phase 1 except for the cutting edge portion 11. In this embodiment, the blade body 12 and the cutting edge portion 11 are integrally formed using the same material and composition.

[0054] The blade body portion 12 has a flange contact portion 14 and a body exposed portion 15 . The flange contact portion 14 is in the shape of an annular plate centered on the central axis O. The flange contact portion 14 is arranged in a portion of the blade body 12 other than the outer periphery. The flange contact portion 14 is a portion of the bonded phase 1 that is pressed axially by the flange F of the main shaft of the cutting device and is held by the flange. In other words, the flange F comes into contact with the flange contact portion 14. The flange contact portion 14 is arranged radially inward of the boundary B between the blade body 12 and the cutting edge portion 11.

[0055] The main body exposed portion 15 has an annular plate shape centered on the central axis O. The main body exposed portion 15 is arranged on the outer periphery of the blade main body 12. The main body exposed portion 15 is located radially outward from the flange F. In other words, the main body exposed portion 15 is a portion of the bond phase 1 that is exposed to the outside without being pressed by the flange F. The main body exposed portion 15 is located between the boundary B and the flange contact portion 14 in the radial direction.

[0056] The attachment hole 13 is located on the central axis O of the bond phase 1. The attachment hole 13 is a circular hole centered on the central axis O. The attachment hole 13 penetrates the bond phase 1 in the axial direction. The attachment hole 13 opens to a pair of plate surfaces 1a, 1a facing the axial direction of the bond phase 1.

[0057] The abrasive grains 2 are, for example, diamond abrasive grains or cBN abrasive grains. The plurality of abrasive grains 2 are dispersed in at least the cutting edge portion 11 of the bond phase 1 (see FIG. 11). Although not particularly shown, in this embodiment, the plurality of abrasive grains 2 are dispersed throughout the bond phase 1. The average particle size of the abrasive grains 2 is, for example, 8 μm or more and 50 μm or less.

[0058] In this embodiment, the "average particle size" refers to a volume-average diameter measured using a laser diffraction / scattering measuring device. The volume-average diameter is a weighted average diameter based on the overall volume distribution of the abrasive grains 2, which are the object of measurement, ranging from small to large grains. As the laser diffraction / scattering measuring device, for example, a Microtrac MT3300EXII-SDC model can be used.

[0059] As shown in Figures 1 and 2, the bond reinforcement portion 3 is disposed in the bond phase 1 and is held by the bond phase 1. The bond reinforcement portion 3 is made of a material having a higher Young's modulus than the bond phase 1. In this embodiment, the bond reinforcement portion 3 is made of a non-conductive material. The bond reinforcement portion 3 is made of, for example, zirconia. In other words, the bond reinforcement portion 3 in this embodiment is made of ceramics. The multiple bond reinforcement portions 3 are disposed in the blade main body portion 12 of the bond phase 1. The bond reinforcement portions 3 are not disposed in the cutting edge portion 11.

[0060] As shown in FIG. 1, the bond reinforcement portion 3 extends in one direction, i.e., a predetermined direction, when viewed from the axial direction. The bond reinforcement portion 3 is rod-shaped and extends in one direction when viewed from the axial direction. Specifically, the bond reinforcement portion 3 is a square rod-shaped portion with a square cross section, and extends linearly. The radial positions of one end and the other end of the bond reinforcement portion 3 are different from each other.

[0061] In this embodiment, each bond reinforcement portion 3 extends along the radial direction. The multiple bond reinforcement portions 3 are arranged at intervals in the circumferential direction. In the illustrated example, eight bond reinforcement portions 3 are arranged at equal intervals in the circumferential direction. The multiple bond reinforcement portions 3 are arranged in rotationally symmetric positions with respect to one another about the central axis O. In the illustrated example, the multiple bond reinforcement portions 3 are arranged radially about the central axis O.

[0062] The bond reinforcement portion 3 is disposed in the blade main body portion 12 across the flange contact portion 14 and the main body exposed portion 15. In this embodiment, the radially inner end of the bond reinforcement portion 3 is located on the inner periphery of the flange contact portion 14. The radially outer end of the bond reinforcement portion 3 is located on the outer periphery of the main body exposed portion 15. When viewed from the axial direction, the bond reinforcement portion 3 has a portion that is disposed overlapping with the flange F and a portion that is disposed radially outward from the flange F (i.e., does not overlap with the flange F). In other words, the bond reinforcement portion 3 has a portion that is pressed by the flange F and a portion that is not pressed by the flange F and protrudes radially outward from the flange F.

[0063] 1 and 2, the bond reinforcement portion 3 is exposed on a plate surface 1a facing the axial direction of the bond phase 1. Specifically, an end surface 3a of the bond reinforcement portion 3 facing the axial direction among the outer surfaces of the bond reinforcement portion 3 is exposed on the plate surface 1a of the bond phase 1. In this embodiment, the axial position of the end surface 3a of the bond reinforcement portion 3 and the axial position of the plate surface 1a of the bond phase 1 are the same. In other words, the end surface 3a and the plate surface 1a are arranged so as to be flush with each other.

[0064] 2, a pair of end faces 3a, 3a facing the axial direction of the bond reinforcement portion 3 are exposed to a pair of plate surfaces 1a, 1a of the bond phase 1. That is, the bond reinforcement portion 3 is exposed to each of the pair of plate surfaces 1a, 1a of the bond phase 1. Therefore, the axial dimension of the bond reinforcement portion 3 is approximately equal to the axial dimension of the bond phase 1.

[0065] As shown in Fig. 5, the bond reinforcement portion 3 has a recess 3c recessed from the outer surface of the bond reinforcement portion 3. The recess 3c is recessed from the side surface 3b of the outer surface of the bond reinforcement portion 3, which faces the blade circumferential direction (corresponding to the width direction of the bond reinforcement portion 3). In this embodiment, the recess 3c is arranged on the side surface 3b of the bond reinforcement portion 3 over the entire axial direction (thickness direction) and opens to a pair of end faces 3a, 3a. In other words, the recess 3c is groove-shaped and penetrates the bond reinforcement portion 3 in the axial direction.

