Cutting work auxiliary material and cutting work method

Abstract

To provide a cutting work auxiliary material which is excellent in film formation property and flexibility, without using a filler component such as a solid lubricant, and a cutting work method using the cutting work auxiliary material.SOLUTION: A cutting work auxiliary material used in cutting work of a fiber-reinforced composite material contains a high molecular weight water-soluble resin (A) having a weight average molecular weight of 5×104 or more and 1×106 or less, a middle molecular weight water-soluble resin (B) having a weight average molecular weight of 1×103 or more and less than 5×104, and a water-soluble substance (Y), wherein the water-soluble substance (Y) contains one or more selected from the group consisting of organic acids, organic acid salts, polyhydric alcohols, and amino alcohols, and with respect to 100 pts.mass of the total of the high molecular weight water-soluble resin (A) and the middle molecular weight water-soluble resin (B), a content of the high molecular weight water-soluble resin (A) is 25 to 50 pts.mass, a content of the middle molecular weight water-soluble resin (B) is 50 to 75 pts.mass, and a content of the water-soluble substance (Y) is 0.05 to 3.0 pts.mass.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a cutting auxiliary material and a cutting method. [Background technology]

[0002] Fiber-reinforced composite materials, such as fiber-reinforced plastics (FRP), and carbon fiber-reinforced plastics (CFRP), in particular, have recently been increasingly used for the outer panels of aircraft and vehicles due to their high tensile strength, tensile elasticity, and low density. CFRP is obtained by laminating one or more prepregs, each of which is carbon fiber impregnated with a matrix resin, and then hot molding them. Components made of this CFRP are fixed to structures using fastening elements such as bolts and rivets. Therefore, when fixing CFRP to structures such as aircraft parts, cutting is required, particularly drilling multiple holes in the CFRP to allow the fastening elements to pass through.

[0003] Several techniques have already been proposed to obtain high-quality holes in CFRP cutting, such as gradually changing the shape of the tool, such as the curvature and point angle of the drill rake face (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-210689 Summary of the Invention [Problem to be solved by the invention]

[0005] Cutting of fiber-reinforced composites is typically performed using a drill. However, drilling with a conventional drill has an extremely short lifespan, and as the number of drilled holes increases, the drill bit wears out, causing a decrease in the quality of the drilled holes. Specifically, the inner diameter of the drilled holes tends to become smaller, and fiber fragments and delamination are also more likely to occur. "Fiber fragments" refers to the phenomenon in which some of the fibers that make up the fiber-reinforced composite material are not cut and remain as fragments around the drilled hole. "Delamination" refers to the separation between the layers of prepreg that make up the fiber-reinforced composite material. These phenomena are recognized as serious defects.

[0006] As mentioned above, when cutting FRP, the more wear on the cutting tool progresses and the greater the cutting resistance, the more likely it is that quality problems will occur with the drilled holes. In particular, the high-strength CFRP used in aircraft applications has a high density of carbon fibers, which increases the frequency with which the drill scrapes the carbon fibers, causing faster wear on the cutting tool. Meanwhile, the manufacture of aircraft structures using CFRP requires particularly high-quality cutting, making it extremely important to resolve issues such as the aforementioned uncut fibers.

[0007] To solve these problems, cutting process auxiliary materials using solid lubricants such as carbon have been developed. While this has prevented the formation of fiber fragments and delamination around the cutting area, it has become clear that a new problem exists: the carbon and other solid lubricants contaminate the workpiece after processing. However, solid lubricants such as carbon not only provide lubrication, but also function as filler components that impart formability and flexibility to cutting process auxiliary materials. Therefore, simply removing the solid lubricants such as carbon will cause them to no longer function as cutting process auxiliary materials.

[0008] The present invention has been made in consideration of the above-mentioned problems, and aims to provide a cutting processing auxiliary material that has excellent film-forming properties and flexibility without using a filler component such as a solid lubricant, and a cutting processing method using the cutting processing auxiliary material. [Means for solving the problem]

[0009] The present inventors have conducted extensive research to solve the above problems, and as a result have found that the above problems can be solved by using a specific water-soluble substance (Y) instead of a solid lubricant, which has led to the completion of the present invention.

[0010] That is, the present invention is as follows. [1] A cutting processing auxiliary material used when cutting a fiber reinforced composite material, Weight average molecular weight is 5 x 10 4 More than 1×10 6 a high molecular weight water-soluble resin (A) which is: Weight average molecular weight is 1×10 3 5x10 or more 4 a medium molecular weight water-soluble resin (B) having a molecular weight of less than a water-soluble substance (Y), the water-soluble substance (Y) contains one or more selected from the group consisting of organic acids, organic acid salts, polyhydric alcohols, and amino alcohols; With respect to 100 parts by mass of the total of the high-molecular-weight water-soluble resin (A) and the medium-molecular-weight water-soluble resin (B), the content of the high-molecular-weight water-soluble resin (A) is 25 to 50 parts by mass, the content of the medium-molecular-weight water-soluble resin (B) is 50 to 75 parts by mass, The content of the water-soluble substance (Y) is 0.05 to 3.0 parts by mass. Cutting auxiliary material. [2] the high molecular weight water-soluble resin (A) is at least one selected from the group consisting of polyalkylene oxide compounds, polyalkylene glycol compounds, ester compounds of polyalkylene glycols, ether compounds of polyalkylene glycols, monostearate compounds of polyalkylene glycols, water-soluble urethanes, water-soluble polyether resins, water-soluble polyesters, sodium poly(meth)acrylate, polyacrylamides, polyvinylpyrrolidones, polyvinyl alcohols, sugars, and modified polyamides; The cutting processing auxiliary material described in [1]. [3] The medium-molecular-weight water-soluble resin (B) is at least one selected from the group consisting of polyalkylene glycol compounds, monoether compounds of polyalkylene oxides, monostearate compounds of polyalkylene oxides, and polyalkylene oxide compounds. The cutting processing auxiliary material according to [1] or [2]. [4] The melt viscosity at 100°C is 100 to 2000 Pa·s. The cutting processing auxiliary material according to any one of [1] to [3]. [5] It has a sheet shape with a thickness of 0.1 mm or more and 10 mm or less, The cutting processing auxiliary material according to any one of [1] to [4]. [6] Further, an adhesive layer is provided on the surface that comes into contact with the workpiece. The cutting processing auxiliary material according to any one of [1] to [5]. [7] The adhesive layer contains an acrylic polymer. The cutting processing auxiliary material according to any one of [1] to [6]. [8] A cutting process includes a cutting step in which the cutting auxiliary material according to any one of [1] to [7] is brought into contact with a cutting tool and / or a portion of a workpiece to be processed, and the workpiece is cut with the cutting tool to form a cut portion. Cutting method. [9] A hole is formed as the cutting portion. The cutting method according to [8].

