METHOD OF MANUFACTURING CHAMFERING WHEEL, CHAMFERING WHEEL, AND METHOD OF ADJUSTING CHAMFERING WHEEL BEFORE USE

Abstract

A method of manufacturing a chamfering wheel includes: forming, to be concentric by coaxial processing: a reference surface serving as one of a pair of side surfaces of a disk; a fitting hole into which a rotary shaft part is fitted in the disk; a first surface of an annular centering groove, the first surface being provided on the reference surface and used to detect a runout corresponding to a runout of an outer peripheral surface of the chamfering wheel when the chamfering wheel rotates; and a second surface of the centering groove, the second surface being provided on the reference surface, adjacent to the first surface, and used to detect a runout of the reference surface when the chamfering wheel rotates; and forming a grinding wheel portion on an outer peripheral surface of the disk.

Description

FIELD

The present invention relates to a method of manufacturing a chamfering wheel, a chamfering wheel, and a method of adjusting a chamfering wheel before use.

BACKGROUND

A chamfering wheel as disclosed by, for example, Jpn. Pat. Appin. KOKAI Publication No. 2006-116686 is attached to a rotary shaft part such as a spindle and rotates together with the rotary shaft part, and is thereby used to chamfer a workpiece such as glass or a silicon wafer with a grinding wheel portion on an outer peripheral surface. For example, when the workpiece is inserted into a groove of the grinding wheel portion formed in an annular shape on the outer peripheral surface of the chamfering wheel, the edge of the workpiece is chamfered into a groove shape.

SUMMARY

A method of manufacturing a chamfering wheel includes: performing coaxial processing on: a reference surface serving as one of a pair of side surfaces of a disk; a fitting hole into which a rotary shaft part is fitted in the disk; a first surface of an annular centering groove, the first surface being provided on the reference surface and used when detecting a runout corresponding to a runout of an outer peripheral surface of the chamfering wheel when the chamfering wheel rotates to adjust a position of the disk; and a second surface of the centering groove, the second surface being provided on the reference surface, adjacent to the first surface, and used when detecting a runout of the reference surface when the chamfering wheel rotates to adjust the position of the disk, while maintaining a state of holding the disk with a machine tool to form the centering groove to be concentric with respect to a center axis of the fitting hole to secure accuracies of the first surface and the second surface; and forming an annular grinding wheel portion on an outer peripheral surface of the disk.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a chamfering wheel according to an embodiment as viewed from a direction indicated by reference sign I in FIG. 2.

FIG. 2 is a cross-sectional view taken along line II-II in FIG. 1.

FIG. 3 is an enlarged view of a position indicated by reference sign III in FIG. 2.

FIG. 4 is a schematic perspective view of a base material for a disk of the chamfering wheel according to the embodiment.

FIG. 5 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 4.

FIG. 6 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 5.

FIG. 7 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 6.

FIG. 8 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 7.

FIG. 9 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 8.

FIG. 10 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 9.

FIG. 11 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 10.

FIG. 12 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 11.

FIG. 13 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 12.

FIG. 14 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 13.

FIG. 15 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 14.

FIG. 16 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 15.

FIG. 17 is a schematic perspective view showing a manufacturing process of the chamfering wheel subsequent to FIG. 16.

FIG. 18 is a schematic perspective view showing a method of adjusting a chamfering wheel before use.

DETAILED DESCRIPTION

A chamfering wheel 10 according to an embodiment will be described with reference to FIGS. 1 to 18.

Note that it has been found that the life of the grinding wheel portion 14 of the chamfering wheel 10 depends on the geometrical accuracy of the chamfering wheel 10. Therefore, it is required to form a disk 12 serving as a base body of the chamfering wheel 10 with high accuracy.

As shown in FIGS. 1 to 3, the chamfering wheel 10 includes a disk 12 having a center axis C defined therein, and a grinding wheel portion 14 formed on an outer peripheral surface of the disk 12.

The disk 12 serves as a base body fixing the grinding wheel portion 14. The disk 12 is preferably made of, for example, an aluminum alloy. The disk 12 is preferably made of, among aluminum alloys, extra super duralumin (A7075 material according to JIS), which is excellent in workability and has abrasion resistance. The disk 12 may be made of various materials, not limited to an aluminum alloy, as long as the disk 12 has a rigidity required for the disk 12 of the chamfering wheel 10, can be processed into a desired condition, and has a desired dimensional stability.

The disk 12 includes a disk body 22 having the center axis C defined therein, a fitting hole 24 penetrating the center axis C of the disk body 22, and a recessed centering groove 26 formed around the center axis C.

