Porous metal bond grinder and method of manufacturing the same

Abstract: A porous iron system metal bond diamond grinder uses diamond as grinding particles and iron system metal powder as binder and has a large number of pores in binder portion. The grinding particles are chemically and physically combined with the iron system metal to be held. The occupancy rate of pores in the whole grinder is 5 to 60 %. The iron system metal is selected from a group composed of mixtures of iron powder, carbon-coated iron powder, iron nitride powder, carbon and iron. Carbon of diamond constituting the grinding particles is reacted to the iron system metal in the surface. In the manufacturing method, grinding particles and binder are mixed to be molded into a predetermined shape and the molded product is then heated and sintered at 900 to 1150 °C. The occupancy rate of pores and/or the concentration of carbon in iron system metal and the concentration gradient of diamond are adjusted. The porous iron system metal bond diamond grinder capable of performing grinding continuously for a long time without loading can be provided.

Description: BACKGROUND OF THE INVENTION The present invention relates to a porous metal band grinder or whetstone used to grind various materials and a method of manufacturing the grinder. More particularly, the porous grinder of the present invention has an increased occupancy rate of pores so that the grinding function by grinding particles is enhanced to improve the grinding quality thereof. The grinder is used to grind various works. The grinder used for the grinding is composed of grinding particles and binder and has innumerable pores formed therein. The grinding particles function as edges for cutting or grinding various works and also functions as a support for combining the grinding particles with each other. Further, a large number of continuous pores function as chip pockets for discharging chips cut off by the grinding particles. Recently, various devices or apparatuses often use material such as ceramics, cemented carbide or hard metal or superspeed steel which is difficult to grind. Accordingly, the need of grinding the material of this type is increased more and more. As a grinder or a grinding wheel for grinding the material of this type, one using super grinding particles such as diamond grinding particles or boron nitride grinding particles of the cubic system is being gradually used. As the grinder using such super grinding particles, there are various kinds of grinders such as a vitrified bond system, a resinoid bond system, a metal bond system, a silicate bond system and a rubber bond system in accordance with kinds of the binder. These grinders have both merits and demerits, while the grinder of the metal bond system using metal and its alloy as the binder thereof is mainly used in view of the strength and the life. The grinder of the metal bond system is manufactured by putting metal powder having grinding particles scattered uniformly into a mold together with a metal base and subjecting it to the pressing and sintering (or hot pressing) processes. The binder of metal used in the metal bond grinder uses, for example, Cu-Sn system, Cu-Sn-Co system, Cu-Sn-Fe-Co system, Cu-Sn-Ni system or Cu-Sn-Fe-Ni system or any of these systems to which phosphorus (P) is added. The conventional metal bond grinder has the extremely strong combination or binding strength of the grinding particles as compared with the resinoid bond grinder and the vitrified bond grinder. Accordingly, the metal bond grinder can advantageously exert sufficient retention force required to perform strong grinding by means of super grinding particles. However, the metal binder does not have sufficiently large pores to help discharging of chips cut off by the grinding particles. Thus, escape places in which chips enter are restricted to minute gaps between the metal bond grinder and a work or minute gaps constituted by portions in the metal bond grinder in which grinding particles fallen off. Further, the metal bond grinder has too strong binding force of the grinding particles and accordingly when the grinding particles are worn, the worn particles are difficult to fall off from the binder. Hence, it is also difficult to form the escape places of chips constructed by the grinding particles falling off. As described above, in the conventional metal bond grinder, discharging of chips is deteriorated and loading occurs easily. Accordingly, the grinding resistance is increased and the grinding quality is deteriorated, so that heat generated is increased. Further, the grinder has the tendency to unsuccessfully finish the surface of a work. Accordingly, it is very difficult to increase the contact area of the grinder and the work and perform grinding with higher efficiency. In addition, the conventional metal bond grinder has a low sintering temperature and is hence apt to be softened at a low temperature. Accordingly, there is a defect