Patent Grant
10960512
This non-provisional application claims priority under 35 U.S.C. § 119(a) on Patent Application No. 2016-255017 filed in Japan on Dec. 28, 2016, the entire contents of which are hereby incorporated by reference.
This invention relates to a method for cutoff machining a rare earth sintered magnet block, typically Nd—Fe—B sintered magnet block into multiple pieces.
Systems for manufacturing commercial products of sintered magnet include a single part system wherein a part of substantially the same shape as the product is produced at the stage of press forming, and a multiple part system wherein once a large block is formed, it is divided into a multiplicity of parts by machining. When it is desired to manufacture parts of small size or parts having a reduced thickness in magnetization direction, the sequence of press forming and sintering is difficult to form sintered parts of normal shape. Thus the multiple part system is the mainstream of sintered magnet manufacture.
As the tool for cutting rare earth sintered magnet blocks, a grinding wheel outer-diameter (OD) blade having diamond abrasive grains bonded to the outer periphery of a thin disk as a core is mainly used from the aspect of productivity. In the case of OD blades, multiple cutting is possible. A multiple blade assembly comprising a plurality of cutoff abrasive blades coaxially mounted on a rotating shaft alternately with spacers, for example, is capable of multiple cutoff machining, that is, to machine a block into a multiplicity of parts at a time.
The current desire for more efficient manufacture of rare earth sintered magnet entails a propensity to enlarge the size of magnet blocks to be cutoff machined, indicating an increased depth of cut. When a magnet block has an increased height, the effective diameter of the cutoff abrasive blade, that is, the distance from the rotating shaft or spacer to the outer periphery of the blade (corresponding to the maximum height of the cutoff abrasive blade available for cutting) must be increased. Such larger diameter cutoff abrasive blades are more liable to deformation, especially to deflect on axial direction. As a result, a rare earth magnet block is cut into pieces of degraded shape and dimensional accuracy. The prior art uses thicker cutoff abrasive blades to avoid the deformation. Thicker cutoff abrasive blades, however, are inconvenient in that more material is removed by cutting. Then the number of magnet pieces cut out of a magnet block of the same size is reduced as compared with thin cutoff abrasive blades. Under the economy where the price of rare earth metals increases, a reduction in the number of magnet pieces is reflected by the manufacture cost of rare earth magnet products.
While there is a desire for the method for cutoff machining a magnet block having an increased depth of cut without increasing the effective diameter of cutoff abrasive blades, a method involving sawing an upper half of a magnet block, turning the block upside down, and sawing a lower half (upper half after the upside-down turning) of the magnet block is known. This method is successful in reducing the effective diameter of cutoff abrasive blades to about one half, as compared with the method of sawing a magnet block in one direction, and thus overcomes the above-discussed problems of dimensional accuracy and the width to be sawn associated with thick blades, but needs strict alignment of the cutting position before and after the upside-down turning. The step of alignment of the cutting position takes a time. If the cutting position is misaligned even slightly, a step is formed between upper and lower cutoff surfaces. If so, the step must be eliminated or smoothened by surface grinding after the cutoff machining. When cutoff machining is continuously performed as is often the case in commercial manufacture, it is impossible in a substantial sense to cutoff machine all magnet blocks without leaving a step between upper and lower cutoff surfaces. Thus a magnet block is typically sawn into slightly thicker pieces, with an allowance for surface grinding being taken into account. The number of magnet pieces cut out of a magnet block of the same size is reduced in this case too.
An object of the invention is to provide a method for cutoff machining a rare earth sintered magnet block having a substantial height into a multiplicity of pieces at a high accuracy, by using a plurality of thin cutoff abrasive blades having a reduced effective diameter, while controlling formation of a step between cutoff surfaces.
The invention is directed to a method for multiple cutoff machining a rare earth sintered magnet block using a multiple blade assembly comprising a plurality of cutoff abrasive blades coaxially mounted on a rotating shaft at axially spaced apart positions, each blade comprising a core in the form of a thin disk and a peripheral cutting part on the outer periphery of the core. The cutoff abrasive blades are rotated and fed to cutoff machine the magnet block into a multiplicity of pieces. The inventors have found that the object is achievable by setting the multiple blade assembly such that it is movable parallel to the plane of rotation of the blades, rotating and feeding the blades, starting the machining operation of the magnet block on one side to form cutting grooves in the magnet block, interrupting the machining operation before the magnet block is cut into pieces, moving the multiple blade assembly to the other side of the magnet block parallel to the plane of rotation of the blades, with the magnet block kept fixed, restarting the machining operation of the magnet block on the other side to form cutting grooves in the magnet block until the cutting grooves formed from the one side and the other side merge with each other, thereby cutting the magnet block into pieces. Then a rare earth sintered magnet block having a substantial height can be cutoff machined or sawn into a multiplicity of pieces at a high accuracy and productivity, by using the multiple blade assembly comprising a plurality of thin cutoff abrasive blades having a reduced effective diameter, and feeding the multiple blade assembly parallel to the plane of rotation of the blades, without a need for alignment of the magnet block, while controlling formation of a step between cutoff surfaces.
