Method for manufacturing mold for molding reflector, method for manufacturing reflector, and cutting tool

Abstract

A method for manufacturing a mold for molding a reflector that reflects light has a cutting step in which a plurality of recesses are formed on the inner surface of the mold by cutting, thereby forming irregularities on the reflecting surface of the reflector. The cutting step includes a planing step in which the plurality of recesses are cut by relative movement of the cutter with respect to the mold without rotation and vibration of the cutter.

Description

Technical Field

[0001] This disclosure relates to a method for manufacturing a mold for forming a reflector, a method for manufacturing a reflector, and a cutting tool. Background Technology

[0002] As reflectors for reflecting light, reflectors with irregularities on their reflecting surfaces are known. A specific example is a rear-facing reflector (sometimes called a retroreflector in Japan, and hereinafter sometimes referred to as "RR") installed at the rear of a car to reflect light from other vehicles. Such reflectors are formed, for example, by filling a mold with a molding material (e.g., resin). Patent documents 1-3 disclose techniques for forming irregularities or similar irregularities in a mold corresponding to the irregularities of an RR by cutting with a cutting tool.

[0003] Patent Document 1 discloses a technique for cutting recesses in a mold using a tool with a rounded tip. It should be noted that although not explicitly described in Patent Document 1, based on the shape of the tool shown and common technical knowledge, the tool is used by rotating around an axis. Patent Document 2 discloses a technique for cutting recesses in a mold by vibrating the tool. Patent Document 3 discloses a technique for cutting recesses using a tool with its cutting edge located on a center line. The tool is used by rotating or by being vibrated. Patent Documents 1 and 2 also disclose molds with irregularities formed on curved surfaces.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2012-108213

[0007] Patent Document 2: Japanese Patent Application Publication No. 2013-202750

[0008] Patent Document 3: Japanese Patent Application Publication No. 2022-87422 Summary of the Invention

[0009] The technical problem that the invention aims to solve

[0010] There has been a long-awaited method for manufacturing molds for reflectors, a method for manufacturing reflectors, and cutting tools that can improve the ease and / or precision of forming concave and convex structures through cutting.

[0011] Technical solutions for solving technical problems

[0012] This disclosure discloses a method for manufacturing a mold for forming a reflector, wherein a cutting step is included, in which a plurality of recesses are formed by cutting the inner surface of the mold, thereby forming an uneven surface on the reflective surface of the reflector. The cutting step includes a planing step, in which the plurality of recesses are cut by relative movement of the cutting tool relative to the mold without the cutting tool rotating or vibrating.

[0013] The present disclosure discloses a method for manufacturing a reflector by forming the reflector using a mold manufactured by the above-described method for manufacturing a mold for forming a reflector.

[0014] The present disclosure discloses a method for manufacturing a reflector that reflects light, wherein a cutting step is included to form a plurality of recesses constituting the reflective surface of the reflector by cutting, the cutting step including a planing step, wherein the plurality of recesses are cut by relative movement of the tool relative to the reflector without the tool rotating or vibrating.

[0015] The present disclosure discloses a cutting tool having a cutting edge extending in a direction intersecting the centerline of the tool holder, wherein the two ends of the cutting edge are referred to as a first end and a second end, the first end is shorter than the second end is shorter than the second end is shorter than the centerline, and a ridge extending from the first end toward the tool holder is inclined such that the closer to the tool holder side, the more it is located on the second end side.

[0016] Invention Effects

[0017] Based on the above steps and structure, the ease of forming the concave and convex shapes and / or the precision of the manufacturing method of the mold for forming the reflector and the manufacturing method of the reflector are improved. Attached Figure Description

[0018] Figure 1 This is a top view showing an example of the shape of the reflecting surface of a reflector.

[0019] Figure 2 This is a cross-sectional view illustrating an example of a method for manufacturing a reflector.

[0020] Figure 3 It means manufacturing Figure 2 A perspective view of an example of a processing machine for a reflector forming mold used in the manufacturing method.

[0021] Figure 4 This indicates that it is installed at Figure 3 A side view of an example of a cutting tool for a machining machine.

[0022] Figure 5 It means Figure 4 A perspective view of an example of the cutting edge of a knife.

[0023] Figure 6 It means Figure 5 A side view of an example of a blade with a cutting edge.

[0024] Figure 7 It means that it was used. Figure 6 A perspective view of an example of a cutting method for a cutting blade.

[0025] Figure 8 It means through Figure 7 A three-dimensional diagram illustrating an example of the sequence in which the cutting method forms the three planes of RR.

[0026] Figure 9 This is a diagram showing the first example of the concave and convex shapes of a mold formed by cutting.

[0027] Figure 10 This is a second example of a diagram showing the concave and convex shapes of a mold formed by cutting.

[0028] Figure 11 This is a third example of a diagram showing the concave and convex shapes of a mold formed by cutting.

[0029] Figure 12 This is a top view of the fourth example showing the concave and convex shape of a mold formed by cutting.

[0030] Figure 13 This is a cross-sectional view representing the fourth example above.

[0031] Figure 14 This is a top view of the fifth example showing the concave and convex shapes of a mold formed by cutting. Detailed Implementation

[0032] In the following description, for convenience, the term "tool position" sometimes refers to its relative position to the workpiece (e.g., a mold), and sometimes to its position in an absolute coordinate system. Unless otherwise specified, and provided there is no contradiction, the tool position can be any position, either relative or absolute. The same applies to the terminology used regarding tool movement. The term "centerline of the tool holder" refers not only to the line segment within the tool holder but also to the straight line extending outwards along its length.

[0033] The term "axis" in the context of machining sometimes refers to the axis of a defined coordinate system (or, in other views, an imaginary line), and sometimes to the drive mechanism that enables movement along such an axis. Furthermore, the term "axis" in the context of machining not only refers to axes associated with linear (parallel) movement (sometimes called "linear axes"), but also sometimes to axes associated with rotational movement (sometimes called "rotation axes"). Here, rotation does not necessarily need to be able to rotate within a 360° angular range (i.e., include tilting).

[0034] (Summary of the implementation method)

[0035] Figure 1 This is a top view showing a portion of the reflecting surface 113 of the reflector 111 in the embodiment. The reflecting surface 113 has a plurality of recesses 115 (or, in other views, a plurality of protrusions 117 located between the plurality of recesses 115). In the illustrated example, the reflector 111 is configured as a so-called pyramidal RR.

[0036] In other viewpoints, Figure 1 This is a diagram showing the surface (outer side) of reflector 111 as viewed from the outside. Reflector 111 is made of a light-transmitting material (e.g., resin or glass) and can reflect light that has passed through reflector 111 from the inside of the paper to the inside of the paper via reflective surface 113. And / or, reflector 111 can also reflect light from the near-front side of the paper (the outside of reflector 111) to the near-front side of the paper via reflective surface 113.

[0037] It should be noted that for light passing through reflector 111 from the inside of the paper and reaching reflective surface 113, the protrusion 117 can be regarded as a concave portion. However, in the description of the embodiment, unless otherwise specified, and unless there is any contradiction, the terms "protrusion" and "concave portion" of reflector 111 refer to the shape observed from the outside of reflector 111.

[0038] Figure 2 This is a cross-sectional view illustrating an example of a method for manufacturing reflector 111. In this example, reflector 111 is formed by filling the space between mold 120 and mold 121 with molding material (e.g., resin). Mold 121 has an inner surface 123 forming a reflective surface 113. This inner surface 123 has a recess 125 corresponding to a protrusion 117 (or, in other views, a protrusion 127 corresponding to a recess 115).

[0039] Figure 3 This is a perspective view illustrating an example of the manufacturing method of mold 121. In this view, an orthogonal coordinate system XYZ is labeled as a mechanical coordinate system (which can be understood as an absolute coordinate system). The +Z side is, for example, the vertical upper side.

