Abstract: A method of making a sintered part includes a step of applying a machining process to a compacted part with a tool to make a machined compacted part having a cogwheel shape, and a step of sintering the machined compacted part to make a sintered part, wherein the machining process is such that a surface of the compacted part on a side where the tool exits is supported by a plate member having a tooth pattern with same specifications as a tooth pattern of the cogwheel shape, and the tool is used to machine portions of the compacted part corresponding to tooth spaces of the plate member.

Abstract: A method of manufacturing a sintered gear includes preparing a green compact having two gear-shaped end surfaces, one on each of two sides in an axial direction of the green compact, and having a plurality of teeth on an outer peripheral surface formed between the two end surfaces; chamfering an edge of the teeth by a brush; and sintering the green compact. The brush is a wheel-type brush including a disk-shaped wheel and a bristle member radially protruding from an outer periphery of the wheel. The chamfering includes disposing the brush with respect to the green compact such that the axial direction of the green compact and an axial direction of the wheel intersect with each other; bringing a tip of the bristle member into contact with a tooth bottom edge; and relatively moving the brush in a circumferential direction of the green compact while rotating the brush.

Abstract: A method of manufacturing a sintered gear includes preparing a green compact having two gear-shaped end surfaces, one on each of two sides in an axial direction of the green compact, and having a plurality of teeth on an outer peripheral surface formed between the two end surfaces; chamfering an edge of the teeth by a brush; and sintering the green compact. The brush is a wheel-type brush including a disk-shaped wheel and a bristle member radially protruding from an outer periphery of the wheel. The chamfering includes disposing the brush with respect to the green compact such that the axial direction of the green compact and an axial direction of the wheel intersect with each other; bringing a tip of the bristle member into contact with a tooth bottom edge; and relatively moving the brush in a circumferential direction of the green compact while rotating the brush.

Abstract: A sintered gear of annular shape which has a composition including a metal, has a plurality of pores in a surface thereof, and has a relative density of 93% or more and 99.5% or less.

Abstract: A tool main body to which an insert is attachable, in which the tool main body is made of sintered metal material, and the sintered metal material includes a parent phase made of a metal and a plurality of pores present in the parent phase.

Abstract: A sintered gear of annular shape which has a composition including a metal, has a plurality of pores in a surface thereof, and has a relative density of 93% or more and 99.5% or less.

Abstract: A sintered material containing a parent phase composed of a metal and a plurality of pores present in the parent phase, wherein the pores in a cross section have an average cross-sectional area of 500 ?m2 or less, and the sintered material has a relative density in the range of 93% to 99.5%.

Abstract: A method for manufacturing a sintered gear comprising the steps of: preparing a cylindrical green compact; gear-cutting the green compact with a hob; and sintering the gear-hobbed green compact, wherein the hob is such that a ratio of a number of cutting edges thereof per round to a number of starts thereof exceeds 8.

Abstract: A method of making a sintered body includes a step of preparing raw material powder containing powder of inorganic material, a step of producing a powder compact having a high-density portion with a relative density of 93% or more and a low-density portion with a relative density of less than 93% by compressing the raw material powder injected into a mold, a step of producing a machined compacted part by machining at least the high-density portion of the powder compact, and a step of sintering the machined compacted part to make a sintered body, wherein a perimeter shape of a cavity constituted by the mold in a cross-section perpendicular to an axial direction of the mold is such than a maximum stress applied to an inner perimeter surface of the mold during a compacting process using the mold is less than or equal to 2.

Abstract: A method of making a sintered part includes a step of applying a machining process to a compacted part with a tool to make a machined compacted part having a cogwheel shape, and a step of sintering the machined compacted part to make a sintered part, wherein the machining process is such that a surface of the compacted part on a side where the tool exits is supported by a plate member having a tooth pattern with same specifications as a tooth pattern of the cogwheel shape, and the tool is used to machine portions of the compacted part corresponding to tooth spaces of the plate member.

Abstract: A powder compaction mold includes a die and upper and lower punches configured to fit into the die and is configured to compress a powder between the upper and lower punches to manufacture a powder compact. Of the members forming the powder compaction mold, at least one of two members in sliding contact with each other has therein a vent passage through which gas is vented from a filling space for the powder surrounded by the die and the lower punch to an outside of the powder compaction mold. The vent passage has a gas intake port that is open to a clearance section formed between the two members and connecting to the filling space.

Abstract: A rare-earth magnet containing Sm, Fe, and N contains an Me and B serving as additive elements, the Me representing at least one element selected from elements in groups 4, 5, and 6 of the periodic table, and a nanocomposite microstructure including an Fe phase, a SmFeN phase, and an MeB phase, in which the SmFeN phase includes at least a Sm2Fe17Nx phase selected from the Sm2Fe17Nx phase and a SmFe9Ny phase, the volume percentage of the SmFe9Ny phase in the microstructure is 65% or less by volume, the atomic percentage of the total content of the Me and B is 0.1 at % or more and 5.0 at % or less with respect to the total amount of Sm, Fe, the Me, and B, and the atomic percentage of Fe in all phases of compounds each containing at least one of the Me and B is 20 at % or less.

Abstract: A method for producing a rare-earth magnet includes a provision step of providing a Sm—Fe-based alloy containing a SmFe9+? phase serving as a main phase by rapidly cooling a molten alloy containing Sm and Fe in an atomic ratio of 1:8.75 to 1:12, a hydrogenation-disproportionation step of subjecting the Sm—Fe-based alloy to hydrogenation-disproportionation treatment to allow part of the SmFe9+? phase (?=0.1 to 3.

Abstract: A powder compaction mold includes a die and upper and lower punches configured to fit into the die and is configured to compress a powder between the upper and lower punches to manufacture a powder compact. Of the members forming the powder compaction mold, at least one of two members in sliding contact with each other has therein a vent passage through which gas is vented from a filling space for the powder surrounded by the die and the lower punch to an outside of the powder compaction mold. The vent passage has a gas intake port that is open to a clearance section formed between the two members and connecting to the filling space.

Abstract: There is provided a compact for a magnet which can produce a magnetic member having high coercive force. The compact for a magnet is produced by compression-molding a rare earth-iron-based alloy powder containing a plurality of particles of a rare earth-iron-based alloy containing a rare earth element and iron, wherein the rare earth-iron-based alloy satisfies configurations (a) to (c) below and has 5% by volume or more and 20% by volume or less of voids formed therein. (a) Having a structure containing 10% by mass or more and 30% by mass or less of Sm, 10% by mass or less of Mn, and the balance consisting of Fe and inevitable impurities. (b) A composition, Sm2MNxFe17-x (x=0.1 or more and 2.5 or less). (c) An average crystal grain diameter of 700 nm or less.

Abstract: The method for producing a granulated powder of the present invention includes the steps of: preparing an R—Fe—B alloy powder; and granulating the alloy powder using at least one kind of granulating agent selected from normal paraffins, isoparaffins and depolymerized oligomers, to prepare a granulated powder. The produced R—Fe—B alloy granulated powder is excellent in flowability and compactibility as well as in binder removability.

Abstract: The method for producing a granulated powder of the present invention includes the steps of: preparing an R—Fe—B alloy powder; and granulating the alloy powder using at least one kind of granulating agent selected from normal paraffins, isoparaffins and depolymerized oligomers, to prepare a granulated powder. The produced R—Fe—B alloy granulated powder is excellent in flowability and compactibility as well as in binder removability.