that the plastic deformation occurs due to heat upon grinding and the loading takes place in the surface of the grinder. In order to improve the above defects, for example, Japanese Patent Application Laid-Open No. 59(1984)-182064 discloses a continuous porous metal bond grinder. However, this metal bond grinder does not utilize the powder sintering method. More particularly, in the manufacturing method of this metal bond grinder, an inorganic compound melted by solvent is sintered to be formed into a desired shape. Thereafter, gaps or spaces of the sintered body are filled with grinding particles and the body having spaces filled with grinding particles is previously heated. Then, melted metal or alloy is put into the spaces of the sintered body filled with the grinding particles in the pressing manner and is then solidified. Thereafter, the inorganic compound is liquated out by solvent. Further, Japanese Patent Publication No. 54(1979)-31727 discloses a grinder having many layers of metal coatings formed thereon and which is sintered to a structure such as vitrified bond by hot press and has pores. In addition to this, various measures for preventing reduction of the grinding quality have been proposed. Furthermore, Japanese Patent Application Laid-Open No. 3(1991)-264263 discloses a grinder using cast iron for the purpose of preventing loading of the grinder. The grinder using the cast iron as a bond advantageously has strong strength and large rigidity and is worn in the brittle fracture manner without occurrence of the plastic deformation, so that the loading is difficult to occur. However, the strength of the bond of this grinder is too large and accordingly the dressing property is deteriorated as compared with the bond of the copper system. By forming a large number of pores within the grinder, grinding liquid can be impregnated into the pores to enhance the cooling characteristic of the grinder and a large number of chip pockets can be formed in the grinding surface to improve the discharging characteristic of chips. Further, the grinding resistance can be made small by the pores to improve the grinding quality. In other words, it can be expected that less heat is generated and the surface of a work is finished with high quality. However, when a large number of pores are formed in the conventional copper system metal bond grinder, the strength and the retention force of grinding particles thereof are naturally reduced, so that the sufficient grinding performance can be obtained. Further, in the grinder using cast iron having no pore as the bond, iron powder is added to cast iron powder because of the inferiority of the sintering characteristic of the cast iron powder and is pressurized with the load of 8,000 kgf/cm 2 to 1,000 kgf/cm 2 . By adding the iron powder, the original brittle fracture characteristic of the cast iron is lost and the plastic deformation is apt to occur due to heat upon grinding in the same manner as the copper system bond, so that the characteristics of the cast iron cannot be drawn out sufficiently. It is an object of the present invention to enable to increase the occupancy rate of pores in the whole grinder. It is a further object of the present invention to reduce wear of the grinder and improve the grinding quality thereof. SUMMARY OF THE INVENTION According to the present invention a metal bonded grinding article formed from a sintered mixture of grinding particles and metal powder is provided wherein (i) said grinding particles comprise diamond or cubic system boron nitride, (ii) said metal powder comprises cast iron powder having a carbon content of 1 to 4.2% by weight of a porous metal binder formed from said metal powder by sintering or iron powder including iron nitride, (iii) the size of the iron powder particles is 0.01 to 500 µm, (iv) said grinding particles are held in the porous structure phase formed by said sintered metal binder and (v) the porosity of the total metal binder is 5 to 60% by volume of said metal bonded grinding article. Generally, pores formed in a grinder serve to temporarily hold chips produced upon grinding and easily discharge the chips when the grinder is separated from a work. By forming the pores, the loading is suppressed and the grinding quality of the grinder is improved. The pores also serve to radiate a large quantity of grinding heat generated upon grinding. When prevention of burning due to grinding is a problem, the grinder having a large occupancy rate of pores is wanted and the grinder having large-diameter pores formed intentionally is often used if necessary. According to the present invention, a large number of pores are formed in so-called matrix-type metal bond surrounding grinding particles in the metal bond grinder to improve the mechanical characteristics of the binder portion (metal bond) and/or the retention force of grinding particles. Further, the mechanical characteristics of the binder and/or the retention force of grinding particles