DIAMOND-CONTAINING BRAZING MATERIAL AND DIAMOND-JOINED TOOL

Abstract

([Problem] To provide a diamond-containing brazing material that is used for easier bonding of diamond surfaces to a tool or the like upon having coated the diamond surfaces with a non-peeling metal and a diamond-bonded tool or the like that utilizes the brazing material.

[Solution] In order to solve the problem, the present invention provides: a diamond-containing brazing material characterized in that non-peeling metal-coated diamonds, the surfaces of which have been coated with a metal in a non-peeling manner, are mixed in a brazing material; a diamond-containing brazing material characterized in that the diamond-containing brazing material is formed into a drop-like or rod-like shape; and a diamond-bonded tool or the like characterized in that upon having formed the diamond-containing brazing material into a tool shape, the brazing material is fused so as to be metal-bonded to a surface of the tool.

Claims

1. A diamond-containing brazing material characterized in that non-peelable metal-coated diamond in which metal is coated on a diamond surface non-peelably is mixed in a brazing material.

2. The diamond-containing brazing material according to claim 1, characterized in that the diamond-containing brazing material is shaped to a drop shape or a rod shape.

3. The diamond-containing brazing material according to claim 1, characterized in that the brazing material is a solder.

4. The diamond-containing brazing material according to claim 1, characterized in that hard metal or abrasive grains indicating heat resistance against melting heat of the brazing material are mixed in the brazing material in order to improve dispersion s performances of the non-peelable metal-coated diamond.

5. A diamond-joined tool characterized in that a brazing material of the diamond-containing brazing material according to claim 1 is melted and metallically bonded on a tool surface.

6. A diamond-joined tool characterized in that the diamond-containing brazing material according to claim 3 is deformed into a tool shape, and the brazing material is melted and metallically bonded to a tool surface.

7. A diamond-joined sheet characterized in that the diamond-containing brazing material according to claim 1 is melted and pressurized on a carbon disk into a sheet shape.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0062] FIGS. 1A, 1B, 1C and 1D are an explanatory view of a method of fabricating a diamond-joined hand file to which a non -peelable metal-coated diamond is soldered.

[0063] FIGS. 2A, 2B, 2C and 2D are an explanatory view of a method of fabricating a diamond-joined round grinding disk to which the non-peelable metal-coated diamond is soldered.

[0064] FIGS. 3A, 3B, 3C, 3D and 3E are an explanatory view of a method of fabricating a diamond-joined rotating cutting disk to which the non-peelable metal-coated diamond is soldered.

[0065] FIGS. 4A, 4B and 4C are an explanatory view of a method of fabricating a diamond-joined blade to which the non-peelable metal-coated diamond is soldered.

[0066] FIGS. 5A, 5B and 5C are an explanatory view of a method of fabricating a diamond-joined disk-shaped blade to which the non-peelable metal-coated diamond is soldered.

[0067] FIGS. 6A, 6B and 6C are an explanatory view of a method of fabricating a diamond-joined plate-shaped blade to which the non-peelable metal-coated diamond is soldered.

[0068] FIGS. 7A and 7 are an explanatory view of a method of fabricating a diamond-joined band-shaped blade to which the non-peelable metal-coated diamond is soldered.

[0069] FIGS. 8A, 8B and 8C are an explanatory view of a method of fabricating a diamond-joined polishing disk to which the non-peelable metal-coated diamond is soldered.

[0070] FIGS. 9A, 9B, 9C and 9D are an explanatory view of a method of fabricating a diamond-joined tool tip end to which the non-peelable metal-coated diamond is soldered.

[0071] FIGS. 10A, 10B, 10C and 10D are an explanatory view of a method of fabricating a diamond-joined sheet to which the non-peelable metal-coated diamond is soldered.

DESCRIPTION OF EMBODIMENT

[0072] An embodiment of the present invention will be described below in detail by referring to the attached drawings. The present invention is not limited to the following example.

[0073] A diamond-containing brazing material is obtained by mixing non-peelable metal-coated diamond with a brazing material such as silver solder, solder or the like. A shape of the non-peelable metal-coated diamond-containing brazing material is flat spherical shape (drop) or a round rod or a square rod (rod=bar) considering ease of use as it is, and the shape is freely changed for use.