The disk body 22 includes a boss 32 having a pair of flat surfaces 32a and 32b, an annular portion 34 having a pair of annular surfaces (recessed surfaces) 34a and 34b formed on the outer side of the boss 32, and an outer peripheral surface 36. The boss 32 forms the fitting hole 24. The flat surfaces 32a and 32b of the boss 32 protrude, for example, with respect to the pair of annular surfaces 34a and 34b, respectively. The flat surfaces 32a and 32b are formed as annular surfaces parallel to each other, and normals of the pair of flat surfaces 32a and 32b are directed in opposite directions. The one flat surface 32a is used as a reference surface serving as a reference for radial runout and side runout, which will be described later. The one annular surface 34a may be formed to be flush with the reference surface as the flat surface 32a of the boss 32. Hereinafter, for the sake of simplicity of description, the one flat surface 32a of the boss 32 and the annular surface 34a are assumed to be flush with each other, and this is referred to as one (first) side surface 38a. When the flat surface 32a and the annular surface 34a are flush with each other, the side surface 38a serves as the reference surface. That is, the reference surface may be the flat surface 32a of the boss 32 in the side surface 38a, or may be a region in which the flat surface 32a and the annular surface 34a are combined. The other annular surface 34b is used as a marking surface (hereinafter, appropriately denoted by reference sign 34b) on which, for example, indication such as a serial number or a manufacturer (not shown) is marked. The other annular surface 34b may be formed to be flush with the flat surface 32b of the boss 32. Hereinafter, the other flat surface 32b of the boss 32 and the annular surface 34b are assumed to be flush with each other, and this is referred to as the other (second) side surface 38b, and this is also referred to as a marking surface (provisional reference surface). In this case, the fitting hole 24 appears to penetrate the pair of side surfaces 38a and 38b. FIGS. 4 to 18 appropriately omit the steps between the pair of flat surfaces 32a and 32b of the boss 32 and the pair of annular surfaces 34a and 34b, and provide illustration of a pair of side surfaces 38a and 38b in an annular flat shape. The outer peripheral surface 36 includes a flange portion 42 having an outer-side outer peripheral surface 42a, and an inner-side outer peripheral surface 44. On the inner-side outer peripheral surface 44 of the disk body 22, the annular grinding wheel portion 14 is arranged. The grinding wheel portion 14 is positioned with respect to the disk body 22 by the flange portion 42.

The fitting hole 24 is perpendicular to the reference surface 38a (flat surface 32a) and formed as an annular surface (inner peripheral surface) in which the normal at each position is directed toward the center axis C. The rotary shaft part 80 or 90 such as a spindle or an arbor is fitted into the fitting hole 24.

The centering groove 26 is formed in the side surface 38a (annular surface 34a) on the inner side of the outer peripheral surface 36 of the disk body 22. The centering groove 26 includes a first surface 52, a second surface 54, and a third surface 56, each of which is annular and concentric with the center axis C. The first surface 52 and the second surface 54 are continuous (adjacent). The second surface 54 and the third surface 56 are continuous (adjacent).

The first surface 52 is orthogonal to the reference surface 38a (flat surface 32a), parallel to the fitting hole 24, and formed in an annular shape. The normal of the first surface 52 is directed toward the center axis C of the disk 12. The first surface 52 is used to detect runout corresponding to runout of the outer-side outer peripheral surface 42a or the inner-side outer peripheral surface 44 of the disk 12, or the outer peripheral surface 66 of the chamfering wheel 10 when the chamfering wheel 10 rotates. The second surface 54 is parallel to the reference surface 38a (flat surface 32a), orthogonal to the fitting hole 24, and formed in an annular shape. The second surface 54 is used to detect runout of the reference surface 38a when the chamfering wheel 10 rotates. The third surface 56 is formed in an annular shape, but is neither parallel nor perpendicular to the reference surface 38a (flat surface 32a) in the present embodiment. In the present embodiment, the third surface 56 has a linear cross section but may have a curved cross section.

The grinding wheel portion 14 is formed as an annular sintered body containing diamond powder, for example. The grinding wheel portion 14 has a pair of end surfaces 62a and 62b, an inner peripheral surface 64, and an outer peripheral surface 66. The one end surface 62a is brought into contact with the flange portion 42. The normal of the other end surface 62b is directed in the same normal direction as the marking surface 34b, for example. A plurality of annular chamfering grooves 68 are formed on the outer peripheral surface 66 of the grinding wheel portion 14. In the present embodiment, nine chamfering grooves 68 are formed along the axial direction of the center axis C at a predetermined pitch in the thickness direction of the chamfering wheel 10. The chamfering grooves 68 may not be made to have the same shape or grain size by appropriately providing a finishing process, depending on a shape or roughness of a chamfered surface of a workpiece.