[10] The workpiece comprises carbon fiber reinforced plastic, glass fiber reinforced plastic, aramid fiber reinforced plastic, or Kevlar fiber reinforced plastic; The cutting method according to [8] or [9]. [Effects of the Invention]

[0011] According to the present invention, it is possible to provide a cutting processing auxiliary material that has excellent film-forming properties and flexibility without using a filler component such as a solid lubricant, and a cutting processing method using the cutting processing auxiliary material. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a schematic diagram illustrating one aspect of a cutting method according to an embodiment of the present invention. [Figure 2] 10A and 10B are schematic diagrams illustrating another aspect of the cutting method of the present embodiment. [Figure 3] FIG. 10 is a schematic view showing still another aspect of the cutting method of the present embodiment. [Figure 4] FIG. 1 is a diagram for explaining the delamination length evaluated in the examples. DETAILED DESCRIPTION OF THE INVENTION

[0013] Below, we will explain in detail the embodiment of the present invention (hereinafter referred to as the ``present embodiment''), but the present invention is not limited to this and various modifications are possible within the scope of the gist of the present invention.

[0014] 1. Cutting auxiliary materials The cutting processing aid of this embodiment is a cutting processing aid used when cutting a fiber reinforced composite material, and has a weight average molecular weight of 5 × 10 4 More than 1×10 6 and a high molecular weight water-soluble resin (A) having a weight average molecular weight of 1×10 or less. 3 5x10 or more 4 and a water-soluble substance (Y), wherein the water-soluble substance (Y) comprises one or more selected from the group consisting of organic acids, organic acid salts, polyhydric alcohols, and amino alcohols, and the content of the high molecular weight water-soluble resin (A) is 25 to 50 parts by mass, the content of the medium molecular weight water-soluble resin (B) is 50 to 75 parts by mass, and the content of the water-soluble substance (Y) is 0.05 to 3.0 parts by mass, relative to 100 parts by mass in total of the high molecular weight water-soluble resin (A) and the medium molecular weight water-soluble resin (B).

[0015] 1 to 3 show an embodiment of a cutting method using the cutting auxiliary material of this embodiment. As shown in Fig. 1 to 3, the cutting auxiliary material 2 of this embodiment is used in cutting (for example, drilling) a fiber-reinforced composite material 1. Specifically, the cutting auxiliary material 2 is placed on the back surface of the fiber-reinforced composite material 1, and the fiber-reinforced composite material 1 is machined using a cutting tool 3 from the fiber-reinforced composite material 1 side toward the cutting auxiliary material 2 side (Fig. 2).

[0016] The cutting process auxiliary material of this embodiment can be suitably used not only when the workpiece has a flat surface, but also when the workpiece has a curved surface, in the same way as when the workpiece has a flat surface. The shape of the cutting process auxiliary material is not particularly limited, but examples thereof include a sheet-shaped cutting process auxiliary material and a block-shaped cutting process auxiliary material such as a round bar or a square bar.

[0017] The cutting processing auxiliary material of this embodiment preferably has a configuration that does not impede the flexibility of the sheet itself or its ability to conform to the processed part, and specifically, it is preferable that it does not include metal foil, etc. This makes it possible to prevent abrasive dust other than the processed material from contaminating the processed material.

[0018] 1.1.High molecular weight water-soluble resin (A) The high molecular weight water-soluble resin (A) can function as a lubricant, improving the lubricity of the cutting process aid and suppressing the formation of uncut fibers around the cutting area. Furthermore, the high molecular weight water-soluble resin (A) can function as a molding agent, improving the moldability of the cutting process aid. This allows cutting process aids to be molded into various shapes, and single-layer formation is also possible. Here, "single-layer formation" refers to the formation of a layer (sheet) using the cutting process aid itself, without using a supporting substrate. Furthermore, the polymer compound (A) imparts conformability and toughness to the cutting process aid, thereby improving the cutting processability of curved surfaces.

[0019] The high molecular weight water-soluble resin (A) has a weight average molecular weight of 5×10 4 That's it, 1 x 106 The high molecular weight water-soluble resin (A) is not particularly limited, and examples thereof include water-soluble thermoplastic resins and water-soluble thermosetting resins. Among these, water-soluble thermoplastic resins are more preferred. The term "water-soluble resin" refers to a polymer compound that dissolves at least 1 g in 100 g of water at 25°C and 1 atmosphere. The high molecular weight water-soluble resin (A) may be used alone or in combination of two or more types.

[0020] The use of a water-soluble resin tends to improve the discharge of cutting chips during cutting due to the lubricity of the water-soluble resin. Furthermore, the use of a water-soluble resin tends to further reduce the load on the cutting tool because the surface hardness of the cutting aid becomes moderately soft. Furthermore, it is possible to easily remove resin components adhering to the cutting area and its surroundings after cutting.