[0066] A plurality of recesses 3c are provided in the bond reinforcement portion 3. The recesses 3c are arranged on each of a pair of side surfaces 3b, 3b of the bond reinforcement portion 3 facing the blade circumferential direction. The plurality of recesses 3c are arranged at intervals from each other in one direction in which the bond reinforcement portion 3 extends (in this embodiment, the blade radial direction). During blade manufacturing, when the bond reinforcement portion 3 is held by the bond phase 1, a portion of the bond phase 1 enters each recess 3c. In other words, a portion of the bond phase 1 is arranged in the recesses 3c.

[0067] Although not specifically shown, the bond reinforcement portion 3 preferably has a rough surface portion on its outer surface, the roughness of which is a predetermined value or more. The rough surface portion is formed, for example, by subjecting the outer surface of the bond reinforcement portion 3 to a blasting treatment. The surface roughness of the rough surface portion is, for example, 0.2 μm or more and 20 μm or less in terms of arithmetic mean roughness Ra. The rough surface portion is disposed at least in a portion of the outer surface of the bond reinforcement portion 3 that comes into contact with the bond phase 1, and in this embodiment, is disposed at least on the side surface 3b. The rough surface portion may also be disposed within the recess 3c.

[0068] Next, a method for manufacturing the cutting blade 10 of this embodiment will be described. As shown in FIG. 3, the manufacturing method of the cutting blade 10 of this embodiment includes a bond reinforcement portion fabrication process S11, a bond reinforcement portion positioning process S12, a plating process S13, an excess plating removal process S14, and an inner and outer diameter processing process S15.

[0069] In the bond reinforcement portion preparation step S11, the bond reinforcement portion 3 is prepared. In this embodiment, as shown in Fig. 4, a plate-shaped reinforcement portion material RM is cut into a thin plate by, for example, electric discharge machining or laser machining, to form the bond reinforcement portion 3 as shown in Fig. 5. A plurality of grooves G that become the recesses 3c when the bond reinforcement portion 3 is cut out are formed in advance in the reinforcement portion material RM.

[0070] In the bond reinforcement portion positioning step S12, the bond reinforcement portion 3 is positioned and fixed to the base metal 100. More specifically, as shown in FIGS. 6 and 7, a plurality of bond reinforcement portions 3 are positioned and fixed to the base metal 100 so that the bond reinforcement portions 3 are arranged as described above. In this embodiment, the bond reinforcement portions 3 are fixed to the base metal 100 with adhesive 101. Specifically, the end surface 3a of the bond reinforcement portion 3 and the upper surface of the base metal 100 are partially bonded at a plurality of locations with the adhesive 101. The end surface 3a of the bond reinforcement portion 3 and the upper surface of the base metal 100 are arranged opposite each other with a gap between them via the scattered adhesive 101.

[0071] In the plating step S13, the bond reinforcement portion 3 and the base metal 100 are immersed in a plating bath, and the bond phase 1 is precipitated on at least the base metal 100 out of the bond reinforcement portion 3 and the base metal 100. In this embodiment, the bond reinforcement portion 3 is made of ceramic, which is a non-conductive material, so the bond phase 1 is precipitated on the base metal 100 by electrolytic plating, as shown in Figures 8 and 9.

[0072] Although not shown in the figure, the plating bath contains metal components such as Ni, which are the raw materials for the bond phase 1, abrasive grains 2, and, as necessary, various fillers. In the plating bath, the bond phase 1 is precipitated to a predetermined thickness on the upper surface of the base metal 100 while incorporating the abrasive grains 2 (and filler), and then the bond phase 1 is peeled off from the base metal 100.

[0073] 8, in the excess plating removal step S14, excess plating portion P1 is removed from the bond phase 1. Specifically, the excess plating portion P1 is, for example, an excess plating layer formed between the upper surface of the base metal 100 and the end surface 3a of the bond reinforcement portion 3 according to the axial dimension (thickness dimension) of the adhesive 101. The excess plating portion P1 is removed from the bond phase 1 by polishing it, for example, by lapping.

[0074] In addition, one of the pair of end faces 3a, 3a of the bond reinforcement portion 3 may be exposed to one of the pair of plate surfaces 1a, 1a of the bond phase 1, and the other of the pair of end faces 3a, 3a of the bond reinforcement portion 3 may not be exposed to the other of the pair of plate surfaces 1a, 1a of the bond phase 1, in which case the excess plating removal process S14 may not be provided.

[0075] In the inner and outer diameter machining step S15, the bond phase 1 is subjected to inner diameter machining and outer diameter machining. Through the above steps, a cutting blade 10 having a predetermined axial dimension (thickness dimension), a predetermined inner diameter dimension, and a predetermined outer diameter dimension is manufactured.

[0076] According to the cutting blade 10 and manufacturing method thereof of this embodiment described above, the bond reinforcement portion 3, which has a higher Young's modulus than the bond phase 1, is disposed in the blade body 12 of the bond phase 1. This increases the rigidity of the blade body 12, and also improves the blade rigidity of the entire cutting blade 10. In this embodiment, the hardness of the material constituting the bond phase 1 is not increased, but the strength of the bond phase 1 is increased by the bond reinforcement portion 3, so that the effect of favorably self-sharpening the abrasive grains 2 in the cutting edge portion 11, i.e., the self-sharpening effect, can be favorably maintained.

[0077] Therefore, according to this embodiment, the cutting blade 10 can be manufactured inexpensively compared to when an expensive cemented carbide alloy or the like is used as the material for the bond phase 1 to increase the rigidity of the bond phase 1. When the cutting blade 10 of this embodiment was used to cut a material to be cut, it was confirmed that the straightness of the blade was maintained even during high-speed cutting at a feed rate of 400 mm / sec.