Next, a method of manufacturing the chamfering wheel 10 will be described with reference to FIGS. 4 to 17. In the example shown in FIGS. 4 to 17, tools T1 to T8 attached to an appropriate machine tool are used. For the tools T1-T8, eight tools are not necessarily used, and the same tools may be used as appropriate.

As shown in FIG. 4, a base material 100, for example, having columnar form and formed of the same material as the disk 12 of the chamfering wheel 10, is prepared. The outer diameter of the base material 100 is equal to or larger than the outer diameter of the outer-side outer peripheral surface 42a of the disk 12 of the chamfering wheel 10. From the base material 100, for example, a plurality of disks 12 of chamfering wheels 10 are cut out to have a predetermined thickness (process 1). From the base material 100 shown in FIG. 4, a plurality of disks 12 of chamfering wheels 10 can be formed.

As shown in FIG. 5, in the disk 12, the fitting hole 24 through which the rotary shaft part 80 or 90 passes is roughly processed with the tool T1 attached to a given machine tool, and the outer peripheral surface 36 is roughly processed with the T2 attached to the given machine tool (process 2).

As shown in FIG. 6, the other side surface 38b of the pair of side surfaces 38a and 38b of the disk 12 is processed to be a provisional reference surface with the tool T3 attached to the given machine tool, and the other side surface 38b is processed as a marking surface on which a serial number, a manufacturer, or the like is marked. Furthermore, the inner diameter of the fitting hole 24 through which the rotary shaft part 80 or 90 passes is increased with the tool T4 attached to the given machine tool (process 3). The inner diameter of the fitting hole 24 at this time is smaller than a predetermined inner diameter of the rotary shaft part 80 or 90. The provisional reference surface (marking surface) 38b and the fitting hole 24 can be processed when the rough processing is performed. Therefore, the processing steps of the provisional reference surface (marking surface) 38b and the fitting hole 24 may be unnecessary.

As shown in FIG. 7, for example, the outer side of the position to be formed as the inner-side outer peripheral surface 44 in the outer peripheral surface 36 of the disk 12 is held from the provisional reference surface 38b side by the given machine tool. That is, the disk 12 is reversed. Then, the side surface 38a is formed with the tool T5 attached to the machine tool so that the surface of the disk 12 on the opposite side to the provisional reference surface 38b is used as a reference surface. As an example, by performing coaxial processing on the disk 12 while maintaining a state of holding the disk 12 by the same machine tool, the side surface 38a in which the flat surface 32a and the annular surface 34a are combined is formed as a flush reference surface.

Furthermore, the fitting hole 24 through which the rotary shaft part 80 or 90 passes is formed with the tool T6 attached to the machine tool so as to be coaxial with the reference surface 38a while maintaining a state of holding the outer peripheral surface 36 of the disk 12 from the marking surface 38b side. Furthermore, the annular centering groove 26 is formed in the reference surface 38a with the machine tool T7 attached to the machine tool so as to be coaxial with the reference surface 38a while maintaining a state of holding the outer peripheral surface 36 of the disk 12 from the marking surface 38b side.

That is, here, the reference surface 38a, the fitting hole 24, and the centering groove 26 are formed so as to be coaxial, with the tools T5, T6 and T7 attached to the given machine tool, in a state such that the outer peripheral surface 36 of the disk 12 is held from the marking surface 38b side as the other side of the pair of side surfaces 38a and 38b, and in a state such that the center axis C of the disk 12 is shared (process 4). By performing coaxial processing on the disk 12 while maintaining a state of holding the disk 12 by the same machine tool, the inner peripheral surface of the fitting hole 24 is formed in a state of being orthogonal to the reference surface 38a. Through this processing, the center axis C of the disk 12 is defined.

The fitting hole 24 and the centering groove 26 are preferably formed through simultaneous processing in which they are simultaneously processed with the plurality of tools T6 and T7. The fitting hole 24 and the centering groove 26 may not be formed simultaneously but formed in a random order.

The first surface 52, the second surface 54, and the third surface 56 of the centering groove 26 shown in FIG. 3 are formed to be coaxial with the reference surface 38a and the fitting hole 24. Therefore, the first surface 52 is formed in a state perpendicular to the reference surface 38a and parallel to the inner peripheral surface of the fitting hole 24, and the second surface 54 is formed in a state parallel to the reference surface 38a and perpendicular to the inner peripheral surface of the fitting hole 24.