In the multiple cutoff machining of a rare earth sintered magnet block, the one side and the other side of the magnet block are preferably opposite sides in a horizontal direction. More preferably, the magnet block at its upper and lower surfaces is clamped by a fastening jig. Further preferably, the fastening jig includes a first clamp on which the magnet block is rested, a second clamp disposed on the magnet block, and a press unit for pressing the first and second clamps to apply a pressing force to the magnet block from one or both of its upper and lower sides. A portion of one clamp (or both clamps) which is disposed adjacent to the magnet block is provided with a generally horizontal channel extending inward from a position corresponding to a work surface of the magnet block, to define a resilient cantilever, whereby the magnet block is held between the first and second clamps by the repulsion force created by vertical movement of the resilient cantilever. Although the magnet block is susceptible to cracking or chipping upon application of a noticeable force because of its construction, the jig ensures that the magnet block is vertically held within the fastening jig in a tight, flexible manner. This further contributes effectively to high-accuracy machining when the magnet block is machined on the one side or the other side in horizontal direction.
Accordingly, in one aspect, the present invention provides a method for multiple cutoff machining a rare earth sintered magnet block using a multiple blade assembly comprising a plurality of cutoff abrasive blades coaxially mounted on a rotating shaft at axially spaced apart positions, each blade comprising a core in the form of a thin disk and a peripheral cutting part on the outer periphery of the core, said method comprising the step of rotating and feeding the cutoff abrasive blades to cutoff machine the magnet block into a multiplicity of pieces,
the method further comprising the steps of:
setting the multiple blade assembly on one side of the magnet block such that it is movable parallel to the plane of rotation of the blades,
rotating the blades,
starting the machining operation of the magnet block on one side to form cutting grooves in the magnet block,
interrupting the machining operation before the magnet block is cut into pieces,
moving the multiple blade assembly to the other side of the magnet block parallel to the plane of rotation of the blades, with the magnet block kept fixed, and
restarting the machining operation of the magnet block on the other side to form cutting grooves in the magnet block until the cutting grooves formed from the one side and the other side merge with each other, thereby cutting the magnet block into pieces.
In a preferred embodiment, the one side and the other side of the magnet block are opposite sides in horizontal direction.
More preferably, in each of the machining operation of the magnet block on the one side and the machining operation of the magnet block on the other side, the magnet block is cutoff machined while the cutoff abrasive blades are vertically fed.
In a preferred embodiment, the magnet block at its upper and lower surfaces is clamped by a fastening jig whereby the magnet block is secured within the fastening jig, and the position of the fastening jig is fixed whereby the position of the magnet block is fixed.
In a more preferred embodiment, the fastening jig includes a first clamp on which the magnet block is rested, a second clamp disposed on the magnet block, and a press unit for pressing the first and second clamps to apply a pressing force to the magnet block from one or both of its upper and lower surfaces. A portion of at least one clamp which is disposed adjacent to the magnet block is provided with a generally horizontal channel extending inward from a position corresponding to a work surface of the magnet block, to define a resilient cantilever, whereby the magnet block is held between the first and second clamps by the repulsion force created by vertical movement of the resilient cantilever.
In a preferred embodiment, the portion of at least one clamp which is disposed adjacent to the magnet block is partially raised to form pads near positions corresponding to opposite work surfaces of the magnet block so that the clamp contacts only at its pads with the opposing surface of the magnet block.
In a preferred embodiment, the portion of at least one clamp which is disposed adjacent to the magnet block is provided with rims at positions corresponding to opposite work surfaces of the magnet block, the rims being engaged with the magnet block for preventing the magnet block from separating apart.
In a preferred embodiment, only the first clamp is provided with the resilient cantilever, and the surface of the second clamp which is disposed adjacent to the magnet block is flat so that the second clamp is in plane contact with the entire opposing surface of the magnet block.