[0078] In this embodiment, the bond reinforcement portion 3 extends in one direction when viewed from the axial direction, and the radial position of one end of the bond reinforcement portion 3 is different from the radial position of the other end. In this case, the strength of the bond phase 1 at each radial position is more easily equalized, and the rigidity of the bond phase 1 at each radial position is stably increased. The strength of the bond phase 1 along the radial direction is increased, and straightness during cutting is more stable.

[0079] In this embodiment, the bond reinforcement portions 3 are arranged at positions that are rotationally symmetrical with respect to one another about the central axis O. That is, the bond reinforcement portions 3 are arranged at equal pitches in the circumferential direction. In this case, the rigidity of the bond phase 1 in the circumferential direction is equalized, and straightness during cutting is more stably ensured.

[0080] In this embodiment, the bond reinforcing portion 3 is exposed on the plate surface 1a of the bond phase 1 facing the axial direction. For example, compared to a case where the bond reinforcement portion 3 is not exposed from the plate surface 1a facing the axial direction of the bond phase 1, the above-described configuration of this embodiment can increase the ratio of the axial dimension of the bond reinforcement portion 3 to the axial dimension (thickness dimension) of the bond phase 1. In other words, a large axial dimension of the bond reinforcement portion 3 can be ensured. This makes it possible to more stably increase blade rigidity. In this embodiment, the bond reinforcing portion 3 is exposed to a pair of plate surfaces 1a, 1a facing the axial direction of the bond phase 1, so that the above-mentioned effects become more pronounced.

[0081] In this embodiment, the bond reinforcement portion 3 has a recess 3c recessed from the outer surface of the bond reinforcement portion 3. In this case, during the manufacturing of the cutting blade 10, a part of the bond phase 1 enters the recess 3c of the bond reinforcement part 3. In other words, a part of the bond phase 1 is disposed in the recess 3c. This provides an anchor effect, increasing the holding power of the bond reinforcement part 3. The bond reinforcement part 3 is firmly integrated with the bond phase 1, and can be prevented from falling off the bond phase 1.

[0082] In this embodiment, the bond reinforcement portion 3 may have a rough surface portion on the outer surface thereof, the surface roughness of which is set to a predetermined value or more, and in this case, the following advantageous effects are obtained. That is, in this case, when the cutting blade 10 is manufactured, the bond phase 1 adheres to the rough surface portion of the bond reinforcement portion 3, thereby ensuring a large contact area between the bond reinforcement portion 3 and the bond phase 1. This increases the holding force of the bond reinforcement portion 3 to the bond phase 1. The bond reinforcement portion 3 is firmly integrated with the bond phase 1, and can be prevented from falling off from the bond phase 1.

[0083] In this embodiment, the bond reinforcement portion 3 has a rod shape extending in one direction when viewed from the axial direction. In this case, when manufacturing the cutting blade 10, the bond reinforcement portions 3 are easily arranged on the blade body 12, making handling easier. Also, there is less variation in the function (action) of each bond reinforcement portion 3. Therefore, the effect of this embodiment is more likely to be stabilized.

[0084] In this embodiment, the bond reinforcement portion 3 is disposed across the flange contact portion 14 and the exposed portion 15 of the blade main body portion 12 . By arranging the bond reinforcement portion 3 from the flange contact portion 14 to the main body exposed portion 15 radially outside thereof, the rigidity of the portion of the bond phase 1 other than the flange contact portion 14, i.e., the rigidity of the main body exposed portion 15 and cutting edge portion 11 that are exposed to the outside without being pressed by the flange F during cutting processing, is stably increased.

[0085] In this embodiment, the bond reinforcing portion 3 is made of ceramics. In this case, the Young's modulus of the bond reinforcement portion 3 can be easily and stably increased compared to the Young's modulus of the bond phase 1 .

[0086] In this embodiment, the bond phase 1 is a plating phase, and the bond reinforcing portion 3 is made of a non-conductive material. In this case, the bond phase 1 that holds the bond reinforcement portion 3 is made of a plated phase, so deformation due to thermal contraction during blade manufacturing is suppressed compared to, for example, a resin bond phase that requires hot pressing during blade manufacturing, making it easier to manufacture the cutting blade 10. Furthermore, since the bond reinforcing portion 3 is non-conductive, plating adhesion to the bond reinforcing portion 3 is suppressed when the bond phase 1 is produced by electrolytic plating. This makes it possible to appropriately reduce the lapping process and other steps that are performed after the plating process.

[0087] Furthermore, according to the method for manufacturing the cutting blade 10 of this embodiment, the cutting blade 10 of the present invention in which the bond phase 1 is made of a plated phase, that is, an electroformed blade, can be stably manufactured.

[0088] Second Embodiment Next, a cutting blade 10 according to a second embodiment of the present invention and a method for manufacturing the same will be described with reference to Figures 10 and 11. In this embodiment, the same components as those in the previous embodiment will be given the same names and symbols, and their descriptions may be omitted. In this embodiment, the same steps as those in the manufacturing method described in the previous embodiment will be given the same names, and their descriptions may be omitted.

[0089] The configuration of the cutting blade 10 of this embodiment is the same as the configuration of the cutting blade 10 described in the previous embodiment. However, in this embodiment, the method of manufacturing the cutting blade 10 is different from the method of manufacturing the cutting blade 10 described in the previous embodiment.

[0090] As shown in FIG. 10, the manufacturing method of the cutting blade 10 of this embodiment includes a bond reinforcement portion manufacturing process S21, a bond reinforcement portion positioning process S22, a preliminary plating process S23, a plating process S24, a preliminary plating removal process S25, and an inner diameter and outer diameter processing process S26. The bond reinforcement portion fabrication step S21, the bond reinforcement portion positioning step S22, and the inner and outer diameter processing step S26 are the same as those in the above-described embodiment, and therefore description thereof will be omitted.

