Method for processing wave emboss molding die

Abstract

To provide a method for processing a wave emboss molding die which enables the processing of a wave emboss molding die in a short processing time by using a few kinds of tools.SOLUTION: By meandering a convex cutting blade cutting tool 44 in parallel with a molding surface of an emboss die and along a trough line 34 between ridge lines 32 (continuous protrusions 28) in a state that the rotation center line C1 of the convex cutting blade cutting tool 44 is perpendicular to the molding surface of the emboss die, a wave emboss molding die can be obtained which press-molds an emboss molding plates 20 in which a plurality of continuous protrusions 28 continuous in one direction while meandering regularly are arranged in parallel at constant intervals. Cutting needs no movement of the concave cutting blade cutting tool 44 in a direction (Z direction) of the rotation center line C1, so that a plurality of continuous protrusions 28 are cut by movement only in a X-Y plane. A single kind of tool is used to enable the processing of a wave emboss molding die (a lower die 40 and an upper die 42) in a short cutting processing time.SELECTED DRAWING: Figure 9

Description

[Technical field]

[0001] The present invention relates to a method for producing a wave embossing die for forming a wave embossed plate having a plurality of continuous protrusions arranged in parallel at regular intervals, the continuous protrusions being continuous in one direction while regularly meandering. [Background technology]

[0002] There is known a wave embossed plate in which a plurality of continuous protrusions are arranged in parallel at regular intervals while regularly meandering along one direction. For example, there is a wave embossed plate shown in Fig. 2 of Patent Document 1. Such a wave embossed plate is formed by pressing using a pair of dies. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6894038 Summary of the Invention [Problem to be solved by the invention]

[0004] Incidentally, when machining the molding die for forming the wave embossed plate described in the above Patent Document 1, a three-axis cutting machine is used that can control the position of a ball end mill, whose cutting edge has a spherical rotational trajectory, in three axial directions while rotating and driving 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, five types of tools with different cutting edge diameters are required for rough cutting, three types of semi-finishing, and finishing, and a lot of machining time is required for each machining process. In addition, each machining process requires large-sized control data for the three-axis position control, and there is a disadvantage that the creation of the control data requires a lot of man-hours.

[0005] The present invention has been made against the background of the above circumstances, and its object is to provide a method for processing a wave embossing mold that press-forms a wave embossing plate in a short processing time using a small number of tools. [Means for solving the problem]

[0006] The gist of the first invention is (a) a method for processing a wave embossing mold for press-molding a wave embossed plate having a plurality of consecutive continuous convex portions arranged in parallel at regular intervals while regularly snaking along one direction, comprising: (b) a convex cutting blade cutting tool preparation step of preparing a convex cutting blade cutting tool having a concave cutting edge having a convex shape corresponding to the concave cross-sectional shape between the continuous convex portions from the peak of the continuous convex portion to the peak of the adjacent continuous convex portion, and a flat straight cutting edge continuing from the concave cutting edge to the outer periphery, and which is rotated about a rotation center line passing through the center of the concave cutting edge; and (c) a cutting step of moving the convex cutting blade cutting tool in a serpentine manner parallel to the molding surface of the wave embossing mold and along the valleys between the continuous convex portions, with the rotation center line of the convex cutting blade being perpendicular to the molding surface of the wave embossing mold.

[0007] The gist of the second invention is that in the first invention, the cutting step includes: (d) a rough processing step in which the convex cutting blade cutting tool is held at a height position that leaves a cutting remainder of a predetermined dimension on the continuous convex portion and the concave cross-sectional shape between the continuous convex portions to be formed on the molding surface of the wave embossing mold, and the convex cutting blade cutting tool is moved in a serpentine manner parallel to the molding surface and along the valleys between the continuous convex portions, and (e) a finish processing step in which the convex cutting blade cutting tool is held at a height position that leaves no cutting remainder, and the convex cutting blade cutting tool is moved in a serpentine manner parallel to the molding surface and along the valleys between the continuous convex portions.

[0008] The gist of the third invention is that, in the first invention, (f) the convex cutting edge cutting tool has an R cutting edge that continues from the straight cutting edge toward the outer periphery and is curved with a predetermined radius of curvature in a direction away from the wave embossing mold.