In a preferred embodiment, on each of the one and other sides of the magnet block, the multiple blade assembly is vertically fed from the first clamp side to the second clamp side, thereby sawing the magnet block into pieces.
In a preferred embodiment, the cutoff abrasive blades are rotated such that the rotational direction of the blades is reverse to the feed direction of the blades at the cutting points of the blades during the machining operation.
Using a plurality of thin cutoff abrasive blades having a reduced effective diameter, a rare earth sintered magnet block having a substantial height can be sawn into a multiplicity of pieces at a high accuracy. The invention is also effective for controlling formation of a step on cutoff surface.
In the following description, like reference characters designate like or corresponding parts throughout the several views shown in the figures. It is understood that terms such as “upper”, “lower”, “outward”, “inward”, “vertical”, and the like are words of convenience, and are not to be construed as limiting terms. Herein, a magnet block of generally rectangular shape has opposite surfaces on one and other sides in a horizontal direction, and upper and lower ends in a vertical direction. The term “work surface” refers to the surface of a magnet block to be cutoff machined.
The method for multiple cutoff machining a rare earth sintered magnet block according to the invention uses a multiple blade assembly comprising a plurality of cutoff abrasive blades coaxially mounted on a rotating shaft at axially spaced apart positions, each blade comprising a core in the form of a thin disk and a peripheral cutting part on the outer periphery of the core. The multiple blade assembly is placed relative to the magnet block. The cutoff abrasive blades are rotated and fed to cutoff machine the magnet block into a multiplicity of magnet pieces. During machining operation, cutting grooves are formed in the magnet block.
Any prior art well-known multiple blade assembly may be used in the multiple cutoff machining method. As shown in
The dimensions of the core are not particularly limited. Preferably the core has an outer diameter of 80 to 250 mm, more preferably 100 to 200 mm, and a thickness of 0.1 to 1.4 mm, more preferably 0.2 to 1.0 mm. The core in the form of a thin doughnut disk has a bore having a diameter of preferably 30 to 100 mm, more preferably 40 to 90 mm. Understandably, the rotating shaft extends through the bores of the blades in the blade assembly.
The core of the cutoff abrasive blade may be made of any desired materials commonly used in cutoff blades including tool steels SK, SKS, SKD, SFT and SKH, although cores of cemented carbide are preferred because the cutting part or blade tip can be thinner. Suitable cemented carbides of which cores are made include alloy forms of powdered carbides of metals in Groups IVA (4), VA (5) and VIA (6) in the Periodic Table, such as WC, TiC, MoC, NbC, TaC, and Cr3C2, which are cemented with Fe, Co, Ni, Mo, Cu, Pb, Sn or alloys thereof. Of these, WC—Co, WC—Ni, TiC—Co, and WC—TiC—TaC—Co systems are typical and preferred for use herein.
The peripheral cutting part or abrasive grain-bonded section is formed to cover the outer periphery of the core and comprises abrasive grains and a binder. Typically diamond grains, cBN grains or mixed grains of diamond and cBN are bonded to the outer periphery of the core using a binder. Three bonding systems including resin bonding with resin binders, metal bonding with metal binders, and electroplating are typical and any of them may be used herein.
The peripheral cutting part or abrasive grain-bonded section has a width W in the thickness or axial direction of the core, which is from (T+0.01) mm to (T+4) mm, more preferably (T+0.02) mm to (T+1) mm, provided that the core has a thickness T. An outer portion of the peripheral cutting part or abrasive grain-bonded section that projects radially outward from the outer periphery of the core has a projection distance which is preferably 0.1 to 8 mm, more preferably 0.3 to 5 mm, depending on the size of abrasive grains to be bonded. The distance of the peripheral cutting part in radial direction of the core (i.e., radial distance of the overall peripheral cutting part) is preferably 0.1 to 10 mm, more preferably 0.3 to 8 mm. The spacing between cutoff abrasive blades may be suitably selected depending on the thickness of magnet pieces after cutting, and preferably set to a distance which is slightly greater than the thickness of magnet pieces, for example, by 0.01 to 0.4 mm. For machining operation, the cutoff abrasive blades are preferably rotated at 1,000 to 15,000 rpm, more preferably 3,000 to 10,000 rpm.
