Method for processing embossment molding die
The use of smaller diameter cutting tools rotating around central axes for embossed plates efficiently processes convex and concave portions, reducing processing time and control data needs, enhancing rigidity and density, and lowering costs.
Patent Information
- Application Number
- JP2023119526
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2023-07-22
- Publication Date
- 2025-02-03
- Estimated Expiration
- 2043-07-22
AI Technical Summary
Existing methods for processing embossed plates with circular convex portions require multiple tools and extensive processing time, necessitating large amounts of control data and man-hours due to complex 3-axis position control.
A method using smaller diameter convex and concave cutting tools, each rotating around a central axis, to efficiently cut and form large and small diameter convex portions on an embossed plate, reducing the need for multiple tools and control data by simplifying the cutting process.
This approach significantly reduces processing time and control data requirements by 95% and 85%, while increasing the rigidity and density of the embossed plate, and decreases tool costs by 45%, all while maintaining the shape integrity of the embossed design.
Smart Images
Figure 2025016409000001_ABST
Abstract
Description
[Technical field]
[0001] The present invention relates to a method for producing an embossing die for forming an embossed plate on which a plurality of circular protrusions are regularly arranged. [Background technology]
[0002] Embossed plates on which a number of circular protrusions are regularly arranged are known. For example, Patent Document 1 discloses an embossed plate in which a number of (six) small-diameter circular protrusions are arranged at equal intervals around a large-diameter circular protrusion formed at equal intervals. Such a round-protrusion embossed plate is formed by pressing using a pair of dies. [Prior art documents] [Patent documents]
[0003] [Patent Document 1] JP 2000-136720 A Summary of the Invention [Problem to be solved by the invention]
[0004] Incidentally, when machining the convex part of the molding die for forming the embossed plate described in the above Patent Document 1, a three-axis cutting machine is used that can control the position of the ball end mill in three axial directions while rotating the ball end mill. In this case, when scanning and cutting the surface of the molding die while controlling the position of the ball end mill, there are drawbacks in that different types of tools for rough cutting, semi-finishing, and finishing are required for each of the rough cutting, semi-finishing, and finishing processes, and a lot of machining time is required for each machining process. In addition, there is a drawback in that large-sized control data used for three-axis position control is required for each machining process, and a lot of man-hours are required to create the control data.
[0005] The present invention has been made against the background of the above circumstances, and its object is to provide a method for machining an embossing mold that can machine the mold in a short processing time using fewer types of tools, and that can reduce the size of the control data used for three-axis position control, thereby reducing the labor required to create that control data. [Means for solving the problem]
[0006] The gist of a first invention is (a) a method for processing an embossing mold consisting of a convex mold and a concave mold for press-molding an embossing plate in which a plurality of small diameter convex portions having diameters smaller than those of large diameter convex portions are arranged at equal intervals in the circumferential direction around large diameter convex portions arranged at predetermined intervals, (b) a large diameter convex portion cutting tool having a large diameter convex portion cutting edge having a concave shape corresponding to the cross-sectional shape of the large diameter convex portion, and a large diameter convex portion outer peripheral cutting edge having a shape corresponding to a flat portion of the outer periphery of the large diameter convex portion formed subsequent to the large diameter convex portion cutting edge, the large diameter convex portion being driven to rotate about a rotation center line passing through a center of the large diameter convex portion cutting edge, and a small diameter convex portion cutting edge having a concave shape corresponding to the cross-sectional shape of the small diameter convex portion ... large diameter convex portion outer peripheral cutting edge having a shape corresponding to the flat portion of the outer periphery of the small diameter convex portion formed subsequent to the small diameter convex portion cutting edge, and a small diameter convex portion cutting tool having a small diameter convex portion outer peripheral cutting edge and driven to rotate about a rotation center line passing through the center of the small diameter convex portion cutting edge; (c) a large diameter convex portion forming protrusion cutting step of moving the large diameter convex portion cutting tool back and forth in the direction of the rotation center line with the rotation center line of the large diameter convex portion cutting tool perpendicular to the molding surface of the convex mold, thereby cutting a large diameter convex portion forming protrusion of a shape corresponding to the large diameter convex portion onto the molding surface of the convex mold; and (d) a small diameter convex portion forming protrusion cutting step of moving the small diameter convex portion cutting tool back and forth in the direction of the rotation center line with the rotation center line of the small diameter convex portion cutting tool perpendicular to the molding surface of the convex mold, thereby cutting a small diameter convex portion forming protrusion of a shape corresponding to the small diameter convex portion onto the molding surface of the convex mold.
[0007] The gist of the second invention is that in the first invention, the large-diameter convex portion cutting blade of the large-diameter convex portion cutting tool is provided with a vertical cutting edge portion for forming an annular vertical wall surface perpendicular to the molding surface of the convex mold on the peripheral edge of the large-diameter convex portion forming projection cut by the large-diameter convex portion cutting edge.
[0008] The gist of the third invention is a method for cutting a large diameter hole having a concave shape corresponding to the cross-sectional shape of the large diameter convex portion, and a large diameter outer peripheral cutting edge having a shape corresponding to a flat portion on the outer periphery of the large diameter convex portion formed subsequent to the large diameter concave hole cutting edge, the method being rotationally driven around a rotation center line passing through the center of the large diameter concave hole cutting edge; and a small diameter concave hole cutting edge having a convex shape corresponding to the cross-sectional shape of the small diameter convex portion, and a small diameter outer peripheral cutting edge having a shape corresponding to the flat portion on the outer periphery of the small diameter convex portion formed subsequent to the small diameter concave hole cutting edge, the method being rotationally driven around a rotation center line passing through the center of the small diameter concave hole cutting edge. (g) a large diameter convexity forming recessed hole cutting step of reciprocating the large diameter concave hole cutting tool in the direction of the rotation center line with the rotation center line of the large diameter concave hole cutting tool perpendicular to the molding surface of the concave mold, thereby cutting a large diameter convexity forming recessed hole of a shape corresponding to the large diameter convexity in the molding surface of the concave mold; and (h) a small diameter convexity forming recessed hole cutting step of reciprocating the small diameter concave hole cutting tool in the direction of the rotation center line with the rotation center line of the small diameter concave hole cutting tool perpendicular to the molding surface of the concave mold, thereby cutting a small diameter convexity forming recessed hole of a shape corresponding to the small diameter convexity in the molding surface of the concave mold.