[0009] The gist of the fourth invention is that, in the first invention, (g) the convex cutting blade cutting tool has a chip discharge groove that is formed with a dimension in the direction of the rotation center line from the tip of the convex cutting blade cutting tool that is shorter than the diameter of the convex cutting blade cutting tool.

[0010] The gist of the 5th invention is that, in the second invention, in the rough machining process or the finish machining process, the convex cutting blade cutting tool is driven at a rotational speed of 2500 rpm or less and moved at a feed speed of 850 mm / min or less. Effect of the Invention

[0011] According to the method for processing a wave embossing die of the first invention, the convex cutting blade cutting tool is moved in a meandering manner parallel to the molding surface and along the valleys between the continuous convex portions with the rotation center line of the convex cutting blade perpendicular to the molding surface of the wave embossing die, thereby obtaining a wave embossing die for press-molding a wave embossing plate in which the continuous convex portions are arranged in parallel at regular intervals while regularly meandering in one direction. As a result, during cutting, the convex cutting blade cutting tool is not moved in the direction of its rotation center line, but is moved only in a plane perpendicular to the rotation center line direction along the molding surface of the wave embossing die, thereby cutting a plurality of continuous convex portions on the molding surface in which the continuous convex portions are arranged in parallel at regular intervals while regularly meandering in one direction. This allows the wave embossing die to be processed in a short cutting processing time by only moving the cutting tool in a plane perpendicular to the rotation center line using fewer tools than before.

[0012] According to the method for processing a wave embossing die of the second invention, the cutting step includes a rough processing step of moving the convex cutting tool parallel to the molding surface and along the valley between the continuous convex parts while holding the convex cutting tool at a height position where a predetermined dimension of cutting residue is formed on the molding surface of the wave embossing die and the concave cross-sectional shape between the continuous convex parts, and a finish processing step of moving the convex cutting tool parallel to the molding surface and along the valley between the continuous convex parts while holding the convex cutting tool at a height position where there is no cutting residue. This allows a molding surface with high shape accuracy to be efficiently obtained in the wave embossing die.

[0013] According to the method for machining a wave embossing die of the third invention, the convex cutting edge cutting tool has an R cutting edge that is continuous with the straight cutting edge toward the outer periphery and is curved with a predetermined radius of curvature in a direction away from the wave embossing die. This allows a beautiful finish to be obtained on the molding surface of the wave embossing die. In addition, the presence of the R cutting edge increases the strength of the straight cutting edge and the concave cutting edge that are connected to the R cutting edge, improving the durability and life of the convex cutting edge cutting tool 44.

[0014] According to the processing method for a wave embossing die of the fourth invention, the convex cutting blade cutting tool has a chip discharge groove formed with a dimension in the rotation center line direction from the tip of the convex cutting blade cutting tool shorter than the diameter of the convex cutting blade cutting tool. This increases the gripping allowance of the chuck of the grinding machine from the chip discharge groove of the convex cutting blade cutting tool, suppressing chattering of the convex cutting blade cutting tool 44 during cutting processing, and improving the finish of the molding surface of the wave embossing die.

[0015] According to the fifth aspect of the present invention, in the rough processing step or the finish processing step, the convex cutting blade cutting tool is driven at a rotation speed of 2500 rpm or less and moved at a feed rate of 850 mm / min or less. This allows the wave embossing die to be finished with a surface accuracy within a range of ±0.01 mm, and improves the durability of the convex cutting blade cutting tool. [Brief description of the drawings]

