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Title: Method of forming an abrasive tool
Claims: I claim: 1. The method of forming an abrasive tool useful in grinding and cutting and having a working surface with a substantially single layer of abrasive particles electroplated thereon which comprises: first providing a tool blank having a working area made of metal and presenting the required profile configuration of the tool; preparing the metal surface of the working area for nickel plating; supporting the blank in an enclosure presenting an impervious confining wall adjacent but spaced from the working surface of the tool blank and also presenting a porous mesh surface beneath the space between the confining wall, and working surface with the openings in the screen being smaller than the cross-sectional dimension of the hereinafter referred to abrasive particles; arranging a compacted mass of abrasive particles in the space between the confining walls, working surface and porous screen surface, with abrasive particles in engagement with all portions of the metallic working surface; covering the blank while supported in the enclosure with nickel plating solution and continuously passing nickel plating solution downwardly over the working surface and through the mass of abrasive particles in the presence of metallic nickel connected in an electrical circuit as an anode and with the working surface connected as a cathode until a thin coating of nickel is applied to the working surface and sides of the first layer of abrasive particles in immediate contact therewith so as to form an initial nickel plating extending for a height of no more than approximately 1/3 the height of the abrasive particles and lightly securing the first layer of abrasive particles to the working surface; removing the surplus abrasive particles above the aforesaid first layer from the area surrounding the working surface; and thereafter applying further nickel plating to the working surfaces and first layer of abrasive particles so as to adhere to the sides of the abrasive particles for approximately 1/2 to 2/3 of the height thereof to firmly secure them in place with the top surfaces of the particles being substantially free of plating and projecting above the surface of the nickel plating between the particles. 2. The method of forming an abrasive tool useful in grinding and cutting as set forth in claim 1 in which the abrasive particles are made of a material selected from natural and synthetic diamonds and borazon and are between approximately 0.005 inch and 0.009 inch in cross-sectional dimension. 3. The method of forming an abrasive tool useful in grinding and cutting as set forth in claim 1 in which the enclosure with the blank supported therein is immersed in nickel plating solution in a plating tank after the blank has been covered with plating solution with the plating solution within the enclosure being at a higher level than the plating solution in the plating tank to thereby provide a gravity head and thereafter nickel plating solution is flowed downwardly over the working surface and through the mass of abrasive particles and thence through the porous surface into the plating tank. 4. The method of making an abrasive tool which comprises: providing a tool blank with a working area surface made of metal and having the desired profile configuration of the tool; retaining a mass of abrasive particles in contact with the working area surface; subjecting the working area surface and the mass of abrasive particles to an electrolyte metal plating solution in the presence of a metal anode while retaining the mass of particles in contact with the working area surface until a layer of particles of single particle thickness is lightly tacked or secured to the working area surface by an electro-deposited thin layer of metal plating applied to the working area surface and to the sides of the said particles, which layer of metal plating extends for a height of no more than approximately 1/3 the height of the abrasive particles; then removing the surplus abrasive particles outside the said layer of single particle thickness; and, finally, electro-depositing further metal plating on the surface of the first layer of metal plating and on the sides of the particles in said layer of single particle thickness to firmly secure them in place, which further metal plating adheres to the sides of the abrasive particles for approximately 1/2 to 2/3 of the height thereof. Other info: Inventors: Haack, William M. (St. Louis, MO, US) Application Number: 545984 Filing Date: 1975-01-31 Publication_date: 1976-05-18 Assignee: Keene Corporation (New York, NY) Primary Class(es): 205/110 205/183 Other Classes: US Patent Ref:
Other Refs:
Primary Examiner: Tufariello, T. M. Assistant Examiner: Attorney: Kane, Dalsimer, Kane, Sullivan and Kurucz |
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