[0009] The gist of a fourth invention is that in the first invention, the embossed plate is formed with a first row in which the large diameter convex portion and the small diameter convex portion are alternately arranged at equal center intervals in the X direction, and a second row in which the small diameter convex portions are arranged at the equal center intervals in the X direction and are arranged in the Y direction at an interval equal to or smaller than the equal center intervals with respect to the first row, the first row being alternately formed in the Y direction, two of the small diameter convex portions in the second row are positioned between the centers in the X direction of the large diameter convex portions in the first row, and the small diameter convex portions have a smaller diameter and radius of curvature than the large diameter convex portions. Effect of the Invention
[0010] According to the processing method for an embossing mold of the first invention, the process includes a large diameter protrusion forming protrusion cutting process in which the large diameter protrusion cutting tool is moved back and forth in the direction of the rotation center line with the rotation center line of the large diameter protrusion cutting tool perpendicular to the molding surface of the convex mold, and a large diameter protrusion forming protrusion of a shape corresponding to the large diameter protrusion is cut onto the molding surface of the convex mold, and a small diameter protrusion forming protrusion cutting process in which the small diameter protrusion cutting tool is moved back and forth in the direction of the rotation center line with the rotation center line of the small diameter protrusion cutting tool perpendicular to the molding surface of the convex mold, and a small diameter protrusion forming protrusion of a shape corresponding to the small diameter protrusion is cut onto the molding surface of the convex mold. As a result, in the large diameter protrusion forming protrusion cutting step, a large diameter protrusion forming protrusion having a shape corresponding to the large diameter protrusion is cut onto the molding surface of the convex mold by only moving the large diameter protrusion cutting tool in the direction of the rotation center line, and in the small diameter protrusion forming protrusion cutting step, a small diameter protrusion forming protrusion having a shape corresponding to the small diameter protrusion is cut onto the molding surface of the convex mold by only moving the small diameter protrusion cutting tool in the direction of the rotation center line. This makes it possible to machine the convex mold in a short cutting processing time by only moving the cutting tool in the direction of the rotation center line using two types of tools, which are fewer than conventionally, and the size of the control data used for three-axis position control can be reduced corresponding to the short processing time with a simpler movement direction than conventionally, and the number of steps required to create the control data can be reduced.
[0011] According to the processing method for an embossing die of the second invention, the large diameter protrusion cutting blade of the large diameter protrusion cutting tool is provided with a vertical cutting blade portion for forming an annular vertical wall surface perpendicular to the molding surface of the convex mold at the peripheral portion of the large diameter protrusion forming protrusion cut by the large diameter protrusion cutting blade, and the diameter of the large diameter protrusion forming protrusion cut into the molding surface of the convex mold can be reduced, so that the density of the number of large diameter protrusion forming protrusions and small diameter protrusion forming protrusions can be increased, and the density of the large diameter protrusions and small diameter protrusions of the embossing plate can be increased to increase the rigidity of the embossing plate. Also, the outer diameter of the small diameter protrusion cutting tool, which is limited so as not to interfere with the large diameter protrusion forming protrusion, can be enlarged, eliminating the remaining cutting portion. Furthermore, when the embossed plate is press-molded between the convex mold and the concave mold, the shapes of the large diameter convex portion and the small diameter convex portion of the embossed plate are formed along the shapes of the large diameter convex portion forming recessed hole and the small diameter convex portion forming recessed hole formed in the concave shape, so there is no need to apply a large load to fill the gaps formed on the outer periphery of the annular vertical wall surface of the large diameter convex portion forming protrusion and the gaps formed on the outer periphery of the small diameter convex portion forming protrusion, and press molding can be performed with a small press load.
[0012] According to the third invention, the processing method for an embossing mold includes a large diameter convexity forming recessed hole cutting process in which the large diameter concave hole cutting tool is moved back and forth in the direction of the rotation center line with the rotation center line of the large diameter concave hole cutting tool perpendicular to the molding surface of the concave mold, and a large diameter convexity forming recessed hole of a shape corresponding to the large diameter convexity is cut into the molding surface of the concave mold, and a small diameter convexity forming recessed hole cutting process in which the small diameter concave hole cutting tool is moved back and forth in the direction of the rotation center line with the rotation center line of the small diameter concave hole cutting tool perpendicular to the molding surface of the concave mold, and a small diameter convexity forming recessed hole of a shape corresponding to the small diameter convexity is cut into the molding surface of the concave mold. As a result, in the large diameter convex portion forming recessed hole cutting process, a large diameter convex portion forming recessed hole having a shape corresponding to the large diameter convex portion is cut in the molding surface of the concave mold only by moving the large diameter concave hole cutting tool in the rotation center line direction, and in the small diameter convex portion forming recessed hole cutting process, a small diameter convex portion forming recessed hole having a shape corresponding to the small diameter convex portion is cut in the molding surface of the concave mold only by moving the small diameter concave hole cutting tool in the rotation center line direction with the rotation center line perpendicular to the molding surface of the concave mold. This makes it possible to machine the concave mold in a short cutting processing time by only moving the cutting tool in the rotation center line direction using two types of tools, which are fewer than conventionally, and the size of the control data used for three-axis position control can be reduced corresponding to a short processing time with a simpler moving direction than conventionally, and the number of steps required for creating the control data can be reduced.