[0021] The water-soluble thermoplastic resin is not particularly limited, but examples thereof include polyalkylene oxide compounds such as polyethylene oxide, polypropylene oxide, and polyethylene oxide-propylene oxide copolymer; polyalkylene glycol compounds such as polyethylene glycol and polypropylene glycol; polyalkylene glycol ester compounds; polyalkylene glycol ether compounds; polyalkylene glycol monostearate compounds such as polyethylene glycol monostearate, polypropylene glycol monostearate, and polyglycerin monostearate; water-soluble urethane; polyether-based water-soluble resins; water-soluble polyesters; poly(sodium meth)acrylate; polyacrylamide; polyvinylpyrrolidone; polyvinyl alcohol; sugars such as cellulose and its derivatives; and modified polyamides. Among these, polyethylene oxide, polyethylene glycol, and polyether-based water-soluble resins are preferred from the above-mentioned viewpoints.

[0022] The weight average molecular weight of the high molecular weight water-soluble resin (A) is 5×10 4 More than 6 × 10 4 That's 1 x 10 5 That is 1.25 x 10 5The weight average molecular weight of the high molecular weight water-soluble resin (A) is 1×10 6 Preferably, it is 8 x 10 or less. 5 is less than 7 x 10 5 is less than or equal to 6 x 10 5 The weight average molecular weight of the high molecular weight water-soluble resin (A) is 5×10 or less. 4 By satisfying the above, moldability is further improved, conformability and toughness can be imparted to the cutting processing auxiliary material, and the cutting processability of curved surfaces tends to be improved. 6 When the ratio is equal to or less than 1, the lubricity is further improved.

[0023] When two or more high molecular weight water-soluble resins (A) are used, it is preferable that each compound satisfies the above weight average molecular weight. In this embodiment, the weight average molecular weight can be measured by the method described in the Examples (hereinafter the same).

[0024] The high molecular weight water-soluble resin (A) has a weight average molecular weight of 6×10 5 That's it, 1 x 10 6 High molecular weight compound (A-1) having a weight average molecular weight of 5×10 or less and / or 4 That's it, 6 x 10 5 The present invention may further include a high molecular weight compound (A-2) having a molecular weight of less than 10 ...

[0025] The weight average molecular weight of the high molecular weight compound (A-1) is preferably 6×10 5 That's 6.5 x 10 5 That's 7 x 10 5 That is 7.5 x 10 5 The weight average molecular weight of the high molecular weight compound (A-1) is preferably 1×10 6 is less than or equal to 9.5 x 10 5 is less than or equal to 9 x 10 5is less than or equal to 8.5 x 10 5 The following is the result.

[0026] The content of the high molecular weight compound (A-1) is preferably 15 parts by mass or more, 20 parts by mass or more, or 25 parts by mass or more, based on 100 parts by mass of the total of the high molecular weight water-soluble resin (A) and the medium molecular weight water-soluble resin (B). The content of the high molecular weight compound (A-1) is preferably 45 parts by mass or less, 40 parts by mass or less, or 35 parts by mass or less, based on 100 parts by mass of the total of the high molecular weight water-soluble resin (A) and the medium molecular weight water-soluble resin (B). When the content of the high molecular weight compound (A-1) is 5 parts by mass or more, moldability tends to be further improved. Furthermore, the conformability and toughness of the cutting processing aid tend to be improved, and the cutting processability of curved surfaces tends to be improved. Furthermore, when the content of the high molecular weight compound (A-1) is 30 parts by mass or less, lubricity tends to be further improved.

[0027] The weight average molecular weight of the high molecular weight compound (A-2) is preferably 5×10 4 That's 1 x 10 5 That is 1.25 x 10 5 The weight average molecular weight of the high molecular weight compound (A-2) is preferably 6×10 5 is less than 5.5 x 10 5 is less than or equal to 5 x 10 5 is less than 4.5 x 10 5 is less than or equal to 4 x 10 5 is less than or equal to 3.5 x 10 5 is less than or equal to 3 x 10 5 The following is the result.

[0028] The content of the high molecular weight compound (A-2) is preferably 5 parts by mass or more, 7.5 parts by mass or more, or 10 parts by mass or more, relative to 100 parts by mass of the total of the high molecular weight water-soluble resin (A) and the medium molecular weight water-soluble resin (B). The content of the high molecular weight compound (A-2) is preferably 30 parts by mass or less, 25 parts by mass or less, 20 parts by mass or less, or 17.5 parts by mass or less, relative to 100 parts by mass of the total of the high molecular weight water-soluble resin (A) and the medium molecular weight water-soluble resin (B). When the content of the high molecular weight compound (A-2) is 5 parts by mass or more, lubricity tends to be further improved. When the content of the high molecular weight compound (A-2) is 30 parts by mass or less, moldability tends to be further improved.

[0029] The content of the high molecular weight water-soluble resin (A) is preferably 25 parts by mass or more, 30 parts by mass or more, 35 parts by mass or more, or 37.5 parts by mass or more, relative to 100 parts by mass of the total of the high molecular weight water-soluble resin (A) and the medium molecular weight water-soluble resin (B). The content of the high molecular weight water-soluble resin (A) is preferably 50 parts by mass or less, 47.5 parts by mass or less, 45 parts by mass or less, or 42.5 parts by mass or less, relative to 100 parts by mass of the total of the high molecular weight water-soluble resin (A) and the medium molecular weight water-soluble resin (B). When the content of the high molecular weight water-soluble resin (A) is 25 parts by mass or more, lubricity tends to be further improved. When the content of the high molecular weight water-soluble resin (A) is 25 parts by mass or more, conformability and toughness tend to be improved, and the cutting workability of curved surfaces tends to be improved. When the content of the high molecular weight water-soluble resin (A) is 50 parts by mass or less, moldability tends to be further improved.

[0030] 1.2.Medium molecular weight water-soluble resin (B) The medium molecular weight water-soluble resin (B) can function as a lubricant, improving the lubricity of the cutting processing aid and reducing the amount of fiber residue remaining around the cutting area.