[0016] [Figure 1] FIG. 1 is a perspective view illustrating a product made of an embossed plate press-molded using a wave embossing die processed by a processing method according to one embodiment of the present invention. [Diagram 2] FIG. 2 is an enlarged view of a main part illustrating the embossed shape of the embossed plate in FIG. 1 and the uneven shape of the molding surface of a wave embossing die for molding the embossed plate, the view showing fillets (circular arcs). [Diagram 3] FIG. 3 is an enlarged plan view of one unit mountain shape without filleting to explain the uneven shape of the embossed plate in FIG. 2. [Figure 4] 4 is a cross-sectional view of the embossing plate of FIG. 2 taken along line IV-IV of FIG. 3. [Diagram 5] 3 showing a cross section of the embossing plate of FIG. 2. FIG. [Figure 6] 6 is a cross-sectional view of the embossing plate of FIG. 2 taken along line VI-VI of FIG. 3. [Figure 7] 7 is a view taken along the line VII of FIG. 3, showing the embossing plate of FIG. 2. [Figure 8] FIG. 3 is a cross-sectional view illustrating a wave embossing die having the molding surface shown in FIG. 2. [Figure 9] 1A to 1C are process diagrams illustrating a method for processing a wave embossing mold according to one embodiment of the present invention. [Figure 10] 10 is a diagram illustrating a cutting tool with a convex cutting edge prepared in the cutting tool preparation step of FIG. 9 . FIG. [Figure 11]11 is a cross-sectional view illustrating a processing method using the cutting tool with a convex cutting blade in FIG. 10 in the cutting step in FIG. 9. [Figure 12] 11 is a perspective view illustrating a processing method using the cutting tool with a convex cutting blade in FIG. 10 in the cutting step in FIG. 9. [Figure 13] FIG. 1 is a diagram showing a ball end mill used in a conventional method for machining a wave embossing mold. [Figure 14] FIG. 1 is a perspective view showing a conventional method for machining a wave embossing die using a ball end mill. [Figure 15] FIG. 1 is a process diagram illustrating a conventional processing process for a wave embossing die. [Figure 16] 1 is a table showing the results of a cutting test of a wave embossing mold conducted by the present inventor. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] An embodiment of the present invention will now be described with reference to the drawings. EXAMPLES

[0018] Fig. 1 is a photograph showing an embossed semi-cylindrical molded product 10 according to one embodiment of the present invention. The embossed semi-cylindrical molded product 10 is elongated in the L1 direction and is used, for example, as a heat insulator that blocks heat from an exhaust pipe of a vehicle. The mountain lines (ridge lines) 32 and valley lines 34 of the embossed metal plate (hereinafter referred to as the embossed plate) 20 in Fig. 2 are formed in the width direction of the embossed semi-cylindrical molded product 10, i.e., in the W1 direction.

[0019] The embossed semi-cylindrical molded product 10 is formed by pressing an embossed plate 20 shown in Fig. 2. The embossed plate 20 is made of, for example, an aluminum alloy A3004P (plate thickness tb is 0.4 mm) specified in JISH4000:2014, and is provided with an embossment that is a predetermined uneven pattern by pressing using, for example, a pair of press dies (lower die 40 and upper die 42) shown in Fig. 8. Fig. 2 is an enlarged view of a main part of the embossed plate 20, with a fillet (circular arc) added.

[0020] Fig. 3 is a plan view without fillets, i.e., an XY plan view, for explaining the uneven shape of the embossing of the embossing plate 20 of Fig. 2, in which mountain lines 32 and valley lines 34 are shown as straight lines. Fig. 3 is a plan view of the embossing plate 20, parallel to the XY plane, as viewed from above the paper surface in the Z-axis direction, in an XYZ orthogonal coordinate system, with the paper surface of Fig. 2 being the XY plane. The forming surfaces, which are the opposing surfaces of the lower die 40 and upper die 42 of Fig. 8, also have an uneven shape similar to that processed on the embossing plate 20 of Fig. 2.

[0021] In Fig. 3, one unit ridge 30, which is a basic unit of the uneven pattern provided on the embossed plate 20 and is composed of four quadrangles (parallelograms) each having four sides with a length a1, is shown by a thick line, and unit ridges 30 adjacent to the unit ridge 30 in the X-direction and Y-direction are shown by solid lines thinner than the thick lines. In Fig. 3, the length a1 of the side 76 on the first transverse line 22 and the second transverse line 24 is shown to be shorter than the length a1 of the side 74 on the mountain line 32 and the valley line 34 because they are oblique lines. The four quadrangular planes are connected in the direction of the mountain line 32 with the side sides sandwiched therebetween, and the four quadrangular planes and the other four quadrangular planes are connected in adjacent directions with the valley line 34 formed by the valley fold between the four quadrangular planes and the other four quadrangular planes sandwiched therebetween, thereby forming unevenness in the X-direction (low rigidity direction).