[0013] According to a fourth aspect of the present invention, the embossing plate has a first row in which the large diameter convex portions and the small diameter convex portions are alternately arranged at equal center intervals in a first direction, and a second row in which the small diameter convex portions are arranged at the equal center intervals in the first direction and arranged in a second direction perpendicular to the first direction at an interval equal to or smaller than the equal center intervals relative to the first row, the first row being alternately arranged in the second direction, two small diameter convex portions among the small diameter convex portions in the second row are positioned between the centers of the large diameter convex portions in the first row in the first direction, and the small diameter convex portions have a smaller diameter and radius of curvature than the large diameter convex portions. This makes it possible to ensure sufficient rigidity without increasing the plate thickness. [Brief description of the drawings]
[0014] [Figure 1] FIG. 1 is a perspective view illustrating a product made of an embossed plate press-molded using an embossing die processed by a processing method according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a diagram illustrating an embossing die for forming the embossed plate of FIG. 1. [Diagram 3] 2 is an enlarged plan view for explaining a main part of the embossing plate of FIG. 1. [Figure 4] 4 is a cross-sectional view of the embossing plate of FIG. 2 taken along line IV-IV of FIG. 2. [Diagram 5] 3 is a cross-sectional view of the embossing plate of FIG. 2 taken along the line V-V of FIG. 2. [Figure 6] FIG. 1 is a diagram illustrating a ball end mill, which is a tool used in a conventional method for machining an embossing die. [Figure 7] FIG. 1 is a perspective view showing a conventional method for machining a convex mold of an embossing die using a ball end mill. [Figure 8] FIG. 1 is a perspective view showing a conventional method for machining a concave mold of an embossing die using a ball end mill. [Figure 9] FIG. 2 is a process diagram illustrating a method for processing a convex mold in an embossing mold processing method according to an embodiment of the present invention. [Figure 10] FIG. 2 is a process diagram illustrating a method for processing a concave mold in an embossing die according to an embodiment of the present invention. [Figure 11] 10 is a diagram illustrating a large-diameter protrusion cutting tool prepared in the large-diameter protrusion cutting tool preparation step of FIG. 9. FIG. [Figure 12] 10 is a diagram illustrating a small diameter convex portion cutting tool prepared in the small diameter convex portion cutting tool preparation step of FIG. 9 . FIG. [Figure 13] 10 is a perspective view illustrating a large diameter protrusion forming protrusion cutting step and a small diameter protrusion forming protrusion cutting step of FIG. 9. [Figure 14] 10 is an enlarged cross-sectional view showing a main part of a cross section of a convex mold cut using the convex processing method of FIG. 9. [Figure 15] 15 is a plan view illustrating cutting using the convex machining method of FIG. 14. [Figure 16] FIG. 10 is an enlarged cross-sectional view showing a main portion of a cross section of a convex mold machined using the convex mold machining method of FIG. 9, showing the case where a ring-shaped vertical wall surface is formed on the outer periphery of a machined large diameter convex portion forming protrusion. [Figure 17] 17 is a plan view illustrating cutting using the convex machining method of FIG. 16. FIG. [Figure 18] 22 is an enlarged cross-sectional view for explaining a state in which an embossing plate is pressed between a convex mold having a large-diameter convex portion forming projection with an annular vertical wall surface formed thereon, as shown in FIG. 16, and a concave mold shown in FIG. 21. FIG. [Figure 19] 11 is a diagram illustrating a large-diameter recessed hole cutting tool prepared in the large-diameter recessed hole cutting tool preparation step of FIG. 10 . FIG. [Figure 20] 11 is a diagram illustrating a small-diameter recessed hole cutting tool prepared in the small-diameter recessed hole cutting tool preparation step of FIG. 10. FIG. [Figure 21] 11 is a perspective view illustrating a large-diameter protrusion-forming recess hole cutting step and a small-diameter protrusion-forming recess hole cutting step shown in FIG. 10. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] An embodiment of the present invention will now be described with reference to the drawings. EXAMPLES
[0016] FIG. 1 is a perspective view illustrating an embossed product INS formed from an embossing plate 10. This embossed product INS is bent to cover, for example, an exhaust pipe EP of a vehicle, and functions as an insulator that blocks heat from reaching the vehicle body by being fixed to a vehicle body (not shown) near the exhaust pipe EP. The embossing plate 10 is made of a thin metal plate having a thickness of, for example, about 0.4 mm, such as stainless steel or aluminum, and is formed by pressing using an embossing mold (hereinafter, referred to as a molding mold) 12 shown in FIG. 2. The molding mold 12 is composed of a convex mold 14 and a concave mold 16 made of, for example, tool steel. In FIG. 2, the convex mold 14 is used as a lower mold, and the concave mold 16 is used as an upper mold.
[0017] FIG. 3 is an enlarged plan view of the embossing plate 10. FIG. IV-IV 5 is a cross-sectional view taken along line VV of Fig. 3. In order to increase the rigidity of the embossed plate 10, a plurality of partially spherical large diameter protrusions 18 each having a predetermined outer diameter D1 in a plan view and protruding in the Z direction, and a plurality of partially spherical small diameter protrusions 20 each having a diameter D2 smaller than the outer diameter D1 and protruding in the Z direction are formed by press working. In the embossed plate 10, a first row L1 in which the large diameter convex portion 18 and the small diameter convex portion 20 are alternately arranged at equal center intervals D1 in the X direction, which is a first direction, and a second row L2 in which the small diameter convex portions 20 are arranged at equal center intervals D1 in the X direction and are parallel to the first row L1 are alternately arranged in the Y direction, which is a second direction perpendicular to the first direction, and are arranged at intervals equal to or less than the equal center intervals or slightly shorter than the equal center intervals, for example, (7 / 8) D1. Two small diameter convex portions 20 of the small diameter convex portions 20 in the second row L2 are located between the centers of the large diameter convex portions 18 in the first row L1 in the X direction, and the outer diameter D2 of the small diameter convex portions 20 is smaller than the outer diameter D1 of the large diameter convex portions 18, for example, about 73%. The radius of curvature R2 of the small diameter convex portions 20 is smaller than the radius of curvature R1 of the large diameter convex portions 18, for example, about 73%.