[0040] In this example, the inner surface 123 of the mold 121 is cut by a machining machine 1 (e.g., a machine tool), thereby forming a plurality of recesses 125 on the inner surface 123 (in Figure 3 (Not shown in the figure). In the illustrated example, the machining machine 1 is a machine tool capable of performing cutting (i.e., rotary cutting) that rotates a rotary tool (though not a rotary tool, but referring to tool 101) about an axis. Figure 3 In the process, the cutting tool 101 for forming the recess 125 is mounted on the machining machine 1.

[0041] Figure 7 This is a perspective view illustrating an example of a cutting method for forming a recess 125 using a cutting tool 101 (more specifically, a cutting blade 103 at the tip of the cutting tool 101). Specifically, the view shows the state of the first plane 129A, one of the three planes (129A to 129C) that form a recess 125. In this view, the cutting blade 103 at a specified moment is represented by a solid line, and the cutting blade 103 at other moments during subsequent movement is represented by a double-dotted line. Arrow a1 indicates the trajectory of the movement of the cutting blade 103.

[0042] As shown in the figure, the cutting tool 101 moves parallel to the mold 121 without rotation, cutting the mold 121 to form the first plane 129A. At this time, the cutting tool 101 is not subjected to vibration (intentional vibration). That is, the cutting tool 101 cuts the mold 121 only through parallel movement. In other words, it performs the action of scraping the mold 121 (in other words, planing). The second plane 129B and the third plane 129C are also formed similarly through planing. The cutting tool 101 has a shape suitable for such cutting.

[0043] By using planing to form multiple recesses 125 as described above, the simplicity and / or precision of forming the multiple recesses 125 are improved. Specifically, as described below.

[0044] For example, in the method of forming the recess 125 by rotating a rotary tool (e.g., an end mill) (i.e., by conventional rotary cutting) (see, for example, Patent Document 1), even if the corners (in other words, concave corners or valley lines) where the planes (129A-129C) intersect are not intended to be rounded, the corners have a radius equal to that of the rotary tool. In other words, the machining accuracy of the corners is limited by the radius of the rotary tool. However, in this embodiment, the tool 101 does not rotate, so such a limitation on machining accuracy does not occur. That is, the machining accuracy is improved.

[0045] Furthermore, for example, in the method of forming the recess 125 by imparting vibration to the tool (see, for example, Patent Document 2), a vibration mechanism is required for imparting vibration to the tool. However, in this embodiment, a vibration mechanism is not required. That is, the ease of machining is improved. It should be noted that, for the sake of caution, in this disclosure, vibration when the tool is moved without vibrating the tool refers to intentional vibration, excluding unavoidable errors.

[0046] Furthermore, in methods such as rotating the tool synchronously with its parallel movement to form the recess 125 (e.g., refer to Patent Document 3), the parallel movement and rotation are controlled by considering their effects on the position and orientation of the cutting edge, thus complicating the control process. However, in this embodiment, such control is unnecessary. That is, the ease of machining is improved.

[0047] For safety reasons, conventional rotary cutting, vibration-based cutting, and / or cutting that synchronizes parallel movement with rotation may be performed before or after planing. For example, the approximate shape of the recess 125 may be formed by conventional rotary cutting, and planing may be performed during finishing. In another viewpoint, the recess 125 may be formed by planing alone, or it may be formed by a combination of planing and other processing methods (including not only other types of cutting, but also grinding and lapping, etc.).

[0048] In the above description, the recess 125 of the mold 121 used to form the reflector is formed by cutting as an example. It is also possible, unlike the above description, that the recess 115 of the reflector 111 is formed directly by cutting. However, in the description of the embodiment, for convenience, the method of using the mold 121 is used as an example. Unless otherwise specified, and as long as no contradiction arises, the description of cutting the recess 125 can be applied to cutting the recess 115.

[0049] The above is a summary of the implementation methods. The implementation methods will now be described in general as follows.

[0050] 1. Reflector ( Figure 1 and Figure 2 )

[0051] 2. Mold ( Figure 2 )

[0052] 3. Processing machine ( Figure 3 )

[0053] 4. Cutting tools ( Figures 4-6 )

[0054] 4.1. Overall tool ( Figure 4 )

[0055] 4.2. Blade ( Figure 5 and Figure 6 )

[0056] 4.3. The top part of the main body ( Figure 5 )

[0057] 4.4. Other examples of cutting tools

[0058] 5. Cutting methods ( Figure 7 and Figure 8 )

[0059] 6. Processing Example

[0060] 6.1. First Processing Example ( Figure 9 )

[0061] 6.2. Second processing example ( Figure 10 )

[0062] 6.3. Third Processing Example ( Figure 11 )

[0063] 6.4. Supplement regarding the fourth processing example and the orientation and size of the concave portion ( Figure 12 and Figure 13 )

[0064] 6.5. Fifth Processing Example ( Figure 14 )

[0065] 7. Summary of Implementation Methods

[0066] (1. Reflector)

[0067] Reflector 111 ( Figure 1 and Figure 2 It can be any reflector for various purposes, and its specific shape, size and material are arbitrary. Figure 1 and Figure 2 It only schematically represents a relatively simple shape of reflector 111.

[0068] For example, reflector 111 can be installed on automobiles, road signs, or advertising media. The shape, size, and material of reflector 111 can correspond to the aforementioned applications. For example, reflector 111 can be a plate-shaped component or a block-shaped component. The length of the ridge line of protrusion 117 (the valley line of recess 115) is, for example, 0.01 mm or more and 10 mm or less.

[0069] As mentioned above, Figure 1 The example reflector 111 is a pyramidal RR. (From...) Figure 1 Taking the light passing through reflector 111 from the inside of the paper as an example, which is reflected by reflective surface 113, the outer surface of protrusion 117 is formed into a triangular pyramid shape by three mutually orthogonal planes. Furthermore, the three planes help to reflect the light in the direction of incidence (retroreflection).

[0070] In the above description, the method of reflecting light from the inside of the paper by reflector 111 is taken as an example, but the method of reflecting light from the near front of the paper by reflector 111 is the same. That is, the inner surface of the recess 115 is formed into a triangular pyramid shape by three mutually orthogonal planes. Furthermore, the three planes facilitate retroreflection.

[0071] Reflector 111 can also be with Figure 1Unlike other examples, retroreflection is not produced. In other viewpoints, the outer surface of the protrusion 117 and / or the inner surface of the recess 115 are not limited to being composed of three mutually orthogonal planes. For example, the three planes may not be mutually orthogonal, or a protrusion 117 (or recess 115) may have four or more planes, or may be provided with curved surfaces. Such multiple protrusions 117 and / or multiple recesses 115 may, for example, contribute to the dispersion and / or homogenization of light, or contribute to light focusing.

[0072] As described above, the reflector 111 may or may not be translucent. Examples of materials for the former include resin and glass. Examples of materials for the latter include metal. In any case, the reflector 111 may be formed by molding or by cutting the recess 115.

[0073] The surface of the protrusion 117 (or concave portion 115 in other views) of the reflector 111 formed by the mold 121 can directly form the reflective surface 113, or it can be overlaid with a reflective film (e.g., a metal film) to enhance reflectivity. In other words, the reflective surface 113 can be directly formed by cutting multiple concave portions 125 formed in the mold 121 to create the protrusions and depressions on the reflective surface 113 of the reflector 111, or it can be left unformed.

[0074] Similarly, in the method of directly cutting the reflector 111 without using the mold 121, the surface of the cut protrusion 117 (or concave portion 115 in other views) can directly form the reflective surface 113, or it can be overlaid with a reflective film (e.g., a metal film) to enhance reflectivity. In other words, the step of forming multiple concave portions 115 constituting the reflective surface 113 by cutting may not be the step of ultimately forming the reflective surface 113.