[0091] 11 , in the preliminary plating step S23, the bond reinforcement portion 3 and the base metal 100 are immersed in a first plating bath, and a preliminary plating phase 102 made of a material different from the bond phase 1 is precipitated on the base metal 100. In this embodiment, for example, Cu, which is a metal material different from Ni of the bond phase 1, is used as the preliminary plating phase 102.

[0092] Although not specifically shown, the first plating bath contains metal components such as Cu, which are raw materials for the preliminary plating phase 102. In the first plating bath, the preliminary plating phase 102 is deposited on the upper surface of the base metal 100 to a predetermined thickness. This predetermined thickness is, for example, the same as the axial dimension (thickness) of the adhesive 101.

[0093] In the plating step S24, the bond reinforcement portion 3, the base metal 100 and the pre-plated phase 102 are immersed in a second plating bath different from the first plating bath, and the bond phase 1 is precipitated on the pre-plated phase 102.

[0094] Although not specifically shown, the second plating bath contains metal components such as Ni, which are raw materials for the bond phase 1, abrasive grains 2, and, as necessary, various fillers. In the second plating bath, the bond phase 1 is precipitated to a predetermined thickness on the upper surface of the preliminary plating phase 102 while incorporating the abrasive grains 2 (and filler), and then the laminate of the bond phase 1 and the preliminary plating phase 102 is peeled off from the base metal 100.

[0095] In the pre-plating removal step S25, the pre-plating phase 102 is removed from the laminate of the bond phase 1 and the pre-plating phase 102. Specifically, for example, only the pre-plating phase 102 is removed from the laminate by dissolution or the like.

[0096] According to the manufacturing method of the cutting blade 10 of the present embodiment described above, it is possible to stably manufacture the cutting blade 10 of the present invention, i.e., an electroformed blade, in which the bond phase 1 is composed of a plated phase. Furthermore, because only the pre-plated phase 102 can be removed from the laminate of the bond phase 1 and the pre-plated phase 102 by, for example, dissolution, it is easier to suppress the effects of external loads, thermal loads, and the like on the manufactured cutting blade 10 compared to removing the pre-plated phase 102 by, for example, lapping. However, the present invention is not limited to this, and the pre-plating layer 102 may be removed from the laminate by lapping or the like.

[0097] <Third embodiment> Next, a cutting blade 30 according to a third embodiment of the present invention and a method for manufacturing the same will be described with reference to Figures 12 and 13. In this embodiment, the same components as those in the previous embodiment will be given the same names and symbols, and their description may be omitted. In this embodiment, the same steps as those in the manufacturing method described in the previous embodiment will be given the same names, and their description may be omitted.

[0098] In the cutting blade 30 of this embodiment, the material of the bond reinforcement portion 33 is different from the material of the bond reinforcement portion 3 described in the previous embodiment. In this embodiment, the bond reinforcement portion 33 is made of a conductive material. Specifically, the bond reinforcement portion 33 is made of a cemented carbide alloy.

[0099] Furthermore, the manufacturing method of the cutting blade 30 of this embodiment includes a bond reinforcement portion fabrication process S11, a bond reinforcement portion positioning process S12, a plating process S13, an excess plating removal process S14, and an inner and outer diameter processing process S15, similar to the first embodiment described above (see FIG. 3).

[0100] In this embodiment, since the bond reinforcement portion 33 is conductive, as shown in Figures 12 and 13, in the plating process S13, a bond phase 1 (plated phase) is precipitated on the base metal 100 and the bond reinforcement portion 33 while incorporating abrasive grains 2, etc.

[0101] For this reason, in the excess plating removal step S14, excess plating portions P1, P2 are removed by lapping or the like from both axial sides of the bond phase 1. That is, depending on the axial dimension of the adhesive 101, excess plating portion P1 formed between the upper surface of the base metal 100 and one end face (lower surface) 3a of the bond reinforcement portion 33 and excess plating portion P2 formed on the other end face (upper surface) 3a of the bond reinforcement portion 33 are each removed by lapping or the like.

[0102] According to the cutting blade 30 of this embodiment and the manufacturing method thereof described above, the same effects as those of the above-described embodiment can be obtained.

[0103] In this embodiment, the bond reinforcement portion 33 is made of a cemented carbide alloy. In this case, the Young's modulus of the bond reinforcement portion 33 can be easily and stably increased compared to the Young's modulus of the bond phase 1 .

[0104] <Fourth embodiment> Next, a cutting blade 40 according to a fourth embodiment of the present invention and a method for manufacturing the same will be described with reference to Figures 14 to 18. In this embodiment, the same components as those in the previous embodiment will be given the same names and symbols, and their description may be omitted. In this embodiment, the same steps as those in the manufacturing method described in the previous embodiment will be given the same names, and their description may be omitted.

[0105] The cutting blade 40 of this embodiment differs from the above-described embodiment in the configuration and material of the bond reinforcement portion 43. As shown in FIG. 14 , in this embodiment, the bond reinforcement portion 43 extends in one direction when viewed from the axial direction. The bond reinforcement portion 43 has a plurality of granular bodies 44 arranged in one direction. That is, the bond reinforcement portion 43 is formed so that it extends in one direction as a whole by arranging the plurality of granular bodies 44 in one direction. In this embodiment, the plurality of granular bodies 44 of the bond reinforcement portion 43 are aligned along the radial direction. Furthermore, the plurality of granular bodies 44 are arranged at intervals from one another. The bond reinforcement portion 43 is arranged across the flange contact portion 14 and the main body exposed portion 15.

