Barrel polishing medium material

Abstract

To provide a barrel polishing medium material of which waste treatment after polishing a barrel is easy, and of which a manufacturing cost is inexpensive.SOLUTION: A barrel polishing medium material is formed from a material that contains a metal of the same quality as a metal to be polished constituting a work-piece as a main component, is formed into a polygonal pipe shape with a prescribed length or a hollow polygonal shape of which a peripheral surface formed by bending a plate material is blocked. Since the medium material has the polygonal pipe shape or the hollow polygonal shape with the blocked peripheral surface that is formed from the material containing the metal of the same quality as the metal to be polished, waste treatment thereof is easy and a manufacturing cost thereof is inexpensive.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a media material for barrel polishing used for deburring, polishing, etc. of products (workpieces) made of iron, aluminum, and other metals. [Background technology]

[0002] Generally, wet barrel polishing is a processing method in which the product (workpiece), media material (polishing stones), abrasives, polishing aids (compounds), and water are placed in a drum-shaped barrel container, and polished by rotating and vibrating the barrel container. As the barrel container rotates and vibrates, the product and the polishing stones rub against each other, polishing the entire product through friction.

[0003] There are two types of media used in wet barrel polishing: ceramic media and resin media. Ceramic media is manufactured by kneading, molding, and firing abrasive grains such as alundum with a clay binder, and has a high grinding power and is mainly used for rough finishing such as deburring and rounding. Resin media is manufactured by mixing the abrasive grains with a resin binder, molding, and hardening, and although its polishing power is lower than that of ceramic media, it is soft and does not scratch the workpiece, so it is mainly used for semi-finishing such as smoothing.

[0004] The media materials are widely used in a variety of shapes, including spheres, cones, cylinders with beveled ends, thick sectors, and irregular shapes. Known shapes of media materials are disclosed in, for example, Patent Document 1 and Patent Document 2. Patent Document 1 discloses a media material that is substantially in the shape of a solid triangular prism, the side surfaces of which are recessed inward, and each apex portion that constitutes the triangle has an arc shape. Patent Document 2 shows a media material in which ceramic media formed into small equilateral triangular prisms is dispersed within a polyamide resin-based resin binder at about 50% by weight. However, because these media are made of ceramics or resin, the media wears away during the polishing process, and is discharged together with the abrasives and polishing aids (compounds) mixed into the water. This poses the problem of requiring large amounts of money to install and treat the sludge and wastewater.

[0005] Patent Document 3 shows a barrel polishing media material made of Fe-based sintered metal that is formed by compacting a raw material whose main component is Fe-based metal powder into a cylindrical shape, sintering it, and then carburizing and quenching it. Because this media material is made of Fe-based sintered metal, the abrasive grains are less likely to peel off and adhere to the workpiece being polished during barrel polishing, as is the case with conventional media materials that have abrasive grains bonded to the surface. This simplifies cleaning after polishing and enables the cleaning process to be completed in a short time. However, since this media material is formed by sintering Fe-based metal powder, there is a problem in that the manufacturing cost is high. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2003-231053 A [Patent Document 2] Japanese Patent Application Publication No. 10-244456 [Patent Document 3] JP 2008-127539 A Summary of the Invention [Problem to be solved by the invention]

[0007] An object of the present invention is to provide a media material for barrel polishing, which allows for easy wastewater treatment after barrel polishing and is inexpensive to manufacture. [Means for solving the problem]

[0008] The present invention relates to a media material for barrel polishing, which is made of a material whose main component is the same metal as the metal to be polished that constitutes the workpiece, and is formed into a polygonal pipe shape of a predetermined length.

[0009] In the present invention, the barrel polishing media formed in the polygonal pipe shape is preferably formed by cutting a polygonal pipe material to a predetermined length.

[0010] In the present invention, the barrel polishing media material formed into the polygonal pipe shape is preferably formed by bending a plate material cut into a predetermined shape.

[0011] In the present invention, the polygon of the barrel polishing media formed into the polygonal pipe shape is preferably a quadrangle or a triangle.

[0012] In the present invention, it is preferable that the polishing tool be formed by bending a plate material mainly composed of the same metal as the metal to be polished that constitutes the workpiece, and that the polishing tool be formed into a hollow polygonal shape with a closed circumferential surface.

[0013] In the present invention, it is preferable that the polishing tool is formed by bending a triangular plate material whose main component is the same metal as the metal to be polished that constitutes the workpiece, and is formed into a hollow, bottomed triangular pyramid shape with closed peripheral surfaces.

[0014] In the present invention, the dimensions of each outer portion of the media material are preferably within a range of 5 to 30 mm.