[0022] Fig. 4 is a view showing a cross section taken along line IV-IV in Fig. 3. Fig. 5 is a view showing a cross section taken along line VV in Fig. 3. Fig. 6 is a view showing a cross section taken along line VI-VI in Fig. 3. Fig. 7 is a view showing line VII in Fig. 3. As shown in Fig. 3, a unit mountain shape 30 in the embossed forming plate 20 is a basic unit made up of four quadrilaterals: a pair of parallelograms which together form a part of the mountain line (ridge line) 32, and another pair of parallelograms which together form another part of the mountain line 32 which is continuous with the part of the mountain line 32 at a predetermined bending angle (opening angle) α.

[0023] The embossed plate 20 is configured by connecting the unit ridges 30 to each other so that the ridges 32 are continuous in the Y direction and are continuous across the valleys 34 in the X direction perpendicular to the Y direction. As a result, the ridges 32 extend in the Y direction while zigzagging at a predetermined bending angle (opening angle) α in the XY plane at a constant pitch P1. Similarly, the valleys 34 extend in the Y direction while zigzagging at a predetermined bending angle α in the XY plane at a constant pitch P1. The ridges 32 and the valleys 34 are alternately positioned at a constant interval in the X direction. The valleys 34 are spaced apart in the X-axis direction at a constant interval P2, and the ridges 32 are spaced apart in the X-axis direction at a constant interval P2. A continuous convex portion 28 is formed in which the convex portions centered on the ridges 32 between the valleys 34 are regularly meandering along the X direction and are continuous.

[0024] The embossed plate 20 is provided with a large number of first transverse lines 22 that extend in a straight line in the X-axis direction in the plan view of FIG. 3 while bending in the XZ plane to connect bend points 38a, 38b of valley line 34 and bend points 36a, 36b of mountain line 32 that protrude in the X-axis (positive) direction, and second transverse lines 24 that extend in a straight line in the plan view of FIG. 3 while bending in the Z-axis direction to connect bend points 38a, 38b of valley line 34 and bend points 36b, 36b of mountain line 32 that are recessed in the X-axis (positive) direction. These first transverse lines 22 are alternately provided and spaced apart in the Y-axis direction.

[0025] The interval in the Y-axis direction of the first transverse lines 22 and the interval in the Y-axis direction of the second transverse lines 24 are both determined according to the pitch P1 of the bent lines of the valley lines 34 and the mountain lines 32, and are the same dimension as each other and the same dimension as the pitch P1. A large number of quadrangular planes surrounded by the valley lines 34, the mountain lines 32, the first transverse lines 22, and the second transverse lines 24 are provided so that valley fold ridgelines are formed along the valley lines 34 and mountain fold ridgelines are formed along the mountain lines 32, and a predetermined uneven pattern is formed by the large number of quadrangular planes.

[0026] 3, the unit mountain shape 30 is made up of a pair of rectangular planes S1, S2 adjacent to each other on both sides of the mountain line 32, and a pair of rectangular planes S3, S4 provided in the Y-axis direction continuous with the pair of rectangular planes S1, S2, totaling four rectangular planes S1 to S4, and has a shape bent into a sideways V shape in plan view. In this embodiment, the bending angles of the sideways V shape of the valley line 34 and mountain line 32 in plan view of the unit mountain shape 30, i.e., the bending angles α of the bending points 38a, 36a protruding in the X-axis direction of the valley line 34 and mountain line 32, are the same, and the four rectangular planes S1 to S4 forming the unit mountain shape 30 are parallelograms with the same shape, in which a pair of upper sides 72 and lower sides 74 and a pair of side sides 76 have the same length a1.

[0027] FIG. 4, which shows a cross-sectional view taken along the line IV-IV in FIG. 3, shows a YZ cross section of the second transverse line 24, which is a ridge between the rectangular planes S1 and S3 of the unit ridge 30. FIG. 5, which shows a cross-sectional view taken along the line VV in FIG. 3, shows a YZ cross section of the second transverse line 24, which is a ridge between the rectangular planes S2 and S4. FIG. 6, which shows a cross-sectional view taken along the line VI-VI in FIG. 3, shows an XZ cross section passing through the bending points 38b and 36b of the second transverse line 24 along the second transverse line 24. FIG. 7, which shows a cross-sectional view taken along the line VII in FIG. 3, shows the continuity in the Y direction of the forming thickness of the embossed plate 20, that is, the height h1 in the Z-axis direction of the embossed pattern. As shown in FIG. 4 to FIG. 6, the ridge portions of the valley folds and mountain folds formed along the valley line 34, the mountain line 32, the first transverse line 22, and the second transverse line 24 are provided with a circular arc-shaped roundness (fillet) having a radius of curvature r1 in a cross section perpendicular to the ridge line. The radius of curvature r1 is, for example, 3 to 3.5 mm, and is 37% to 50% of the length a1 of one side of the quadrangular planes S1 to S4.

