Patent Application
20190358773
The present invention relates to a formed rotary dresser and a dressing method.
A diamond dresser is generally used for dressing of a CBN grindstone. In a precision mass-production grinding field of recent years, a dressing frequency increases in terms of high-precision continuous production, and a reduction in a dressing time is also required to reduce a cycle time. As a result, the diamond dresser has been considered to be problematic in that a lifespan is short and time and a cost is increased. Thus, a technique for improving wear resistance of the diamond dresser to prolong the lifespan has been developed. For example, a rotary diamond dresser in which one crystal plane of an octahedral diamond abrasive grain is embedded to be exposed approximately in parallel to an outer circumference of the dresser with the main intention of improving the wear resistance of the diamond dresser is disclosed in Patent Document 1. In addition, a rotary diamond dresser in which any edge of an octahedral diamond abrasive grain is embedded to be exposed approximately in parallel with a relative rotational velocity vector of a grindstone is disclosed in Patent Document 2. Further, a rotary diamond dresser in which a spiral concave groove is buried and diamond abrasive grains are arranged on a surface excluding the groove at a density of no less than 150 grains/cm2 is disclosed in Patent Document 3.
However, when the wear resistance of the rotary dresser is generally improved, there occurs a problem that sharpness of the dresser is reduced. For this reason, in the rotary diamond dressers of Patent Documents 1 and 2, although the improvement of the wear resistance is recognized, a further improvement in sharpness was needed. In a configuration of Patent Document 3, sufficient sharpness may not be obtained under severe conditions, neither mention nor suggestion is given especially with regard to the octahedral diamond abrasive grain, and no contribution is made to an arrangement relation between the octahedral diamond abrasive grain and the concave groove.
The present invention was made in view of the above circumstances, and an object thereof is to provide a formed rotary dresser and a dressing method that make excellent wear resistance compatible with excellent sharpness and has a long lifespan.
As described above, the following contents are disclosed herein.
(1) A formed rotary dresser includes regions in which diamond abrasive grains are scattered and arranged on an outer circumferential surface thereof brought into contact with a grindstone, and slit regions in which the diamond abrasive grains are not arranged on the outer circumferential surface thereof,
wherein the plurality of slit regions are provided to be inclined with respect to a rotational axis, and
a plurality of octahedral diamond abrasive grains are arranged along downstream edges of the slit regions in a rotating direction such that any face of an octahedron is parallel with the outer circumferential surface.
According to the formed rotary dresser, the plurality of slit regions in which the diamond abrasive grains are not arranged are provided to be inclined with respect to the rotational axis, and one face of each of the plurality of octahedral diamond abrasive grains arranged along the downstream edges of the slit regions is arranged in parallel with the outer circumferential surface brought into contact with the grindstone. Thereby, the grindstone is dressed by hardest diamond crystal planes of the octahedral diamond abrasive grains. For this reason, wear resistance of the formed rotary dresser is improved, and discharge of come-out abrasive grains is accelerated by a coolant supplied to the slit regions, so that sharpness of the formed rotary dresser can be maintained over a long period.
(2) The formed rotary dresser according to (1), wherein the octahedral diamond abrasive grains arranged along the edges at approximately equal intervals, and
in a pair of slit regions adjacent to each other in the rotating direction, a row of the octahedral diamond abrasive grains in one of the slit regions and a row of the octahedral diamond abrasive grains in the other slit region are arranged with the octahedral diamond abrasive grains are mutually shifted in a direction of the rotational axis.
According to the formed rotary dresser, an entire surface of the grindstone can be dressed with high shape transcription precision by a small number of octahedral diamond abrasive grains.
(3) The formed rotary dresser according to (1) or (2), wherein the diamond abrasive grains are arranged on the outer circumferential surface in a spiral shape, and are arranged at approximately equal intervals.
According to the formed rotary dresser, since the diamond abrasive grains are arranged on the outer circumferential surface in the spiral shape, a load loaded on the grindstone at the time of dressing is reduced, so that the generation of vibration can be prevented.
(4) The formed rotary dresser according to any one of (1) to (3), wherein the diamond abrasive grains are arranged to be shifted from each other at upstream and downstream sides of the rotating direction in the direction of the rotational axis.
According to the formed rotary dresser, the entire surface of the grindstone can be dressed with high precision.