[0075] It should be noted that the term "reflector 111" can refer to the entire component having the reflective surface 113, or it can refer to a portion of the component having the reflective surface 113 that includes the reflective surface 113. In the description of the embodiments, for convenience, unless otherwise specified and unless contradictions arise, the former term will be used. Furthermore, the term "reflective surface 113" can refer to the entire reflective surface having multiple protrusions 117 (or multiple recesses 115), or it can refer to a portion of the surface. In the description of the embodiments, for convenience, unless otherwise specified and unless contradictions arise, the former term will be used. The term "multiple protrusions 117" can refer to all the protrusions 117 of the reflective surface 113, or it can refer to a portion of the protrusions 117. In the description of the embodiments, for convenience, unless otherwise specified and unless contradictions arise, the former term will be used. The same applies to the multiple recesses 115. The terms used to describe the reflective surface 113, the plurality of protrusions 117, and the plurality of recesses 115 are described, but the terms used to describe the inner surface 123, the plurality of recesses 125, and the plurality of protrusions 127 of the mold 121 that correspond to them are also described.

[0076] (2. Mold)

[0077] Molds 120 and 121 Figure 2 It is made of metal. The specific type of metal is arbitrary. It should be noted that, unlike the implementation method, molds other than molds (molds made of materials other than metal) can also be used. The specific form of the mold is arbitrary. For example, the mold can be a direct engraving mold formed essentially as a single piece, or a nested mold with nesting elements that directly facilitate molding and a master mold for nesting insertion. In addition, the mold combination can consist of two molds facing each other (as illustrated in the example), or it can consist of three or more molds. In other words, the number of mold divisions is arbitrary. Furthermore, the mold can also be combined with a core.

[0078] (3. Processing machine)

[0079] Processing machine 1 ( Figure 3 The device includes a mechanical part 3 for performing mechanical actions and a control device 5 for controlling the mechanical part 3. The structure of the mechanical part 3 can be various structures including known structures. The hardware of the control device 5 can be various hardware including known hardware. The operation (control) of the control device 5, in addition to the control of planing operations already described, can be set to various operations including known operations.

[0080] The structure of the machine part 3 is arbitrary as long as it can perform the planing process described above. For example, the structure of the machine part 3 can be the structure of a machine part generally used in machine tools (as shown in the example), or the structure of a machine part generally used in industrial robots, or a structure that cannot be distinguished in this way. The machine part 3 in the example shown in the figure is a structure that can perform milling, but it can also be a structure that cannot perform milling. In other words, the machine part 3 can also be a structure that does not have a spindle 7 (described later) that can rotate the tool around the axis.

[0081] The mechanical unit 3 can, for example, be configured to allow the tool 101 and the mold 121 to move relatively parallel to each other in the directions of three mutually orthogonal axes (X-axis, Y-axis, and Z-axis). Furthermore, in addition to the three linear axes described above, the mechanical unit 3 may also have one or more linear axes and / or one or more rotary axes (or none). The rotary axis can be any one of the A-axis (axis about the X-axis), B-axis (axis about the Y-axis), and C-axis (axis about the Z-axis). For example, the machining machine 1 can be a 5-axis machining machine with three linear axes and two rotary axes (the example shown). It should be noted that the two rotary axes referred to here are those other than the rotation of the spindle 7 holding the tool 101 about its axis.

[0082] The specific structure of the machining machine 1 that has three or more axes as described above is arbitrary. For example, the relative movement of each axis (linear axis or rotary axis) can also be achieved by movement in the absolute coordinate system of the tool 101 and either the absolute coordinate system of the mold 121.

[0083] Figure 3 The illustrated mechanical part 3 is merely one example of a structure that realizes three linear axes and two rotational axes. However, the structure of the illustrated mechanical part 3 will be briefly explained below for reference.

[0084] The mechanical unit 3 enables relative movement of the cutting tool 101 and the mold 121 along the X, Y, Z, A, and C axes. The cutting tool 101 is held on the spindle 7, and the mold 121 is held on the worktable 9. Therefore, in another viewpoint, the mechanical unit 3 is capable of moving the spindle 7 relative to the worktable 9 along the aforementioned linear axis 3 and rotary axis 2.

[0085] The relative movement of the Y-axis, Z-axis, and A-axis is achieved by the movement of the tool 101 along these axes in an absolute coordinate system. To achieve this movement (absolute coordinate system), the mechanical unit 3 has, for example, the following components: The Y-axis movable part 11 is supported by a fixed component (reference numerals omitted) to be able to move along the Y-axis direction. The Z-axis movable part 13 is supported by the Y-axis movable part 11 to be able to move along the Z-axis direction. The spindle head 15 is supported by the Z-axis movable part 13 to be able to move along the A-axis direction (able to rotate about the X-axis). The spindle head 15 holds the spindle 7 in such a manner that the axis of the spindle 7 is orthogonal to the X-axis.

[0086] The relative movement of the X-axis and C-axis is achieved by the movement of the mold 121 along these axes in an absolute coordinate system. To achieve this movement (absolute coordinate system), the mechanical part 3 has, for example, the following components: an X-axis movable part 17 supported by fixed components (reference numerals omitted) capable of moving along the X-axis direction; and a worktable 9 supported by the X-axis movable part 17 capable of moving along the C-axis direction (capable of rotating about the Z-axis). The worktable 9 holds the mold 121, for example, with the inner surface 123 of the mold 121 facing the +Z-axis direction. However, the worktable 9 may also hold the mold 121 in a different orientation than described above.

[0087] Example 5: Representative structures other than those shown in the diagram of a five-axis machining center. Spindle 7 moves along the X, Y, and Z axes, and table 9 moves along the A and C axes. Spindle 7 moves along the Y, Z, A, and B axes, and table 9 moves along the X axis. Spindle 7 moves along the Y, Z, and B axes, and table 9 moves along the X and C axes.

[0088] The drive source for each axis (including spindle 7) can be an electric motor, a hydraulic device, or a pneumatic device. Alternatively, the electric motor can be a rotary electric motor or a linear electric motor. It should be noted that when the drive source for the linear axis is a linear motor, machining accuracy is easily improved. The drive source for spindle 7 can, for example, be an electric motor capable of rotating at high speeds (e.g., 20,000 rpm or higher). Therefore, for example, it is easy to use a conventional rotary tool (a tool different from tool 101) for rough machining of the recess 125, or to form the shape of the portion of the mold 121 other than the recess 125.

[0089] The linear guides or bearings of each axis (including spindle 7) can be sliding guides where the movable part slides between the movable part and the fixed part, rolling guides where rolling elements roll between the movable part and the fixed part, hydrostatic guides that allow air or oil to pass between the movable part and the fixed part, or combinations of two or more of these. It should be noted that when the bearing of spindle 7 is set as an air hydrostatic bearing, it is easy to achieve a mirror finish through milling.

[0090] Although not specifically illustrated, the mechanical unit 3 may also include an automatic tool changer (ATC) for changing the tool being used. This would allow, for example, automatic cutting with a tool different from tool 101 (as described above).

[0091] The machining accuracy (or positioning accuracy, in other viewpoints) of the machining section 3 (machine 1) can be appropriately set. For example, the linear axis of the machining section 3 can be positioned with sub-micron level accuracy (error less than 1 μm) or nanometer level accuracy (error less than 10 nm). Additionally, for example, the rotary axis (including spindle 7) can be positioned with an accuracy of 0.001°. Machine tools with such accuracy of linear and / or rotary axes have been put into practical use by the applicant (e.g., UVM series, ULG series, and ULC series). Of course, the machining accuracy of the machining machine 1 can also be lower than described above.

[0092] The control device 5 can perform NC program-based control, teach-based control, or other types of control. From another perspective, the machining machine 1 can be classified as a machine tool, a robot, or something else entirely.

[0093] (4. Knives)

[0094] (4.1. Overall tool)

[0095] Figure 4 This is a side view showing an example of tool 101. For convenience, the following labels are provided in this figure. Figure 3 The Z-axis is also marked in the diagram. Additionally, a fixed orthogonal coordinate system xyz is added to the tool 101. The Z-axis and z-axis are parallel to each other. The z-direction is defined as parallel to the center line CL1 of the tool holder 105s (described later). The y-direction is defined as parallel to the cutting edge 103a (described later). For convenience, the +z side is sometimes designated as "upper," and terms such as "upper end" are used.

[0096] The shape of the cutting tool 101 is, for example, generally axial, extending along the z-direction (axial direction of the spindle 7). The cutting tool 101 has a body 105 occupying most of the body and a cutting blade 103, as described, fixed to the top end 105a of the body 105. The cutting blade 103 is fixed, for example, by brazing.