are improved even by the interstitial solid solution reaction of the binder if necessary. More particularly, the porous metal bond grinder of the present invention comprises grinding particles constituted by super grinding particles and binder constituted by metal powder and the super grinding particles are held by the binder portion constituting the porous structural phase formed by sintering of powder. The present invention moreover relates to a method of manufacturing the metal bonded grinding article. This method comprises the following steps: (i) mixing the grinding particles comprising diamond or cubic system boron nitride with the metal powder comprising cast iron powder having a carbon content of 1 to 4.2% by weight or iron powder including iron nitride, said iron powder particles having a size of 0.01 to 500 µm, (ii) molding the mixture obtained in step (i) above and shaping the molded mixture into a predetermined shape and (iii) heating and sintering the shaped mixture to form the porous metal bonded grinding article. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 schematically illustrates diamond grinding particles and cast iron powder of a porous cast iron bond diamond grinder according to the present invention which are reacted to be joined with each other; Fig. 2 is a microscopic photograph showing diamond grinding particles and cast iron bond joined with each other in the case where an amount of carbon of cast iron powder is 3.5 % and the diameter of particles thereof is 20 µm; Fig. 3 is a diagram showing the relation of grinding pressure and a removing speed of the grinder according to an embodiment of the present invention; and Fig. 4 is a diagram showing the relation of a grinding time and an amount of removal of the grinder according to the embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT In the present invention diamond grinding particles or boron nitride grinding particles of the cubic system are used as grinding particles and iron powder capable of effecting the interstitial solid solution reaction is used as a binder. The metal bond is characterized in that force of retaining grinding particles is increased since the binding strength of the bond is extremely large. Pores bringing about reduction of the retention force of the grinding particles are not formed in the metal bond positively heretofore. In the present invention, by forming pores in the metal bond positively, the binding strength of the metal bond can be controlled and the metal bond can be worn properly without resistance in the grinding process. When the occupancy rate of pores in the bond is too small, the retention force of retaining grinding particles is made too strong, so that grinding particles worn by the grinding operation do not fall off and are left as they are to thereby reduce the grinding force of the grinder. On the contrary, when the occupancy rate of pores in the bond is made too large, the retention force of retaining grinding particles is made too weak, so that grinding particles have the tendency to fall off from the binder metal. Consequently, wear of the whole grinder is increased and the life of the grinder is shortened. In the present invention, the mechanical characteristic of the binder portion and/or the retention force of grinding particles is controlled by adjusting the occupancy rate of pores and/or the concentration gradient of an interstitial solid solution element. The occupancy rate of pores and/or the concentration gradient of the interstitial solid solution element is adjusted by a diameter of particles constituting metal powder, a molding condition and/or a sintering condition of the grinder, and an amount of carbon, nitrogen of the binder. Further, in the present invention, diamond constituting grinding particles are combined with iron system metal chemically and physically and the retention force of grinding particles is controlled so that the grinding particles do not fall off until the particles are worn. The chemical combination means that the carbon component of diamond constituting grinding particles reacts to the iron system metal. The occupancy rate of pores of the vitrified bond grinder is largest and is about 50 % at maximum except any special case. Most of the ranges of the occupancy rate used actually are about 35 to 45 %. If the occupancy rate of pores is increased to about 50 %, the strength of the grinder is reduced considerably and there is the possibility that the grinder is broken. However, in order to sufficiently exhibit the performance of the super grinding particles capable of effecting grinding strongly and utilize the expensive grinder effectively, there is considered that it is preferable that the content rate of grinding particles is basically reduced and the metal bond having the strong retention force of grinding particles is used as the binder and it is desirable that the occupancy rate of pores is increased. Heretofore, cast iron in the grinder using the