[0031] The medium molecular weight water-soluble resin (B) has a weight average molecular weight of 1 × 10 3 That's it, 5 x 10 4As long as the molecular weight is less than 1000 ppm, there are no particular limitations on the resin, and examples thereof include water-soluble thermoplastic resins and water-soluble thermosetting resins. Of these, water-soluble thermoplastic resins are more preferred. The medium-molecular-weight water-soluble resin (B) may be used alone or in combination of two or more.

[0032] The medium molecular weight water-soluble resin (B) is not particularly limited, but examples thereof include polyalkylene glycol compounds such as polyethylene glycol, polypropylene glycol, and polytetramethylene glycol; polyalkylene oxide monoether compounds such as polyethylene oxide oleyl ether, polyethylene oxide cetyl ether, polyethylene oxide stearyl ether, polyethylene oxide lauryl ether, polyethylene oxide nonylphenyl ether, and polyethylene oxide octylphenyl ether; polyalkylene oxide monostearate compounds such as polyethylene oxide monostearate, polyethylene oxide sorbitan monostearate, and polyglycerin monostearate; and polyalkylene oxide compounds such as polyethylene oxide, polypropylene oxide, and polyethylene oxide-propylene oxide copolymers. Among these, polyethylene oxide monostearate is preferred. The use of such a medium molecular weight water-soluble resin (B) tends to further improve lubricity.

[0033] The weight average molecular weight of the medium molecular weight water-soluble resin (B) is 1 x 10 3 or more, preferably 1.25 × 10 3 That is 1.5 x 10 3 That's 2 x 10 3 That is 2.5 x 10 3 The weight average molecular weight of the medium molecular weight water-soluble resin (B) is 5×10 4 less than 2.5 x 10 4 is less than or equal to 2 x 10 4 is less than or equal to 1 x 10 4 is less than or equal to 7.5 x 10 3 is less than or equal to 5 x 10 3The weight average molecular weight of the medium molecular weight water-soluble resin (B) is 1×10 or less. 3 When the weight average molecular weight of the medium molecular weight water-soluble resin (B) is 5×10 or more, the moldability is further improved. 4 When the amount is less than 10 ...

[0034] The content of the medium molecular weight water-soluble resin (B) is preferably 50 parts by mass or more, 55 parts by mass or more, or 57.5 parts by mass or more, relative to 100 parts by mass of the total of the high molecular weight water-soluble resin (A) and the medium molecular weight water-soluble resin (B). Furthermore, the content of the medium molecular weight water-soluble resin (B) is preferably 75 parts by mass or less, 70 parts by mass or less, 67.5 parts by mass or less, or 65 parts by mass or less, relative to 100 parts by mass of the total of the high molecular weight water-soluble resin (A) and the medium molecular weight water-soluble resin (B). When the content of the medium molecular weight water-soluble resin (B) is 50 parts by mass or more, lubricity tends to be further improved. Furthermore, when the content of the medium molecular weight water-soluble resin (B) is 75 parts by mass or less, moldability tends to be further improved.

[0035] The high-molecular-weight water-soluble resin (A) and the medium-molecular-weight water-soluble resin (B), which have different molecular weights, may also have different melt viscosities and melting points. By using such a high-molecular-weight water-soluble resin (A) and a medium-molecular-weight water-soluble resin (B) in combination, it is possible to prevent the formability and lubricity of the cutting process auxiliary material from decreasing due to a significantly high viscosity or melting point of the cutting process auxiliary material, which would occur if only the high-molecular-weight water-soluble resin (A) were used. On the other hand, it is possible to prevent the formability and lubricity of the cutting process auxiliary material from decreasing due to a significantly low viscosity or melting point of the cutting process auxiliary material, which would occur if only the medium-molecular-weight water-soluble resin (B) were used.

[0036] 1.3. Additive (Y) By using the water-soluble substance (Y), it is possible to improve film-forming properties and flexibility without using a solid lubricant. The water-soluble substance (Y) includes one or more substances selected from the group consisting of organic acids, organic acid salts, polyhydric alcohols, and amino alcohols.

[0037] Examples of organic acids include, but are not limited to, 1-hydroxyethylidene-1,1-diphosphonic acid (HEDP), formic acid, acetic acid, propionic acid, butyric acid, valeric acid, 2-methylbutyric acid, n-hexanoic acid, 3,3-dimethylbutyric acid, 2-ethylbutyric acid, 4-methylpentanoic acid, n-heptanoic acid, 2-methylhexanoic acid, n-octanoic acid, 2-ethylhexanoic acid, benzoic acid, glycolic acid, salicylic acid, glyceric acid, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, maleic acid, phthalic acid, fumaric acid, malic acid, tartaric acid, citric acid, and lactic acid, as well as methanesulfonic acid, ethanesulfonic acid, and isethionic acid.

[0038] The polyhydric alcohol is not particularly limited, but examples thereof include ethylene glycol, propylene glycol, dipropylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, butylene glycol, 3-methyl-1,5-pentanediol, propanediol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,9-nonanediol, neopentyl glycol, octanediol, butylethylpentanediol, 2-ethyl-1,3-hexanediol, cyclohexanediol, cyclohexanedimethanol, tricyclodecane dimethanol, cyclopentadiene dimethanol, glycerin, trimethylolpropane, 1,4-cyclohexanedimethanol, neopentyl glycol, erythritol, sorbitol, xylitol, and inositol.