[0097] The main body 105 has a tool holder 105s that is detachable from the spindle 7. Alternatively, the main body 105 may have a neck (reference numerals omitted) with a smaller diameter towards the tip 105a between the tool holder 105s and the tip portion 105a. The structure of the main body 105, except for the shape of the tip portion 105a, can be the same as known structures, and detailed description is omitted. The shape of the tip portion 105a will be described after the description of the cutting tool 103.

[0098] (4.2. Blade)

[0099] Figure 5 This is a magnified perspective view of the tip side of the cutting tool 101. For convenience, the following labels are provided in this figure. Figure 4 The Z-axis and orthogonal coordinate system xyz are also marked in the text.

[0100] The insert 103 has a cutting edge 103a (in other words, the bottom edge) facing the tip side (-z side). The surfaces that intersect each other with the cutting edge 103a as the ridge line are the rake face 103b and the flank face 103c.

[0101] For example, in the formation Figure 7 In the case of the first plane 129A, the cutting edge 103a passes through in the approximately +x direction ( Figure 5 The first plane 129A is formed on the -z side by moving the blade 103 (to the right side of the paper and near the front of the paper). At this time, the third plane 129C is located on the -y side of the blade 103. Figure 5 The left side of the paper and the front side of the paper). In other words, the first end 103e of the two ends of the cutting edge 103a ( Figure 5 Located on the side of the third plane 129C. The first end 103e can help form the first corner 131A of the first plane 129A and the third plane 129C. Figure 7 ( ) cutting.

[0102] It should be noted that, by Figure 7 It is known that the direction of movement of the cutting edge 103a during planing can also be inclined relative to the x-direction (the direction orthogonal to the cutting edge 103a). However, for convenience, in the description of the implementation method, unless otherwise specified, the embodiment based on the cutting edge 103a moving in the x-direction (parallel to the x-axis) is sometimes used.

[0103] The overall shape of the insert 103 is arbitrary, as long as it has a cutting edge 103a, a rake face 103b, and a flank face 103c. For example, it can be appropriately formed into a plane to properly fix the insert 103 to the body 105. Furthermore, Figures 4-7 The shapes of the blades 103 shown in the figures are not strictly consistent with each other.

[0104] exist Figure 5 In the example shown, the insert 103 does not have a cutting edge other than the cutting edge 103a. However, the portion near the first end 103e in the ridge line 103h extending from the first end 103e toward the tool holder 105s side (+z side) can also function as a cutting edge. In addition, unlike the example shown, the insert 103 may also have more than two cutting edges.

[0105] Cutting edge 103a is, for example, the center line CL1 of the tool holder 105s ( Figure 4The cutting edge 103a is orthogonal and straight. However, the cutting edge 103a may also be inclined relative to the center line CL1 within the range of ±30°, ±10°, or ±5°. Furthermore, the cutting edge 103a may also appear curved when viewed in a direction orthogonal to the plane being cut. Contrary to the description of the embodiment, if a curved surface is formed by the cutting edge 103a, the cutting edge 103a may also appear curved when viewed from its direction of travel. The length of the cutting edge 103a (in other views, the length of the insert 103 in the y-direction) is arbitrary. As an example, the length of the cutting edge 103a is 0.005 mm or more and 30 mm or less.

[0106] The rake face 103b and flank face 103c are, for example, planar. However, they can also be curved, a combination of multiple planar faces, or have grooves. The rake angle, clearance angle, and tool angle are arbitrary. The rake angle can be negative ( Figure 5 (For example), it can be a positive value or 0°. To be on the safe side, in the case of a negative rake angle, the rake face 103b is tilted such that the closer it is to the tool holder 105s side (+z side), the more it is located in the travel direction (+x side) of the cutting edge 103a. Various angles can be set considering the machinability or the anisotropy of the material of the insert 103 (e.g., diamond).

[0107] Figure 6 This is a diagram showing the cutting tool 103 viewed along the x-direction. As mentioned above, the x-direction is approximately the same as the direction in which the cutting tool 103 moves during planing.

[0108] The first end 103e is located, for example, on the center line CL1 of the tool holder 105s. Therefore, even if the rotational position of the tool 101 (spindle 7) has an error, the effect of this error on the positional error of the first end 103e is reduced (theoretically, it has no effect). Furthermore, the positional accuracy of the corner (131A, etc.) formed by the first end 103e is improved. It should be noted that even if the first end 103e is located on the center line CL1, there can still be unavoidable manufacturing errors in the tool 101.

[0109] Here, we consider a configuration where the first distance of the first end 103e from the centerline CL1 is the same as the second distance of the other end of the cutting edge 103a (the second end 103f) from the centerline CL1 (this configuration may also be included in the technology of this disclosure). Compared to this configuration, if the first distance is slightly shorter than the second distance, the aforementioned effect can be achieved to some extent. Therefore, in other viewpoints, the first distance can be shorter than the second distance by an appropriate difference. For example, the first distance can be set to less than 1 / 2, less than 1 / 5, or less than 1 / 10 of the second distance.

[0110] The ridge line 103h extending from the first end 103e toward the shank 105s side (+z side) is inclined relative to the centerline CL1 in such a way that the closer to the shank 105s side, the further away from the centerline CL1. In another viewpoint, the ridge line 103h is inclined such that the closer to the shank 105s side, the closer to the second end 103f side. In yet another viewpoint, viewed in the direction of movement of the blade 103 (e.g., the x-direction), the blade 103 does not have a portion located on the opposite side (-y side) to the second end 103f than the first end 103e.

[0111] Therefore, for example, when the first plane 129A is formed by the cutting edge 103a and the first corner 131A is formed by the first end 103e, the possibility of interference between the ridge 103h (in other views, the portion of the insert 103 other than the cutting edge 103a) and the third plane 129C is reduced. It should be noted that the term ridge 103h may refer only to a portion of the ridge extending from the first end 103e towards the tool holder 105s side. However, in the description of the embodiment, for convenience, the term ridge 103h refers to the entire ridge described above.

[0112] The inclination angle of the edge 103h is arbitrary. In addition, the edge 103h can be straight (as illustrated in the example) or curved. Unlike the example illustrated, the upper end of the edge 103h (the end on the +z side) may not reach the upper end of the blade 103 (the blade 103 may also have a plane or curved surface facing the -y side on the side above the edge 103h).

[0113] The material of the cutting tool 103 is arbitrary. For example, the material of the cutting tool 103 can be diamond (single crystal or polycrystalline), CBN (Cubic Boron Nitrides), ceramics (e.g., alumina-based or silicon nitride-based), cermet, or superhard alloy.

[0114] (4.3. Top part of the main body)

[0115] When viewed in the direction of movement of the blade 103 (e.g., the x-direction), Figure 4 and Figure 5 The top end 105a of the example body 105 is located on the side (+y side) closer to the second end 103f than the first end 103e (or, in another view, the centerline CL1) of the blade 103. Thus, for example, as... Figure 7 As shown, when the first plane 129A is formed by the cutting edge 103a and the first corner 131A is formed by the first end 103e, the possibility of interference between the top end 105a and the third plane 129C is reduced.

[0116] The specific shape of the tip 105a is arbitrary. Figure 5In the figure, the top portion 105a is generally shaped as a straight column with a fan-shaped base and a central angle of 90°. However, the central angle of the fan may not be 90°. The shape of the straight column base may not be fan-shaped, for example, it may be rectangular or other polygonal. Furthermore, the top portion 105a may not be a straight column, but rather a frustum-shaped structure with the cross-sectional area decreasing or increasing closer to the -z side.

[0117] As described above, the direction of movement of the cutting edge 103a is not limited to a direction orthogonal to the cutting edge 103a (y-axis) (x-direction), but can also be a direction inclined towards the x-direction. The shape of the tip portion 105a can also take into account the specific direction of movement of the cutting edge 103a. For example, as Figure 7 As exemplified, when the cutting edge 103a is tilted so that the first end 103e side is forward relative to the direction of travel, the center angle can be less than 90° so that the tip 105a does not interfere with the third plane 129C.