[0015] In the present invention, the plate thickness of the media material is preferably set within a range of 1 to 5 mm.

[0016] In the present invention, the media material is preferably made of iron or aluminum. Effect of the Invention

[0017] According to the present invention, the media material for barrel polishing is formed from a material whose main component is the same metal as the metal to be polished that constitutes the workpiece, and is formed into a polygonal pipe shape of a predetermined length, or into a hollow polygonal shape with a closed circumferential surface. Therefore, the polishing powder generated during barrel polishing is different from the sludge of ceramic media or resin media and is made of the same material as the workpiece, which makes it easy to treat the wastewater after polishing, and it is possible to provide a media material that is inexpensive to manufacture. [Brief description of the drawings]

[0018] [Figure 1] FIG. 1 is a perspective view showing a first embodiment of the present invention. [Diagram 2] FIG. 4 is a perspective view showing a second embodiment of the present invention. [Diagram 3] 11A to 11C are diagrams showing a third embodiment of the present invention, in which (A) is an overall perspective view, (B) is a development view, and (C) is a side view of (B). [Figure 4] 11A to 11C are diagrams showing a fourth embodiment of the present invention, in which (A) is an overall perspective view, (B) is a development view, and (C) is a side view of (B). [Diagram 5] 11A to 11C are diagrams showing a fifth embodiment of the present invention, where (A) is an overall perspective view, (B) is a development view, and (C) is a side view of (B). [Figure 6] 13A to 13C are diagrams showing a sixth embodiment of the present invention, in which (A) is an overall perspective view, (B) is a development view, and (C) is a bottom view of (B). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Hereinafter, each embodiment of the present invention will be described with reference to the drawings. A first embodiment of the present invention is shown in Fig. 1. In Fig. 1, a first media material 10 formed in a polygonal pipe shape, in this embodiment a square pipe shape, is constructed by cutting an iron square pipe material 15 to a predetermined length L. The dimensions of each side of the first media material 10 are A and B, respectively, and the plate thickness is t. The length L and the side dimensions A and B are appropriately set depending on the material and shape of the workpiece, the state of burrs, etc., but are selected from the range of 5 to 30 mm in terms of use as a media material. If the dimensions of each part, i.e., the length L and the side dimensions A and B, are smaller than 5 mm or larger than 30 mm, it is difficult to efficiently remove burrs from the workpiece. The plate thickness t is also appropriately set depending on the material and shape of the workpiece, the state of burrs, etc., but is selected from the range of 1 to 5 mm in terms of its use as a media material. If the plate thickness t is less than 1 mm, the media material will wear out rapidly and it will be difficult to efficiently remove burrs from the workpiece. Also, if the plate thickness t is more than 5 mm, the weight of the media material will increase, making it difficult to handle and possibly damaging the workpiece. In addition, in each drawing, the dimensions of each part are not proportional to the dimensions of the actual product.

[0020] If the side dimensions A, B are equal, the quadrangular pipe material 15 is a square pipe material, and if they are different, it is a rectangular pipe material. The length L can be set appropriately, but if the side dimensions A, B are all equal, the media material becomes a cube. The first media material 10 is preferably a cube in which the length L and side dimensions A, B are all equal. There is no problem if it is a rectangular parallelepiped with different dimensions for each part. The surface of each corner of the square pipe material 15 is appropriately rounded, and the inner corners of each corner are either rounded or not rounded. The square pipe material 15 can be a commercially available square pipe material.

[0021] According to this embodiment, the first media 10 can be easily and inexpensively manufactured using commercially available square pipes 15. In addition, since the first media 10 is made of iron, when the workpiece is made of iron, burrs of the workpiece and grinding powder of the first media 10 can be easily collected by a magnet or the like in the same way as a chip collection device of a normal cutting machine. Therefore, it is possible to achieve the effect that the treatment device for wastewater after grinding can be inexpensive and the wastewater treatment can be simplified.