cast iron bond is characterized by the strong strength as well as the brittle fracture. Iron is mixed with carbon to form a solid solution to thereby form the brittle fracture. In the copper system metal bond, the surface of the grinder is covered by the bond component due to wearing of the plastic deformation, while the cast iron bond can prevent the loading by the brittle fracture. In order to utilize the merit that the loading is difficult to occur, it is necessary to overcome the defect that the strength is too strong by adjusting the strength. In the present invention, the occupancy rate of pores in the whole grinder is adjusted to 5 to 60 % and preferably 5 to 45 %. In the porous metal bond grinder of the present invention, the occupancy rate of pores of the whole grinder corresponds to the occupancy rate of pores in the binder. The occupancy rate of pores is adjusted in accordance with the diameter of particles constituting metal powder, the molding condition of the grinder and/or the sintering condition of the grinder. The bond itself of the conventional cast iron bond diamond grinder has almost no pore and it is necessary to obtain gaps or spaces by means of interposition of grinding particles or to add pore giving agency. On the contrary, the present invention is characterized in that the metal bond itself contains a large number of pores. Thus, when the occupancy rate of pores of the whole grinder of the present invention is smaller than 5 %, the strength of the bond thereof is increased considerably and the wearing characteristic of the binding metal, that is, the brittle fracture cannot be exhibited sufficiently. Accordingly, the lower limit of the occupancy rate of pores is set to 5 %. Further, when the occupancy rate of pores is too large, the strength of the grinder is reduced and the grinder is probably destroyed. Accordingly, the occupancy rate of pores is set to 60 % or less, preferably 45 % or less. In the present invention, grinding particles are held by the porous phase having a lower sintering density of particles of the binder. The occupancy rate of pores is adjusted by the diameter of particles constituting metal powder, the molding condition of the grinder and the sintering condition of the grinder. That is, in order to control the mechanical strength of the metal bond and the retention force of grinding particles, the diameter of particles constituting metal powder, the molding condition of the grinder and the sintering condition of the grinder are adjusted. Further, in the present invention, in addition to adjustment of the occupancy rate of pores, the concentration gradient of the interstitial solid solution element can be adjusted to control the mechanical strength of the metal bond and the retention force of grinding particles. Accordingly, the present invention involves the aspect that grinding particles are porous and the grinding particles are retained or held by the phase constituted by the interstitial solid solution among the binder. The reaction of alloy powder capable of effecting the solid solution reaction to carbon, nitrogen and/or silicon is adjusted by the diameter of particles of carbon, nitrogen and/or silicon and alloy powder. This adjustment is made to control the mechanical strength of the metal bond and the retention force of grinding particles. When super grinding particles are mixed with binder powder, for example, cast iron power to be sintered and a sintering temperature is reached, the surface of iron power begins to be melted partially and the sintering is started. At this time, when an amount of carbon, nitrogen and/or silicon of iron does not reach the allowable range, it can be reacted (diffusion binding) to adjacent carbon. The concentration gradient occurs among the binder due to movement of material by diffusion upon sintering. Accordingly, the interstitial solid solution reaction is also influenced by the sintering density. As described above, when diamond is used as grinding particles, the interstitial solid solution reaction occurs in the surface of binder and grinding particles depending on conditions. Generally, iron includes varieties of material from pure iron containing no carbon, carbon steel containing a little carbon to cast iron containing carbon of 1.7 % or more. In the present invention, since carbon component of diamond which is an example of grinding particles is reacted to iron to improve the binding strength, iron system metal power is represented by cast iron having a carbon content of 1-4.2 %. In the case of mixed powder of iron and carbon, iron and diamond or iron and carbon can be reacted together in the sintering of the grinder of the present invention and can form iron bond exhibiting the brittle fracture operation as cast iron depending on a reaction amount of carbon and iron. When diamond is mixed with iron power to be sintered and a sintering temperature is reached, the surface of iron powder begins to be melted partially and the sintering