[0074] The non-peelable metal-coated diamond has such bonding performances that the brazed surface is not non-peelable and the diamond is broken in a measurement test of coating strength and thus, it can be mixed in the brazing material or a lead-less solder and applied to a surface of an arbitrary metal material of an iron plate with a required dimension and shape or a used file so to as make a machining tool, and a tool optimal for machining of a trial product can be made by a user. [0075] (A) When the non-peelable metal-coated diamond single grain is added to a drop or a bar:

[0076] Though an effect depends on a size of an abrasive grain, it is important to give consideration so that the abrasive grains are not packed too closely as a diamond particle becomes larger. Even diamond can be crushed by a force or a shock, and since a lower half of the abrasive grain is fixed to a base metal, an upper half becomes a plane, which looks as if a diamond plane is formed, and a machining speed of a workpiece lowers or machining becomes impossible.

[0077] The larger a mesh size is, the larger plane is formed in many cases. The file can be reproduced by washing the surface of the used file well and by brazing the non-peelable metal-coated diamond with an appropriate size to a hole after a shaved blade of the file which has been worn and lost. Moreover, a notch with a required dimension is provided on an outer circumference of a disk, and the notch of the disk is filled and brazed by using a drop, a bar, a chip or the like of the non-peelable metal coated diamond with a required size so that it can be used as a cutting board.

[0078] As described above, by having the diamond abrasive grains contained in the brazing material or the solder and by flexibly deforming them to a preferred shape, the tool can be manufactured, which has been in demand for a long time by machining workers who are requested to meet required shapes and dimensions. [0079] (B) When an effect of a cutting blade of diamond is required by appropriately dispersing the non-peelable metal-coated diamond:

[0080] When the single grain of the non-peelable metal-coated diamond abrasive is mixed in the brazing material or solder, it is difficult to fix it to an application target material at a certain interval in many cases. In those cases, hard metal (metal such as tungsten, for example) which is not melted/mixed in a brazing material with a mesh equal to or slightly smaller than that of the diamond, solder or the like and other abrasive grains (materials having heat resistance such as SiC, Al.sub.2O.sub.3, GC and the like and a dispersing agent in which Cu, Ni, Ag and the like are electroless or electrolytic-plated on the surface thereof) are prepared and mixed so as to achieve a required surface dispersion value of diamond and to create a drop or a bar, and by applying on a tool having an intended shape or a tool having an arbitrary shape, an optimal tool to which the non-peelable metal-coated diamond with favorable dispersion is joined can be fabricated by the user.

[0081] The round rod or a square rod in which the non-peelable metal-coated diamond is appropriately dispersed may be used as a file as it is by utilizing its accuracy or as a tool for drilling or the like since it can be thermally deformed easily, it can be finished to a pellet or to a required shape to be used as a forming file. [0082] (C) When used as a pellet:

[0083] A conventional pellet is such that diamond is mixed without processing in a metal matrix as described above and fixed to a base, and a material to be ground is shaped to a required surface such as a plane, a curved surface, an irregular surface and the like with a required motion such as sliding or rotation.

[0084] In the present invention, by replacing a part of the diamond used in the conventional pellet by the non-peelable metal-coated diamond or by further adding the non-peelable metal-coated diamond in the conventional pellet in which raw diamond is mixed, early abrasion of the tool is improved, and finishing accuracy of the workpiece can be improved. Pa (D) In the case of the non-peelable metal-coated diamond-containing brazing material:

[0085] For example, by applying silver solder or a solder to a base having a required shape such as a wavy shape or a dent and by adjusting a balance, it can be used as a drill or a grinding blade tool used for a dental use, a grinder tool of a Leutor for characters and drawings in ceramic, glass and plastic.

[0086] The embodiment of the present invention will be described more specifically below by referring to the drawings.

EXAMPLE 1

[0087] A diamond-joined hand file 300 illustrated in FIG. 1 can be manufactured by (A) to (D) processes. In a plate 301 (A) made of metal and having a hand file shape and including an attachment portion 306 to be attached to a grip, grooves 302 each having a circular shape, a square shape, a V-shape, a U-shape or the like are arbitrarily drilled in plural rows (B), a rod-shaped diamond-containing brazing material 303 (hereinafter referred to simply as a diamond-containing brazing material 303) in which the non-peelable metal-coated diamond 304 adjusted to a length of the groove 302 by cutting or the like is contained in a brazing material 305 is placed in the groove 302 (C), and the diamond-containing brazing material 303 is heated/melted so that the non-peelable metal-coated diamond 304 is joined to the groove 302 in the plate 301 made of metal through the brazing material 305 (D). The brazing material 305 is soldered to the metal non-peelably coated on the non-peelable metal-coated diamond 304 and the plate 301 made of metal. As a result, the diamond is fixed to the hand file.