(5) The formed rotary dresser according to any one of (1) to (4), wherein the diamond abrasive grains includes the octahedral diamond abrasive grains, and diamond abrasive grains having a different shape from the octahedral diamond abrasive grains.
According to the formed rotary dresser, since the octahedral diamond abrasive grains are configured to be provided only in specified regions, production man-hours and material costs of the dresser are inhibited while maintaining desired working precision.
(6) A dressing method includes dressing a grindstone using a formed rotary dresser including regions in which diamond abrasive grains are scattered and arranged on an outer circumferential surface thereof brought into contact with a grindstone, and slit regions in which the diamond abrasive grains are not arranged on the outer circumferential surface thereof, and in which the plurality of slit regions are provided to be inclined with respect to a rotational axis, and a plurality of octahedral diamond abrasive grains are arranged along downstream edges of the slit regions in a rotating direction such that any face of an octahedron is parallel with the outer circumferential surface.
According to the dressing method, since the grindstone is dressed by hardest diamond crystal planes of the octahedral diamond abrasive grains, the wear resistance of the formed rotary dresser is improved, and the discharge of the come-out abrasive grains is accelerated by a coolant supplied to the slit regions, so that the sharpness of the formed rotary dresser can be maintained over a long period.
(7) The dressing method according to (6), wherein the diamond abrasive grains includes the octahedral diamond abrasive grains, and diamond abrasive grains having a different shape from the octahedral diamond abrasive grains.
According to the dressing method, the formed rotary dresser in which the octahedral diamond abrasive grains are provided only in specified regions is used, so that running costs of the dresser can also be reduced while maintaining working precision.
According to the present invention, the formed rotary dresser can reconcile excellent wear resistance and excellent sharpness to make a lifespan longer.
Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.
A case in which a formed rotary dresser of the present invention dresses a grindstone that grinds a raceway surface in a raceway of a ball bearing will be described herein by way of example, but the formed rotary dresser is not limited to this application. In the following description, “dressing” refers to including “turning.”
The grinding device 100 includes a chuck 11, a grindstone 19, a quill 13 that is driven to move and rotate the grindstone 19, and a formed rotary dresser 15 that dresses the grindstone 19. In the grinding device 100 of this configuration, a case in which a raceway surface of an outer race of the ball bearing is ground by the grindstone 19 is shown.
A ball bearing outer race 17 that is a workpiece is mounted on the chuck 11, and the chuck 11 is driven to rotate the ball bearing outer race 17 at the working position illustrated in
The formed rotary dresser 15 has a rotational axis Ax parallel with a rotational axis of the grindstone 19, and is journalled at a position at which it can be brought into contact with a grinding surface 19a of the grindstone 19. A support shaft 20 of the formed rotary dresser 15 is driven to rotate via a pulley 23 by a driving belt 21 connected to a drive source (not shown). In addition, the formed rotary dresser 15 may be configured to be driven to rotate in various driving modes such as a mode in which it is directly driven by a motor, a mode in which it is driven via gears, and so on.
The grindstone 19 disposed at the working position illustrated in
After the grinding is performed a predetermined number of times, the grindstone 19 is displaced to the dressing position based on the formed rotary dresser 15 in a direction of an arrow D2 by the drive of the quill 13 as illustrated in
The formed rotary dresser 15 has the support shaft 20 and a sintered metal part 25 made of tungsten carbide (WC). The sintered metal part 25 is provided on an outer circumference of a mandrel 20a of the support shaft 20, and a groove portion 29 having a radius R of curvature is formed in the middle of a large diameter portion 27 in an axial direction throughout a circumference thereof.
Numerous abrasive grains made of a diamond are embedded in at least a surface of the groove portion 29 of the sintered metal part 25, that is, in the outer circumferential surface of the formed rotary dresser 15 which is brought into contact with the grindstone 19 (see
The abrasive grains include numerous common diamond abrasive grains 31 and octahedral diamond abrasive grains 33 (octahedron diamonds, hereinafter referred to as octahedral diamond abrasive grains) having an octahedral structure. Hereinafter, the diamond abrasive grains 31 and the octahedral diamond abrasive grains 33 will be described in distinction from each other. That is, the octahedral diamond abrasive grains 33 shall not be included in the diamond abrasive grains 31.