For example, it is preferable to process the disk 12 by using the same machine tool from process 2 shown in FIG. 5 to process 4 shown in FIG. 7.

The holding state of the given machine tool is changed from the state where the outer peripheral surface 36 of the disk 12 is held from the marking surface 38b side to a state where the outer peripheral surface 36 of the disk 12 is held from the reference surface 38a side. That is, the outer side of the position that will become an outer-side outer peripheral surface 42a of the outer peripheral surface 36 of the disk 12 is held from the reference surface 38a side by the machine tool. Then, as shown in FIG. 8, the outer peripheral surface 36 of the disk 12 is cut from the marking surface 38b side with the tool T8 attached to the machine tool (process 5). On the outer peripheral surface 36 of the disk 12, the flange portion 42 on the reference surface 38a side and the inner-side outer peripheral surface 44 on the marking surface 38b side are formed.

As shown in FIG. 9, the annular grinding wheel portion 14 formed by, for example, sintering diamond powder is fitted from the marking surface 38b side toward the flange portion 42. The inner peripheral surface of the grinding wheel portion 14 is, for example, bonded and fixed to the inner-side outer peripheral surface 44 (process 6). At this time, the end surface 62a of the grinding wheel portion 14 on the reference surface 38a side is brought into contact with the flange portion 42. Therefore, the grinding wheel portion 14 is positioned by the flange portion 42. The end surface 62b of the grinding wheel portion 14 on the marking surface 38b side may protrude with respect to the marking surface 38b. The outer peripheral surface 66 of the grinding wheel portion 14 is positioned radially outward of the outer-side outer peripheral surface 42a of the disk 12, for example.

After the grinding wheel portion 14 is fixed to the inner-side outer peripheral surface 44 of the disk 12, as shown in FIG. 10, for example, the chamfering wheel 10 is rotated in a predetermined direction R1 and another grinding wheel 72 is rotated in a predetermined direction R2 to grind the end surface 62b of the grinding wheel portion 14 on the marking surface 38b side, making the end surface 62b of the grinding wheel portion 14 on the marking surface 38b side flat (process 7). The direction R1 is a direction around the center axis C. The direction R2 is a direction around the center axis Cl of the grinding wheel 72 (orthogonal to the center axis C of the disk 12). At this time, the grinding wheel 72 is moved in a direction D1 and a direction D2 opposite to the direction D1 as necessary. The directions D1 and D2 are orthogonal to the center axis C and parallel to the center axis of the grinding wheel 72.

As shown in FIG. 11, a rotary shaft part (coaxial arbor) 80 is incorporated as a processing shaft into the chamfering wheel 10 in this state. Then, centering operation between the rotary shaft part 80 and the disk 12 is performed (process 8). The centering operation is performed using distance detection sensors S1 and S2. While an example of using two distance detection sensors S1 and S2 will be described here, one sensor may detect both radial runout and side runout.

In the centering operation, as shown in FIG. 12, for example, first, the rotary shaft part 80 is rotated while, for example, a dial gauge as the first distance detection sensor S1 is brought into contact with the first surface 52 of the centering groove 26, and the chamfering wheel 10 is rotated together with the rotary shaft part 80, thereby detecting runout of the first surface 52 of the centering groove 26. Since the first surface 52 is formed with higher accuracy than the outer peripheral surface 66 of the grinding wheel portion 14, detection of runout of the first surface 52 by the first distance detection sensor S1 can be regarded as detecting runout corresponding to runout (radial runout) of the outer peripheral surface 66 of the chamfering wheel 10. In the centering operation, as shown in FIG. 13, for example, second, the rotary shaft part 80 is rotated while, for example, a dial gauge as the second distance detection sensor S2 is brought into contact with the second surface 54 of the centering groove 26, and the chamfering wheel 10 is rotated together with the rotary shaft part 80, thereby detecting runout of the second surface 54 of the centering groove 26. Since the second surface 54 is formed to be coaxial with the reference surface 38a, detection of runout of the second surface 54 by the second distance detection sensor S2 can be regarded as detecting runout corresponding to runout (side runout) of the reference surface 38a of the chamfering wheel 10. After detection of radial runout and side runout of the chamfering wheel 10, the attachment state of the chamfering wheel 10 with respect to the rotary shaft part 80 is adjusted as necessary based on the detection result. That is, the attachment state of the chamfering wheel 10 with respect to the rotary shaft part 80 is adjusted based on runout of the first surface 52 with respect to the rotary shaft part 80 detected by the dial gauge (distance detection sensor) S1. Furthermore, the attachment state of the chamfering wheel 10 with respect to the rotary shaft part 80 is adjusted based on runout of the second surface 54 with respect to the rotary shaft part 80 detected by the dial gauge (distance detection sensor) S2. In this manner, the centering operation for adjusting the attachment state of the rotary shaft part 80 and the chamfering wheel 10 secures the coaxiality of the center axis C between the rotary shaft part 80 and the chamfering wheel 10, the perpendicularity of the center axis of the rotary shaft part 80 with respect to the reference surface 38a of the chamfering wheel 10, and the perpendicularity of the surface of the fitting hole 24 with respect to the reference surface 38a of the chamfering wheel.