[0022] A second embodiment of the present invention is shown in Fig. 2. In Fig. 2, in this embodiment, the polygonal pipe is a second media material 20 formed into a triangular pipe shape. The second media material 20 is formed by cutting an iron triangular pipe material 25 to a predetermined length L. The dimensions of each side of the second media material 20 are C and D, respectively, and the plate thickness is t. The length L and side dimensions C and D are set appropriately depending on the material and shape of the workpiece, the state of burrs, etc., as in the first embodiment, but are selected from the range of 5 to 30 mm for use as a media material. If the dimensions of each part, i.e., the length L and the side dimensions C and D, are smaller than 5 mm or larger than 30 mm, it is difficult to efficiently remove burrs from the workpiece. Similarly to the first embodiment, the plate thickness t is appropriately set depending on the material and shape of the workpiece, the state of burrs, etc., but is selected from the range of 1 to 5 mm in terms of use as a media material. If the plate thickness t is less than 1 mm, the media material will wear out rapidly and it will be difficult to efficiently remove burrs from the workpiece. Also, if the plate thickness t is more than 5 mm, the weight of the media material will increase, making it difficult to handle and possibly damaging the workpiece. The surfaces of each corner of the triangular pipe material 25 are appropriately rounded, and the inner corners of each corner are either rounded or not rounded. The triangular pipe material 25 can be a commercially available triangular pipe material.

[0023] According to this embodiment, the same effects as those of the first embodiment can be achieved. That is, the second media material 20 can be easily and inexpensively manufactured using commercially available triangular pipe material 25. In addition, the wastewater after polishing can be easily disposed of.

[0024] A third embodiment of the present invention is shown in Fig. 3. In Fig. 3, a third medium 30 formed in a polygonal pipe shape shown in the overall perspective view of (A) or a square pipe shape in this embodiment is formed by folding a long plate material 35 folded in four that has been cut out in a predetermined length (width) L from a commercially available iron plate, as shown in (B) and (C). The dimensions of each side of the third medium 30 in the folded state are E and F, respectively, and the plate thickness is t. As in the first embodiment, the length L and the side dimensions E and F are appropriately set depending on the material and shape of the workpiece, the state of burrs, etc., but are selected from the range of 5 to 30 mm for use as a media material. If the dimensions of each part, i.e., the length L and the side dimensions E and F, are smaller than 5 mm or larger than 30 mm, it is difficult to efficiently remove burrs from the workpiece. Similarly to the first embodiment, the plate thickness t is appropriately set depending on the material and shape of the workpiece, the state of burrs, etc., but is selected from the range of 1 to 5 mm in terms of use as a media material. If the plate thickness t is less than 1 mm, the media material will wear out rapidly and it will be difficult to efficiently remove burrs from the workpiece. Also, if the plate thickness t is more than 5 mm, the weight of the media material will increase, making it difficult to handle and possibly damaging the workpiece. The surfaces of the corners of the folded portion of the third medium material 30 are appropriately rounded.

[0025] According to this embodiment, it is possible to achieve the same effects as those of the first and second embodiments. In addition, since the third media material 30 can be cut into any shape from a commercially available iron plate using a die and a press machine, and then folded and molded, it is possible to achieve the effect that the third media material 30 can be easily formed into any size.

[0026] A fourth embodiment of the present invention is shown in Fig. 4. In Fig. 4, the fourth media material 40 is formed in a hollow polygonal shape with closed peripheral surfaces shown in the overall perspective view of (A), in this embodiment in a hollow quadrangular shape (cubic shape), and is formed by bending a cross plate material 45 cut out of a commercially available iron plate into a predetermined shape, in this embodiment in a cross shape, as shown in (B) and (C). The dimensions of the three sides of the fourth media material 40 in the folded state are G, H, and J, respectively, and the plate thickness is t. The dimensions G, H, and J of the three sides are appropriately set according to the material and shape of the workpiece, the state of burrs, and the like, as in the first embodiment, but are selected from the range of 5 to 30 mm in terms of use as a media material. If the dimensions G, H, and J of the three sides are smaller than 5 mm or larger than 30 mm, it is difficult to efficiently remove burrs from the workpiece. Similarly to the first embodiment, the plate thickness t is appropriately set depending on the material and shape of the workpiece, the state of burrs, etc., but is selected from the range of 1 to 5 mm in terms of use as a media material. If the plate thickness t is less than 1 mm, the media material will wear out rapidly and it will be difficult to efficiently remove burrs from the workpiece. Also, if the plate thickness t is more than 5 mm, the weight of the media material will increase, making it difficult to handle and possibly damaging the workpiece. The surfaces of the corners of the bent portion of the fourth medium 40 are appropriately rounded. In addition, in order to obtain the shape of each side of the cube shown in (A), the dimensions of each part of the cross shape shown in (B) will not necessarily be the same shape as shown, taking into account the plate thickness, bending allowance, etc., but since these are design issues, they are not taken into consideration here.

[0027] According to this embodiment, it is possible to achieve the same effects as in the first and second embodiments. In addition, as in the third embodiment, the fourth media material 40 can be cut out into any shape from a commercially available iron plate using a mold and a press machine, etc., so that it is possible to easily form the fourth media material 40 in any size. In addition, since the fourth media material 40 is a hollow rectangular body with a closed circumferential surface, no burrs or other debris accumulates inside the fourth media material 40.