The diamond abrasive grains 31 are diamond abrasive grains that are widely generally used, such as synthetic diamonds or metal coating synthetic diamonds that are used for a diamond tool or the like.
As illustrated in
In the arrangement pattern of the abrasive grains illustrated in
In the arrangement of the diamond abrasive grains 31 along the oblique line La(1), a plurality of rows similarly provided at intervals to in a rotating direction. That is, the plurality of diamond abrasive grains 31 are mutually arranged at equal intervals along the oblique lines La(1) to La(n) (n is the integer). The oblique lines La(1) to La(n) have a spiral shape in which, in the top development view of the outer circumferential surface of the sintered metal part 25 illustrated in
The diamond abrasive grains 31 on the oblique lines that are adjacent to each other in a rotating direction among the plurality of oblique lines La(1) to La(n) are arranged with the pitches P1 in the direction of the rotational axis shifted from each other (in the shown example, a shift of ½ of the pitch P1 is shown as an example). Thereby, a pitch of the practical arrangement of the diamond abrasive grains 31 at the time of dressing can be smaller than the pitch P1 of one row. Therefore, precision of the shape transcription can be improved, and the grindstone after the transcription enables grinding of a stable curve shape.
Further, a plurality of slit regions SL in which the diamond abrasive grains 31 and the octahedral diamond abrasive grains 33 are not arranged are provided on the outer circumferential surface of the formed rotary dresser 15 in parallel with the oblique lines La(1) to La(n) in the rotating direction. The slit regions SL are provided at a predetermined slit width in the rotating direction. These slit regions SL may be simply provided on the outer circumferential surface on which the diamond abrasive grains 31 and the octahedral diamond abrasive grains 33 are not arranged, or may be provided in the groove having a predetermined width and depth.
The plurality of octahedral diamond abrasive grains 33 are provided along a downstream edge of each slit region SL in the rotating direction. The octahedral diamond abrasive grains 33 are arranged at approximately equal intervals at a pitch P2, which is almost the same as the pitch P1 of the aforementioned diamond abrasive grains 31, in the direction of the rotational axis Ax. The octahedral diamond abrasive grains 33 are arranged in parallel with an outer circumferential surface on which any one of the eight faces of the octahedron becomes a contact surface with the grindstone 19. The octahedral diamond abrasive grains 33 that are adjacent to each other across the oblique line La(1) to La(n) in the rotating direction are arranged while being shifted from each other in the direction of the rotational axis Ax (in the shown example, a shift of ½ of the pitch P2 is shown as an example).
A row Lb of the octahedral diamond abrasive grains 33 is provided at an interval tb in the rotating direction from the oblique line La(1) that is a row of the diamond abrasive grains 31 arranged downstream from the row Lb in the rotating direction. This interval tb may be approximately the same as or be different from each of the intervals ta for the aforementioned oblique lines La(1) to La(n). As described above, the diamond abrasive grains 31 and the octahedral diamond abrasive grains 33 are discretely arranged in abrasive grain arrangement region excluding the slit regions SL within the outer circumferential surface of the formed rotary dresser 15 at an interval therebetween.
Here, amounts of shift between the diamond abrasive grains 31 and between the octahedral diamond abrasive grains 33 in the direction of the rotational axis of each oblique line are individually set according to a material or a shape of the grindstone to be dressed. The angle α in a spiral direction is mainly determined depending on machinability of a targeted dresser. That is, various parameters such as the intervals ta and tb, the pitches P1 and P2, the angle α, etc. are set such that a probability (the number of times of contact) that the diamond abrasive grains 31 are brought into contact with the surface of the grindstone at the time of dressing is approximately the same as the octahedral diamond abrasive grains 33 in the direction of the rotational axis. Further, the parameters are set in consideration of machinability, costs, and so on.
As described above, the slit regions SL, the octahedral diamond abrasive grains 33, and the diamond abrasive grains 31 are arranged on the outer circumferential surface of the formed rotary dresser 15 which is brought into contact with the grindstone 19 in the opposite rotating direction in this order. Therefore, the slit regions SL, the octahedral diamond abrasive grains 33, and the diamond abrasive grains 31 of the formed rotary dresser 15 are brought into contact with the grindstone 19 in this order. Such a relation is the same at any position of the direction of the rotational axis.