is started. At this time, when an amount of carbon in iron does not reach the allowable range, it can be reacted (diffusion binding) to adjacent carbon. When the sintering temperature is not reached, the carbon concentration gradient of diamond and iron power is infinite. The concentration gradient occurs in diamond and iron due to movement of material by diffusion upon sintering. Particularly, when a content amount of carbon in iron is little, the concentration gradient is large and more carbon can be reacted to iron. When the reaction is advanced to excess, grinding particles are deteriorated and accordingly it is necessary to select the sintering condition that the reaction is made in the surface. The grinder of the present invention is now described by taking a porous cast iron bond diamond grinder using diamond as super grinding particles and cast iron as the binder by way of example. In the present invention, in order to cause the porous cast iron bond diamond grinder to have the same strength and retention force of grinding particles as those of the copper system metal bond grinder, an amount of carbon in cast iron powder and the diameter of particles constituting the cast iron powder are adjusted. The strength of the cast iron bond itself can be controlled by the carbon amount and the diameter of the cast iron powder. Further, the cast iron powder and diamond are be reacted to be joined with each other as shown in Fig. 1. The joining strength can be also controlled by the carbon amount and the diameter of the cast iron powder. A manufacturing method of the porous metal bond grinder of the present invention is now described. In the manufacturing method of the porous metal bond grinder of the present invention, the grinding particles are mixed with metal powder constituting the binder to be formed into a specific shape having a specific size and are then heated and sintered to thereby manufacture the porous metal bond grinder. At this time, it is featured that the mechanical characteristics of the binder portion and the retention force of grinding particles are controlled by the occupancy rate of pores. In addition to the occupancy rate of pores, the mechanical characteristics of the binder portion and the retention force of grinding particles are controlled by utilizing the concentration gradient of the interstitial solid solution element. Adjustment of the occupancy rate of pores and/or utilization of the concentration gradient of the interstitial solid solution element for control of the mechanical characteristics of the binder portion and the retention force of grinding particles are made by changing the diameter of particles constituting the metal powder as the binder, the molding condition of the grinder and the sintering condition of the grinder. The sintering temperature is within a temperature range of 0.8 Tm to Tm (where Tm is a melting point of the binder or a liquid phase producing temperature K). The sintering temperature varies depending on a kind of metal, the particle size of its powder and the like and since grinding particles constituted by diamond are carbonized at about 1100 to 1200 °C even under vacuum and even in an insoluble atmosphere, a temperature lower than this temperature is adopted as the sintering temperature. A manufacturing method of the grinder of the present invention is now described by taking a manufacturing method of the porous cast iron bond diamond grinder by way of example. The porous bond diamond grinder is manufactured by mixing diamond constituting grinding particles with cast iron powder constituting the binder to form it into a predetermined shape having a predetermined size and then heating and sintering it at 900 to 1150 °C. A product molded into the form of the grinder is sintered by the sintering process. The sintering process is made with a normal pressure and the sintering temperature is set to be larger than at least 900 °C. The sintering temperature is determined in consideration of thermal deterioration in the case where diamond is used as grinding particles and the fact that when the sintering temperature is high, sintering is advanced and a desired occupancy rate of pores of 5 to 60 % in the whole grinder is not obtained. The desirable sintering temperature is considered to be within a range of 900 to 1150 °C. Further, the sintering temperature is changed depending on an amount of carbon in cast iron and the particle size of its powder. Control of the mechanical characteristics of the binder portion and the retention force of grinding particles is made by adjusting the average particle size of cast iron powder in a range of 0.01 to 500 µm and/or adjusting an amount of carbon in cast iron powder 1 to 4.2 %. The preferable average particle size of cast iron is in a range of 5 to 80 µm and the maximum diameter thereof is preferably 500 µm or less. Since the retention force for retaining grinding particles is too strong when the occupancy rate of pores is reduced