[0039] The amino alcohols are not particularly limited, but examples thereof include monoethanolamine, diethanolamine, triethanolamine, monoisopropanolamine, diisopropanolamine, triisopropanolamine, 5-amino-1-pentanol (pentanolamine), 2-amino-2-methyl-1-propanol, 2-amino-3-phenyl-1-propanol, monoethanoldiisopropanolamine, N,N-dimethylethanolamine, N,N-diethylethanolamine, Examples include N-(2-hydroxyethyl)ethylenediamine, N,N'-bis(2-hydroxyethyl)ethylenediamine, N-(2-hydroxypropyl)ethylenediamine, N,N,N',N'-tetrakis(2-hydroxyethyl)ethylenediamine, N,N,N',N'-tetrakis(2-hydroxyethyl)-1,6-hexamethylenediamine, N,N-bis(2-hydroxyethyl)isopropanolamine, and N,N-bis(2-hydroxyethyl)-1,3-diaminopropane.

[0040] The content of the water-soluble substance (Y) is preferably 0.05 parts by mass or more, 0.10 parts by mass or more, or 0.15 parts by mass or more, relative to 100 parts by mass of the total of the high-molecular-weight water-soluble resin (A) and the medium-molecular-weight water-soluble resin (B). The content of the water-soluble substance (Y) is preferably 3.0 parts by mass or less, 2.0 parts by mass or less, 1.0 parts by mass or less, 0.75 parts by mass or less, 0.50 parts by mass or less, or 0.30 parts by mass or less, relative to 100 parts by mass of the total of the high-molecular-weight water-soluble resin (A) and the medium-molecular-weight water-soluble resin (B). When the content of the water-soluble substance (Y) is within the above range, moldability and flexibility tend to be further improved.

[0041] 1.4.Other Ingredients The cutting processing auxiliary material of this embodiment may contain other components as needed, such as lubricity improving components, sheet formability improving components, plasticizers, softeners, surface conditioners, leveling agents, antistatic agents, emulsifiers, antifoaming agents, wax additives, coupling agents, rheology control agents, preservatives, antifungal agents, antioxidants, light stabilizers, nucleating agents, organic fillers, inorganic fillers, solid lubricants, heat stabilizers, and colorants.

[0042] The lubricity-improving component is not particularly limited, but examples thereof include amide compounds exemplified by ethylene bisstearamide, oleic acid amide, stearic acid amide, and methylene bisstearamide; fatty acid compounds exemplified by lauric acid, stearic acid, palmitic acid, and oleic acid; fatty acid ester compounds exemplified by butyl stearate, butyl oleate, and glycol laurate; aliphatic hydrocarbon compounds exemplified by liquid paraffin; and higher aliphatic alcohols exemplified by oleyl alcohol, and at least one of these can be selected.

[0043] The sheet formability improving component is not particularly limited, but examples thereof include thermosetting resins such as epoxy resins, phenolic resins, cyanate resins, melamine resins, urea resins, and thermosetting polyimides, and at least one of these can be selected.

[0044] By including a plasticizer and a softener, when the cutting processing aid is placed on the curved surface of the workpiece, for example, stress and strain on the cutting processing aid can be reduced, thereby suppressing cracking of the cutting processing aid and tending to further improve its ability to conform to the curved surface. The plasticizer and the softener are not particularly limited, but examples thereof include phthalate esters, adipate esters, trimellitate esters, polyesters, phosphate esters, citrate esters, epoxidized vegetable oils, and sebacate esters.

[0045] The solid lubricant is not particularly limited, but examples thereof include molybdenum disulfide, tungsten disulfide, molybdenum compounds, polytetrafluoroethylene, and polyimide.

[0046] Among these, it is preferable that organic fillers, inorganic fillers, solid lubricants, etc. are not contained from the viewpoint of preventing contamination. It is also preferable that water-insoluble components are not contained. Even if organic fillers, inorganic fillers, solid lubricants, water-insoluble components, etc. are contained, the content thereof is preferably 1 part by mass or less, 0.5 parts by mass or less, or 0.1 parts by mass or less per 100 parts by mass of the cutting processing auxiliary material.

[0047] 1.5. Adhesive layer The cutting process auxiliary material of this embodiment may further have an adhesive layer on the surface that comes into contact with the workpiece. By having an adhesive layer, the adhesion between the cutting process auxiliary material and the workpiece tends to be further improved.

[0048] The components of the adhesive layer are not particularly limited, but examples thereof include thermoplastic resins and / or thermosetting resins. Thermoplastic resins are not particularly limited, but examples thereof include urethane polymers, acrylic polymers, vinyl acetate polymers, vinyl chloride polymers, polyester polymers, and copolymers thereof. Thermosetting resins are not particularly limited, but examples thereof include phenolic resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, thermosetting polyimides, cyanate resins, and other resins. Among these, acrylic polymers are preferred because they are required to leave no adhesive residue on the workpiece and to be easily adhesive at room temperature, and solvent-based acrylic adhesives and water-based acrylic emulsion-type adhesives are more preferred.

[0049] 1.7.Melt Viscosity The melt viscosity of the cutting process auxiliary material at 100°C is preferably 100 Pa·s or more, 125 Pa·s or more, 150 Pa·s or more, 175 Pa·s or more, 200 Pa·s or more, or 225 Pa·s or more. The melt viscosity of the cutting process auxiliary material at 100°C is preferably 2000 Pa·s or less, 1500 Pa·s or less, 1000 Pa·s or less, 750 Pa·s or less, 500 Pa·s or less, or 400 Pa·s or less. When no filler component such as a solid lubricant is included, a melt viscosity at 100°C within the above range makes it easier for the shape to be maintained when a film is formed, which tends to further improve film formability.

[0050] The melt viscosity at 100° C. can be adjusted by the composition and content ratio of the high molecular weight water-soluble resin (A), the medium molecular weight water-soluble resin (B), and the water-soluble substance (Y).

[0051] Thickness The thickness of the cutting processing auxiliary material excluding the adhesive layer is not particularly limited, and can be appropriately selected depending on the cutting method, cutting method, area and volume of the part to be processed, type of cutting tool, composition and thickness of the workpiece when cutting the workpiece.

