Cov ntaub ntawv tawv thiab nkig xws li iav kho qhov muag, silicon carbide, alumina ceramics, thiab cemented carbides feem ntau cia siab rau pob zeb diamond abrasive cov cuab yeej rau siab -precision nto shaping, tiaj sib tsoo, thiab contour machining. Txawm li cas los xij, feem ntau ntawm cov cuab yeej pob zeb diamond tam sim no tseem siv kev sib xyaw ua ke - thiab - cov txheej txheem molding, qhov twg pob zeb diamond nplej tau muab faib rau hauv daim ntawv cog lus. Qhov kev npaj tsis sib xws no feem ntau ua rau cov nplej tsis sib xws, qhov sib txawv loj hauv qhov siab qhov siab, thiab qhov chaw tsis zoo ntawm cov chips, ncaj qha ua rau cov khoom siv tsis zoo, cov cuab yeej siv tsis sib xws, thiab cov khoom ua haujlwm tsis zoo -ua rau nws nyuaj rau ua kom tau raws li ultra-precision thiab siab -kev ruaj khov brittle 8} cov ntaub ntawv nyuaj thiab siab heev.
Yog li ntawd, kev npaj cov nplej tau dhau los ua ib qho tseem ceeb ntawm kev txhim kho cov cuab yeej pob zeb diamond tom ntej. Hauv tsab xov xwm no, peb ua tib zoo tshuaj xyuas peb cov txheej txheem tseem ceeb -sintering, electroplating, thiab brazing- thiab categorize lub hauv paus ntsiab lus thiab daim ntawv thov yam ntxwv ntawm ntau yam kev txiav txim grain tso technologies.
Yuav Ua Li Cas Pob Zeb Diamond Grains Yuav Tsim Rau Kev Npaj?
Lub hauv paus ntawm kev txiav txim yog nyob rau hauv tus qauv tsim ntawm spatial faib ntawm abrasive grains, nrog rau qhov tseem ceeb tsis xws li: grain protrusion qhov siab, embedment qhov tob, lateral spacing, thiab longitudinal spacing. Uniform protrusion qhov siab ua kom ntseeg tau tias tag nrho cov nplej koom nrog kev txiav ib txhij, zam kev ua tsis tiav ntxov ntawm qee cov nplej vim qhov siab qhov sib txawv thiab tiv thaiv kev ua haujlwm ntxov ntxov ntawm qhov chaw ua haujlwm los ntawm daim ntawv cog lus. Embedment qhov tob cuam tshuam ncaj qha rau daim ntawv cog lus tuav lub zog ntawm cov nplej. Lateral thiab longitudinal spacings txiav txim grain ceev, nti qhov chaw, thiab lub load ntawm txhua tus neeg lis, yog li cuam tshuam kev sib tsoo efficiency. Tam sim no, cov qauv kev txiav txim tseem ceeb yog:
Array kev npaj- Cov nplej tau muab tso rau hauv cov kab sib npaug sib npaug thiab kab. Qhov no yog cov qauv yooj yim tshaj plaws uas tsis tshua muaj kev nyuaj, muab kev sib tsoo ruaj khov thiab kev ua haujlwm siab, tab sis kev cuam tshuam ntawm cov nplej tuaj yeem tshwm sim, thiab cov khoom ua haujlwm saum npoo roughness kuj qis dua.
Txoj kev kho kom zoo- Cov kab uas nyob ib sab yog offset los ntawm ib nrab ntawm kab sib nrug, rhuav txoj kev ncaj ncaj, muab qhov chaw nti tsim nyog, ua kom muaj txiaj ntsig zoo rau lub sijhawm sib tsoo, thiab sib npaug smoothness nrog nti khiav tawm.