EXAMPLE 2

[0088] A diamond-joined round grinding disk 310 illustrated in FIG. 2 can be manufactured by (A) to (D) processes. In a disk 311 (A) made of metal and having a connection portion 313 to be connected to a rotating shaft, a groove 312 having a circular shape, a square shape, a V-shape, a U-shape or the like is arbitrarily drilled radially (B), the diamond-containing brazing material 303 adjusted to a length of the groove 312 by cutting or the like is placed in the groove 312 (C), and the diamond-containing brazing material 303 is heated/melted so that the non-peelable metal-coated diamond 304 is joined to the groove 312 in the disk 311 made of metal through the brazing material 305 (D). The brazing material 305 is soldered to the metal non-peelably coated on the non-peelable metal-coated diamond 304 and the disk 311 made of metal. As a result, the diamond is fixed to the grinding disk.

EXAMPLE 3

[0089] A diamond-joined rotating cutting disk 320 illustrated in FIG. 3 can be, manufactured by (A) to (E) processes. In an outer peripheral surface 321a of a disk 321 (A) (B) having a hole 322 and made of metal, a groove 323 having a circular shape, a square shape, a V-shape, a U-shape or the like is arbitrarily drilled (C), the diamond-containing brazing material 303 adjusted to a length of the groove 323 by cutting or the like is wound around the groove 323 (D), and the diamond-containing brazing material 303 is heated melted so that the non-peelable metal-coated diamond 304 is joined to the groove 323 in the disk 321 made of metal through the brazing material 305 (E). The brazing material 305 is soldered to the metal non-peelably coated on the non-peelable metal-coated diamond 304 and the disk 321 made of metal. As a result, the diamond is fixed to the rotating cutting disk.

EXAMPLE 4

[0090] Subsequently, a method of fixing the non-peelable metal-coated diamond 304 in a screw groove of a metal drill sold in the market will be described. By winding the diamond-containing brazing material 303 in the screw groove of the metal drill and by heating/melting the diamond-containing brazing material 303, the non-peelable metal-coated diamond 304 is joined to the screw groove of the metal drill through the brazing material 305. The brazing material 305 is soldered to the metal non-peelably coated on the non-peelable metal-coated diamond 304 and the metal screw. As a result, the diamond is fixed to the metal drill. To the screw groove, the non-peelable metal-coated diamond 304 may be soldered with the diamond-containing brazing material 303 after adjustment to a desired depth.

EXAMPLE 5

[0091] A diamond-joined blade 330 illustrated in FIG. 4 can be manufactured by (A) to (C) processes. In a side surface of a metal plate such as a steel plate, a groove 332 is drilled so as to have a base metal 331 (A). The groove 332 may have a section with a circular shape, a square shape, a V-shape, a U-shape or the like. Then, the diamond-containing brazing material 303 adjusted to a length of the groove 332 by cutting or the like is placed in the groove 332 (B), and the diamond-containing brazing material 303 is heated/melted so that the non-peelable metal-coated diamond 304 is joined to the groove 332 in the base metal 331 through the brazing material 305 (C). The brazing material 305 is soldered to the metal non-peelably coated on the non-peelable metal-coated diamond 304 and the base metal 331 made of metal. As a result, the diamond is fixed to the blade.

EXAMPLE 6

[0092] Each of diamond-joined disk-shaped blades 340(A), 340a(B), 340b(C) illustrated in FIG. 5 has a trapezoidal groove 341a, a spherical groove 342a or a square groove 343a drilled in a circumferential surface of each of base metals 341, 342, 343 made of metal, a chip shape matching a shape of each of them, that is, one of a trapezoidal diamond-containing brazing material 341b, a spherical diamond-containing brazing material 342b, a square diamond-containing brazing material 343b is inserted, and by heating/melting the diamond-containing brazing material 341b, 342b or 343b, the non-peelable metal-coated diamond 304 is joined to the groove 341a, 342a or 343a of the base metal 341, 342 or 343 through the brazing material 305. The brazing material 305 is soldered to the metal non-peelably coated on the non-peelable metal-coated diamond 304 and further the brazing material 305 is soldered to the base metal 341, 342 or 343 made of metal by a soldering portion 341c, 342c and 343c. As a result, the diamond is fixed to the disk-shaped blade. In this case, workability is good when a chip thicker than the blade is used.