A rare earth sintered magnet block is held as presenting one and other sides in a horizontal direction and upper and lower surfaces in a vertical direction. The multiple blade assembly is set such that it is movable parallel to the plane of rotation of the blades. The magnet block is machined or sawn into a multiplicity of pieces by rotating and feeding the cutoff abrasive blades. According to the invention, the magnet block is cutoff machined by starting the machining operation of the magnet block on one side to form cutting grooves in the magnet block, interrupting the machining operation before the magnet block is cut into pieces, moving the multiple blade assembly to the other side of the magnet block parallel to the plane of rotation of the blades, with the magnet block kept in place, and restarting the machining operation of the magnet block on the other side to form cutting grooves in the magnet block until the cutting grooves formed from the one side and the other side merge with each other, thereby cutting the magnet block into pieces. Differently stated, the magnet block is machined from the front surface and the back surface in sequence.
By referring to
According to the invention, a workpiece (or rare earth sintered magnet block) to be replaced on every cutoff machining step is secured stationary during the machining operation. On the other hand, the cutting tool (or multiple blade assembly) is easy to repeat the same operation at the same position. Thus, the multiple blade assembly is moved parallel to the plane of rotation of cutoff abrasive blades, specifically the multiple blade assembly is moved from the one side to the other side of the magnet block such that the plane of rotation of cutoff abrasive blades remains on the same imaginary plane before and after the movement. Then machining operation can be repeated without causing any misalignment between the cutting grooves formed from the one and other sides. Thus using a plurality of thin cutoff abrasive blades having a reduced effective diameter, a rare earth sintered magnet block having a substantial height can be sawn into a multiplicity of pieces at a high accuracy while minimizing a step on the cutoff surface at the merger point between cutting grooves.
The inventive method deals with a rare earth sintered magnet block having a height of at least 5 mm, typically 10 to 100 mm and uses cutoff abrasive blades having a core thickness of up to 1.2 mm, more preferably 0.2 to 0.9 mm and an effective diameter of up to 200 mm, more preferably 10 to 180 mm. Notably, the effective diameter is the distance from the rotating shaft or spacer to the outer edge of the blade and corresponds to the maximum height of a magnet block that can be cut by the blade. Then the magnet block can be cutoff machined at a high accuracy and high efficiency as compared with the prior art.
In the practice of the invention, it is possible that the one side and the other side of the magnet block be one and other sides in a vertical direction, that is, the work surfaces of the magnet block be set as upper and lower surfaces in a vertical direction, and the magnet block be machined on the upper side and then on the lower side. However, it is recommended that the one side and the other side of the magnet block be set as one and other sides in a horizontal direction as shown in
In each of the machining operations on the one and other sides, it is possible to machine the magnet block while the cutoff abrasive blades are fed perpendicular to the work surface of the magnet block, for example, in the arrangement of the multiple blade assembly 1 and the magnet block M shown in
A rare earth sintered magnet block is cutoff machined into a multiplicity of pieces by rotating cutoff abrasive blades (i.e., OD blades), feeding a cutting fluid, and moving the blades relative to the magnet block with the abrasive portion of the blade kept in contact with the magnet black (specifically moving the blades in the transverse and/or thickness direction of the magnet block). Then the magnet block is cut or machined by the cutoff abrasive blades. It is noted that the cutting fluid used herein is also known as a coolant and is a liquid, typically water, which may contain liquid or solid additives.
In the multiple cutoff machining of a magnet block, the magnet block is fixedly secured by any suitable means. In one method, the magnet block is bonded to a support plate (e.g., of carbon base material) with wax or a similar adhesive which can be removed after machining operation, whereby the magnet block is fixedly secured prior to machining operation. In another method, the magnet block is fixedly secured by a fastening jig.
In the machining of a magnet block, first on the one side of the magnet block, either one or both of the multiple blade assembly and the magnet block are relatively moved in the cutting or transverse direction of the magnet block from one end to the other end of the magnet block (parallel to the work surface of the magnet block), whereby the work surface of the magnet block is machined to a predetermined depth throughout the transverse direction to form cutting grooves in the magnet block.
The cutting grooves may be formed by a single machining operation or by repeating plural times machining operation in a direction perpendicular to the work surface of the magnet block. The depth of the cutting grooves is preferably 40 to 70%, most preferably about 50% of the height of the magnet block to be cut although the depth varies somewhat on every machining operation, depending on the degree of wear of cutoff abrasive blades. The width of the cutting grooves is determined by the width of cutoff abrasive blades. Usually, the width of the cutting grooves is slightly greater than the width of the cutoff abrasive blades due to the vibration of the cutoff abrasive blades during machining operation, and specifically in a range equal to the width of the cutoff abrasive blades (or peripheral cutting parts) plus 1 mm at most, more preferably plus 0.5 mm at most, and even more preferably plus 0.1 mm at most.