[0052] Among these, the thickness of the cutting process auxiliary material having a sheet shape is preferably 0.1 mm or more, 0.2 mm or more, or 0.5 mm or more. Furthermore, the thickness of the cutting process auxiliary material is preferably 10 mm or less, 7.5 mm or less, or 5 mm or less. When the thickness of the cutting process auxiliary material is 0.1 mm or more, sufficient reduction in cutting stress is obtained, the load on the cutting tool is reduced, and drill breakage and the like tend to be more effectively prevented. Furthermore, when the thickness of the cutting process auxiliary material is 10 mm or less, the wrapping of the cutting process auxiliary material around the cutting tool is reduced, and the occurrence of cracks in the cutting process auxiliary material tends to be more effectively prevented.

[0053] 2. Manufacturing method of cutting processing auxiliary material The manufacturing method of the cutting processing auxiliary material of this embodiment is not particularly limited, and a conventionally known method of molding a resin composition containing a resin such as a polymeric material and a filler (e.g., an inorganic filler) into a sheet or a block shape such as a round bar or a square bar can be widely used.

[0054] For example, there is a method in which a high molecular weight water-soluble resin (A), a medium molecular weight water-soluble resin (B), and a water-soluble substance (Y) are mixed in the presence or absence of a solvent, applied to a support, cooled, and solidified to form a sheet, and then the support is removed and peeled off to obtain a cutting processing aid; and there is a method in which a high molecular weight water-soluble resin (A), a medium molecular weight water-soluble resin (B), and a water-soluble substance (Y) are mixed in the presence or absence of a solvent, extruded into a sheet, and stretched as necessary to obtain a cutting processing aid.

[0055] When the cutting processing auxiliary material is the laminate described above (for example, a cutting processing auxiliary lubricating sheet having an adhesive layer or a protective layer), the method for manufacturing the laminate is not particularly limited, and examples thereof include a method of directly forming another layer on at least one side of a pre-prepared layer, and a method of bonding a pre-prepared layer and another layer using an adhesive resin or a thermal lamination method.

[0056] In addition, the method for forming the adhesive layer on the surface of the cutting processing auxiliary material is not particularly limited, as long as it is a known method that is industrially used.Specifically, examples include the method of forming the adhesive layer by roll method, curtain coating method, spray spraying method, etc., and the method of forming the adhesive layer with a desired thickness in advance using roll or T-die extruder, etc.The thickness of the adhesive layer is not particularly limited, and can be appropriately selected to be optimal according to the curvature of the workpiece and the configuration of the cutting processing auxiliary material.

[0057] In addition, when producing a cutting processing aid in a molten state, a resin composition obtained by mixing a resin and a filler is used as the cutting processing aid, or a resin composition obtained by mixing a resin, a filler, and a solvent is used as the cutting processing aid.

[0058] 3.Cutting method The cutting method of this embodiment includes a cutting process step in which a cutting auxiliary material is brought into contact with a cutting tool and / or a portion of a workpiece to be processed, and the workpiece is cut with the cutting tool to form a cutting portion.

[0059] Here, "while in contact" is not particularly limited, but examples include a case where, before cutting, a contact process is carried out in which the cutting processing auxiliary material is attached to a cutting tool, and then the cutting processing is carried out using the cutting tool to which the cutting processing auxiliary material is attached; a case where, after a contact process is carried out in which the cutting processing auxiliary material is attached to the processed portion of the workpiece, the processed portion of the workpiece is cut from the cutting processing auxiliary material side; or a case where both of these are used in combination.

[0060] Furthermore, the term "cutting" is not particularly limited as long as it is a process for cutting a workpiece, and examples thereof include drilling, grooving, turning, cutting, etc. Among these, drilling using a drill (hereinafter also referred to as "drilling"), which forms a hole as the cutting portion, is preferred.

[0061] The cutting method of this embodiment is not particularly limited, but for example, the cutting process may be carried out with a cutting process auxiliary material in close contact with the part of the workpiece that will be the exit of the cutting tool (FIG. 1), or the cutting process may be carried out with a cutting process auxiliary material in close contact with the part of the workpiece that will be the entrance of the cutting tool (FIG. 2), or the workpiece with the cutting process auxiliary material in close contact may be cut with the cutting tool in contact with the cutting process auxiliary material to form a cutting portion (FIG. 3).

[0062] In the cutting process, the workpiece may be cut using a cutting tool to which a cutting processing auxiliary material is attached, or the adhesive bond between the cutting processing auxiliary material and the workpiece may be cut using the cutting tool. The use of a cutting processing auxiliary material in this way increases the lubricity between the cutting tool surface (including the cutting tool blade) and the inner wall surface of the cutting section, particularly when cutting continuously. This facilitates the removal of fibers cut by the cutting tool blade and difficult-to-cut particles in the hard-to-cut metal, reducing the frequency and degree of abrasion with the cutting tool blade, and therefore reducing wear on the cutting tool blade. This principle of action is applicable to cutting tools in general.

[0063] In the cutting process, it is preferable to use a drill as a cutting tool and form a hole as the cutting portion by drilling. By using the cutting auxiliary material of this embodiment, the load on the drill can be reduced, and the amount of fiber remaining around the drilled hole can be reduced, which is expected to improve the quality of the cut portion of the workpiece. The cutting tool used is not particularly limited as long as it is a commonly used one. For example, when a drill is used as the cutting tool, there are no particular limitations on the diameter, material, shape, or presence or absence of a surface coating of the drill.

[0064] The fiber reinforced composite material to be processed is not particularly limited as long as it is a composite material composed of a matrix resin and reinforcing fibers.

[0065] The matrix resin is not particularly limited, but examples thereof include thermosetting resins such as epoxy resin, phenol resin, cyanate resin, vinyl ester resin, and unsaturated polyester resin; and thermoplastic resins such as ABS (acrylonitrile-butadiene-styrene) resin, PA (polyamide) resin, PP (polypropylene) resin, PC (polycarbonate) resin, methyl methacrylate resin, polyethylene, acrylic, and polyester resin.