to excess, grinding particles having worn cutting or grinding portions are left without falling off from the binder metal and as a result the grinding capability of the grinder is deteriorated. Further, since the retention force for retaining grinding particles is too weak when the occupancy rate of pores is increased to excess, many grinding particles fall off from the binder metal, so that wear of the grinder is increased and the life of the grinder is shortened. By adjusting the average particle size and the carbon amount of cast iron particles in the above range, diamond and cast iron can be diffused in solid phase and the retention force of grinding particles can be improved. Cast iron has the function for holding grinding particles and accordingly it is desirable that there exist grinding particles having a small diameter so as to increase the contact area with grinding particles. The porous cast iron diamond grinder of the present invention is manufactured by mixing cast iron powder with diamond grinding particles uniformly and putting it into a press device together with a metal base as usual to mold it with pressure in the same manner as that of the normal grinder. The grinder thus sintered is joined to a cup-shaped grinder of 6A2 type having a grinder diameter of 100 mm and is evaluated by the constant pressure grinding examination. The superiority of the porous cast iron bond grinder of the present invention has been confirmed as compared with the usual no-pore type cast iron bond grinder, vitrified grinder and resinoid grinder. In the manufacturing of the grinder, commercially available cast iron is used. Since the average diameter of particles constituting cast iron powder thereof is 100 µm or more and the distribution of the particle size thereof is wide, it is difficult to sinter it even if the temperature is increased to the melting point of cast iron. Accordingly, by controlling the carbon amount and the particle diameter of cast iron powder, the sintering characteristic, the mechanical strength and the occupancy rate of pores of cast iron powder are adjusted. In order to examine the influence of the carbon amount, commercially available cast iron powder of three kinds of 3.0 %, 3.5 % and 4.0 % passed through a sieve of 38 µm or less is used. In order to examine the influence of the particle diameter, cast iron powder having the carbon amount of 3.5 % passes through a sieve to classify it into 20 µm or less, 20 to 32 µm, 38 to 45 µm and 45 to 75 µm. Each cast iron powder and diamond grinding particles of the mesh size 100/200 are mixed with each other to have the convergence degree of 125 and is sintered under the atmosphere of argon at temperature of 1120 °C. Further, the grinder manufactured above was subjected to the constant pressure grinding examination at the peripheral speed of the grinder of 100 m/min while using aluminum ceramics as material to be grinded. Table 1 (physical properties and grinding performances of the grinder manufactured by way of trial) shows the physical property values and the grinding results of the sintered porous bond diamond grinder. Influence of Carbon Amount Influence of Particle Diameter Particle Diameter µm <38 <38 <38 <20 20-32 32-38 38-45 Carbon Amount % 3.0 3.5 4.0 3.5 3.5 3.5 3.5 Occupancy Rate of Pores % 33 30 29 26 29 32 34 Bending Strength MPa 31 48 40 88 53 38 27 Young's Modulus GPa 29 36 34 59 36 28 25 Grinding Energy GJ/m3 25 25 25 15 18 22 31 Grinding Ratio 100 80 40 100 50 50 5 As apparent from TABLE 1, the bending strength and the Young's modulus are increased and the strength is increased as the particle diameter of cast iron powder is smaller. When the carbon amount of cast iron powder is 3.5%, the bending strength and the Young's modulus indicate the maximum values thereof. Further, with respect to the grinding performance, the grinding energy (energy necessary for removing material to be grinded) is reduced as the particle diameter of cast iron powder is smaller and the material to be grinded can be removed with about half energy. The grinding ratio also indicates the same result as the grinding energy. Fig. 2 shows a microscopic photograph in the case of the carbon amount of 3.5 % and the particle diameter of cast iron powder of 20 µm. It can be confirmed that joining between cast iron particles and between diamond and cast iron bond is made by the chemical reaction. Carbon in the surface of diamond is formed into solid solution together with cast iron to enhance the joining strength. The inclination thereof is increased as the particle diameter is smaller and since the contact points are increased, the bending strength and the Young's modulus are increased. Thus, since the retention force of diamond grinding particles is increased upon grinding, grinding particles do not fall off and since material to be grinded is removed, the grinding energy is reduced and the grinding ratio is increased. As described above, the physical properties or the grinding