The machining operation is interrupted before the magnet block is divided into discrete pieces. The multiple blade assembly is moved from the one side to the other side of the magnet block. The machining operation is restarted on the other side of the magnet block. Like on the one side, either one or both of the multiple blade assembly and the magnet block are relatively moved in the cutting or transverse direction of the magnet block from one end to the other end of the magnet block (parallel to the work surface of the magnet block), whereby the work surface of the magnet block is machined to a predetermined depth throughout the transverse direction to form cutting grooves in the magnet block. Likewise, the cutting grooves may be formed by a single machining operation or by repeating plural times machining operation in the height direction of the magnet block. In this way, the portion of the magnet block left after the first groove cutting is cutoff machined.
During the machining operation, the cutoff abrasive blades are preferably rotated at a circumferential speed of at least 10 m/sec, more preferably 20 to 80 m/sec. Also, the cutoff abrasive blades are preferably fed at a feed or travel rate of at least 10 min/min, more preferably 20 to 500 mm/min. Advantageously, the inventive method capable of high speed machining ensures a higher accuracy and higher efficiency during machining than the prior art methods.
During multiple cutoff machining of a rare earth sintered magnet block, a coolant or cutting fluid is generally fed to the cutoff abrasive blades to facilitate machining. To this end, a coolant feed nozzle is preferably used which has a coolant inlet at one end and a plurality of slits formed at another end and corresponding to the plurality of cutoff abrasive blades.
One exemplary coolant feed nozzle is illustrated in
The outer peripheral portion of each cutoff abrasive blade which is inserted into the corresponding slit in the feed nozzle functions such that the coolant coming in contact with the cutoff abrasive blades is entrained on the surfaces (outer peripheral portions) of the cutoff abrasive blades and transported to points of cutoff machining on the magnet block. Then the slit has a width which must be greater than the width of the cutoff abrasive blade (i.e., the width W of the outer cutting part). Through slits having too large a width, the coolant may not be effectively fed to the cutoff abrasive blades and a more fraction of coolant may drain away from the slits. Provided that the peripheral cutting part of the cutoff abrasive blade has a width W (mm), the slit in the feed nozzle preferably has a width of from more than W mm to (W+6) mm, more preferably from (W+0.1) mm to (W+6) mm. The slit has such a length that when the outer peripheral portion of the cutoff abrasive blade is inserted into the slit, the outer peripheral portion may come in full contact with the coolant within the feed nozzle. Often, the slit length is preferably about 2% to 30% of the outer diameter of the core of the cutoff abrasive blade.
In the method for multiple cutoff machining a rare earth sintered magnet block, a fastening jig consisting of a pair of clamps is preferably used for clamping the magnet block in the vertical (or machining) direction for fixedly securing the magnet block. In one embodiment, the fastening jig includes a first clamp on which the magnet block is rested, a second clamp disposed on the magnet block, and a press unit for pressing the first and second clamps to apply a pressing force to the magnet block from one or both of its upper and lower surfaces. Further, a portion of at least one clamp which is disposed adjacent to the magnet block is provided with a generally horizontal channel extending inward from a position corresponding to one work surface of the magnet block, to define a resilient cantilever, whereby the magnet block is held between the first and second clamps by the repulsion force created by vertical movement of the resilient cantilever. The material of which the first and second clamps are made should be a material which has a balance of rigidity and resilience (deflection) and/or elasticity, and preferably is easily workable. Suitable materials include metal materials, typically steel materials such as chromium molybdenum steel, and aluminum alloys such as duralumin, and resin materials, typically engineering plastics such as polyacetal.