When detecting radial runout and side runout of the chamfering wheel 10, the chamfering wheel 10 may be fixed and the distance detection sensors S1 and S2 may be moved in an annular manner. Therefore, when detecting the radial runout and the side runout of the chamfering wheel 10, it is preferable to move the distance detection sensor S1 relative to the first surface 52 of the centering groove 26 in the circumferential direction to adjust the position of the chamfering wheel 10 based on the runout (radial runout) of the chamfering wheel 10 with respect to the rotary shaft part 80, and to move the distance detection sensor S1 or another distance detection sensor S2 relative to the second surface 54 of the centering groove 26 in the circumferential direction to adjust the position of the chamfering wheel 10 based on the runout (side runout) of the reference surface 38a of the chamfering wheel 10 with respect to the rotary shaft part 80.

As shown in FIG. 14, the outer diameter of the outer peripheral surface 66 of the grinding wheel portion 14 of the chamfering wheel 10, in which the rotary shaft part 80 is incorporated and the centering operation is performed, is processed to be constant by using another grinding wheel 74 (process 9). For example, while the chamfering wheel 10 is rotated about the axis in a predetermined direction R3 and the grinding wheel 74 is rotated about the shaft in the predetermined direction R4, the grinding wheel 74 is reciprocated in a direction D3 and a direction D4 opposite to the direction D3. At this time, the center axis C of the chamfering wheel 10 and the center axis C2 of the grinding wheel 74 are parallel to each other, and the directions D3 and D4 are parallel to the center axis C.

As shown in FIG. 15, thereafter, the radial runout of the chamfering wheel 10 shown in FIG. 12 and the side runout of the chamfering wheel 10 shown in FIG. 13 are checked, and the centering operation for securing the coaxiality and the perpendicularity of the rotary shaft part 80 and the chamfering wheel 10 is performed again (process 10).

As shown in FIG. 16, chamfering grooves (product grooves) 68 for chamfering edges of various plate-like members (not shown) are formed on the outer peripheral surface 66 of the grinding wheel portion 14 by using an electric discharge machining electrode 76 (process 11). At this time, the center axis C of the chamfering wheel 10 and the center axis C3 of the electric discharge machining electrode 76 are parallel to each other.

As shown in FIG. 17, dressing is performed on the chamfering grooves (product grooves) 68 of the chamfering wheel 10 (process 12). Therefore, the chamfering grooves (product grooves) 68 of the chamfering wheel 10 exhibit a desired performance when chamfering edges of various plate-like members (not shown).

Lastly, the chamfering wheel 10 is removed from the rotary shaft part 80, and shipment inspection is performed. Here, the process shape inspection and the dimension inspection of the chamfering grooves (product grooves) 68 and the dimension inspection of the entire chamfering wheel 10 are performed.

In the above-described manner, the chamfering wheel 10 is manufactured and shipped to the user.

Hereinafter, a method of adjusting the chamfering wheel 10 shipped from a manufacturer before use, performed by the user, for example, will be described with reference to FIG. 18.

For example, a user of the chamfering wheel 10 who wishes to chamfer the edge of the plate-like body fits a predetermined rotary shaft part 90 into the fitting hole 24 of the chamfering wheel 10. Then, the user performs centering operation between the rotary shaft part 90 and the chamfering wheel 10. The centering operation is performed using the distance detection sensors S1 and S2. While the dial gauges S1 and S2 are used as the distance detection sensors in the above example, optical sensors that can detect distances in a non-contact manner for the first surface 52 and the second surface 54 of the centering groove 26 may be used.