Phyllotactic kev npaj- Kev tshoov siab los ntawm cov qauv kev loj hlob ntawm cov nplooj ntoo, cov nplej tau sib xyaw ua ke raws Fibonacci kauv, tsis muaj qhov rov ua dua tshiab hauv kev faib tawm. Txoj kev txiav tsis sib tshooj, ua rau muaj kev sib tsoo qis dua tab sis tshem tawm qhov waviness ntawm qhov chaw, ua rau nws tsim nyog rau daim iav sib tsoo.
Kauv kev npaj- Cov nplej tau muab faib ua cov voj voog loj lossis ib qho Archimedean kauv, nrog qhov sib txawv ntawm lub vojvoog. Chip tshem tawm yog du, haum rau txoj kev nkhaus nto machining. Thaum sib hloov, cov npoo txiav txuas txuas ntxiv, ua rau muaj kev cuam tshuam qis thiab txo kev co.
Yuav Ordered Abrasive Tools Fabricated li cas?
Raws li cov txheej txheem tseem ceeb ntawm pob zeb diamond sib sau ua ke, cov txheej txheem muab cov khoom lag luam tuaj yeem muab faib ua peb pawg: hlau sintering, electroplating, thiab brazing.
01 Txoj Kev Sintering
Sintering yog cov txheej txheem ntau tshaj plaws rau cov cuab yeej pob zeb diamond, qhov twg pob zeb diamond nplej tau tov nrog cov ntawv khi, nias rau hauv cov duab, thiab sintered. Los ntawm kev hloov pauv thev naus laus zis, txoj kev no tam sim no ua tiav kev npaj cov nplej feem ntau ntawm ob txoj hauv kev:
(1) Template method:
Cov hmoov sib tov sib xyaw nrog cov organic binder thiab hnyav, thiab nyias - txheej daim ntawv cog lus yog npaj los ntawm hydraulic nias. Ib daim ntawv tshwj xeeb nrog cov qauv tsim ua ntej ntawm micro-qhov (loj me ntsis ntawm pob zeb diamond grain loj) yog siv los nias cov nplej rau hauv daim ntawv nyias nyias. Tom qab demolding, ntau txheej uas muaj cov nplej txiav txim tau muab tso ua ke thiab sib sau ua ke los ntawm kev kub nias sintering. Cov txheej txheem no yog tus nqi qis thiab tsim nyog rau kev tsim khoom loj, tab sis cov micro-qhov yuav deform thaum nias, txwv nws daim ntawv thov rau loj-inch superabrasive nplej.
(2) AI-tswj lub tshuab nqus tsev vacuum:
Cov thev naus laus zis no siv cov cuab yeej ntse tsis zoo-siab nqus cov cuab yeej los khaws cov pob zeb diamond los ntawm lub tshuab nqus tsev mus rau ib qho kev taw qhia ntawm daim phiaj xwm txheej ua ntej, tom qab ntawd los ntawm ib tug neeg hlau caj npab uas raug hloov mus rau hauv lub cuab tam substrate nto, ua tiav kev txiav txim thiab kev taw qhia. Cov txheej txheem yog automated siab, nrog cov qoob loo khaws cov txiaj ntsig zoo thiab qhov tseeb qhov chaw zoo, haum rau kev ua haujlwm siab, kev tsim cov cuab yeej abrasive.