The press unit 33 includes a frame 331 enclosing the first clamp 31, the magnet block M, and the second clamp 32, and screws 332, 332 for pressing the second clamp 32 on the upper surface remote from the magnet block M. The screws 332, 332 axe extended throughout the top beam of the frame 331 in thread engagement. As the screws 332, 332 are turned in the threaded holes in the frame 331, they press down the second clamp 32 for applying a pressing force to the magnet block M via the second clamp 32. The magnitude of pressing force may be controlled by the fastening torque of the screws or by using springs if necessary. Then the magnitude of pressing force may be adjusted in accordance with a particular machining load. If the magnitude of pressing force is too low, meaning that the pressing force is overwhelmed by the machining load, the workpiece can be shifted and the machining accuracy is worsened. If the magnitude of pressing force is too high, the workpiece can be moved at the final stage of cutoff machining, that is, when the magnet block is divided into pieces, causing chipping or flaws to the magnet pieces. Although the press unit 33 consists of the frame 331 and the screws 332 in the illustrated embodiment, the construction of the press unit is not limited thereto, for example, the press unit may be constructed by a frame, additional members, and a pneumatic or hydraulic cylinder, piston or the like.
The fastening jig of the above construction is effective particularly when the one side and the other side of the magnet block are opposite sides in horizontal direction during multiple cutoff machining, that is, the work surfaces of the magnet block are disposed in right-left direction (or front-back direction) and the magnet block is machined from the right side and the left side (or from the front side and the back side). The use of the fastening jig ensures that the magnet block is vertically secured in a tight, flexible manner.
In a preferred embodiment of the fastening jig, the portion of the clamp on its magnet block-adjoining side where the resilient cantilevers are defined is partially raised at positions near the work surfaces of the magnet block to form pads so that the clamp contacts only at the pads with the opposing surface of the magnet block. Specifically, as shown in
In a preferred embodiment of the fastening jig, the portion of the clamp on its magnet block-adjoining side where the resilient cantilevers are defined is provided with rims at its ends corresponding to the work surfaces of the magnet block, the rims being engaged with the magnet block to prevent the magnet block from separating apart. Specifically, as shown in
In the illustrated embodiment, the portion of the first clamp which is disposed adjacent to the magnet block is provided with generally horizontal channels each extending inward from the position corresponding to the work surface of the magnet block to define resilient cantilevers above the channels, that is, two channels extend in opposite directions and two resilient cantilevers are formed. The invention is not limited to the illustrated embodiment. For example, in the case of the first clamp 31 shown in
In a further embodiment, the fastening jig may be provided with a plurality of guide grooves corresponding to the cutoff abrasive blades of the multiple blade assembly so that the outer peripheral portion of each cutoff abrasive blade may be inserted into the corresponding guide groove. For example, as shown in
During machining operation, an outer peripheral portion of each cutoff abrasive blade 11 is inserted into the corresponding guide groove 31a in the first clamp 31 or guide groove 32a of the second clamp 32. Then the grooves 31a, 32a are arranged at a spacing which corresponds to the spacing between cutoff abrasive blades 11, and the grooves 31a, 32a extend straight and parallel to each other. The spacing between guide grooves 31a, 32a is equal to or less than the thickness of magnet pieces cut from the magnet block M.
The width of each guide groove should be greater than the width of each cutoff abrasive blade (i.e., the width of the peripheral cutting part). Provided that the peripheral cutting part of the cutoff abrasive blade has a width W (mm), the guide groove should preferably have a width of more than W mm to (W+6) mm and more preferably from (W+0.1) mm to (W+6) mm. The length (in cutting direction) and height of each guide groove are selected such that the cutoff abrasive blade may be moved within the guide groove during machining of the magnet block.
In the preferred embodiment of the fastening jig, only one of the first and second clamps is provided with a resilient cantilever(s), and the other is not provided with a resilient cantilever. For example, the surface of the second clamp in contact with the magnet block is preferably flat so that the surface comes in plane contact with the entire opposing surface of the magnet block. Specifically, as shown in
Notably, the clamp not having resilient cantilevers may also be provided, on its magnet block-adjoining side and at its ends corresponding to the work surfaces of the magnet block, with engagement rims for preventing the magnet block from separating away. Specifically, as shown in
During cutoff machining, the cutoff abrasive blades are preferably rotated such that the rotational direction of the blades at the cutting point of the blades is reverse to the feed direction of the blades. Referring to the arrangement of the multiple blade assembly 1 and the magnet block M shown in
The workpiece which is intended herein to cutoff machine is a rare earth sintered magnet block. The rare earth sintered magnet (or rare earth permanent magnet) as the workpiece is not particularly limited. Suitable rare earth magnets include sintered rare earth magnets of R—Fe—B systems wherein R is at least one rare earth element inclusive of yttrium. Suitable sintered rare earth magnets of R—Fe—B systems are those magnets containing, in weight percent, 5 to 40% of R, 50 to 90% of Fe, and 0.2 to 8% of B, and optionally one or more additive elements selected from C, Al, Si, Ti, V, Cr, Mn, Co, Ni, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Sn, Hf, Ta, and W, for the purpose of improving magnetic properties and corrosion resistance. The amounts of additive elements added are conventional, for example, up to 30 wt % of Co, and up to 8 wt % of other elements. Suitable sintered rare earth magnets of R—Fe—B systems may be prepared, for example, by weighing source metal materials, melting, casting into an alloy ingot, finely pulverizing the alloy into particles with an average particle size of 1 to 20 μm, i.e., sintered R—Fe—B magnet powder, forming a compact from the powder in a magnetic field, sintering the compact at 1,000 to 1,200° C. for 0.5 to 5 hours, and heat treating at 400 to 1,000° C.