[0028] Next, specific examples of dimensions and angles of each part of the embossed plate 20 provided with such an embossed uneven pattern will be described. The plate thickness ta of the embossed plate 20 is suitably within the range of about 0.3 mm to 0.6 mm, and is 0.4 mm in this embodiment. That is, the plate thickness tb of the aluminum alloy plate, which is the material, is 0.3 to 0.5 mm, and the plate thickness is slightly reduced due to elongation caused by embossing the plate to form the uneven pattern. For example, when the plate thickness tb is 0.4 mm, the plate thickness becomes smaller after embossing, for example, the plate thickness ta of the embossed plate 20 becomes about 0.38 mm. When the radius of curvature of the bending point in the cross section along the mountain line is r1, the length a1 of each side of the quadrangular planes S1 to S4 that are equal to each other is within the range of 6 mm to 8 mm. The height h1 of the embossed pattern in the Z-axis direction (the height between the mountain line 32 and the valley line 34) is within the range of 1.6 mm to 1.8 mm. The bending angle α of the bend points 38a, 36a of the valley line 34 and the mountain line 32 protruding in the X-axis direction (the opening angle of the mountain line 32 about the bend point in a plan view) is 100° or more, preferably in the range of 110° to 120°.

[0029] According to such an embossed plate 20, the first transverse line 22 and the second transverse line 24, which are provided in the X direction so as to be perpendicular to the folded valley line 34 and the mountain line 32, respectively have a folded line shape that is zigzag folded in the Z direction in a plan view. In addition, in the X direction, as shown in the XZ cross section of Fig. 6, mountains with the mountain line 32 as a ridge line and valleys with the valley line 34 as a valley line are alternately continuous. In the Y direction, as shown in the YZ plane (side surface) of Fig. 7, mountains with the mountain line 32 as a ridge line and valleys with the valley line 34 as a valley line are continuous. For this reason, the embossed plate 20 has anisotropy of bending rigidity, that is, bending rigidity is low in the X direction and bending rigidity is high in the Y direction.

[0030] Fig. 8 shows a wave embossing die consisting of a pair of lower and upper dies 40 and 42, which applies embossing to the embossed plate 20 by pressing. On the molding surfaces, which are the opposing faces of the pair of lower and upper dies 40 and 42, concave and convex shapes similar to those machined into the embossed plate 20 in Fig. 2 are formed by cutting. The embossed plate 20 is obtained by press molding in which a metal plate (material) is sandwiched between the lower and upper dies 40 and 42.

[0031] Fig. 9 is a process diagram for explaining the main parts of a processing method, i.e., a manufacturing method, of a pair of lower and upper dies 40 and 42 for applying embossing by pressing to the embossed forming plate 20. In Fig. 9, in a convex cutting blade cutting tool preparation step P11, for example, a convex cutting blade cutting tool 44 shown in Fig. 10 is prepared. The convex cutting blade cutting tool 44 is a shaft-shaped rotary cutting tool that is rotated around its rotation center line C1.

[0032] As shown in FIG. 10, the convex cutting blade cutting tool 44 has a concave cutting edge 46 having a convex shape corresponding to the concave cross-sectional shape between the continuous convex portions from the crest of the continuous convex portion to the crest of the adjacent continuous convex portion, a flat straight cutting edge 48 continuing from the concave cutting edge 46 to the outer periphery, an R cutting edge 50 continuing from the straight cutting edge 48 to the outer periphery and curved with a predetermined curvature radius in a direction away from the wave embossing mold, a rake face 52 formed on the upstream side of the rotation direction from the concave cutting edge 46, a chip discharge groove 54 for discharging chips generated by the concave cutting edge 46 and the straight cutting edge 48, and a 0 to 5° flank face 56 formed behind the concave cutting edge 46 and the straight cutting edge 48 in the rotation direction. The convex cutting blade cutting tool 44 is attached to the chuck of a three-axis cutting machine (not shown) for cutting, and is rotated around a rotation center line C1 passing through the center of the concave cutting edge 46. The convex cutting edge cutting tool 44 has a 0 to 5° flank 56 which increases the strength of the cutting edge, resulting in a long durable life.