performances of the porous cast iron diamond grinder can be controlled in accordance with the particle diameter and the carbon amount of cast iron powder. Detail of the present invention is now described with reference to embodiments. The present invention is not limited by these embodiments. Embodiment 1: Diamond grinding particles of meshes of 120 and cast iron powder of the carbon amount of 3.5 % and the average particle diameter of 20 µm were used to be sintered under the atmosphere of argon gas at the temperature of 1120 °C to obtain the porous cast iron bond diamond grinder. The porous cast iron bond diamond grinder was compared with the commercially available vitrified grinder, resinoid grinder and no-pore cast iron bond grinder. The shape of respective grinders is of a cup-shaped grinder of 6A2 type having the diameter of 100 mm and the convergence degree is unified to 125. The constant pressure grinding examination was made at the peripheral speed of the grinder of 1100 m/min using alumina as material to be grinded. The result thereof is shown in Fig. 3 (diagram showing the relation of a grinding pressure and the removing speed). In any grinders, the removing speed is increases as the grinding pressure is increased. The porous cast iron bond exhibited about double grinding performance as compared with the commercially available vitrified grinder which is said that the grinding quality thereof is excellent. Further, the grinding ratio exhibited double performance as compared with the other bond. Embodiment 2: The grinder manufactured in the embodiment 1 was used to make the grinding examination of silicon nitride under the same condition as that of the embodiment 1. The result thereof is shown in Fig. 4 (diagram showing the relation of the grinding time and the removal amount by grinding). In case of the commercially available vitrified bond grinder and the commercially available resinoid bond grinder, the removal amount by grinding was increased in proportion to the time until 30 seconds after starting of the grinding, but thereafter the grinder was loaded, so that the removal amount was not increased. In the case of the porous cast iron bond grinder of the present invention, the removal amount by grinding was increased in proportion to the time from just after starting of the grinding to the completion of the examination. Since the porous cast iron bond has the excellent fractural characteristic, it is considered that cutting edges of diamond are maintained and the grinding force is sustained. As described above, according to the present invention, there can be provided the porous metal bond grinder having a desired strength and occupancy rate of pores. There can be provided the porous metal bond grinder capable of performing grinding continuously for a long time without loading. There can be provided the grinder having the excellent grinding quality as compared with the vitrified bond grinder and having less wear than that of the resinoid bond grinder. The grinder of the present invention can be used in the general-purpose grinding machine sufficiently and has the excellent dressing characteristic. Accordingly, the dressing on the machine can be performed in the same manner as the vitrified bond and the resinoid bond and since the grinding ratio is large, the grinding cost can be improved greatly.

Claims: A porous metal bonded grinding article formed from a sintered mixture of grinding particles and metal powder wherein, (i) said grinding particles comprise diamond or cubic system boron nitride, (ii) said metal powder comprises cast iron powder having a carbon content of 1 to 4.2% by weight of a porous metal binder formed from said metal powder by sintering or iron powder including iron nitride, (iii) the size of the iron powder particles is 0.01 to 500 µm, (iv) said grinding particles are held in the porous structure phase formed by said sintered metal binder and (v) the porosity of the total metal binder is 5 to 60% by volume of said porous metal bonded grinding article. A method of manufacturing the porous metal bonded grinding article as claimed in claim 1 comprising the following steps: (i) mixing the grinding particles comprising diamond or cubic system boron nitride with the metal powder comprising cast iron powder having a carbon content of 1 to 4.2% by weight or iron powder including iron nitride, said iron powder particles having a size of 0.01 to 500 µm, (ii) molding the mixture obtained in step (i) above and shaping the molded mixture into a predetermined shape and (iii) heating and sintering the shaped mixture to form the porous metal bonded grinding article. The method of claim 2 wherein step (iii) is carried out at a temperature of 900 to 1150°C.

Inventors: ISHIZAKI KOTO, KONDO YOSHIHITO, TAKADA ATUSHI, YAMAMOTO SHIN, ISHIZAKI, KOTO, KONDO, YOSHIHITO, TAKADA, ATUSHI, YAMAMOTO, SHIN
Applicants: ISHIZAKI KOZO, ISHIZAKI, KOZO
Application year: 1995
Main classification: B24D3
IPC codes: C22C26, B24D3