[0018] The molding surface 14a of the convex mold 14 is formed with large diameter convex portion forming protrusions 22 and small diameter convex portion forming protrusions 24 which protrude with shapes and intervals corresponding to the large diameter convex portion 18 and the small diameter convex portion 20, respectively. In addition, the molding surface 16a of the concave mold 16 is formed with large diameter convex portion forming recessed holes 26 and small diameter convex portion forming recessed holes 28 which are recessed with shapes and intervals corresponding to the large diameter convex portion 18 and the small diameter convex portion 20, respectively. The large diameter convex portion 18 is machined by pressing the large diameter convex portion forming protrusions 22 into the large diameter convex portion forming recessed holes 26 with the embossing plate 10 sandwiched therebetween, and the small diameter convex portion 20 is machined by pressing the small diameter convex portion forming protrusions 24 into the small diameter convex portion forming recessed holes 28 with the embossing plate 10 sandwiched therebetween.
[0019] Conventionally, the convex mold 14 of the molding die 12 was formed by cutting the large-diameter convex portion forming protrusion 22 and the small-diameter convex portion forming protrusion 24 using three types of ball end mills 30 with tip curvature radii of 3 mmφ, 5 mmφ, and 6 mmφ as shown in FIG. 6. FIG. 7 is a perspective view explaining this cutting process. In this case, the ball end mill 30 is moved forward while changing the up-down position (Z-direction position) along a cutting path in the X direction, for example, and then moved a predetermined feed pick (for example, 0.3 mm) in the Y direction, and then moved backward along a new cutting path parallel to the above cutting path. Such XYZ position control of the ball end mill requires a data size of 1.368 GB if the molding surface 14a of the convex mold 14 is 700 mm x 1200 mm, and requires a long data creation time and a long cutting process time.
[0020] FIG. 8 is a perspective view for explaining cutting of the concave mold 16 by the ball end mill. In this case, as in the case of the convex mold 14 in FIG. 7, the ball end mill 30 is moved forward, for example, along a cutting path in the X direction while changing its up-down position (Z direction position), and then moved a predetermined feed pick (for example, 0.3 mm) in the Y direction, and then moved backward along a new cutting path parallel to the above cutting path. In this case, as in the case of the convex mold 14, the XYZ position control of the ball end mill required a large data size of 0.932 GB, assuming that the concave mold 16 is 700 mm x 1200 mm, and required a long data creation time and a long cutting processing time. In the end, a large data size of 2.3 GB was required for the convex mold 14 and the concave mold 16.
[0021] Fig. 9 is a process diagram illustrating a method for processing the convex die 14 of the embossing die of this embodiment. Fig. 10 is a process diagram illustrating a method for processing the concave die 16 of the embossing die of this embodiment.
[0022] In FIG. 9, in the large diameter convex cutting tool preparation step P1, for example, a large diameter convex cutting tool 32 shown in FIG. 11 is prepared. The large diameter convex cutting tool 32 is an axial concave cutting blade cutting tool that is rotationally driven around its rotation center line C1. The large diameter convex cutting tool 32 includes a large diameter convex cutting edge 34, which is a concave cutting edge having a concave shape corresponding to the convex cross-sectional shape of the large diameter convex forming protrusion 22 of the convex mold 14, and a large diameter convex outer peripheral cutting edge 36 having a flat shape corresponding to the flat part of the outer periphery of the large diameter convex 18 formed following the large diameter convex cutting edge 34, and is rotationally driven around the rotation center line C1 passing through the center of the large diameter convex cutting edge 34. A rake face 38 is formed on the upstream side of the large diameter convex cutting edge 34 and the large diameter convex outer peripheral cutting edge 36 of the large diameter convex cutting tool 32 in the rotation direction.
[0023] In the small diameter convex cutting tool preparation process P2, for example, a small diameter convex cutting tool 40 shown in FIG. 12 is prepared. The small diameter convex cutting tool 40 is an axial concave cutting blade cutting tool that is rotationally driven around its rotation center line C2. The small diameter convex cutting tool 40 includes a small diameter convex cutting edge 42, which is a concave cutting edge having a concave shape corresponding to the convex cross-sectional shape of the small diameter convex forming protrusion 24 of the convex mold 14, and a small diameter convex outer peripheral cutting edge 44 having a flat shape corresponding to the flat part of the outer periphery of the small diameter convex 20 formed following the small diameter convex cutting edge 42, and is rotationally driven around the rotation center line C2 passing through the center of the small diameter convex cutting edge 42. A rake face 46 is formed on the upstream side of the small diameter convex cutting edge 42 and the small diameter convex outer peripheral cutting edge 44 of the small diameter convex cutting tool 40 in the rotation direction. In this embodiment, the large diameter convex cutting tool preparation process P1 and the small diameter convex cutting tool preparation process P2 correspond to the concave cutting blade cutting tool. Note that the large diameter convex cutting tool preparation process P1 and the small diameter convex cutting tool preparation process P2 may be performed in any order.
[0024] 13, in the large diameter protrusion forming protrusion cutting process P3, the large diameter protrusion cutting tool 32 is controlled in XY position so that its rotation center line C1 coincides with a preset center point PA of the large diameter protrusion forming protrusion 22, and is moved forward and backward in the Z direction toward the convex mold 14 while rotated, thereby forming the large diameter protrusion forming protrusion 22 and its surrounding large diameter protrusion forming protrusion outer peripheral flat portion 22a on the molding surface 14a of the convex mold 14. This type of cutting process is repeated for each center point PA of the large diameter protrusion forming protrusion 22 on the convex mold 14.
[0025] 13, in the small diameter protrusion forming protrusion cutting process P4, the small diameter protrusion cutting tool 40 is controlled in XY position so that its rotation center line C2 coincides with a preset center point PB of the small diameter protrusion forming protrusion 24, and is moved forward and backward in the Z direction toward the convex mold 14 while rotated, thereby forming the small diameter protrusion forming protrusion 24 and its surrounding small diameter protrusion forming protrusion outer peripheral flat portion 24a on the molding surface 14a of the convex mold 14. This cutting process is repeated for each center point PB of the small diameter protrusion forming protrusion 24 on the convex mold 14. It does not matter which of the large diameter protrusion forming protrusion cutting process P3 and the small diameter protrusion forming protrusion cutting process P4 is performed first.