[0106] The granular material 44 is made of a non-conductive material. Specifically, the granular material 44 is a diamond abrasive grain, that is, made of diamond. As shown in FIG. 18, the granular material 44 has a larger average grain size than the abrasive grains 2. The average grain size of the granular material 44 is, for example, 40 μm or more and 150 μm or less. The average grain size of the granular material 44 is, for example, equal to or less than the axial dimension of the cutting blade 40 (bond phase 1). Furthermore, the average grain size of the granular material 44 is, for example, equal to or more than half the axial dimension of the cutting blade 40.

[0107] The manufacturing method of the cutting blade 40 of this embodiment also includes a bond reinforcement portion positioning step S12, a plating step S13, an excess plating removal step S14, and an inner and outer diameter processing step S15 (see FIG. 3).

[0108] In this embodiment, the bond reinforcement portion 43 is made up of an arrangement of multiple granular bodies 44, so as shown in Figures 15 and 16, in the bond reinforcement portion positioning process S12, each granular body 44 of the bond reinforcement portion 43 is fixed onto the base metal 100 with adhesive 101.

[0109] In the plating step S13, the bond reinforcement portion 43 and the base metal 100 are immersed in a plating bath, and the bond phase 1 is precipitated on the base metal 100, as shown in Figures 17 and 18. In this embodiment, the bond reinforcement portion 43 is made of diamond, which is a non-conductive material, and therefore the bond phase 1 is precipitated only on the base metal 100 by electrolytic plating.

[0110] Although not shown in the figure, the plating bath contains metal components such as Ni, which are the raw materials for the bond phase 1, abrasive grains 2, and, as necessary, various fillers. In the plating bath, the bond phase 1 is precipitated to a predetermined thickness on the upper surface of the base metal 100 while incorporating the abrasive grains 2 (and filler), and then the bond phase 1 is peeled off from the base metal 100.

[0111] In the excess plating removal step S14, as shown in Fig. 18, excess plating portion P1 is removed from the bond phase 1. Specifically, the excess plating portion P1 is an excess plating layer formed between the upper surface of the base metal 100 and the lower surface of the bond reinforcement portion 43, i.e., the lower surface of each granular body 44, depending on the axial dimension (thickness dimension) of the adhesive 101. The excess plating portion P1 is removed from the bond phase 1 by polishing it, for example, by lapping.

[0112] According to the cutting blade 40 of this embodiment and the manufacturing method thereof described above, the same effects as those of the above-described embodiment can be obtained.

[0113] In this embodiment, the bond reinforcement portion 43 has a plurality of granular bodies 44 arranged in one direction. In this way, the bond reinforcement portion 43 can be provided on the blade body 12 by using a plurality of granular bodies 44 arranged in one direction. In this case, the degree of freedom in the shape of the bond reinforcement portion 43 is also increased.

[0114] In this embodiment, the bond reinforcing portion 43 is made of diamond. In this case, the Young's modulus of the bond reinforcement portion 43 can be more stably increased than that of the bond phase 1 .

[0115] In this embodiment, the plurality of particles 44 are arranged at intervals from one another in one direction. For example, if multiple granular bodies 44 are arranged in close contact with each other in one direction, when these granular bodies 44 are fixed to the base metal 100 with adhesive 101 in the bond reinforcement portion positioning step S12, the adhesive strength between the entire multiple granular bodies 44, i.e., the bond reinforcement portion 43, and the base metal 100 may become too strong, making it difficult to peel the bond reinforcement portion 43 and the bond phase 1 from the base metal 100 after the plating step S13. On the other hand, according to the above-mentioned configuration of this embodiment, the lower surfaces of the multiple granular bodies 44 and the upper surface of the base metal 100 can be partially bonded at multiple locations using adhesive 101, making it easy to peel the bond reinforcement portion 43 and bond phase 1 from the base metal 100 after the plating process S13.

[0116] In this embodiment, the average particle size of the granular material 44 is equal to or larger than half the axial dimension of the cutting blade 40. The average particle size of the granular material 44 is equal to or smaller than the axial dimension of the cutting blade 40. When the average particle size of the granular material 44 is equal to or greater than half the axial dimension of the cutting blade 40, the effect of increasing the blade rigidity by the bond reinforcement portion 43 becomes more pronounced. Furthermore, if the average particle size of the granular material 44 is equal to or less than the axial dimension of the cutting blade 40, the flange contact portion 14, ie, the bond phase 1, can be stably pressed by the flange F, resulting in a stable cutting state.

[0117] Fifth Embodiment Next, a cutting blade 50 according to a fifth embodiment of the present invention and a method for manufacturing the same will be described with reference to Figures 19 and 20. In this embodiment, the same components as those in the previous embodiment will be given the same names and reference numerals, and their description may be omitted. In this embodiment, the same steps as those in the manufacturing method described in the previous embodiment will be given the same names, and their description may be omitted.

[0118] As shown in Figure 19, in the cutting blade 50 of this embodiment, the bond reinforcement portion 53 has multiple rows of multiple granular bodies 44 arranged in one direction when viewed from the axial direction (hereinafter, may be simply referred to as rows of granular bodies 44). In the example shown, each bond reinforcement portion 53 has two rows of granular bodies 44. The two rows of granular bodies 44 in the bond reinforcement portion 53 are arranged adjacent to each other in the circumferential direction. However, this is not limiting, and each bond reinforcement portion 53 may have three or more rows of granular bodies 44.

[0119] Furthermore, the manufacturing method of the cutting blade 50 of this embodiment includes a bond reinforcement portion positioning step S12, a plating step S13, an excess plating removal step S14, and an inner and outer diameter processing step S15, similar to the fourth embodiment described above (see FIG. 3). As shown in FIG. 20, in the bond reinforcing portion positioning step S12, each of the particles 44 of the bond reinforcing portion 53 is positioned and fixed on the base metal 100 with an adhesive 101.

[0120] According to the cutting blade 50 of this embodiment and the manufacturing method thereof described above, the same effects as those of the above-described embodiment can be obtained.