[0033] The convex cutting edge cutting tool 44 is more resistant to cutting loads and less prone to breakage than a case where the straight cutting edge 48 and the outer peripheral surface are at a pin angle due to the presence of the R cutting edge 50, so that a high grinding efficiency can be obtained and the unevenness of the molding surface of the wave embossing mold can be smoothly cut. In addition, the chip discharge groove 54 is formed with a dimension in the direction of the rotation center line that is shorter than the diameter of the convex cutting edge cutting tool 44 from the tip of the convex cutting edge cutting tool 44. This increases the gripping allowance of the convex cutting edge cutting tool 44 to the chip discharge groove 54 by the chuck of the three-axis cutting machine, so that chattering of the convex cutting edge cutting tool 44 during cutting processing is suppressed and the finish of the molding surface of the wave embossing mold is improved.

[0034] Next, in the cutting process (rough processing process P12 and finish processing process P13) of Fig. 9, on the molding surface which is the mating surface of the lower die 40 or the upper die 42 constituting the wave embossing mold, as shown in Figs. 11 and 12, the convex cutting blade cutting tool 44 is moved while the rotation center line C1 of the convex cutting blade cutting tool 44 is perpendicular to the molding surface of the wave embossing mold and the rotation center line C1 is parallel to the molding surface and meanders along the valley line 34 or the mountain line 32 between the continuous convex parts (between the mountain lines 32). The convex cutting blade cutting tool 44 performs cutting of the mating surface of the lower die 40 or the upper die 42 by controlling the position so as to meander in the XY plane without changing the position in the Z direction. Such cutting processing is repeated for each valley line 34 or mountain line 32.

[0035] In the rough machining step P12 included in the cutting process, a convex cutting blade cutting tool 44 is held at a height position that will form a predetermined dimension of cutting remainder for the continuous convex portions 28 and the concave cross-sectional shape between the continuous convex portions 28 to be formed on the molding surface, which is the mating surface of the lower mold 40 or the upper mold 42 that constitutes the embossing mold, while being moved in a serpentine manner along the valley lines 34 between the continuous convex portions 28, parallel to the molding surface.

[0036] In the finish processing step P13 included in the cutting process, a cutting tool 44 with a convex cutting blade is held at a height position that leaves no cutting residue with respect to the continuous convex portions 28 and the concave cross-sectional shape between the continuous convex portions 28 to be formed on the molding surface, which is the mating surface of the lower mold 40 or the upper mold 42 that constitutes the embossing mold, and the cutting tool with a convex cutting blade is moved in a serpentine manner parallel to the molding surface and along the valley lines 34 between the continuous convex portions 28 for each valley line 34. In the cutting process of this embodiment, for example, compared to the conventional process of Figs. 14 and 15, the processing time of the lower mold 40 or the upper mold 42 was reduced by 83%, the tool cost was reduced by 41%, and the processing data creation time was reduced by 90%.

[0037] Incidentally, in the past, for example, a ball end mill shown in FIG. 13 was used to cut the molding surfaces of the lower die 40 and the upper die 42 of a wave embossing mold while controlling the position of the ball end mill in three dimensions in the X, Y, and Z directions as shown in FIG. 14, and an embossed shape as shown in FIG. 2 was processed, which required a significantly long processing time and a large amount of control data used for three-axis position control, and required many steps to create the control data. In addition, multiple types of ball end mills with different diameters at the tip were used, as shown in FIG. 15, which required not only multiple types of tools but also more processing time and control data creation steps. In FIG. 15, a rough cutting process B1 using a 30 mmφ ball end mill, a semi-finishing process B2 using a 20 mmφ ball end mill, a semi-finishing process B3 using a 16 mmφ ball end mill, a semi-finishing process B4 using a 10 mmφ ball end mill, and a finishing process B5 using a 6 mmφ ball end mill are used.