[0026] According to the machining process of the convex mold 14 of the present embodiment, the following remarkable effects were obtained compared to the conventional cutting method using the above-mentioned three types of ball end mills. That is, in the case of machining the convex mold 14 with a molding surface 14a of 700 mm x 1200 mm, it is only necessary to move the two types of large-diameter convex cutting tool 32 and small-diameter convex cutting tool 40 forward and backward in the Z direction to cut the convex mold 14, so machining can be performed in a short machining time, and the size of the control data used for axis position control is a simpler moving direction than before, so the machining time can be shortened by 95%. Correspondingly, the control data for machining can be significantly reduced from 1.368 GB to 64 KB, and the man-hours required for creating the control data can be reduced by 85%. In addition, the tool cost can be reduced by 45%.
[0027] 14 shows a cross section of a molding surface 14a of a convex mold 14 having large diameter convex-forming protrusions 22 cut in large diameter convex-forming protrusion cutting step P3 and their surrounding large diameter convex-forming protrusion outer peripheral flat portion 22a, and small diameter convex-forming protrusions 24 cut in small diameter convex-forming protrusion cutting step P4 and their surrounding small diameter outer peripheral convex-forming protrusion flat portion 24a. On the molding surface 14a of the convex mold 14, the large diameter convex-forming protrusion outer peripheral flat portion 22a and the small diameter convex-forming protrusion outer peripheral flat portion 24a are at the same height. In this case, if an attempt is made to increase the number density of the large diameter convex portion forming protrusions 22 that form the large diameter convex portions 18 of the embossed plate 10 and the small diameter convex portion forming protrusions 24 that form the small diameter convex portions 20 of the embossed plate 10 in order to increase the rigidity of the embossed plate 10, the outer diameter d32 of the large diameter convex portion cutting tool 32 is limited so as not to interfere with the small diameter convex portion forming protrusions 24, and the outer diameter d40 of the small diameter convex portion cutting tool 40 is limited so as not to interfere with the large diameter convex portion forming protrusions 22, so that as shown in Figure 15, a cutting remaining portion 48 is formed between the large diameter convex portion forming protrusion outer peripheral flat portion 22a and the small diameter convex portion forming protrusion outer peripheral flat portion 24a, and the improvement in the rigidity of the embossed plate 10 may be limited.
[0028] In contrast, preferably, as shown in Fig. 11, a vertical cutting edge 34a parallel to the rotation center line C1 is formed at the outer peripheral end of the large diameter convex portion cutting edge 34 of the large diameter convex portion cutting tool 32, and the diameter d341 of the large diameter convex portion cutting edge 34 is made smaller than the diameter d34 in the case where the vertical cutting edge 34a is not present. As a result, as shown in Figs. 16 and 17, an annular vertical wall surface 22b perpendicular to the molding surface 14a of the convex mold 14 is formed on the outer peripheral portion of the large diameter convex portion forming projection 22 cut by the large diameter convex portion cutting edge 34. On the molding surface 14a of the convex mold 14, the outer diameter d341 of the large diameter convex portion forming projection 22 is formed smaller than the outer diameter d34 of the large diameter convex portion forming projection 22 without the annular vertical wall surface 22b shown in Figs. 14 and 15. 17, the outer diameter d401 of the small-diameter protrusion cutting tool 40, which is limited so as not to interfere with the large-diameter protrusion forming protrusion 22, can be enlarged from the diameter d40 in FIG. 15, and the cutting remaining portion 48 is eliminated, so that the density of the large-diameter protrusion 18 and the small-diameter protrusion 20 of the embossed plate 10 can be increased to further improve the rigidity. Note that the present inventors have found that there is no change in the shape of the large-diameter protrusion 18 press-formed by the large-diameter protrusion forming protrusion 22 on which the annular vertical wall surface 22b is formed, and the height of the annular vertical wall surface 22b or the reduction value (=d34-d341) of the diameter d341 of the large-diameter protrusion forming protrusion 22 due to the formation of the annular vertical wall surface 22b is set within a range that does not affect the shape of the large-diameter protrusion 18 press-formed.
[0029] When the embossed plate 10 is press-molded between the convex mold 14 and the concave mold 16, the outer peripheral shape of the large diameter convex portion 18 of the embossed plate 10 is formed along the shape of the concavely formed large diameter convex portion forming recessed hole 26, so that it is not necessary to apply a large load to close the gap SP formed on the outer peripheral side of the annular vertical wall surface 22 of the large diameter convex portion forming protrusion 22, and the large diameter convex portion forming projection 22 can be molded with a small press load. As shown in Fig. 18, the radius of curvature R26 (approximately 1.5 mm) between the large diameter convex portion forming recessed hole 26 of the concave mold 16 and its outer peripheral large diameter convex portion forming recessed hole outer peripheral flat portion 26a is orders of magnitude larger than the radius of curvature R22 (approximately 0.1 mm) of the corner between the annular vertical wall surface 22 of the convex mold 14 and its outer peripheral large diameter convex portion forming protrusion outer peripheral flat portion 22a. Similarly, for the small diameter protrusion 20, the radius of curvature between the small diameter protrusion-forming recessed hole 28 of the recessed die 16 and its outer periphery flat portion 28a of the small diameter protrusion-forming recessed hole is orders of magnitude larger than the radius of curvature (about 0.1 mm) of the corner between the small diameter protrusion-forming protrusion 24 and the small diameter protrusion-forming protrusion outer periphery flat portion 24a. For this reason, when the convex die 14 and the concave die 16 are 200 mm × 200 mm, the press load of 32 t is reduced by 35%.
[0030] Returning to FIG. 10, in the large diameter recessed hole cutting tool preparation process P11, for example, Figure 19 A large diameter recessed hole cutting tool 52 shown in is prepared. The large diameter recessed hole cutting tool 52 is an axial convex cutting blade cutting tool that is rotationally driven around its rotation center line C3. The large diameter recessed hole cutting tool 52 includes a large diameter recessed hole cutting edge 54, which is a convex cutting edge having a convex shape corresponding to the concave cross-sectional shape of the large diameter convex portion forming recessed hole 26 of the recessed mold 16, and a large diameter recessed hole outer peripheral cutting edge 56 having a flat shape corresponding to the flat part of the outer periphery of the large diameter convex portion forming recessed hole 26 formed following the large diameter recessed hole cutting edge 54, and is rotationally driven around the rotation center line C3 passing through the center of the large diameter recessed hole cutting edge 54. A rake face 58 is formed on the upstream side of the large diameter recessed hole cutting edge 54 and the large diameter recessed hole outer peripheral cutting edge 56 of the large diameter recessed hole cutting tool 52 in the rotation direction.