EXAMPLE 7

[0093] A diamond-joined plate-shaped blade 350 illustrated in FIG. 6 can be manufactured by (A) to (B) processes. (C) is a sectional schematic view of an enlarged portion of a diamond-containing brazing material 353 and a base metal 351 after soldering. In a groove 352 drilled between a projection 352a and a projection 352a of the base metal 351 (A) made of metal, the diamond-containing brazing material 353 having a chip shape matching a shape of the groove 352 is fitted, and by heating/melting the diamond-containing brazing material 353, the non-peelable metal-coated diamond 304 is joined to the groove 352 of the base metal 351 made of metal through the brazing material 305 (B). The brazing material 305 is soldered to the metal non-peelably coated on the non-peelable metal-coated diamond 304 by a soldering portion 355 and is soldered also to the base metal 351 made of metal by a soldering portion 354. As a result, the diamond is fixed to the plate-shaped blade.

[0094] If the diamond-containing brazing material 353 has the same thickness as that of the base metal 351, a side surface of the diamond-containing brazing material 353 cannot be used for polishing/grinding and moreover, if the side surface of the base metal 351 comes into contact with a work, a work is damaged. In order to improve/prevent it, the chip-shaped diamond-containing brazing material 353 thicker than the base metal 351 may be fixed so as to form an overhang 356. Moreover, when a lower end portion of the diamond-containing brazing material 353 is soldered by covering a part of the side surface of the base metal 351, abrasion is reduced, and fixing strength of the diamond-containing brazing material 353 is improved. If a cutting width by the diamond-containing brazing material 353 is to be narrowed, it is only necessary that the diamond-containing brazing material 353 having the same thickness as that of the base metal 351 is fixed to the base metal 351.

EXAMPLE 8

[0095] A diamond-joined band-shaped blade 360 (A), (B) illustrated in FIG. 7 is formed by soldering a chip-shaped diamond-containing brazing material 362 to one side surface of a cylindrical band-shaped base metal 361 made of metal in which metal plates such as springs are connected by a seam portion 361a (A) or by soldering a chip-shaped diamond-containing brazing material 362 to two side surfaces (B). At that time, on a side surface of the band-shaped base metal 361, a chip is disposed in a spot cut out having a chip shape, and by heating/melting the diamond-containing brazing material 353, the non-peelable metal-coated diamond 304 is joined to the side-surface spot of the band-shaped base metal 361 made of metal through the brazing material 305. The brazing material 305 is soldered to the metal non-peelably coated on the non-peelable metal-coated diamond 304 and the band-shaped base metal 361 made of metal. As a result, the diamond is fixed to the band-shaped blade.

EXAMPLE 9

[0096] A chip-shaped diamond-containing brazing material 372 and its use example are illustrated in FIG. 8. A diamond-containing brazing material 372 is a brazing material formed into a so-called drop shape by having the non-peelable metal-coated diamond 304 contained in the brazing material 305 containing solder. It is capable of easy polishing/grinding of a portion difficult to be worked by free deformation according to convenience of the user. Other abrasive grains and inclusions can be mixed as necessary.

[0097] If a surface to be worked is large, grinding chips from a surface machined by the abrasive grains interfere with the subsequent grinding work and lower working efficiency and thus, it is desirable that abrasive grains other than the non-peelable metal-coated diamond 304 are contained in the diamond-containing brazing material 372. The abrasive grains other than the non-peelable metal-coated diamond 304 are easily removed during the grinding work, the grinding chips enter a hole (chip pocket) formed by the removal and maintain the grinding effect, whereby the wide surface to be worked can be efficiently ground.

[0098] A diamond-joined polishing disk 370 illustrated in FIG. 8 can be manufactured by (A) to (C) processes. On a circular base metal 371 (A) made of metal, a diamond-containing brazing material 372 is placed (B), and the diamond-containing brazing material 3 72 is heated/melted and then, the diamond-containing brazing material 372 is spread thinly on a surface of the circular base metal 371 by a spatula or the like so as to form a diamond-containing coating 373 (C). As a result, the non-peelable metal-coated diamond 304 is joined to a surface of the circular base metal 371 made of metal through the brazing material 305 (C). The brazing material 305 is soldered to the metal non-peelably coated on the non-peelable metal-coated diamond 304 and the circular base metal 371 made of metal. As a result, the diamond is fixed to the polishing disk. By applying the metal brazing material 305 such as a solder on a diffusion surface of the diamond-containing brazing material 372 of the circular base metal 371 in advance, a spreading work of the diamond-containing brazing material 372 is easy. If the abrasive grains other than the non-peelable metal-coated diamond 304 are mixed in the brazing material 305, grinding chips are taken in, and polishing workability is not lowered.