[0038] The inventors conducted a test under the following test conditions to cut the uneven shape of the molding surface of the wave embossing die for forming the embossed plate 20 by changing the rotation speed and feed rate of the convex cutting blade cutting tool 44. Figure 16 shows the test results. (Cutting test conditions) 3-axis cutting machine: MVR25Ex manufactured by NIDEK Machine Tools Co., Ltd. Convex cutting edge cutting tool: 16mmφ×100mm Mold material: Tool steel Cutting oil: Sugicut (manufactured by Sugimura Chemical Industry Co., Ltd.)

[0039] 16, according to the cutting test of the wave embossing mold, the higher the rotation speed of the convex cutting blade cutting tool 44 and the higher the feed speed of the convex cutting blade cutting tool 44, the more defects in the surface finish and the worse the tool condition. Preferably, the rotation speed of the convex cutting blade cutting tool 44 is 3000 rpm or less and the feed speed of the convex cutting blade cutting tool 44 is 850 mm / min or less, and more preferably, the rotation speed of the convex cutting blade cutting tool 44 is 2500 rpm or less and the feed speed of the convex cutting blade cutting tool 44 is 650 mm / min or less.

[0040] As described above, according to the processing method of the wave embossing die of this embodiment, the convex cutting blade cutting tool 44 is moved in a meandering manner parallel to the molding surface and along the valley line 34 between the crest lines 32 (continuous convex portions 28) with the rotation center line C1 of the convex cutting blade cutting tool 44 perpendicular to the molding surface of the wave embossing die, thereby obtaining a wave embossing die for press-molding the embossing plate 20 in which the continuous convex portions 28 that are regularly meandering and continuous in one direction are aligned at regular intervals. As a result, during cutting, it is not necessary to move the convex cutting blade cutting tool 44 in the direction of its rotation center line C1 (Z direction), and the continuous convex portions 28 in which the continuous convex portions 28 that are regularly meandering and continuous in one direction are aligned at regular intervals are cut on the molding surface by only moving the convex cutting blade cutting tool 44 in a plane (XY plane) perpendicular to the direction of the rotation center line C1 along the molding surface of the wave embossing die. This makes it possible to machine the wave embossing mold (lower mold 40 and upper mold 42) in a short cutting time using fewer tools of a single type than before, and only by moving the convex cutting blade cutting tool 44 in a plane perpendicular to the rotation center line C1.

[0041] According to the method for processing the wave embossing die of this embodiment, the cutting steps (P12, P13) of the convex cutting blade cutting tool 44 include a rough processing step P12 in which the convex cutting blade cutting tool 44 is moved in a zigzag manner parallel to the molding surface and along the valley line 34 between the continuous convex portions 28 while holding the convex cutting blade cutting tool 44 at a height position where a predetermined dimension of cutting residue is formed with respect to the continuous convex portions 28 and the concave cross-sectional shape between the continuous convex portions 28 to be formed on the molding surface of the wave embossing die, and a finish processing step P13 in which the convex cutting blade cutting tool 44 is moved in a zigzag manner parallel to the molding surface and along the valley line 34 between the continuous convex portions 28 while holding the convex cutting blade cutting tool 44 at a height position where there is no cutting residue. This allows a molding surface with high shape accuracy to be efficiently obtained in the wave embossing die.

[0042] According to the method for processing the wave embossing die of this embodiment, the convex cutting edge cutting tool 44 has an R cutting edge 50 that is continuous with the straight cutting edge 48 toward the outer periphery and is curved with a predetermined radius of curvature in a direction away from the wave embossing die. This allows the wave embossing die to have a beautiful finish. The presence of the R cutting edge 50 also increases the strength of the straight cutting edge 48 and the concave cutting edge 46 that are connected to the R cutting edge 50, improving the durability and life of the convex cutting edge cutting tool 44.