The hardest equilateral triangular faces 37 (see
The slit regions SL are arranged upstream from the octahedral diamond abrasive grains 33 in the rotating direction, supply of a coolant to a dressing point can be accelerated. Along with this, the abrasive grains coming out by dressing are discharged from the slit regions SL, and then the octahedral diamond abrasive grains 33 can be brought into contact with the grindstone. For this reason, the octahedral diamond abrasive grains 33 can dress the grindstone without being affected by unnecessary substances such as come-out abrasive grains. Further, the diamond abrasive grains 31 are brought into contact with the grindstone to dress the grindstone afterward. Accordingly, an ideal dressing process in which the surface of the grindstone is roughly mashed and formed by the octahedral diamond abrasive grains 33 first, and then the surface of the grindstone is precisely finished and formed by the diamond abrasive grains 31 can be realized.
As described above, the diamond abrasive grains 31 and the octahedral diamond abrasive grains 33 are spirally arranged, so that dressing resistance can be reduced and dressing precision can be improved. Both the diamond abrasive grains 31 and the octahedral diamond abrasive grains 33 are used, so that the wear resistance can be improved. In this case, a reduction in sharpness due to the combined use of the abrasive grains is avoided by providing the slit regions SL. The octahedral diamond abrasive grains 33 are arranged only in specified regions (downstream edges of the slit regions SL in the rotating direction) of the surface of the formed rotary dresser 15. Thereby, in comparison with a case in which the octahedral diamond abrasive grains 33 are arranged in all the abrasive grain arrangement regions on the surface of the dresser, production man-hours and material costs of the dresser are inhibited while maintaining desired working precision. In addition, running costs of the dressing can also be reduced. Thereby, the formed rotary dresser in which dressing performance is compatible with the wear resistance and the sharpness, the vibration is reduced, and long-lifespan and high-precision dressing can be performed can be realized.
The present invention is not limited to the above embodiment, the configurations of the embodiment are mutually combined, or modified or applied by those skilled in the art on the basis of the mention of the specification and a well-known technique, which is expected in the present invention and is included in the scope for protection.
Here, a lifespan test of a rotary dresser was performed on test conditions shown in Table 1 using the formed rotary dresser illustrated in
As shown in Table 1, a new grindstone having a diameter of 27.0 mm was prepared. This grindstone was dressed and adjusted to a maximum dimension. After a workpiece was ground, dressing was performed 20 times per 1 μm (40 μm that is a diameter per dressing). When a diameter of the grindstone reached a minimum dimension, this was set to a lifespan of the grindstone. Dressing spark-out (dressing S.O) that was a holding time of a state in which a cutting operation was completed was set to 0.5 sec.
A difference (7.2 mm) between the maximum dimension and the minimum dimension was divided into four equal parts (1.8 mm), and skip 1 (26.7 mm to 24.9 mm), a skip 2 (24.9 mm to 23.1 mm), a skip 3 (23.1 mm to 21.3 mm), and a skip 4 (21.3 mm to 19.5 mm) were set. That is, since the diameter of the dresser was reduced to 40 μm by dressing once, one skip was terminated (40 μm×45=1.8 mm) by dressing 45 times.
The number of produced workpieces after the dressing was set to 400 pieces for skip 1, 300 pieces for skip 2, 200 pieces for skip 3, and 150 pieces for skip 4.
Here, when the workpiece was ground by the dressed grindstone, the grindstone was not correctly formed when the dresser was worn, and a workpiece shape (a groove shape, a groove dimension) deviated from an allowable range. Therefore, the workpiece shape of the produced workpiece was measured. When the workpiece shape did not enter the allowable range even after the dressing, this was set to a lifespan of the formed rotary dresser.
The above test results are shown in Tables 2 and 3.
In the formed rotary dresser of the present embodiment, as shown in Table 2, the number of produced workpieces until the formed rotary dresser reached the lifespan was 445,000 that was an average value in test results of five times. In contrast, in a formed rotary dresser of a conventional product, an average value in test results of nine times was 289,000. It can be confirmed that the lifespan of the formed rotary dresser of the present invention is about 1.5 times longer.
This application is based on Japanese Patent Application No. 2017-114570, filed on Jun. 9, 2017, the content of which is incorporated herein by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2017-114570 | Jun 2017 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2017/032801 | 9/12/2017 | WO | 00 |