[0121] In this embodiment, the bond reinforcement portion 53 has a plurality of rows of the granular bodies 44 . In this case, the bond reinforcement portion 53 increases the blade rigidity more stably.

[0122] Sixth Embodiment Next, a cutting blade 60 according to a sixth embodiment of the present invention and a method for manufacturing the same will be described with reference to Fig. 21. In this embodiment, the same components as those in the previous embodiments will be given the same names and reference numerals, and their description may be omitted. In this embodiment, the same steps as those in the manufacturing method described in the previous embodiments will be given the same names, and their description may be omitted.

[0123] As shown in Fig. 21, in the cutting blade 60 of this embodiment, the bond reinforcement portion 63 has a plurality of granular bodies 44 arranged in one direction when viewed from the axial direction. The bond reinforcement portion 63 extends in the circumferential direction as it moves in the radial direction. In the illustrated example, the bond reinforcement portion 63 is located on one side in the circumferential direction (counterclockwise in Fig. 21) as it moves radially outward.

[0124] The manufacturing method of the cutting blade 60 is the same as that of the fourth and fifth embodiments described above, except for the placement of the bond reinforcement portion 63 on the base metal 100 (bond reinforcement portion positioning step S12). Fig. 21 shows the bond reinforcement portion positioning step S12 of this embodiment.

[0125] According to the cutting blade 60 of this embodiment and the manufacturing method thereof described above, the same effects as those of the above-described embodiment can be obtained.

[0126] In this embodiment, the bond reinforcement portion 63 extends in the circumferential direction as it extends in the radial direction. In this case, the bond reinforcement portion 63 is disposed over a wide range in the radial and circumferential directions in the blade body 12. Therefore, the effect of increasing the blade rigidity by the bond reinforcement portion 63 becomes more stable.

[0127] Specifically, the strength of the bond phase 1 is more easily equalized at each radial position and each circumferential position. This stably increases the rigidity of the bond phase 1 at each radial position and each circumferential position. Furthermore, the strength of the bond phase 1 along the radial direction and the strength along the circumferential direction are increased, which further stabilizes the straightness during cutting.

[0128] Seventh Embodiment Next, a cutting blade 70 according to a seventh embodiment of the present invention and a method for manufacturing the same will be described with reference to Figures 22 to 24. In this embodiment, the same components as those in the previous embodiments will be given the same names and reference numerals, and their description may be omitted. In this embodiment, the same steps as those in the manufacturing method described in the previous embodiments will be given the same names, and their description may be omitted.

[0129] The cutting blade 70 of this embodiment differs from the cutting blade 50 of the fifth embodiment (FIG. 19) described above in the configuration of the bond phase 1. As shown in FIG. 22, the cutting blade 70 of this embodiment has a blade body 12 and a cutting edge 11 that are formed separately from different materials and compositions, or from the same material and composition, and then integrated together.

[0130] Specifically, the cutting blade 70 of this embodiment can employ various configurations, such as those described below. That is, for example, the material of the plating phase forming the blade body 12 is different from the material of the plating phase forming the cutting edge portion 11. Also, for example, abrasive grains 2 are contained only in the cutting edge portion 11, and abrasive grains 2 are not contained in the blade body 12. Alternatively, the abrasive grains 2 contained in the cutting edge portion 11 are different from the abrasive grains (abrasive grains other than the granules 44) contained in the blade body 12. Also, for example, the filler contained in the cutting edge portion 11 is different from the filler contained in the blade body 12. By appropriately using the above-described configuration, it is preferable to give the blade body 12 and the cutting edge 11 functions suited to each other.

[0131] As shown in FIG. 23, the method for manufacturing the cutting blade 70 of this embodiment includes a bond reinforcement portion positioning step S71, a blade body plating step S72, a cutting edge portion plating step S73, and an inner and outer diameter processing step S74.

[0132] In the bond reinforcement portion positioning step S71, the bond reinforcement portion 53, ie, the plurality of granular bodies 44, are positioned and fixed to the base metal 100 by the adhesive 101, as in the fifth embodiment described above.

[0133] In the blade body plating step S72, the bond reinforcement portion 53 and the base metal 100 are immersed in a plating bath, and the blade body 12 of the bond phase 1 is precipitated on the base metal 100. Although not shown in the figure, the plating bath contains metal components such as Ni, which are the raw materials for the blade body 12, as well as abrasive grains 2 and various fillers, etc., as necessary. In the plating bath, the blade body 12 is precipitated on the upper surface of the base metal 100 to a predetermined thickness while incorporating the abrasive grains 2 and various fillers, and then the blade body 12 is peeled off from the base metal 100.

[0134] In the cutting edge plating process S73, the blade body 12 and bond reinforcement portion 53 peeled off from the base metal 100 are rotated around the central axis O in a plating bath PB as shown in Figure 24, while a cutting edge portion 11 is deposited on the outer periphery of the blade body 12, protruding radially outward from the outer periphery and extending circumferentially.

[0135] Specifically, in this embodiment, a cylindrical support shaft 103 is fitted to the inner periphery of each of the blade bodies 12, each having an annular plate shape. Non-conductive annular plate-shaped spacers S having approximately the same outer diameter as the blade body 12 are provided on both axial sides of the blade body 12. That is, the blade body 12 is sandwiched between the pair of spacers S from both axial sides. Then, the blade bodies 12 are rotated around the central axis O together with the support shafts 103 by a motor M, and a cutting edge portion 11 is deposited on the radially outer end of each blade body 12. During this process, abrasive grains 2 and various fillers are precipitated into the plating bath PB from above each blade body 12. While incorporating the abrasive grains 2 and various fillers, a ring-shaped cutting edge portion 11 is deposited around the central axis O on the outer periphery of each blade body 12, with a predetermined radial dimension. This produces a bond phase 1 including the blade body 12 and the cutting edge portion 11.