[0118] (4.4. Other examples of cutting tools)

[0119] The shape of the cutting tool 101 shown in the illustration is just one example. Various other cutting tools besides those shown in the illustration can be used for planing. Examples are given below.

[0120] As described above, the cutting edge 103a can cross the center line CL1 or be curved. The cutting edge 103a may also not be a bottom cutting edge, but an outer peripheral cutting edge along the center line CL1 (parallel to the center line CL1 or inclined relative to the center line CL1).

[0121] The insert 103 may also have two or more cutting edges. For example, the insert 103 may have a bottom cutting edge and an outer peripheral cutting edge. In this case, two intersecting planes (e.g., a first plane 129A and a third plane 129C) can be formed simultaneously by planing. The bottom cutting edge and the outer peripheral cutting edge may be orthogonal to each other. In this case, two pyramidal RR planes can be formed simultaneously. Of course, the bottom cutting edge and the outer peripheral cutting edge may not be orthogonal to each other.

[0122] The blade 103 may not be brazed to the main body 105, but can be attached to and detached from the main body 105 by screws or the like. Alternatively, the tool 101 may not have a blade 103, but the cutting edge 103a may be integrally formed with the tool holder 105s. When such an arrangement is also considered, the term "blade 103" in the description of the embodiment may be replaced, for example, with the terms "cutting edge" or "blade tip".

[0123] (5. Cutting method)

[0124] As described in the summary of the embodiments, for example, all the planes (129A to 129C) of the recess 125 can be formed by planing with the cutting edge 103a. Furthermore, all the corners (131A to 131C) between these planes can be formed by the first end 103e of the cutting edge 103a. Roughing and / or finishing can also be performed using tools other than the tool 101 and / or machining processes other than planing (e.g., rotary cutting) (or may not be performed at all).

[0125] Based on the understanding that roughing and / or finishing can also be performed, for example, when forming the recess 125 by planing, all the steps for forming the recess 125 can also be performed without planing (of course, this is also possible).

[0126] Furthermore, for example, when all the planes (129A to 129C) of the recess 125 are formed by planing, the entire area of ​​each plane can be formed by planing, or only a portion of the area can be formed by planing. As an example of the latter, after the recess 125 is substantially formed by rotary cutting with a tool other than tool 101, only the corner (131A to 131C) and its surrounding area can be formed by planing.

[0127] It should be noted that, for convenience, in the description of the embodiments, machining processes other than planing performed by the cutting tool 101 are sometimes omitted. Furthermore, for convenience, unless otherwise specified, the embodiments are sometimes presented as being formed entirely by planing.

[0128] exist Figure 7 In the example, the length of the cutting edge 103a is shorter than the width of the first plane 129A (the length of the second corner 131B) when viewed from the direction of travel of the cutting edge 103a. Such a cutting edge 103a can contribute to the formation of the entire area of ​​the first plane 129A through repeated planing operations, or it can only contribute to the formation of a portion of the area (e.g., the area surrounding the first corner 131A as described above) through at least one planing operation. This also applies to the other planes (129B and 129C).

[0129] Unlike the example shown, the length of the cutting edge 103a can also be longer than the length of the second corner 131B. In this manner, the entire area of ​​the first plane 129A can be cut in a single planing operation. However, in this manner, planing operations can also be performed repeatedly. In other words, the recess 125 can gradually increase in size. The same applies to other planes.

[0130] When forming multiple recesses 125, multiple first planes 129A can be formed, followed by multiple second planes 129B, and then multiple third planes 129C (hereinafter referred to as the "first step"). Alternatively, the multiple recesses 125 can repeatedly undergo the action of forming the three planes (129A to 129C) of a single recess 125 (hereinafter referred to as the "second step"). That is, the multiple recesses 125 can be formed gradually as a whole (first step), or they can be formed one by one sequentially (second step).

[0131] It should be noted that, although it also depends on the shape of the mold 121, the processing time of the first step is usually shorter. Alternatively, after forming a first number (two or more) of recesses 125 in the first region through the first step, a second number (two or more) of recesses 125 can be formed in the second region that is inclined relative to the first region through the first step.

[0132] Figure 8 This is a perspective view illustrating a more detailed aspect of the cutting method.

[0133] In this diagram, arrows a1 to a3 are... Figure 7 Arrow a1 similarly represents the trajectory of blade 103. Blade 103 moves, for example, in the order of arrows a1, a2, and a3. That is, in the illustrated example, the three planes are formed in the order of first plane 129A, second plane 129B, and third plane 129C.

[0134] It should be noted that, referring to Figure 8 The actions described (the actions of arrows a1 to a3) can be the actions when focusing on a single recess 125 during the process of gradually forming multiple recesses 125 through the first step described above, or the actions during the process of sequentially forming one recess 125 after another through the second step.

[0135] As explained earlier, when forming a recess 125, the planing operations indicated by arrows a1 to a3 can be performed either without repetition or repeatedly. In the latter case, the actions of arrows a1, a2, and a3 can be performed sequentially (hereinafter referred to as "step three"), or the actions of arrows a1, a2, and a3 can be performed sequentially (hereinafter referred to as "step four"), or a combination of both can be combined.

[0136] It should be noted that, for the sake of caution, the third or fourth step may be combined with either the first or second step. Furthermore, in the description of the implementation method, for convenience, sometimes a non-repetitive approach is taken without specific explanation.

[0137] During the formation of the first plane 129A, the blade 103 moves parallel to the second plane 129B (its predetermined formation position) which is formed next, along the first plane 129A (a pre-formed imaginary plane). At this time, the cutting edge 103a forms the first plane 129A, and the first end 103e forms the first corner 131A (the valley line between the third plane 129C and the first plane 129A). Afterward, the blade 103 retracts from the recess 125 (a pre-formed imaginary space) along the second plane 129B (a pre-formed imaginary plane). It should be noted that the retraction path of the blade 103 may also differ from the above description.

[0138] The formation of the second plane 129B and the third plane 129C is the same as described above. For the sake of clarity, only a portion will be described. In the formation of the second plane 129B, the blade 103 moves parallel to the second plane 129B (the pre-formed imaginary plane) towards the third plane 129C (its pre-formed position), which will be formed subsequently. At this time, the cutting edge 103a forms the second plane 129B, and the first end 103e forms the second corner 131B (the valley line between the first plane 129A and the second plane 129B). In the formation of the third plane 129C, the blade 103 moves parallel to the third plane 129C (the pre-formed imaginary plane) towards the first plane 129A. At this time, the cutting edge 103a forms the third plane 129C, and the first end 103e forms the third corner 131C (the valley line between the second plane 129B and the third plane 129C).

[0139] However, the steps (or directions of movement in other viewpoints) for forming three planes sequentially can also differ from those described above. For example, when forming the first plane 129A, the blade 103 can move toward the third plane 129C that will be formed next.

[0140] (6. Processing example)

[0141] When manufacturing mold 121 using cutting tool 101, various shapes and sizes of the recess 125 can be achieved by controlling its cutting direction and cutting amount. Several examples are shown below. In the following description, for convenience and to distinguish between the various examples, the reference numerals for mold 121 and its parts are sometimes labeled with capital letters. The various examples described below can be combined with each other as long as they do not cause contradictions. For example, two or more examples can be applied to one mold 121.

[0142] (6.1. First Processing Example)

[0143] Figure 9This is a cross-sectional view of mold 121A showing a first processing example. In mold 121A, a plurality of recesses 125 (125A and 125B) include recesses 125A and 125B facing different from each other. It should be noted that in the illustrated example, the plurality of recesses 125 have the same shape and size as each other.

[0144] More specifically, a plurality of recesses 125A are arranged two-dimensionally in a planar first region, all facing the same direction (more specifically, facing the normal direction of the first region). Additionally, a plurality of recesses 125B are arranged two-dimensionally in a planar second region, all facing the same direction (more specifically, facing the normal direction of the second region). Furthermore, the orientations of the recesses 125A and 125B are different from each other. Alternatively, the planar first region and the planar second region face different directions.