EXAMPLE 10

[0099] A diamond-joined tool tip end 380 illustrated in FIG. 9 can be manufactured by (A) to (D) processes. A carbon mold 381 (A) in which a groove 381a with a desired shape is drilled and to which the brazing material 305 is not soldered and a carbon presser 382 covering the groove 381a are prepared (A). A hole 382a is drilled in the carbon presser 382, and a rod 383 made of metal is inserted therein.

[0100] Subsequently, a drop-shaped diamond-containing brazing material 384 is input (B) in the groove 381a, and the diamond-containing brazing material 384 is heated/melted, while the diamond-containing brazing material 384 is pressed by the carbon presser 382 in the hole 382a of which the rod 383 is inserted, the rod 383 is fitted in the diamond-containing brazing material 384 (C). After cooling, the diamond-containing brazing material 384 is formed into a shape of the groove 381a and is soldered to a tip end of the rod 383 made of metal (D). On the other hand, the brazing material 305 is not soldered to the carbon mold 381 or the carbon presser 382.

[0101] The non-peelable metal-coated diamond 304 is joined to the rod 383 made of metal through the brazing material 305. The brazing material 305 is soldered (soldering portion 385) to the metal non-peelably coated on the non-peelable metal-coated diamond 304 and the rod 383 made of metal. As a result, the diamond-containing brazing material 384 containing diamond is fixed to the metal rod-shaped tip end and becomes a tip end of a machining tool such as a Leutor.

EXAMPLE 11

[0102] A diamond-joined sheet 390 illustrated in FIG. 10 can be manufactured by (A) to (D) processes. A chip-shaped diamond-containing brazing material 372 is placed (B) between two upper and lower carbon disks 391 and 392 (A) and heated/melted, and the diamond-containing brazing material 372 is pressurized 393. After cooling, the sheet-shaped diamond-joined sheet 390 containing the non-peelable metal-coated diamond 304 is formed without being bonded to the upper and lower carbon disks 391 and 392.

[0103] After that, the sheet-shaped diamond-joined sheet 390 is cut to arbitrary shape and size and adhered to a desirable plate or rod by using a double-sided adhesive tape and used for grinding of a workpiece. As a result, a tool to which the diamond abrasive grains are joined can be easily manufactured.

REFERENCE SIGNS LIST

[0104] 300 diamond-joined hand file [0105] 301 plate [0106] 302 groove [0107] 303 diamond-containing brazing material [0108] 304 non-peelable metal-coated diamond [0109] 305 brazing material [0110] 306 attachment portion [0111] 310 diamond-joined round grinding disk [0112] 311 disk [0113] 312 groove [0114] 313 connection portion [0115] 320 diamond-joined rotating cutting disk [0116] 321 disk [0117] 321a outer peripheral surface [0118] 322 hole [0119] 323 groove [0120] 330 diamond-joined blade [0121] 331 base metal [0122] 332 groove [0123] 340 diamond-joined disk-shaped blade [0124] 340a diamond-joined disk-shaped blade [0125] 340b diamond-joined disk-shaped blade [0126] 341 base metal [0127] 341a groove [0128] 341b diamond-containing brazing material [0129] 341c soldering portion [0130] 342 base metal [0131] 342a groove [0132] 342b diamond-containing brazing material [0133] 342c soldering portion [0134] 343 base metal [0135] 343a groove [0136] 343b diamond-containing brazing material [0137] 343c soldering portion [0138] 350 diamond-joined plate-shaped blade [0139] 351 base metal [0140] 352 groove [0141] 352a projection [0142] 353 diamond-containing brazing material [0143] 354 soldering portion [0144] 355 soldering portion [0145] 355 overhang [0146] 360 diamond-joined band-shaped blade [0147] 361 band-shaped base metal [0148] 361a seam portion [0149] 362 diamond-containing brazing material [0150] 370 diamond-joined polishing disk [0151] 371 circular base metal [0152] 372 diamond-containing brazing material [0153] 373 diamond-containing coating [0154] 380 diamond-joined tool tip end [0155] 381 carbon mold [0156] 381a groove [0157] 382 presser [0158] 382a hole [0159] 383 rod [0160] 384 diamond-containing brazing material [0161] 385 soldering portion [0162] 390 diamond-joined sheet [0163] 391 upper carbon disk [0164] 392 lower carbon disk [0165] 393 pressurization