[0136] In the inner and outer diameter machining step S74, the bond phase 1 is subjected to inner diameter machining and outer diameter machining. In the manufacturing method of the cutting blade 70 of this embodiment, the excess plating removal process described in the previous embodiment may be performed after the blade body plating process S72 or the cutting edge plating process S73, as appropriate and necessary, or a preliminary plating process and a preliminary plating removal process may be performed before or after the blade body plating process S72.

[0137] According to the cutting blade 70 of this embodiment and the manufacturing method thereof described above, the same effects as those of the above-described embodiment can be obtained.

[0138] Furthermore, the manufacturing method for the cutting blade 70 of this embodiment allows for stable manufacturing of the cutting blade 70 of the present invention, i.e., an electroformed blade, in which the bond phase 1 is composed of a plating phase. It is also possible to change the type of plating bath for the blade body 12 and the cutting edge portion 11 of the bond phase 1. For example, the plating material, the size of the contained abrasive grains 2, the type of filler, etc. can be appropriately set for each of the blade body 12 and the cutting edge portion 11, making it possible to add various functions to the cutting blade 70.

[0139] Specifically, in this embodiment, the blade body 12 and the cutting edge portion 11 of the bond phase 1 are formed separately and fixed together. This makes it easy to flexibly accommodate, for example, the functions required for the blade body 12 (such as blade rigidity) and the functions required for the cutting edge portion 11 (such as self-sharpening, chip removal, and maintaining good sharpness).

[0140] Eighth Embodiment Next, a cutting blade according to an eighth embodiment of the present invention and a method for manufacturing the same will be described with reference to Fig. 25. In this embodiment, the same components as those in the previous embodiments will be given the same names and symbols, and their descriptions may be omitted. In this embodiment, the same steps as those in the manufacturing method described in the previous embodiments will be given the same names, and their descriptions may be omitted.

[0141] The cutting blade of this embodiment differs from the above-described embodiment in the material of the bond phase 1. In this embodiment, the bond phase 1 is any one of a resin bond phase, a metal bond phase, and a vitrified bond phase. That is, when the bond phase 1 is a resin bond phase, the cutting blade is a resin blade. When the bond phase 1 is a metal bond phase, the cutting blade is a metal blade. When the bond phase 1 is a vitrified bond phase, the cutting blade is a vitrified blade.

[0142] As shown in FIG. 25, the method for manufacturing a cutting blade of this embodiment includes a bond reinforcement portion positioning step S81, a compression molding step S82, a sintering step S83, and an inner and outer diameter processing step S84.

[0143] Although not shown, in the bond reinforcement portion positioning step S81, the bond reinforcement portions are positioned and fixed in the mold. Specifically, for example, of the upper and lower molds of the mold, a plurality of bond reinforcement portions are positioned and fixed to the bottom surface of the lower mold using an adhesive or the like so as to be arranged in the same manner as in any of the above-described embodiments.

[0144] In the compression molding step S82, a mixed powder containing the raw material powder of the bond phase 1 is filled into a mold and compression molded to form a disk-shaped blade. The mixed powder may contain, in addition to the raw material powder of the bond phase 1, other additives such as abrasive grains, various fillers, binders, and solvents, depending on the material of the bond phase 1. The compression molding may be, for example, molding by cold pressing.

[0145] In the sintering step S83, the blade molded body is sintered. Specifically, the blade molded body produced in the compression molding step S82 is placed in a mold for hot pressing and hot pressed at a predetermined temperature and pressure to form a bond phase 1.

[0146] In the inner and outer diameter machining step S84, the bond phase 1 is subjected to inner diameter machining and outer diameter machining. Furthermore, if necessary, the bond layer 1 is subjected to a lapping process, an etching process, or the like.

[0147] According to the cutting blade and the manufacturing method thereof of this embodiment described above, the same effects as those of the above-described embodiment can be obtained.

[0148] In this embodiment, the bond phase 1 is any one of a resin bond phase, a metal bond phase, and a vitrified bond phase. In this case, the cutting blade of the present invention can be easily used appropriately and suitably in accordance with various requirements for the cutting blade.

[0149] Furthermore, the cutting blade manufacturing method of this embodiment can stably manufacture cutting blades of the present invention having bond phases 1 made of various materials other than the plating phase. Specifically, this manufacturing method can suitably manufacture, for example, resin blades in which the bond phase 1 is a resin bond phase, metal blades in which the bond phase 1 is a metal bond phase, and vitrified blades in which the bond phase 1 is a vitrified bond phase.

[0150] The present invention is not limited to the above-described embodiment, and the configuration can be changed within the scope of the present invention, as will be described below.

[0151] In the first to third embodiments described above, the bond reinforcement portions 3, 33 are each a rectangular rod having a cross section perpendicular to one direction that is rectangular, but the present invention is not limited to this. For example, the bond reinforcement portions 3, 33 may be a rod having a cross section perpendicular to one direction that is polygonal or circular, other than a rectangular shape.

[0152] In the fourth to seventh embodiments described above, examples have been given in which the bond reinforcement portions 43, 53, 63 have diamond abrasive grains as the plurality of granular bodies 44, but this is not limiting. The plurality of granular bodies 44 may be, for example, cBN abrasive grains other than diamond abrasive grains. That is, in this case, the bond reinforcement portions 43, 53, 63 are made of cBN or the like.

[0153] In addition, although the bond reinforcement portion extends linearly in the above-described embodiments, the present invention is not limited to this. That is, the bond reinforcement portion may extend, for example, in a curved shape when viewed in the axial direction.