[0066] Examples of reinforcing fibers include, but are not limited to, glass fibers, carbon fibers, and aramid fibers. Examples of the form of reinforcing fibers include, but are not limited to, filaments, tows, cloths, braids, chopped fibers, milled fibers, felt mats, papers, and prepregs.

[0067] Specific examples of such fiber reinforced composite materials are not particularly limited, but carbon fiber reinforced plastics (CFRP), glass fiber reinforced plastics (GFRP), aramid fiber reinforced plastics (AFRP), or Kevlar fiber reinforced plastics are preferred. [Example]

[0068] The present invention will be specifically described below using examples and comparative examples. Note that the following examples merely illustrate embodiments of the present invention, and the present invention is not limited thereto.

[0069] Example 1 To a mixture of 30 parts by mass of polyethylene oxide (AIII: ALKOX E-45, manufactured by Meisei Chemical Industry Co., Ltd., weight-average molecular weight = 800,000) as a high molecular weight water-soluble resin (A), 10 parts by mass of polyethylene oxide (AI: PEO-1, manufactured by Sumitomo Seika Chemicals Co., Ltd., weight-average molecular weight = 275,000), and 60 parts by mass of polyethylene oxide monostearate (B: NONION S-40, manufactured by NOF Corporation, weight-average molecular weight = 3,000) as a medium molecular weight water-soluble resin (B), 0.17 parts by mass of succinic acid (YI: manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.) as a water-soluble substance (Y), and the mixture was thoroughly mixed to obtain a water-soluble resin composition.

[0070] The mixed water-soluble resin composition was further thoroughly mixed using a single-screw extruder and molded at a temperature of 120° C. to produce a cutting process auxiliary material sheet with a thickness of 0.5 mm. Then, the strong adhesive side of a 0.12 mm thick acrylic double-sided tape (No. 535A, manufactured by Nitto Denko Corporation) that would serve as an adhesive layer was attached to one side of the produced cutting process auxiliary material sheet so that the strong adhesive side was in contact with the sheet side to form an adhesive layer.

[0071] [Method for measuring molecular weight] The weight average molecular weight of the high molecular weight water-soluble resin (A) and the medium molecular weight water-soluble resin (B) was calculated as a relative average molecular weight by dissolving and dispersing the high molecular weight water-soluble resin (A) or the medium molecular weight water-soluble resin (B) in 0.05% saline, and measuring the molecular weight using a liquid chromatograph equipped with a GPC (Gel Permeation Chromatography) column with polyethylene glycol as a standard substance.

[0072] [Method for measuring melt viscosity] A portion of the cutting processing auxiliary material was molded using a tabletop tablet molding machine, and the melt viscosity of the cutting processing auxiliary material was measured using a melt viscosity measuring device (CFT-500EX: manufactured by SHIMADZU CORPORATION) under the conditions of a capillary diameter of 1.0 mm, a length of 1.0 mm, a temperature of 100°C, and a test pressure of 980,000 Pa.

[0073] [Film-forming property evaluation] When a cutting processing auxiliary material sheet having a thickness of 0.5 mm could be produced using a single-screw extruder, the film-forming property was evaluated as ◯, and when a film could not be formed, the film-forming property was evaluated as ×. Incidentally, "film-forming is not possible" refers to a case where it is difficult to extrude the resin using an extruder in the first place and extrusion is practically impossible, or a case where uniform extrusion is not possible and the material extruded from the extruder does not form a sheet.

[0074] [Flexibility evaluation] The flexibility of the cutting processing auxiliary material sheet, which was 50 mm x 100 mm in size, was confirmed by holding both ends of the long side of the sheet and repeatedly bending it until the distance between the ends was 25 mm, and checking whether cracks or tears occurred in the cutting processing auxiliary material sheet. (Evaluation criteria) 〇: No cracks or splits occur even after repeated bending operations four or more times △: Cracks or splits occur after repeated bending 2-3 times ×: Cracks or splits occur after one bending operation

[0075] [Cutting process evaluation] The adhesive layer of the cutting processing auxiliary material sheet was attached to the outlet of the cutting tool (carbide drill) of the workpiece, and the cutting processing auxiliary material sheet and the workpiece were fixed to a drilling machine using a jig. Then, a hole was drilled using a drill bit from the side of the workpiece where the auxiliary tape was not attached to the side where the auxiliary tape was attached.

[0076] The workpiece used in this study was carbon fiber reinforced plastic (CFRP). Cutting (drilling) using a cemented carbide drill was performed at a cutting speed of V = 100 m / min and a feed rate of f = 0.05 mm / rev. The exit side of the drill bit after drilling was measured using a one-shot 3D shape measuring machine (VR-5200, manufactured by KEYENCE Corporation). From the measured data, analysis software was used to measure the maximum length of delamination (fiber peeling) around the cutting area (machined hole) at the exit side of the drill bit.

[0077] Figure 4 shows an example of delamination (fiber peeling) around the cutting section (machined hole) on the exit side of the drill bit. The length of the delamination refers to the length from the edge of the drilled hole to the end of the peeled portion. Therefore, in Figure 4, the distances indicated by arrows A and B are the lengths from the edge of the drilled hole to the end of the peeled portion (delamination length). In this example, the maximum length of this delamination length, the length indicated by arrow B in Figure 4, was measured. This was measured every 10 holes from the first hole to the 120th hole, and the results are shown in Table 1 as the average value for each hole.

[0078] [Evaluation of contamination after cutting] The adhesive layer of the cutting processing auxiliary material sheet was attached to the outlet of the cutting tool (carbide drill) of the workpiece, and the cutting processing auxiliary material sheet and the workpiece were fixed to a drilling machine using a jig. Then, a hole was drilled using a drill bit from the side of the workpiece where the auxiliary tape was not attached to the side where the auxiliary tape was attached.