As shown in FIGS. 12 and 13, the chamfering wheel 10 is rotated together with the rotary shaft part 90, and runout (radial runout) of the first surface 52 and runout (side runout) of the second surface 54 of the centering groove 26 are detected. After the radial runout and the side runout of the chamfering wheel 10 are checked, the attachment state of the rotary shaft part 90 and the chamfering wheel 10 is adjusted as necessary based on the detection results of the radial runout and the side runout. The adjustment of the attachment state is performed manually, for example. The user understands the runout of the first surface 52 and the runout of the second surface 54, and uses so-called craftsmanship to move the chamfering wheel 10 slightly with respect to the rotary shaft part 90 so as to suppress the runout of the first surface 52 and the runout of the second surface 54. The user then ensures the coaxiality of the center axis C between the rotary shaft part 90 and the chamfering wheel 10, the perpendicularity of the center axis of the rotary shaft part 90 with respect to the reference surface 38a of the chamfering wheel 10, and the perpendicularity of the inner circumferential surface of the fitting hole 24 with respect to the outer peripheral surface of the rotary shaft part 90.

Even in this case, after the adjustment of the attachment state of the chamfering wheel 10 to the rotary shaft part 90, before using the chamfering wheel 10, the user detects the runout of the first surface 52 and the runout of the second surface 54 again, and checks whether or not there is a problem in the attachment state. Alternatively, without moving the chamfering wheel 10 slightly with respect to the rotary shaft part 90, the user detaches the chamfering wheel 10 from the rotary shaft part 90 and attaches the chamfering wheel 10 to the rotary shaft part 90 again, detects the runout of the first surface 52 and the runout of the second surface 54 again, and checks whether or not there is a problem in the attachment state again. If detection results of the runout of the first surface 52 and the runout of the second surface 54 are within the above-described threshold range, for example, the chamfering wheel 10 is used as it is, and if the detection results of the runout of the first surface 52 and the runout of the second surface 54 are outside the above-described threshold range, the attachment state of the rotary shaft part 90 and the chamfering wheel 10 is adjusted again.

The adjustment to be performed as necessary can be appropriately performed by a so-called person skilled in the art such as a user of the chamfering wheel 10. For example, when chamfering the edge of various plate-like members, the chamfering wheel 10 needs to exhibit a desired performance. As one of the determination criteria for adjusting the attachment state of the chamfering wheel 10 with respect to the rotary shaft part 90, the user can use, for example, the degree of dimensional accuracy required for chamfering a workpiece such as a glass or a silicon wafer to be chamfered and whether or not the dimensional accuracy is secured in the current attachment state. Therefore, for example, when the user of the chamfering wheel 10 sets a certain threshold for each of the runout of the first surface 52 and the runout of the second surface 54 and the runout is within a range of the certain threshold, adjustment of the attachment state of the chamfering wheel 10 with respect to the rotary shaft part 90 is not required. On the other hand, if the runout of the first surface 52 and the runout of the second surface 54 are outside the range of the certain threshold, adjustment of the attachment state of the chamfering wheel 90 with respect to the rotary shaft part 90 is required.

Such adjustment of the attachment state is performed not only when the chamfering wheel 10 is attached to the rotary shaft part 90 but also when the chamfering wheel 10 is attached to the rotary shaft part 80.

In this manner, the centering operation for adjusting the attachment state of the rotating shaft part 90 and the chamfering wheel 10 secures the coaxiality of the center axis C between the rotary shaft part 90 and the chamfering wheel 10, the perpendicularity of the center axis of the rotary shaft part 90 with respect to the reference surface 38a of the chamfering wheel 10, and the perpendicularity of the inner peripheral surface of the fitting hole 24 with respect to the outer peripheral surface of the rotary shaft part 90.

By using the chamfering wheel 10 adjusted in this manner, the user chamfers an edge of each plate-like body. When the plate-like body is, for example, a wafer, chamfering can be performed on an edge of an orientation flat by relatively moving the chamfering wheel 10 and the wafer. Furthermore, chamfering can be performed on an edge of a wafer having a notch.

The grinding wheel portion 14 is maintained, for example, after being used an appropriate number of times, or after a predetermined period of time has elapsed. At the time of maintenance, the chamfering wheel 10 is returned from the shipping destination to, for example, the manufacturer of the chamfering wheel 10.

As an example, the grinding wheel portion 14 is removed from the disk 12, and a new grinding wheel portion 14 is bonded and fixed to the inner-side outer peripheral surface 44 of the disk 12. Thereafter, processes 7 to 12 are performed in order, and the chamfering wheel 10 is shipped again to the same user, for example. In this manner, the disk 12 of the chamfering wheel 10 is reusable. The shape of the chamfering grooves 68 may be changed from that before maintenance based on an instruction from a customer during maintenance.