[0154] The present invention may be combined with the various configurations described in the above-described embodiments and modifications, and may also include additions, omissions, substitutions, and other modifications within the scope of the present invention, without departing from the spirit of the present invention. Furthermore, the present invention is not limited to the above-described embodiments, but is limited only by the claims. [Industrial Applicability]

[0155] The cutting blade and the method for manufacturing the cutting blade of the present invention can increase blade rigidity while maintaining good sharpness of the cutting edge, and therefore have industrial applicability. [Explanation of symbols]

[0156] 1...bond phase, 1a...plate surface, 2...abrasive grain, 3,33,43,53,63...bond reinforcement portion, 3c...recess, 10,30,40,50,60,70...cutting blade, 11...cutting edge portion, 12...blade main body portion, 14...flange contact portion, 15...exposed main body portion, 44...granular body, 100...base metal, 102...preliminary plating phase, B...boundary, F...flange, O...center axis, PB...plating bath, S12, S22, S71, S81...bond reinforcement portion positioning step, S13, S24...plating step, S23...preliminary plating step, S25...preliminary plating removal step, S72...blade main body plating step, S73...cutting edge portion plating step, S82...compression molding step, S83...sintering step

Claims

1. a bond phase that is disc-shaped and has a cutting edge portion disposed on its outer periphery; a plurality of abrasive grains dispersed at least in the cutting edge portion; a plurality of bond reinforcement portions held by the bond phase and having a Young's modulus higher than that of the bond phase; The bond phase is The cutting edge portion; a blade body portion located radially inward of the cutting edge portion, a plurality of the bond reinforcement portions are disposed on the blade body portion; The bond reinforcement portion extends in one direction when viewed from the axial direction, The bond reinforcement portion has a plurality of granular bodies arranged in the same direction. Cutting blade.

2. a bond phase that is disc-shaped and has a cutting edge portion disposed on its outer periphery; a plurality of abrasive grains dispersed at least in the cutting edge portion; A cutting blade comprising: a plurality of bond reinforcement portions held in the bond phase and having a Young's modulus higher than that of the bond phase; The thickness of the cutting blade is 50 μm or more and 250 μm or less, The bond phase is The cutting edge portion; a blade body portion located radially inward of the cutting edge portion, a plurality of the bond reinforcement portions are disposed on the blade body portion; The bond reinforcement portions are arranged at intervals in the circumferential direction, the bond reinforcement portion has a recess recessed from an outer surface of the bond reinforcement portion, The recess is recessed from a side surface of the bond reinforcement portion facing a circumferential direction, Cutting blade.

3. The bond reinforcement portion extends in one direction when viewed from the axial direction, The radial position of one end of the bond reinforcement portion is different from the radial position of the other end of the bond reinforcement portion.

3. The cutting blade according to claim 1 or 2.

4. the bond reinforcement portions are arranged at positions rotationally symmetrical to one another about the central axis; A cutting blade according to any one of claims 1 to 3.

5. The bond reinforcement portion is exposed on a plate surface facing the axial direction of the bond phase, A cutting blade according to any one of claims 1 to 4.

6. The bond reinforcement portion has a rough surface portion on an outer surface of the bond reinforcement portion, the roughness of which is set to a predetermined value or more. A cutting blade according to any one of claims 1 to 5.

7. The bond reinforcement portion has a rod shape extending in one direction when viewed from the axial direction.

3. The cutting blade of claim 2.

8. The blade body portion is a main body exposed portion disposed on an outer periphery of the blade main body; a portion of the blade body other than the outer periphery, The bond reinforcement portion is disposed across a portion of the blade main body other than the outer periphery and the main body exposed portion. A cutting blade according to any one of claims 1 to 7.

9. The bond reinforcement portion is made of ceramics. A cutting blade according to any one of claims 1 to 8.

10. The bond reinforcement portion is made of diamond. A cutting blade according to any one of claims 1 to 8.

11. the bond phase is a plating phase, The bond reinforcement portion is made of a non-conductive material. A cutting blade according to any one of claims 1 to 10.

12. The bond reinforcement portion is made of cemented carbide. A cutting blade according to any one of claims 1 to 8.

13. The bond phase is any one of a resin bond phase, a metal bond phase, and a vitrified bond phase. A cutting blade according to any one of claims 1 to 10 and 12.

14. 10. A method for manufacturing the cutting blade of claim 1, comprising: a bond reinforcement portion positioning step of positioning and fixing the bond reinforcement portion to a base metal; a plating step of immersing the bond reinforcement portion and the base metal in a plating bath to precipitate the bond phase on the base metal, A method for manufacturing a cutting blade.

15. 10. A method for manufacturing the cutting blade of claim 1, comprising: a bond reinforcement portion positioning step of positioning and fixing the bond reinforcement portion to a base metal; a preliminary plating step of immersing the bond reinforcement portion and the base metal in a first plating bath to deposit a preliminary plating phase made of a material different from the bond phase on the base metal; a plating step of immersing the bond reinforcement portion, the base metal, and the pre-plated phase in a second plating bath different from the first plating bath to precipitate the bond phase on the pre-plated phase; A pre-plating removal step of removing the pre-plating phase from the laminate of the bond phase and the pre-plating phase. A method for manufacturing a cutting blade.

16. 10. A method for manufacturing the cutting blade of claim 1, comprising: a bond reinforcement portion positioning step of positioning and fixing the bond reinforcement portion to a base metal; a blade body plating step of immersing the bond reinforcement portion and the base metal in a plating bath to deposit the blade body on the base metal; a cutting edge plating step of rotating the blade body and the bond reinforcement portion separated from the base metal in a plating bath to deposit the cutting edge on the outer periphery of the blade body, the cutting edge protruding radially outward from the outer periphery and extending in a circumferential direction. A method for manufacturing a cutting blade.

17. 10. A method for manufacturing the cutting blade of claim 1, comprising: a bond reinforcement portion positioning step of positioning and fixing the bond reinforcement portion within a mold; a compression molding step of filling the mold with a mixed powder containing the raw material powder of the bond phase and compressing it to form a disk-shaped blade body; a sintering step of sintering the blade molded body. A method for manufacturing a cutting blade.

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