[0028] A fifth embodiment of the present invention is shown in Fig. 5. In Fig. 5, a fifth media material 50 formed in a polygonal pipe shape shown in the overall perspective view of (A), or in a triangular pipe shape in this embodiment, is formed by folding a long tri-fold plate material 55 cut out in a predetermined length (width) L from a commercially available iron plate, as shown in (B) and (C). The dimensions of the three sides of the fifth media material 50 in the folded state are K, M, and N, respectively, and the plate thickness is t. As in the first embodiment, the length L and the dimensions K, M, and N of the three sides are set appropriately depending on the material and shape of the workpiece, the condition of the burrs, etc., but are selected from the range of 5 to 30 mm for use as a media material. If the dimensions of each part, i.e., the length L and the dimensions of the three sides K, M, and N, are smaller than 5 mm or larger than 30 mm, it is difficult to efficiently remove burrs from the workpiece. Similarly to the first embodiment, the plate thickness t is appropriately set depending on the material and shape of the workpiece, the state of burrs, etc., but is selected from the range of 1 to 5 mm in terms of use as a media material. If the plate thickness t is less than 1 mm, the media material will wear out rapidly and it will be difficult to efficiently remove burrs from the workpiece. Also, if the plate thickness t is more than 5 mm, the weight of the media material will increase, making it difficult to handle and possibly damaging the workpiece. The surfaces of the corners of the bent portion of the fifth medium material 50 are appropriately rounded.

[0029] According to this embodiment, it is possible to achieve the same effects as in the first and second embodiments. In addition, as in the third embodiment, the fifth media material 50 can be cut out into any shape from a commercially available iron plate using a mold and a press machine, etc., so that it is possible to easily form the fifth media material 50 into any size.

[0030] A sixth embodiment of the present invention is shown in Fig. 6. In Fig. 6, the sixth media material 60 is formed in a hollow polygonal shape with closed peripheral surfaces shown in the overall perspective view of (A), and in this embodiment, in a hollow triangular shape (triangular pyramid shape), which is formed by bending a triangular plate material 65 cut out of a commercially available iron plate into a triangular shape with a predetermined side length, as shown in (B) and (C). The dimensions of the three sides of the sixth media material 60 in the folded state are P, Q, and R, respectively, and the plate thickness is t. As in the first embodiment, the length L and the dimensions K, P, Q, and R of the three sides are set appropriately depending on the material and shape of the workpiece, the condition of the burrs, etc., but are selected from the range of 5 to 30 mm considering their use as media materials. If the dimensions of each part, i.e., the length L and the dimensions of the three sides K, P, Q, and R, are smaller than 5 mm or larger than 30 mm, it is difficult to efficiently remove burrs from the workpiece. Similarly to the first embodiment, the plate thickness t is appropriately set depending on the material and shape of the workpiece, the state of burrs, etc., but is selected from the range of 1 to 5 mm in terms of use as a media material. If the plate thickness t is less than 1 mm, the media material will wear out rapidly and it will be difficult to efficiently remove burrs from the workpiece. Also, if the plate thickness t is more than 5 mm, the weight of the media material will increase, making it difficult to handle and possibly damaging the workpiece. The surfaces of the corners of the bent portion of the sixth medium 60 are appropriately rounded.

[0031] According to this embodiment, it is possible to achieve the same effects as in the first and second embodiments. In addition, as in the third embodiment, the sixth media 60 can be cut out of a commercially available iron plate into a triangular shape of any size using a mold and a press machine, and therefore, it is possible to achieve the effect that the sixth media 60 of any size can be easily formed. In addition, since the sixth media 60 is formed into a hollow triangular pyramid shape with a closed circumferential surface, powder such as burrs does not accumulate inside the sixth media 60.

[0032] Next, a description will be given of the methods of using the first to sixth media materials 10, 20, 30, 40, 50, and 60 of the respective embodiments according to the present invention. The media material to be used is appropriately determined in consideration of the shape, material, and the like of the workpiece.

[0033] The wet barrel polishing machine prepared in advance is equipped with a drum-shaped barrel container, into which a product (workpiece), an abrasive, a polishing aid (compound), and a media material selected in advance from the first to sixth media materials 10, 20, 30, 40, 50, 60 are poured, and a predetermined amount of water is also poured. In this state, a rotational motion and vibration are imparted to the barrel container. As the barrel container rotates and vibrates, the workpiece and the media material rub against each other, and the entire workpiece is polished by friction.