[0079] In this study, glass fiber reinforced plastic (GFRP) was used as the workpiece. Cutting (drilling) using a cemented carbide drill was performed at a cutting speed of V = 40 m / min and a feed rate of f = 0.03 mm / rev. After drilling, the workpiece was cleaned with air blow and ethanol, and 1,000 drilled holes were visually inspected to count the number of holes with dirt that appeared to be sheet residue. The number of holes with dirt observed out of 1,000 holes is shown in Table 1.

[0080] Examples 2 to 6 Cutting process auxiliary material sheets of Examples 2 to 6 were produced in the same manner as in Example 1, except that the components shown in Table 1 were used. In Examples 2 and 3, cutting process evaluation was carried out in the same manner as in Example 1, and in Example 3, post-cutting contamination evaluation was carried out in the same manner as in Example 1.

[0081] The components used in Table 1 are as follows: AI: Polyethylene oxide, PEO-1, manufactured by Sumitomo Seika Chemicals Co., Ltd., weight average molecular weight = 275,000 A-II: Polyethylene oxide, Alcox R-150, manufactured by Meisei Chemical Industry Co., Ltd., weight average molecular weight = 150,000 A-III: Polyethylene oxide, Alcox E-45, manufactured by Meisei Chemical Industry Co., Ltd., weight average molecular weight = 800,000 B: Polyethylene oxide monostearate, Nonion S-40, manufactured by NOF Corporation, weight average molecular weight = 3000 YI: succinic acid, manufactured by Fujifilm Wako Pure Chemical Industries, Ltd. Y-II: Stearyl alcohol, manufactured by Tokyo Chemical Industry Co., Ltd.

[0082] Comparative Examples 1 to 6 Cutting process auxiliary material sheets of Comparative Examples 1, 3, and 6 were produced in the same manner as in Example 1, except that the components shown in Table 1 were used. For Comparative Examples 2, 4, and 5, film formation using an extruder was impossible, and therefore they were evaluated as x in Table 1. Furthermore, flexibility evaluation was not performed for those for which film formation was not possible.

[0083] In Comparative Example 6, the cutting process evaluation and the post-cutting contamination evaluation were carried out in the same manner as in Example 1.

[0084] Comparative Example 7 Table 1 shows the results of a cutting evaluation of carbon fiber reinforced plastic (CFRP) without using a cutting auxiliary material sheet, and the results of a contamination evaluation after cutting glass fiber reinforced plastic (GFRP).

[0085] [Table 1]

[0086] It was found that cutting process auxiliary materials excellent in film-forming property and flexibility could be obtained in all of Examples 1 to 6 without using filler components such as solid lubricants. Furthermore, it was found that the cutting process auxiliary materials of Examples 1 to 6 not only had excellent cutting processability, but also had no contamination due to the inclusion of solid lubricants, and also had reduced contamination due to the components of the cutting process auxiliary materials. [Industrial Applicability]

[0087] The present invention has industrial applicability as a cutting auxiliary material used in cutting fiber-reinforced composite materials.

Claims

1. A cutting processing auxiliary material used when cutting a fiber reinforced composite material, Weight average molecular weight is 5 × 10 ４ 1x10 or more ６ a high molecular weight water-soluble resin (A) which is: Weight average molecular weight is 1 x 10 ３ 5x10 or more ４ a medium molecular weight water-soluble resin (B) having a molecular weight of less than a water-soluble substance (Y), the water-soluble substance (Y) contains one or more selected from the group consisting of organic acids, organic acid salts, polyhydric alcohols, and amino alcohols; per 100 parts by mass of the high-molecular-weight water-soluble resin (A) and the medium-molecular-weight water-soluble resin (B) in total, the content of the high-molecular-weight water-soluble resin (A) is 25 to 50 parts by mass, the content of the medium-molecular-weight water-soluble resin (B) is 50 to 75 parts by mass, The content of the water-soluble substance (Y) is 0.05 to 3.0 parts by mass. Cutting auxiliary material.

2. the high molecular weight water-soluble resin (A) is at least one selected from the group consisting of polyalkylene oxide compounds, polyalkylene glycol compounds, polyalkylene glycol ester compounds, polyalkylene glycol ether compounds, polyalkylene glycol monostearate compounds, water-soluble urethanes, polyether-based water-soluble resins, water-soluble polyesters, poly(sodium meth)acrylate, polyacrylamides, polyvinylpyrrolidones, polyvinyl alcohols, sugars, and modified polyamides; The cutting processing auxiliary material according to claim 1.

3. the medium-molecular-weight water-soluble resin (B) is at least one selected from the group consisting of polyalkylene glycol compounds, polyalkylene oxide monoether compounds, polyalkylene oxide monostearate compounds, and polyalkylene oxide compounds; The cutting processing auxiliary material according to claim 1.

4. The melt viscosity at 100°C is 100 to 2000 Pa s. The cutting processing auxiliary material according to claim 1.

5. It has a sheet shape with a thickness of 0.1 mm or more and 10 mm or less, The cutting processing auxiliary material according to claim 1.

6. Further, an adhesive layer is provided on the surface that comes into contact with the workpiece. The cutting processing auxiliary material according to claim 1.

7. The adhesive layer contains an acrylic polymer. The cutting processing auxiliary material according to claim 1.

8. The cutting process includes a cutting step of cutting the workpiece with the cutting tool while contacting the cutting auxiliary material according to any one of claims 1 to 7 with a cutting tool and / or a portion of the workpiece to be processed, thereby forming a cutting portion. Cutting method.

9. A hole is formed as the cutting portion. The cutting method according to claim 8.

10. The workpiece comprises carbon fiber reinforced plastic, glass fiber reinforced plastic, aramid fiber reinforced plastic, or Kevlar fiber reinforced plastic; The cutting method according to claim 8.

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