02 Txoj kev electroplating
Lub hauv paus ntsiab lus tseem ceeb ntawm electroplating yog hluav taws xob-field deposition: nyob rau hauv hluav taws xob tam sim no, npib tsib xee ions nyob rau hauv lub plating tov decompose thiab deposit, zuj zus encapsulating lub pob zeb diamond nplej ua ntej muab tso rau ntawm lub substrate nto los tsim ib tug muaj zog nickel-pob zeb diamond txheej. Electroplated cov cuab yeej muab cov qoob loo ruaj khov thiab tsim nyog rau kev sib tsoo ntau yam nyuaj thiab nkig nyuaj rau tshuab. Ntxiv nrog rau kev tuav tes tuav, cov txheej txheem kev txiav txim-txhim kho cov txheej txheem suav nrog:
(1) Electrostatic tso chaw:
Siv electrostatic attraction, ib qho khoom siv electrostatic dispersion adsorbs pob zeb diamond nplej mus rau pre-designed order adhesive droplet arrays (cov kua nplaum-coated thaj chaw) ntawm lub substrate nto, yog li ua tau raws li kev txiav txim grain. Feem ntau, cov nplaum nplaum array yog siv los ntawm lub computer tswj micro-dispensing taub hau. Tag nrho cov txheej txheem nta automation siab, ceev ceev deposition, thiab zoo positioning raug, thiab tuaj yeem hloov mus rau complex-shaped workpieces. Txawm li cas los xij, cov teeb meem me me xws li cov nplej uas ploj lawm lossis cov nplej agglomeration yog qhov nyuaj rau kev tshem tawm tag nrho thaum lub sij hawm nplaum nplaum.
(2) Mask-opening method:
Ib daim npog ntsej muag nyias yog siv los yog coated rau ntawm qhov chaw substrate, nrog rau qhov qhib tsuas yog ntawm qhov chaw tso chaw ua ntej. Tom qab ua ntej plating txheej txheej hlau, pob zeb diamond nplej tsuas yog tso rau hauv qhov qhib; tshem tawm lub npog ntsej muag yields ib-txheej uas tau txiav txim grain array. Tam sim no cov npog ntsej muag muaj kev vam meej suav nrog cov npog ntsej muag, cov npog ntsej muag, cov npog ntsej muag, cov npog ntsej muag, thiab cov npog ntsej muag photolithographic. Ntawm cov no, daim npog ntsej muag tshuaj ntsuam tau siv dav rau kev txiav txim siab tso rau ntawm qhov chaw nyuaj. Photolithographic qhov ncauj qhov ntswg koom nrog cov txheej txheem nyuaj thiab cov nqi tsim khoom ntau dua, thiab feem ntau yog siv rau kev ua haujlwm siab ultra-nyias electroplated sib tsoo lub log.
03 Txoj Kev Brazing
Brazing cia siab rau cov khoom siv hluav taws xob ua kom muaj zog los tsim cov ntawv cog lus metallurgical nrog pob zeb diamond, muab cov qoob loo ntau dua li cov khoom siv electroplating lossis cov pa sintering. Ib txheej txheej brazed cov cuab yeej muaj cov qoob loo loj dua thiab qhov chaw nti loj, ua rau lawv qhov kev xaiv zoo tshaj plaws rau kev sib tsoo, kev ua haujlwm siab. Tam sim no paub tab cov txheej txheem muab tso rau grain muaj xws li:
(1) Ceramic hole-template method:
Lub brazing muab tub lim yog thawj uniformly thov mus rau lub cuab tam substrate. Cov qauv ceramic nrog micro-qhov arrays yog tom qab ntawd muab tso rau ntawm qhov chaw substrate, thiab pob zeb diamond nplej tau ntim rau hauv qhov dhau los rau qhov chaw. Tom qab tag nrho cov kev sib dhos yog brazed nyob rau hauv ib lub tshuab nqus tsev vacuum voj voog. Txij li cov qauv ceramic yog cov cua sov-resistant thiab tsis ua raws li lub brazing muab tub lim, nws tuaj yeem rov qab siv tau ntau zaus, nrog rau qhov kev tso kawm ruaj khov, tsim nyog rau batch zus tau tej cov sib tsoo log.
(2) Laser-spot brazing:
In this method, brazing filler and diamond grains are uniformly distributed on the metal substrate surface. A laser scanner is controlled to selectively irradiate specific spots; the grains at the irradiated spots are locally brazed and fixed onto the substrate. After removing loose grains from non‑irradiated areas, a single‑layer ordered grain structure is formed. This process offers extremely high positioning accuracy and is suitable for high‑precision single‑layer ordered abrasive tools, but the equipment investment is relatively high, and it is mostly used for high‑end custom‑made tool production.