[0034] After the polishing for a predetermined period of time has finished, the workpieces and media materials are removed from the barrel container, and the workpieces, other materials such as the media materials, and water are separated, completing the polishing. In this case, the wastewater discharged together with the media contains not only burrs from the workpiece, but also polishing powder from the media, which is made of the same metal as the metal being polished that constitutes the workpiece. However, if the workpiece is made of an iron-based material, both the burrs and the polishing powder from the media are iron-based, so the wastewater can be easily treated using a magnet or the like. The device for collecting burrs and other debris using magnets can use the chip collection device of a machine tool. The wastewater from which burrs and the like have been removed can be reused as water for the next barrel polishing, making wastewater treatment extremely easy overall.

[0035] According to each of the above-described embodiments, the following effects are obtained. The first to sixth media materials 10, 20, 30, 40, 50, 60 are formed from a material whose main component is the same metal as the metal to be polished that constitutes the workpiece. Therefore, unlike conventional ceramic media materials, burrs and polishing powder of the media materials that get mixed into the liquid discharged during barrel polishing can be easily separated from the liquid using a magnetic device, etc., making wastewater treatment extremely easy. Therefore, not only does it eliminate the need for a full-scale wastewater treatment device, but it also enables the wastewater to be recycled, which is environmentally friendly and allows barrel polishing to be carried out at low cost.

[0036] Furthermore, the first to sixth media 10, 20, 30, 40, 50, 60 can be made using commercially available pipes or plates, so that material costs can be reduced, and in this respect, barrel polishing can be carried out inexpensively. Furthermore, the first to sixth media 10, 20, 30, 40, 50, and 60 each have a rectangular or triangular shape, so that the structure is simple and the media can be manufactured at low cost. In addition, a comparative experiment in which the media materials 10, 20, 30, 40, 50, and 60 of the present embodiment and conventional commercially available ceramic media materials were polished using an actual barrel polishing machine confirmed that the media materials 10, 20, 30, 40, 50, and 60 of the present embodiment could be polished to a degree that was comparable to the conventional commercially available ceramic media materials.

[0037] Although the embodiments of the present invention have been described in detail above with reference to the drawings, the specific configurations of the present invention are not limited to these embodiments, and even if there are design changes and the like that do not deviate from the gist of the present invention, they are included in the present invention.

[0038] For example, the shape of the media material is not limited to a rectangle or triangle, but may be other polygons such as a pentagon or hexagon. However, as the number of corners increases, the sharpness of the corners decreases and the polishing power decreases, so other than a rectangle or triangle, a shape with a relatively small number of corners such as a pentagon or hexagon is preferable.

[0039] The material of the media is not limited to iron-based materials, but may be other metals such as aluminum-based and copper-based materials. [Explanation of symbols]

[0040] 10 First Media Material 15 Square pipe material 20 Second Media Material 25 Triangular pipe material 30 The third media material 35 Four-fold long board material 40 The fourth media material 45 Cross board material 50 The fifth media material 55 Tri-fold long board material 60 6th Media Material 65 Triangular plate material L Length (width) A~H Side dimensions J,K side dimensions M, N side dimensions P~R side dimensions t Plate thickness

Claims

1. A barrel polishing media material, which is made of a material whose main component is the same metal as the metal to be polished that constitutes the workpiece, and is formed into a polygonal pipe shape of a predetermined length.

2. 2. The barrel polishing media according to claim 1, wherein the polygonal pipe-shaped barrel polishing media is formed by cutting a polygonal pipe material to a predetermined length.

3. 2. The barrel polishing media according to claim 1, wherein the polygonal pipe-shaped barrel polishing media is formed by bending a plate material cut into a predetermined shape.

4. 2. The barrel polishing media according to claim 1, wherein the polygon of the barrel polishing media formed into the polygonal pipe shape is a rectangle or a triangle.

5. This is a media material for barrel polishing, which is formed by bending a plate material whose main component is the same metal as the metal to be polished that constitutes the workpiece, and is formed into a hollow polygonal shape with a closed circumferential surface.

6. 6. The barrel polishing media material according to claim 5, wherein the hollow polygonal body is formed by bending a triangular plate material whose main component is the same metal as the metal to be polished that constitutes the workpiece, and is formed into a hollow, bottomed triangular pyramid shape with a closed circumferential surface.

7. 7. The barrel polishing media according to claim 1, wherein each of the outer dimensions of the media is within a range of 5 to 30 mm.

8. 7. The barrel polishing media according to claim 1, wherein the thickness of the media is within a range of 1 to 5 mm.

9. 7. The barrel polishing media according to claim 1, wherein the media is made of iron or aluminum.

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