Examples and Comparative Examples are given below for further illustrating the invention although the invention is not limited thereto.
Cutoff abrasive blades (OD blades) were fabricated by providing a doughnut-shaped disk core of cemented carbide (consisting of 90 wt % WC and 10 wt % Co) having an outer diameter 115 mm, inner diameter 60 mm, and thickness 0.35 mm, and bonding, by the resin bonding technique, artificial diamond abrasive grains to the outer periphery of the core to form an abrasive section (peripheral cutting part) containing 25% by volume of diamond grains with an average particle size of 150 μm. The axial extension of the abrasive section from the core was 0.025 mm on each side, that is, the abrasive section had a width of 0.4 mm (in the thickness direction of the core).
Using the cutoff abrasive blades, a cutting test was carried out on a workpiece which was a Nd—Fe—B rare earth sintered magnet block, under the following conditions. A multiple blade assembly was manufactured by coaxially mounting 46 blades on a shaft at an axial spacing of 1.68 mm, with spacers interposed therebetween. The spacers each had an outer diameter 82 mm, inner diameter 60 mm, and thickness 1.68 mm. This setting of the multiple blade assembly was such that the magnet block was cut into magnet strips having a thickness of 1.6 mm. The multiple blade assembly was combined with a coolant feed nozzle as shown in
The workpiece was a Nd—Fe—B rare earth sintered magnet block having a length 94 mm, width 45 mm and height 23 mm. By the multiple blade assembly, the magnet block was machined at 46 longitudinally equally spaced positions and divided into 47 magnet strips. With two magnet strips at opposite ends excluded, 45 magnet strips of 1.6 mm thick were recovered as effective products (rare earth sintered magnet pieces). Namely, the system was designed to produce 45 magnet strips from one magnet block.
The Nd—Fe—B rare earth sintered magnet block was secured by a fastening jig as shown in
Machining operation is as follows. While the fastening jig with which the magnet block was fixedly secured was held stationary, a coolant was fed at a flow rate of 60 L/min from the coolant feed nozzle. Then as shown in
Next, while the coolant was fed from the coolant feed nozzle, the multiple blade assembly 1, which was placed adjacent to the first clamp 31 of the fastening jig, was moved from the one side to the other side of the magnet block M (from right to left in
Then, as shown in
Next, while the coolant was fed from the coolant feed nozzle, the multiple blade assembly 1, which was placed adjacent to the first clamp 31 of the fastening jig, was moved from the other side to the one side of the magnet block M (from left to right in
Twelve Nd—Fe—B rare earth sintered magnet blocks were cutoff machined, and a sawing accuracy was evaluated. For each of magnet strips recovered after the division, the maximum height of a step at the merger between cutting grooves (from one and other sides) was measured on the opposite cutoff surfaces of the magnet strip. To evaluate a variation of the thickness of discrete magnet strips, the thickness between the opposite cutoff surfaces of each magnet strip was measured at five points including the center and four corners of the cutoff surface by a micrometer. A difference (A value) between maximum and minimum of thickness at 5 measurement points ranged from 3 to 46 μm, and an average of A values was calculated 15 μm. Also to evaluate a variation of the thickness of discrete magnet strips, an average (B value) of measurements of the thickness between the opposite cutoff surfaces at five points including the center and four corners of the cutoff surface ranged from 1.566 to 1.641 mm, and an average of B values was calculated 1.601 mm.
A magnet block on one side was cutoff machined by the same procedure as in Example 1, The fastening jig was unfastened, the magnet block was released from the jig and turned upside down, and the magnet block was secured by the fastening jig again, with the cutting grooves in the magnet block being aligned with the guide grooves in the jig after the upside-down turning. The magnet block on the other side was cutoff machined by the same procedure as the one side machining in Example 1. In this way, the cutting grooves formed from the one and other sides merged together, whereby the magnet block M was sawn throughout its thickness, that is, divided into magnet strips.