[0031] In the small diameter recessed hole cutting tool preparation process P12, for example, a small diameter recessed hole cutting tool 60 shown in FIG. 20 is prepared. The small diameter recessed hole cutting tool 60 is an axial convex cutting blade cutting tool that is rotated around its rotation center line C4. The small diameter recessed hole cutting tool 60 includes a small diameter recessed hole cutting edge 62, which is a convex cutting edge having a convex shape corresponding to the concave cross-sectional shape of the small diameter convex portion forming recessed hole 28 of the concave mold 16, and a small diameter recessed hole outer peripheral cutting edge 64 having a flat shape corresponding to the flat part of the outer periphery of the small diameter convex portion forming recessed hole 28 formed following the small diameter recessed hole cutting edge 62, and is rotated around the rotation center line C4 passing through the center of the small diameter recessed hole cutting edge 62. A rake face 66 is formed on the upstream side of the small diameter recessed hole cutting edge 62 and the small diameter recessed hole outer peripheral cutting edge 64 of the small diameter recessed hole cutting tool 60 in the rotation direction. In this embodiment, the large diameter recessed hole cutting tool preparation process P11 and the small diameter recessed hole cutting tool preparation process P12 correspond to the convex cutting blade cutting tool. Note that the large diameter recessed hole cutting tool preparation process P11 and the small diameter recessed hole cutting tool preparation process P12 can be performed in any order.
[0032] In the large diameter convex portion forming recess hole cutting process P13, Figure 21 2, the large diameter recessed hole cutting tool 52 is controlled in XY position so that its rotation center line C3 coincides with a preset center point PC of the large diameter protrusion-forming recessed hole 26, and is moved forward and backward in the Z direction toward the concave mold 16 while rotated, thereby forming the large diameter protrusion-forming recessed hole 26 and its surrounding outer peripheral flat portion 26a on the molding surface 16a of the concave mold 16. This type of cutting process is repeated for each center point PC of the large diameter protrusion-forming recessed hole 26 on the concave mold 16.
[0033] In the small diameter convex portion forming recess hole cutting process P14, Figure 211, the small diameter recessed hole cutting tool 60 is controlled in XY position so that its rotation center line C4 coincides with a preset center point PD of the small diameter protrusion-forming recessed hole 28, and is moved forward and backward in the Z direction toward the concave mold 16 while rotated, thereby forming the small diameter protrusion-forming recessed hole 28 and its surrounding small diameter outer peripheral flat portion 28a on the molding surface 16a of the concave mold 16. This cutting process is repeated for each center point PD of the small diameter protrusion-forming recessed hole 28 on the concave mold 16. It is not important whether the large diameter protrusion-forming recessed hole cutting process P13 or the small diameter protrusion-forming recessed hole cutting process P14 is performed first.
[0034] According to the machining process of the concave mold 16 of this embodiment, in comparison with the conventional cutting method using the above-mentioned three types of ball end mills, in the case of machining the concave mold 16 having a molding surface 16a of 700 mm x 1200 mm, it is only necessary to repeat forward and backward movements in the Z direction toward the concave mold 16 side using two types of large diameter concave hole cutting tool 52 and small diameter concave hole cutting tool 60, so machining can be performed in a short machining time, and the size of the control data used for controlling the axis position is a simpler moving direction than in the past, so that the machining time can be significantly shortened as in the case of the convex mold 14. Correspondingly, the control data for machining can be significantly reduced from 0.932 GB to 64 KB, and the man-hours required for creating the control data can also be significantly reduced. In addition, the tool cost can also be reduced. In the end, the control data for machining the above-mentioned convex mold 14 and concave mold 16 was significantly reduced from 2.3 GB to 1284 KB.
[0035] As described above, the processing method for the molding die 12 used for the embossing of this embodiment includes a large diameter protrusion forming protrusion cutting process P3 in which the large diameter protrusion cutting tool 32 is moved back and forth in the direction of the rotation center line C1 while the rotation center line C1 of the large diameter protrusion cutting tool 32 is perpendicular to the molding surface 14a of the convex mold 14, to cut a large diameter protrusion forming protrusion 22 having a shape corresponding to the large diameter protrusion 18 into the molding surface 14a of the convex mold 14, and a small diameter protrusion forming protrusion cutting process P4 in which the small diameter protrusion cutting tool 40 is moved back and forth in the rotation center line direction C2 while the rotation center line C2 of the small diameter protrusion cutting tool 40 is perpendicular to the molding surface 14a of the convex mold 14, to cut a small diameter protrusion forming protrusion 24 having a shape corresponding to the small diameter protrusion 20 into the molding surface 14a of the convex mold 14. As a result, in the large diameter protrusion forming protrusion cutting process P3, the large diameter protrusion forming protrusion 22 having a shape corresponding to the large diameter protrusion 18 is cut into the molding surface 14a of the convex mold 14 only by the reciprocating movement of the large diameter protrusion cutting tool 32 in the direction of the rotation center line C1, and in the small diameter protrusion forming protrusion cutting process P4, the small diameter protrusion forming protrusion 24 having a shape corresponding to the small diameter protrusion 20 is cut into the molding surface 14a of the convex mold 14 only by the reciprocating movement of the small diameter protrusion cutting tool 40 in the direction of the rotation center line C2. As a result, the convex mold 14 can be machined in a short cutting processing time by repeating the forward and backward movements of the two types of cutting tools toward the convex mold 14 in the direction of the rotation center line using two types of tools, which are fewer than conventionally, and the size of the control data used for the position control of the three axes can be reduced corresponding to the short processing time with a simpler moving direction than conventionally, and the number of steps required for creating the control data can be reduced.