[0145] The angle between the first region and the second region is arbitrary. Alternatively, one or more recesses 125 may be sandwiched between the first region and the second region, with the orientation of recess 125A and recess 125B being between them. Two or more planar regions may also be provided. It should be noted that the planarity of the first and second regions can be determined, for example, by considering whether the opening surfaces of multiple recesses 125A and 125B (an imaginary plane blocking the opening of the recess 125) are approximately located in the same plane.

[0146] (6.2. Second processing example)

[0147] Figure 10 This is a cross-sectional view of mold 121B, representing the second processing example. In mold 121B, similar to mold 121A, the plurality of recesses 125 include two or more recesses 125 with different orientations. However, the specific manner of their arrangement differs from that of mold 121A.

[0148] More specifically, the multiple recesses 125 have different orientations between adjacent recesses. In another viewpoint, the angles of the recesses 125 gradually change in at least one arrangement direction in a two-dimensional arrangement. In yet another viewpoint, the multiple recesses 125 are arranged in a curved region with their normal directions facing each other. Furthermore, regarding whether the multiple recesses 125 are arranged along a curved surface, for example, when considering the opening faces of the multiple recesses 125, it can be determined by whether the multiple opening faces are connected and form a generally curved surface (strictly speaking, a polygon).

[0149] The degree of change in orientation and the pattern (or, in other views, the curvature and shape of the surface) are arbitrary. For example, the curvature can be constant (as illustrated in the example) or it can vary. The surface of the second processing example can also be located between two planar regions in the mold 121A of the first processing example that are oriented differently from each other.

[0150] (6.3. Third Processing Example)

[0151] Figure 11 This is a cross-sectional view of mold 121C, representing the third processing example. In mold 121C, a plurality of recesses 125 include two or more recesses 125C and 125D of different sizes. It should be noted that, in the illustrated example, the shapes of the plurality of recesses 125 are different.

[0152] More specifically, in the illustrated example, two types of recesses 125C and 125D, which are of different sizes, are arranged two-dimensionally on the same plane. The two types of recesses 125C and 125D are located in different regions.

[0153] Unlike the example shown, there can be more than three types of sizes. The recesses 125 of different sizes may not be concentrated in different areas, but rather exist in a mixed manner. The sizes of the multiple recesses 125 may also gradually change individually or at predetermined intervals along the arrangement direction.

[0154] Recesses 125 of different sizes can also be combined with the first processing example and / or the second processing example. For example, the orientations of the recesses 125 of different sizes can also be different. More specifically, for example, in Figure 9 In this process, recess 125A may be larger or smaller than recess 125B. And / or, a plurality of recesses 125 located on a curved surface between recesses 125A and recesses 125B, as in the second processing example, may be larger or smaller relative to recesses 125A and / or recesses 125B.

[0155] (6.4. Supplement regarding the fourth processing example and the orientation and size of the concave portion)

[0156] Figure 12 This is a top view of mold 121D representing the fourth processing example. Figure 13 This is a cross-sectional view of mold 121D. It should be noted that both figures are schematic diagrams, therefore... Figure 12 and Figure 13 The shape of the concave portion 125 is inconsistent.

[0157] In mold 121D, the plurality of recesses 125 include two or more recesses 125E that are different in shape, size, and / or orientation. More specifically, the shape, size, and orientation of the plurality of recesses 125E are random. It should be noted that the randomness in this case is similar to that of a pseudo-random number sequence and does not need to be strict. For example, it is sufficient that an ordinary person or a person skilled in the art cannot observe regularity in mold 121D. The reflector 111 formed by such a plurality of recesses 125E can, for example, homogenize the distribution of the amount of radiation and / or the amount of light in the cross-section of the light source when reflecting light from the light source.

[0158] First processing example ( Figure 9 ) and the second processing example ( Figure 10 In this example, recesses 125 with different orientations have the same shape (though their sizes may differ), making it easy to determine their orientation differences. As in the fourth processing example, when multiple recesses 125 have different shapes, the orientation differences of the multiple recesses 125 can be determined, for example, by using the optical axis LA (…). Figure 13 The orientation of the object is used as a reference for judgment.

[0159] The orientation of the optical axis LA can be defined, for example, in this disclosure as follows. Consider the case where parallel light is incident on a recess 125 and reflected. As the incident direction of the parallel light, the direction in which the amount of reflected light (e.g., the beam of light in a sufficiently wide plane parallel to the opening surface of the recess 125) is maximized can be selected. Furthermore, the direction in which the amount of reflected light (e.g., the intensity of light) is maximized is set as the orientation of the optical axis LA. When the intensity of the maximum intensity of light extends over a solid angle of a certain size, the orientation of its centerline can be set as the orientation of the optical axis LA. It should be noted that the optical axis LA of the recess 125 of the pyramidal RR is a straight line equidistant from the three planes (129A to 129C).

[0160] The recess 125 is formed in the mold 121, and therefore, unlike the protrusion 117 (or recess 115) of the reflector 111, it is not intended for light reflection. However, for convenience, the optical axis LA is used to determine the similarity or difference in orientation. Furthermore, the difference or difference here is only determined by the similarity or difference in the orientation of the shape of the recess. Therefore, it can be assumed that the surface properties related to reflection of the multiple planes (129A to 129C) constituting the inner surface of the recess are the same as each other.

[0161] In addition, in the third processing example ( Figure 11In this example, recesses 125 of different sizes have the same shape, making it easy to determine their size differences. As in the fourth processing example, when multiple recesses 125 have different shapes, the size differences can be determined, for example, based on the area of ​​the inner surface of the recess 125. This is because, although it also depends on the shape of the recess 125, a larger inner surface area results in a greater amount of light reflected by the recess 125. Alternatively, the volume of the recess 125's space or the area of ​​the recess 125's opening surface can also be compared.

[0162] Figure 12 This is also an example of a non-triangular pyramidal concave portion 125. However, as... Figure 13 As shown, the recesses 125, which vary in shape, size, and orientation (and are therefore random), can also be triangular pyramidal. Additionally, in Figure 12 and Figure 13 In the middle, the shape, size, and orientation are all random, but only one or only two can be random. Multiple recesses 125 with random shape, size, and / or orientation can also be set along a curved surface instead of a plane.

[0163] (6.5. Fifth Processing Example)

[0164] Figure 14 This is a cross-sectional view of mold 121E representing the fifth processing example. In mold 121E, a plurality of recesses 125 include two or more recesses 125F and 125G that face away from each other.

[0165] More specifically, the multiple recesses 125F have the same shape, size, and orientation, and form a pyramidal RR. The optical axis (not shown) is parallel to the normal (vertical direction in the figure) of the plane with the multiple recesses 125. Furthermore, the multiple recesses 125F and... Figure 1 The examples are also arranged equally in two dimensions.

[0166] Furthermore, a portion of these multiple recesses 125F are replaced with recesses 125G that face a different direction from the recesses 125F. Recesses 125G are based, for example, on a triangular pyramidal shape forming a pyramidal RR. However, to avoid disrupting the arrangement of the multiple recesses 125F, additional planes are added to the three planes forming the triangular pyramid. The optical axis (not shown) of the triangular pyramid of recess 125G is inclined relative to the normal to the plane on which the multiple recesses 125 are arranged (in other views, the optical axis of recesses 125F) in a manner that the higher up in the figure, the more it is located on the right side of the figure. The degree of this inclination (inclination angle) can be appropriately set in a way that achieves the effect described below.

[0167] For convenience, we will assume that mold 121E is a reflector and explain the effect of setting the orientation of the recess 125 as described above. Furthermore, for ease of understanding, we will omit precision in the following explanation.

[0168] As shown in eye E1, imagine viewing a plane with multiple recesses 125 arranged from above, parallel to the normal direction of the plane (the direction of the optical axis of the recess 125F). In this case, light incident on the plane in the direction of the line of sight is reflected upwards by both recesses 125F and 125G, parallel to the direction of the line of sight. As a result, the reflected light can be seen over the entire plane.