The reference surface 38a (flat surface 32a), the fitting hole 24, and the centering groove 26 of the disk body 22 of the chamfering wheel 10 manufactured according to the present embodiment are formed to be coaxial in a state of holding the disk body 22 by a given machine tool. When the reference surface 38a (flat surface 32a), the fitting hole 24, and the centering groove 26 are formed, the holding state of the outer peripheral surface 36 of the disk body 22 is not changed even once. Therefore, the inner peripheral surface of the fitting hole 24 and the first surface 52 and the second surface 54 of the centering groove 26 can achieve a desired coaxiality and roundness depending on a machine tool.

When the chamfering wheel 10 is rotated, the outer peripheral surface 66 of the grinding wheel portion 14 does not become a perfect circle due to projection of the abrasive grains. Therefore, even when the outer peripheral surface 66 of the grinding wheel portion 14 is measured by a dial gauge or the like, the measurement is easily affected by variation in measurement. In the present embodiment, the first surface 52 of the centering groove 26 is used to measure the radial runout. At this time, since the first surface 52 is formed so as to secure the coaxiality with the inner peripheral surface of the fitting hole 24, the measurement accuracy of the radial runout can be much higher than in the case where the outer peripheral surface 66 of the grinding wheel portion 14 is measured. Therefore, according to the present embodiment, with the centering groove 26 having the first surface 52 orthogonal to the reference surface 38a (flat surface 32a) and the second surface 54 parallel to the reference surface 38a (flat surface 32a), the centering operation can be performed with a much higher accuracy than in the case where the centering groove 26 is not provided.

When the chamfering wheel 10 is rotated, the end surface 62b of the outer peripheral surface 66 of the grinding wheel portion 14 is not flat due to projection of the abrasive grains. Therefore, even when the side runout (flatness) of the end surface 62b of the outer peripheral surface 66 of the grinding wheel portion 14 is measured by a dial gauge or the like, the measurement is easily affected by variation in measurement. In the present embodiment, the second surface 54 of the centering groove 26 is used to measure the side runout. At this time, since the second surface 54 of the centering groove 26 is formed so as to secure the perpendicularity with the inner peripheral surface of the fitting hole 24, the measurement accuracy of the side runout can be much higher than in the case where the end surface 62b portion of the outer peripheral surface 66 of the grinding wheel portion 14 is measured. Therefore, according to the present embodiment, with the centering groove 26 having the first surface 52 orthogonal to the reference surface 38a (flat surface 32a) and the second surface 54 parallel to the reference surface 38a (flat surface 32a), the centering operation can be performed with a much higher accuracy than in the case where the centering groove 26 is not provided.

In the present embodiment, as shown in FIGS. 11 to 14, the centering operation is performed before the outer peripheral surface 66 of the grinding wheel portion 14 is processed. Therefore, when the chamfering wheel 10 in which the rotary shaft part 80 is incorporated is rotated to grind the outer peripheral surface 66 of the grinding wheel portion 14 by another grinding wheel 74, the outer peripheral surface 66 of the grinding wheel portion 14 having a high roundness is formed.

In the chamfering wheel 10 of the present embodiment, as shown in FIGS. 15 and 16, the centering operation is performed before the chamfering grooves 68 are formed in the outer peripheral surface 66 of the grinding wheel portion 14. Therefore, when the chamfering wheel 10 in which the rotary shaft part 80 is incorporated is rotated to form the chamfering grooves 68 in the outer peripheral surface 66 of the grinding wheel portion 14 by the electric discharge machining electrode 76, the depth with respect to the outer peripheral surface 66 of the grinding wheel portion 14 can be easily kept constant.

By performing a centering operation before forming the chamfering grooves 68 of the chamfering wheel 10, a desired coaxiality and roundness are obtained between the rotary shaft part 80 and the disk 12 of the chamfering wheel 10 and between the electric discharge machining electrode 76 and the chamfering grooves 68 of the chamfering wheel 10. Therefore, the electric discharge machining electrode 76 is brought into good contact with the chamfering grooves 68 of the chamfering wheel 10, and as a result, the life of the chamfering wheel 10 can be extended, and chipping of the chamfering grooves 68 can be suppressed.

In the chamfering wheel 10 of the present embodiment, as shown in FIG. 18, the centering operation is performed before the edge of the plate-like body is processed with the chamfering grooves 68 of the outer peripheral surface 66 of the grinding wheel portion 14. Therefore, when the chamfering wheel 10 in which the rotary shaft part 90 is incorporated is rotated, the dimensional error of the chamfering wheel 10 can be suppressed.