Twelve Nd—Fe—B rare earth sintered magnet blocks were cutoff machined, and a sawing accuracy was evaluated as in Example 1. As a result, the A value ranged from 6 to 98 μm, the average of A values was 35 μm, the B value ranged from 1.551 to 1.633 mm, and the average of B values was 1.592 mm.
Cutoff abrasive blades (OD blades) were fabricated by providing a doughnut-shaped disk core of cemented carbide (consisting of 90 wt % WC and 10 wt % Co) having an outer diameter 125 mm, inner diameter 60 mm, and thickness 0.35 mm, and bonding, by the resin bonding technique, artificial diamond abrasive grains to the outer periphery of the core to form an abrasive section (peripheral cutting part) containing 25% by volume of diamond grains with an average particle size of 150 μm. The axial extension of the abrasive section from the core was 0.025 mm on each side, that is, the abrasive section had a width of 0.4 mm (in the thickness direction of the core).
Using the cutoff abrasive blades, a cutting test was carried out on a workpiece which was a Nd—Fe—B rare earth sintered magnet block, under the following conditions. A multiple blade assembly was manufactured by coaxially mounting 30 blades on a shaft at an axial spacing of 1.79 mm, with spacers interposed therebetween. The spacers each had an outer diameter 93 mm, inner diameter 60 mm, and thickness 1.79 mm. This setting of the multiple blade assembly was such that the magnet block was cut into magnet strips having a thickness of 1.71 mm. The multiple blade assembly was combined with a coolant feed nozzle as shown in
The workpiece was a Nd—Fe—B rare earth sintered magnet block having a length 63 mm, width 44 mm and height 21.5 mm. By the multiple blade assembly, the magnet block was machined at 30 longitudinally equally spaced positions and divided into 31 magnet strips. With two magnet strips at opposite ends excluded, 29 magnet strips of 1.71 mm thick were recovered as effective products (rare earth sintered magnet pieces). Namely, the system was designed to produce 29 magnet strips from one magnet block.
The Nd—Fe—B rare earth sintered magnet block was secured by a fastening jig as shown in
Machining operation is as follows. While the fastening jig with which the magnet block was fixedly secured was held stationary, a coolant was fed at a flow rate of 60 L/min from the coolant feed nozzle. Then as shown in
Next, while the coolant was fed from the coolant feed nozzle, the multiple blade assembly 1, which was placed adjacent to the first clamp 31 of the fastening jig, was moved from the one side to the other side of the magnet block M (from right to left in
Then, as shown in
Next, while the coolant was fed from the coolant feed nozzle, the multiple blade assembly 1, which was placed adjacent to the first clamp 31, was moved from the other side to the one side of the magnet block M (from left to right in
Five Nd—Fe—B rare earth sintered magnet blocks were cutoff machined, and a sawing accuracy was evaluated as in Example 1. As a result, the A value ranged from 1 to 25 μm, the average of A values was 8 μm, the B value ranged from 1.697 to 1.734 mm, and the average of B values was 1.717 mm.
A magnet block on one side was cutoff machined by the same procedure as in Example 2. The fastening jig was unfastened, the magnet block was released from the jig and turned upside down, and the magnet block was secured by the fastening jig again, with the cutting grooves in the magnet block being aligned with the guide grooves in the jig after the upside-down turning. The magnet block on the other side was cutoff machined by the same procedure as the one side machining in Example 2. In this way, the cutting grooves formed from the one and other sides merged together, whereby the magnet block M was sawn throughout its thickness, that is, divided into magnet strips.
Five Nd—Fe—B rare earth sintered magnet blocks were cutoff machined, and a sawing accuracy was evaluated as in Example 1. As a result, the A value ranged from 7 to 79 μm, the average of A values was 40 μm, the B value ranged from 1.667 to 1.717 mm, and the average of B values was 1.693 mm.
Japanese Patent Application No. 2016-255017 is incorporated herein by reference.
Although some preferred embodiments have been described, many modifications and variations may be made thereto in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described without departing from the scope of the appended claims.
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| JP2016-255017 | Dec 2016 | JP | national |
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| Number | Date | Country | |
|---|---|---|---|
| 20180178345 A1 | Jun 2018 | US |