[0043] Furthermore, according to the processing method for the wave embossing die of this embodiment, the convex cutting blade cutting tool 44 has a chip discharge groove 54 formed with a dimension in the rotation center line direction from the tip of the convex cutting blade cutting tool 44 shorter than the diameter of the convex cutting blade cutting tool 44. This increases the gripping allowance of the chuck of the grinding machine up to the chip discharge groove 54 of the convex cutting blade cutting tool 44, suppressing chattering of the convex cutting blade cutting tool 44 during cutting processing, and improving the finish of the molding surface of the wave embossing die.

[0044] According to the method for processing the wave embossing die of this embodiment, in the rough processing step P12 or the finish processing step P13, the convex cutting blade cutting tool 44 is driven at a rotation speed of 3000 rpm or less and moved at a feed speed of 850 mm / min or less. This allows the wave embossing die to be finished with a surface accuracy within the range of ±0.01 mm, and improves the durability of the convex cutting blade cutting tool 44.

[0045] Although the method for processing the wave embossing die has been explained 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.

[0046] For example, in the above embodiment, the wave embossing mold is composed of the lower mold 40 and the upper mold 42, but it may be composed of a left mold and a right mold that are combined in the horizontal direction.

[0047] Moreover, the convex cutting edge cutting tool 44 of the above-described embodiment does not necessarily have to be provided with the R cutting edge 50.

[0048] 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]

[0049] 10: embossed semi-cylindrical molded product, 20: embossed molded plate, 22: first transverse line, 24: second transverse line, 28: continuous convex portion, 30: unit mountain shape, 32: mountain line (ridge line), 34: valley line, 36a, 36b: mountain line bend points, 38a, 38b: valley line bend points, 40: lower die (wave embossed mold), 42: upper die (wave embossed mold), 44: convex cutting edge cutting tool, 46: concave cutting edge, 48: straight cutting edge, 50: R cutting edge, 52: rake face, 54: chip discharge groove, 60: ball end mill, P11: convex cutting edge cutting tool preparation process, P12: rough machining process (cutting process), P13: finish machining process (cutting process), C1: rotation center line

Claims

1. A method for processing a wave embossing die for press-molding a wave embossed plate having a plurality of continuous protrusions arranged in parallel at regular intervals while regularly snaking along one direction, comprising the steps of: a convex cutting edge cutting tool preparation process for preparing a convex cutting edge cutting tool having a concave cutting edge having a convex shape corresponding to the concave cross-sectional shape between the continuous convex portions from a peak of the continuous convex portion to a peak of an adjacent continuous convex portion, and a flat straight cutting edge continuing from the concave cutting edge to an outer periphery side, the convex cutting edge being rotationally driven about a rotation center line passing through the center of the concave cutting edge; A cutting process in which the convex cutting blade cutting tool is moved in a serpentine manner parallel to the molding surface of the wave embossing mold and along the valleys between the continuous convex portions with the rotation center line of the convex cutting blade cutting tool perpendicular to the molding surface of the wave embossing mold. A method for processing a wave embossing mold, comprising the steps of:

2. The cutting step includes: a rough machining process in which the convex cutting blade cutting tool is held at a height position at which a predetermined dimension of cutting residue is formed with respect to the continuous convex portions and the concave cross-sectional shape between the continuous convex portions to be formed on the molding surface of the wave embossing mold, and the convex cutting blade cutting tool is moved in a serpentine manner parallel to the molding surface and along the valleys between the continuous convex portions; and a finishing process step of moving the convex cutting blade cutting tool in a serpentine manner parallel to the molding surface and along the valleys between the continuous convex portions while holding the convex cutting blade cutting tool at a height position where there is no cutting residue.

2. A method for processing a wave embossing die according to claim 1.

3. The convex cutting edge cutting tool has an R cutting edge that is continuous with the straight cutting edge toward the outer periphery and is curved with a predetermined curvature radius in a direction away from the wave embossing die.

2. A method for processing a wave embossing die according to claim 1.

4. The cutting tool has a chip discharge groove that is formed with a dimension in a direction of a rotation center line from a tip of the cutting tool having a convex cutting edge that is shorter than a diameter of the cutting tool having a convex cutting edge.

2. A method for processing a wave embossing die according to claim 1.

5. In the rough machining step or the finish machining step, the cutting tool with the convex cutting blade is driven at a rotational speed of 3000 rpm or less and moved at a feed rate of 850 mm / min or less.

3. The method for processing a wave embossing die according to claim 2.

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