[0036] According to the processing method of the molding die 12 used for embossing in this embodiment, the large diameter protrusion cutting edge 34 of the large diameter protrusion cutting tool 32 is provided with a vertical cutting edge portion 34a for forming an annular vertical wall surface 22b perpendicular to the molding surface 14a of the convex mold 14 at the peripheral portion of the large diameter protrusion 18 cut by the large diameter protrusion cutting edge 34, so that it is possible to increase the density of the numbers of the large diameter protrusion forming protrusions 22 and the small diameter protrusion forming protrusions 24 cut into the molding surface 14a of the convex mold 14. Also, the outer diameter of the small diameter protrusion cutting tool 40, which is limited so as not to interfere with the large diameter protrusion forming protrusions 22, can be enlarged, and the remaining cutting portion 48 is eliminated. Furthermore, when the embossed plate 10 is press-molded between the convex mold 14 and the concave mold 16, the outer peripheral shapes of the large diameter convex portion 18 and the small diameter convex portion 20 of the embossed plate 10 are formed along the shapes of the large diameter convex portion forming recessed hole 26 and the small diameter convex portion forming recessed hole 28, which are formed in a concave shape. Therefore, even if there are corners with a small radius of curvature of about 0.1 mmR, there is no need to apply a large load to fill the gap SP formed on the outer peripheral side of the annular vertical wall surface 22 of the large diameter convex portion forming projection 22 or to fill those corners, and molding can be performed with a small press load.
[0037] According to the processing method of the molding die 12 used for the embossing of this embodiment, the process includes a large diameter convexity forming recessed hole cutting process P13 in which a large diameter concave hole cutting tool 52 is moved back and forth in the direction of the rotation center line C3 while the rotation center line C3 of the large diameter concave hole cutting tool 52 is perpendicular to the molding surface 16a of the concave mold 16, to cut a large diameter convexity forming recessed hole 26 of a shape corresponding to the large diameter convexity 18 on the molding surface 16a of the concave mold 16, and a small diameter convexity forming recessed hole cutting process P14 in which a small diameter concave hole cutting tool 60 is moved back and forth in the direction of the rotation center line C4 while the rotation center line C4 of the small diameter concave hole cutting tool 60 is perpendicular to the molding surface 16a of the concave mold 16, to cut a small diameter convexity forming recessed hole 28 of a shape corresponding to the small diameter convexity 20 on the molding surface 16a of the concave mold 16. As a result, in the large diameter convex portion forming recessed hole cutting process P13, the large diameter convex portion forming recessed hole 26 having a shape corresponding to the large diameter convex portion 18 is cut in the molding surface 16a of the concave mold 16 only by the reciprocating movement of the large diameter concave hole cutting tool 52 in the direction of the rotation center line C3, and in the small diameter convex portion forming recessed hole cutting process P14, the small diameter convex portion forming recessed hole 28 having a shape corresponding to the small diameter convex portion 20 is cut in the molding surface 16a of the concave mold 16 only by the reciprocating movement of the small diameter concave hole cutting tool 60 in the direction of the rotation center line C4 while the rotation center line C4 is perpendicular to the molding surface 16a of the concave mold 16. As a result, the concave mold can be machined in a short cutting processing time by only repeating the forward and backward movements of the cutting tool toward the concave mold 16 in the direction of the rotation center line using two types of tools, which are fewer than conventionally, and the size of the control data used for the position control of the three axes can be reduced corresponding to the short processing time with a simpler moving direction than conventionally, and the number of steps required for creating the control data can be reduced.
[0038] According to the processing method of the molding die 12 used for the embossing of this embodiment, the embossed plate 10 has a first row L1 in which the large diameter convex portions 18 and the small diameter convex portions 20 are alternately arranged at equal center intervals in the X direction, and a second row L2 in which the small diameter convex portions 20 are arranged at equal center intervals in the X direction and arranged at intervals equal to or less than the equal center intervals in the Y direction with respect to the first row L1, which are alternately formed in the Y direction, and two of the small diameter convex portions 20 in the second row L2 are located between the centers in the X direction of the large diameter convex portions 18 in the first row L1, and the small diameter convex portions 20 have a diameter and a radius of curvature smaller than those of the large diameter convex portions 18. This makes it possible to ensure sufficient rigidity without increasing the thickness of the embossed plate 10.
[0039] Although the method for machining the molding die 12 has been described above with reference to the drawings, the present invention can be embodied in various forms with various modifications and improvements based on the knowledge of those skilled in the art.
[0040] For example, in the molding die 12 of the above-mentioned embodiment, the convex die 14 is used as the lower die and the concave die 16 is used as the upper die, but the concave die 16 may be used as the lower die and the convex die 14 as the upper die, or the convex die 14 and the concave die 16 may be used as the left and right die that are combined horizontally.
[0041] Furthermore, the large diameter convex portion 18 and the small diameter convex portion 20 provided on the embossed plate 10 in the above-described embodiment were partially spherical in shape with a certain radius of curvature, but they may also be other convex shapes such as cylindrical or conical.