[0169] Next, as shown in eye E2, imagine observing a plane with multiple recesses 125 arranged from above, parallel to the direction of the optical axis of the recess 125G. In this case, light incident on the plane in the direction of the line of sight is reflected upwards by the recesses 125G, parallel to the direction of the line of sight. On the other hand, the direction of the line of sight is outside the angle range in which the recesses 125F produce retroreflection, and the recesses 125F do not reflect light in the direction of the line of sight. As a result, (relatively strong) reflected light is only seen at the position of the recesses 125G.

[0170] Here, for example, multiple recesses 125G are arranged into a specific pattern (graphics and / or text, etc.). In this way, a clever effect is achieved where the pattern, which cannot be seen when viewing the plane with multiple recesses 125 from the front, is seen when the plane is viewed at an angle.

[0171] The aforementioned ingenious effect can be further developed. Specifically, for example, as described below. In the aforementioned ingenious effect, a recess 125G is provided that is visible to both eyes E1 and E2, and a recess 125F is visible to eye E1 but not to eye E2. In addition, although not specifically illustrated, recesses 125 that are invisible to both eyes E1 and E2, and recesses 125 that are invisible to eye E1 but visible to eye E2 are also provided. In this way, different patterns can be seen when viewing the plane from the front and when viewing the plane at an angle.

[0172] (7. Summary of implementation methods)

[0173] As described above, the method for manufacturing a mold for forming a reflector according to the embodiment is a method for manufacturing a mold 121 for forming a reflector 111 that reflects light. This method includes a cutting step in which a plurality of recesses 125 are formed on the inner surface of the mold 121 by cutting to form concave and convex portions 117 on the reflective surface of the reflector 111. Figure 7 The cutting steps include the planing step (). Figure 7In this planing step, multiple recesses 125 are cut by relative movement of the tool 101 relative to the mold 121 without the tool 101 rotating or vibrating.

[0174] In another viewpoint, the manufacturing method of the reflector 111 in the embodiment uses a mold 121 manufactured by the manufacturing method of the reflector forming mold of the above embodiment to form the reflector 111.

[0175] Therefore, as described in the summary of the embodiments, for example, compared to forming the recess 125 by cutting with a rotating tool (rotary cutting), the accuracy of the corners (131A to 131C) of the recess 125 can be improved. Compared to forming the recess 125 by cutting with a vibrating tool, the structure of the machining machine 1 can be simplified. Compared to synchronizing the parallel movement and rotation of the tool, control can be simplified. From another perspective, the creation of NC programs or teach programs can be facilitated.

[0176] The cutting tool 101 may have a cutting edge 103a extending in a direction intersecting the center line CL1 of the tool holder 105s. When referring to the two ends of the cutting edge 103a as the first end 103e and the second end 103f, the distance of the first end 103e from the center line CL1 may be shorter than the distance of the second end 103f from the center line CL1. The ridge line 103h extending from the first end 103e toward the tool holder 105s side may be inclined such that it is closer to the second end 103f the closer it is to the tool holder 105s side.

[0177] In this case, for example, as described above, when the first plane 129A is formed by the cutting edge 103a and the first corner 131A is formed by the first end 103e, the influence of the positioning error of the tool 101 around the axis on the accuracy of the first corner 131A is reduced. Furthermore, the possibility of interference between the edge 103h and the third plane 129C is reduced. As a result, for example, the possibility of undesirable shapes being formed in the first corner 131A and / or the third plane 129C can be reduced, and the accuracy of these parts can be improved. Furthermore, at the first end 103e, the angle between the cutting edge 103a and the edge 103h is less than 90°, so when the corners (131A to 131C) are formed by the first end 103e during planing, it is easy to make the angle of the corner any size.

[0178] The first end 103e can be located on the center line CL1. The ridge 103h can be inclined such that the closer to the tool holder 105s side, the further away from the center line CL1.

[0179] In this case, for example, the aforementioned effect (reducing the impact of the error of the tool 101 around the axis on the accuracy of the first corner 131A) is improved.

[0180] During the planing step, all surfaces (129A to 129C) of each of the multiple recesses 125 can be cut by the same straight cutting edge 103a of the tool 101.

[0181] In this case, for example, compared to the method of simultaneously forming two planes (e.g., first plane 129A and third plane 129C) by the bottom cutting edge and the outer peripheral cutting edge (which may also be included in the technology of this disclosure), the cutting conditions of the two planes are similar. As a result, for example, the surface characteristics of the two planes of the mold 121 tend to become equal, and consequently, the surface characteristics of the two planes of the reflector 111 corresponding to the two planes tend to become equal. As a result, for example, the uniformity related to light reflection is improved.

[0182] In each of the plurality of recesses 125, all corners (131A to 131C) between adjacent surfaces can be cut by the first end 103e of the first end 103e of the cutting edge 103a and the second end 103f.

[0183] In this case, for example, all corners are cut from the same first end 103e, so the micro-radius fillets (manufacturable errors) of all corners tend to become uniform. As a result, for example, the radii of the edges of the protrusions 117 of the reflector 111 corresponding to the corners of the mold 121 tend to become uniform. As a result, for example, the uniformity related to light reflection is improved.

[0184] Multiple recesses 125 may each have a first plane 129A, a second plane 129B, and a third plane 129C that are orthogonal to each other. The planing process may include a first step (…). Figure 8 Arrow a1), second step ( Figure 8 Arrow a2) and the third step ( Figure 8 (arrow a3). In the first step, the cutting edge 103a can be moved relative to a predetermined position for forming the second plane 129B, forming the first plane 129A through the cutting edge 103a, and forming the first corner 131A between the third plane 129C and the first plane 129A through the first end 103e. In the second step, after the first step, the cutting edge 103a can be moved relative to a predetermined position for forming the third plane 129C, forming the second plane 129B through the cutting edge 103a, and forming the second corner 131B between the first plane 129A and the second plane 129B through the first end 103e. In the third step, after the second step, the cutting edge 103a can be moved relative to the first plane 129A, forming the third plane 129C through the cutting edge 103a, and forming the third corner 131C between the second plane 129B and the third plane 129C through the first end 103e.

[0185] In this case, for example, because both the plane and the corner are formed simultaneously, machining can be performed efficiently. When the cutting edge 103a is moved toward the second plane 129B to form the first plane 129A (first step), there is a possibility that chips may remain at the location where the second corner 131B should be. However, since the second corner 131B is formed in the subsequent second step, these chips can be removed.

[0186] A tool 101 can be mounted on the spindle 7 of a machining center 1 that can simultaneously control three linear axes and two rotary axes.

[0187] In this case, for example, by using two rotating axes to change the orientation of the tool 101 and the mold 121, the orientations of the multiple recesses 125 can be made different from each other. Therefore, for example, when forming multiple recesses 125 with the same shape and size, the amount of linear three-axis movement during the formation of each recess 125 (except for the positioning corresponding to the different positions of the multiple recesses 125) can be made the same among the multiple recesses 125. As a result, for example, the creation of NC programs or teach data becomes easier. In addition, for example, it is easier to reduce the deviation of the errors of the multiple recesses 125.

[0188] Multiple recesses 125 may include two or more recesses 125 with different orientations of the optical axis. Figure 9 , Figure 10 , Figures 12-14 ).

[0189] As a method for forming multiple recesses 125 that differs from the embodiment, an example is a method of forming a bundle of pins with triangular pyramidal tips, and then forming a mold at the tips of the bundle by electroforming. Compared to such a method, the method for forming multiple recesses 125 in the embodiment uses a tool 101 to form multiple recesses 125 individually, thus making it easy to achieve two or more recesses 125 with different orientations.

[0190] Mold 121 including recesses 125 facing different directions, for example from Figure 9 and Figure 10 It is understood that the RR, located at the rear of the vehicle, can be used to integrally form a protrusion 117 capable of reflecting light from the rear and a protrusion 117 capable of reflecting light from the side. Additionally, for example, as from... Figure 12 and Figure 13 As understood, the mold 121, including the recesses 125 facing different directions, can be used as a reflector to homogenize light from a light source (e.g., a component that reflects light from a car's headlights outwards). Additionally, for example, as from... Figure 14 As understood, molds 121, including recesses 125 facing different directions, can be used to achieve a technique, such as a cylindrical lens, where different patterns are seen depending on the viewing direction.