When the centering groove 26 is formed by using the method of manufacturing the chamfering wheel 10 according to the present embodiment, there is no need to introduce a machine tool capable of performing machining with a higher accuracy. Therefore, it is possible to provide a chamfering wheel 10 whose life can be extended while suppressing the manufacturing cost.

In the present embodiment, the first surface 52, the second surface 54, and the third surface 56 are arranged in this order from a position distal to the center axis C of the disk 12 toward a position proximal to the center axis C of the disk 12, but the order may be reversed. In the present embodiment, the example in which the normal of the first surface 52 is directed toward the center axis C, that is, directed radially inward with respect to the center axis C has been described. For example, the normal of the third surface 56 may be formed so as to be directed outward in the radial direction with respect to the center axis C. In this case, the third surface 56 may be used as a radial runout measurement surface. When the third surface 56 is used as the radial runout measurement surface, the first surface 52 may be formed as a surface that is neither parallel nor perpendicular to the flat surface 32a serving as the reference surface.

According to the present embodiment, it is possible to provide a method of manufacturing a chamfering wheel 10 formed with higher accuracy, a chamfering wheel 10, and a method of adjusting the chamfering wheel 10 before use.

The present invention is not limited to the above-described embodiments, and can be modified in various manners in practice, without departing from the gist of the invention. Moreover, the embodiments can be suitably combined; in such case, combined advantages are obtained. Furthermore, the above-described embodiments include various inventions, and various inventions can be extracted by a combination selected from structural elements disclosed herein. For example, if the problem can be solved and the effects can be attained even after some of the structural elements are deleted from all the structural elements disclosed in the embodiment, the structure made up of the resultant structural elements may be extracted as an invention.

Claims

1. A method of manufacturing a chamfering wheel comprising: performing coaxial processing on: a reference surface serving as one of a pair of side surfaces of a disk;a fitting hole into which a rotary shaft part is fitted in the disk;a first surface of an annular centering groove, the first surface being provided on the reference surface and used when detecting a runout corresponding to a runout of an outer peripheral surface of the chamfering wheel when the chamfering wheel rotates to adjust a position of the disk; anda second surface of the centering groove, the second surface being provided on the reference surface, adjacent to the first surface, and used when detecting a runout of the reference surface when the chamfering wheel rotates to adjust the position of the disk,while maintaining a state of holding the disk with a machine tool to form the centering groove to be concentric with respect to a center axis of the fitting hole to secure accuracies of the first surface and the second surface; andforming an annular grinding wheel portion on an outer peripheral surface of the disk.

2. The method according to claim 1, wherein the forming the first surface comprises forming the first surface so as to be orthogonal to the reference surface formed as a flat surface, andthe forming the second surface comprises the second surface so as to be parallel to the reference surface.

3. A chamfering wheel, comprising: a disk in which a reference surface is formed on one of a pair of side surfaces;a fitting hole having an inner peripheral surface orthogonal to the reference surface, and into which a rotary shaft part is fitted in the disk;an annular recessed centering groove provided in the reference surface, and formed concentrically with a center axis of the fitting hole; andan annular grinding wheel portion provided on an outer peripheral surface of the disk,the centering groove including:a first surface orthogonal to the reference surface, used when detecting a runout corresponding to the outer peripheral surface of the disk or the outer peripheral surface of the grinding wheel portion when the chamfering wheel rotates in accordance with rotation of the rotary shaft part to adjust a position of the disk, and securing an accuracy; anda second surface adjacent to the first surface, parallel to the reference surface, used when detecting a runout of the reference surface when the chamfering wheel rotates in accordance with rotation of the rotary shaft part to adjust the position of the disk, and securing an accurary.

4. A method of adjusting a chamfering wheel before use comprising: fitting a predetermined rotary shaft part into the fitting hole of the chamfering wheel according to claim 3;detecting a runout of the first surface with respect to the rotary shaft part detected by a distance detection sensor, by rotating the rotary shaft part to rotate the chamfering wheel together with the rotary shaft part, and moving the distance detection sensor relative to the first surface of the centering groove in a circumferential direction;detecting a runout of the second surface with respect to the rotary shaft part detected by the distance detection sensor or another distance detection sensor, by rotating the rotary shaft part to rotate the chamfering wheel together with the rotary shaft part, and moving the distance detection sensor or the another distance detection sensor relative to the second surface of the centering groove in the circumferential direction;adjusting an attachment state of the rotary shaft part and the chamfering wheel based on a detection result of the runout of the first surface detected by the distance detection sensor and a detection result of the runout of the second surface detected by the distance detection sensor or the another distance detection sensor.