[0042] It should be noted that the above is merely one embodiment of the present invention, and various modifications can be made to the present invention without departing from the spirit and scope of the present invention. [Explanation of symbols]
[0043] 10: embossing plate, 12: molding die, 14: convex mold, 14a: molding surface, 16: concave mold, 16a: molding surface, 18: large diameter convex portion, 20: small diameter convex portion, 22: large diameter convex portion forming projection, 22a: large diameter convex portion forming projection outer circumferential flat portion, 22b: annular vertical wall surface, 24: small diameter convex portion forming projection, 24a: small diameter convex portion forming projection outer circumferential flat portion, 26: large diameter convex portion forming recessed hole, 26a: large diameter convex portion forming recessed hole outer circumferential flat portion, 28: small diameter convex portion Forming recessed hole, 28a: outer peripheral flat portion of small diameter convex portion forming recessed hole, 30: ball end mill, 32: large diameter convex portion cutting tool, 26a: outer peripheral flat portion of large diameter convex portion forming recessed hole, 34: large diameter convex portion cutting edge, 34a: vertical cutting edge portion, 36: large diameter convex portion outer peripheral cutting edge, 38: rake face, 40: small diameter convex portion cutting tool, 42: small diameter convex portion cutting edge, 44: small diameter convex portion outer peripheral cutting edge, 46: rake face, 48: remaining cutting portion, 52: large diameter recessed hole Cutting tool, 54: cutting edge for cutting large diameter concave hole, 56: outer peripheral cutting edge for large diameter concave hole, 58: rake face, 60: cutting tool for cutting small diameter concave hole, 62: cutting edge for cutting small diameter concave hole, 64: outer peripheral cutting edge for small diameter concave hole, 66: rake face, D1: outer diameter of large diameter convex part, D2: outer diameter of small diameter convex part, R1: radius of curvature of large diameter convex part, R2: radius of curvature of small diameter convex part, L1: first row, L2: second row, PA: center point of protrusion forming large diameter convex part, PB: shape of small diameter convex part P1: large diameter protrusion cutting tool preparation process; P2: small diameter protrusion cutting tool preparation process; P3: large diameter protrusion forming protrusion cutting process; P4: small diameter protrusion forming protrusion cutting process; P11: large diameter recessed hole cutting tool preparation process; P12: small diameter recessed hole cutting tool preparation process; P13: large diameter protrusion forming recessed hole cutting process; P14: small diameter protrusion forming recessed hole cutting process
Claims
1. A method for processing an embossing die including a convex die and a concave die for press-molding an embossing plate in which a plurality of small diameter convex parts having diameters smaller than the large diameter convex parts are arranged at equal intervals around the large diameter convex parts, the method comprising the steps of: a concave cutting blade cutting tool preparation process for preparing a large diameter convex cutting tool having a large diameter convex cutting edge having a concave shape corresponding to the cross-sectional shape of the large diameter convex, and a large diameter convex outer peripheral cutting edge having a shape corresponding to a flat portion on the outer periphery of the large diameter convex formed subsequent to the large diameter convex cutting edge, the large diameter convex cutting tool being rotationally driven about a rotation center line passing through the center of the large diameter convex cutting edge, and a small diameter convex cutting tool having a small diameter convex cutting edge having a concave shape corresponding to the cross-sectional shape of the small diameter convex, and a small diameter convex outer peripheral cutting edge having a shape corresponding to the flat portion on the outer periphery of the small diameter convex formed subsequent to the small diameter convex cutting edge, the small diameter convex cutting tool being rotationally driven about a rotation center line passing through the center of the small diameter convex cutting edge; a large diameter protrusion cutting process for cutting a large diameter protrusion forming protrusion having a shape corresponding to the large diameter protrusion into the molding surface of the convex mold by reciprocating the large diameter protrusion cutting tool in the direction of the rotation center line while the rotation center line of the large diameter protrusion cutting tool is perpendicular to the molding surface of the convex mold; a small diameter protrusion cutting step of reciprocating the small diameter protrusion cutting tool in the direction of the rotation center line with the rotation center line of the small diameter protrusion cutting tool perpendicular to the molding surface of the convex mold, thereby cutting a small diameter protrusion forming protrusion having a shape corresponding to the small diameter protrusion into the molding surface of the convex mold. A method for processing an embossing die comprising the steps of:
2. The large-diameter protrusion cutting edge of the large-diameter protrusion cutting tool is provided with a vertical cutting edge portion for forming an annular vertical wall surface perpendicular to the molding surface of the convex mold on the peripheral edge of the large-diameter protrusion forming projection cut by the large-diameter protrusion cutting edge.
2. The method for processing an embossing die according to claim 1.
3. a convex cutting blade cutting tool preparation process for preparing a large diameter recessed hole cutting tool having a large diameter recessed hole cutting blade having a convex shape corresponding to the cross-sectional shape of the large diameter convex portion, and a large diameter recessed hole outer peripheral cutting blade having a shape corresponding to a flat portion on the outer periphery of the large diameter convex portion formed subsequent to the large diameter recessed hole cutting blade, the large diameter recessed hole cutting tool being rotationally driven about a rotation center line passing through the center of the large diameter recessed hole cutting blade; and a small diameter recessed hole cutting tool having a small diameter recessed hole cutting blade having a convex shape corresponding to the cross-sectional shape of the small diameter convex portion, and a small diameter recessed hole outer peripheral cutting blade having a shape corresponding to the flat portion on the outer periphery of the small diameter convex portion formed subsequent to the small diameter recessed hole cutting blade, the small diameter recessed hole cutting tool being rotationally driven about a rotation center line passing through the center of the small diameter recessed hole cutting blade; a large diameter convex portion forming recessed hole cutting process for cutting a large diameter convex portion forming recessed hole having a shape corresponding to the large diameter convex portion into the molding surface of the concave mold by reciprocating the large diameter convex portion cutting tool in the direction of the rotation center line while the rotation center line of the large diameter concave hole cutting tool is perpendicular to the molding surface of the concave mold; a small diameter convex portion forming recessed hole cutting process for cutting a small diameter convex portion forming recessed hole having a shape corresponding to the small diameter convex portion on the molding surface of the concave mold by reciprocating the small diameter concave hole cutting tool in the direction of the rotation center line with the rotation center line of the small diameter concave hole cutting tool being perpendicular to the molding surface of the concave mold.
3. The method for processing an embossing die according to claim 1 or 2.
4. The embossed plate is a first row in which the large diameter convex portion and the small diameter convex portion are alternately arranged at equal center intervals in a first direction, and a second row in which the small diameter convex portions are arranged at the equal center intervals in the first direction and are arranged in a second direction perpendicular to the first direction at intervals equal to or less than the equal center intervals with respect to the first row, are alternately formed in the second direction, two small diameter protrusions among the small diameter protrusions in the second row are located between centers of the large diameter protrusions in the first row in the first direction; The small diameter convex portion has a smaller diameter and a smaller radius of curvature than the large diameter convex portion.
2. The method for processing an embossing die according to claim 1.
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