[0191] Multiple recesses 125 may include two or more recesses 125 with different inner surface areas. Figures 11-14 ).

[0192] Similar to the two or more recesses 125 with different orientations described above, the method for forming multiple recesses 125 in the embodiment uses a cutting tool 101 to form multiple recesses 125 individually, thus making it easy to realize two or more recesses 125 with different sizes.

[0193] A mold 121, including recesses 125 of different sizes, is provided, for example, at the rear of a vehicle, and can be used to integrally form an RR including protrusions 117 of different sizes. By making the multiple protrusions 117 of different sizes, the appearance design of the vehicle can be improved, for example. In addition, by combining this with things that have different orientations, it is possible to set performance suitable for reflecting light from the rear and performance suitable for reflecting light from the sides, respectively.

[0194] Multiple recesses 125 may include two or more recesses 125 with different shapes. Figures 12-14 ).

[0195] The method for forming the plurality of recesses 125 in this embodiment uses a tool 101 to individually form the plurality of recesses 125, thus making it easy to achieve two or more recesses 125 with different shapes. With such a plurality of recesses 125, for example, it is easy to impart randomness to the reflection pattern of the plurality of recesses 125 (…). Figure 12 and Figure 13 Furthermore, for example, it is easy to maintain the regularity of the arrangement of multiple recesses 125, and to make the orientation of the optical axis different from each other. Figure 14 ).

[0196] Multiple recesses 125 may include two or more recesses 125 arranged along a curved surface. Figure 10 ).

[0197] The method for forming the plurality of recesses 125 in this embodiment uses a tool 101 to individually form the plurality of recesses 125, thus making it easy to realize two or more recesses 125 arranged along a curved surface. A mold 121 including the recesses 125 arranged along a curved surface is provided, for example, at the rear of a vehicle, and can be used to integrally form a RR extending from the rear to the side. In this case, for example, the RR of the vehicle can be set to any curved surface, thereby easily improving the vehicle's exterior design.

[0198] The orientation of the optical axis of the multiple recesses 125 can be random. Figure 12 and Figure 13 ).

[0199] The method of forming the plurality of recesses 125 in the embodiment uses a cutting tool 101 to form the plurality of recesses 125 individually, thus making it easy to realize a plurality of recesses 125 with random orientation. The mold 121 including a plurality of recesses 125 with random orientation can be used, for example, to manufacture a reflector for the purpose of homogenizing light.

[0200] In another example, the manufacturing method of the reflector 111 in the embodiment is a method for manufacturing a reflector 111 that reflects light, and includes a cutting step in which a plurality of recesses 115 constituting the reflective surface 113 of the reflector 111 are formed by cutting (see the figure of cutting the mold 121, see figure). Figure 7 The cutting step includes a planing step, in which multiple recesses 115 are cut by relative movement of the tool 101 relative to the reflector 111 without the tool 101 rotating or vibrating.

[0201] In this case, it also has the same effect as the case described above where the reflector 111 is formed via mold 121.

[0202] It should be noted that in the above embodiments, mold 121 is an example of a mold for forming a reflector. Tool 101 is an example of a cutting tool.

[0203] The technology disclosed herein is not limited to the embodiments described above and can be implemented in various ways. For example, it can also be formed by planing only a portion of the multiple faces of the inner surface of the recess of the mold.

[0204] Inventions that do not require planing, reflectors, or multiple recesses can be extracted from this disclosure. For example, an invention describing a method for manufacturing a mold that forms two or more recesses 125 of different shapes and / or sizes by cutting without planing can be extracted. Additionally, for example, a method for manufacturing a mold that uses the cutting tool 101 of the embodiment for rotary cutting can be extracted.

[0205] Explanation of reference numerals in the attached figures

[0206] 111: Reflector, 113: Reflecting surface, 115: (Reflector) Recess, 117: (Reflector) Protrusion, 121: Mold (Mold for forming reflector), 123: (Mold) Inner surface, 125: (Mold) Recess.

Claims

1. A method for manufacturing a mold for forming a reflector, the mold forming a reflector for reflecting light, characterized in that, It includes a cutting step, in which multiple recesses are formed on the inner surface of the mold, thereby creating an uneven surface on the reflective surface of the reflector. The cutting step includes a planing step, in which the plurality of recesses are cut by the relative movement of the cutting tool relative to the mold without the tool rotating or vibrating.

2. The method for manufacturing a mold for forming a reflector according to claim 1, characterized in that, The tool has a cutting edge extending in a direction intersecting the centerline of the tool holder. When the two ends of the cutting edge are referred to as the first end and the second end, the distance from the first end to the center line is shorter than the distance from the second end to the center line. The ridge extending from the first end toward the handle side slopes in such a way that the closer it is to the handle side, the more it is located on the second end side.

3. The method for manufacturing a mold for forming a reflector according to claim 2, characterized in that, The first end is located at the center line. The ridge is inclined such that the closer to the handle side, the further away from the center line.

4. The method for manufacturing a mold for forming a reflector according to claim 1, characterized in that, In the planing step, all the surfaces of the plurality of concave portions are cut by the same straight cutting edge of the tool.

5. The method for manufacturing a mold for forming a reflector according to claim 4, characterized in that, In each of the plurality of recesses, all corners between adjacent surfaces are cut by the first end of the first end and the second end of the cutting edge.

6. The method for manufacturing a mold for forming a reflector according to claim 5, characterized in that, The plurality of concave portions each have a first plane, a second plane, and a third plane that are orthogonal to each other. The planing step has the following characteristics: The first step involves moving the cutting edge relative to a predetermined position for forming the second plane, forming the first plane through the cutting edge, and forming the corner between the third plane and the first plane through the first end; The second step, after the first step, involves moving the cutting edge relative to the predetermined position for forming the third plane, forming the second plane through the cutting edge, and forming the corner between the first plane and the second plane through the first end; The third step, after the second step, involves moving the cutting edge relative to the first plane, forming the third plane through the cutting edge, and forming the corner between the second plane and the third plane through the first end.

7. The method for manufacturing a mold for forming a reflector according to claim 4, characterized in that, The cutting tool is mounted on the spindle of a machining center capable of simultaneously controlling three linear axes and two rotary axes.

8. The method for manufacturing a mold for forming a reflector according to claim 1, characterized in that, The plurality of recesses includes two or more recesses with different orientations of the optical axis.

9. The method for manufacturing a mold for forming a reflector according to claim 1, characterized in that, The plurality of recesses includes two or more recesses with different areas on their inner surfaces.

10. The method for manufacturing a mold for forming a reflector according to claim 1, characterized in that, The plurality of recesses includes two or more recesses with different shapes.

11. The method for manufacturing a mold for forming a reflector according to claim 1, characterized in that, The plurality of recesses includes two or more recesses arranged along the curved surface.

12. The method for manufacturing a mold for forming a reflector according to claim 1, characterized in that, The orientation of the optical axis of the plurality of recesses is random.

13. A method for manufacturing a reflector, wherein the reflector is formed using a mold manufactured by the method for manufacturing a mold for forming a reflector as described in claim 1.

14. A method for manufacturing a reflector, wherein the reflector reflects light, characterized in that, The process includes a cutting step that forms multiple recesses constituting the reflective surface of the reflector through cutting. The cutting step includes a planing step, in which the plurality of recesses are cut by relative movement of the tool relative to the reflector without the tool rotating or vibrating.

15. A cutting tool, characterized in that, It has a cutting edge that extends in a direction intersecting the centerline of the tool holder. When the two ends of the cutting edge are referred to as the first end and the second end, the distance from the first end to the center line is shorter than the distance from the second end to the center line. The ridge extending from the first end toward the handle side slopes in such a way that the closer it is to the handle side, the more it is located on the second end side.

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