Film wrapping processing device

Abstract

To provide a film wrapping processing device which is capable of suitably polishing an entire range of a groove bottom of a screw for injection molding and improving work efficiency by automating complicated work when processing the screw for injection molding.SOLUTION: A configuration of a film wrapping processing device polishes a workpiece 100 with a polishing film 202 by NC control. In the film wrapping processing device, the workpiece 100 is a screw for injection molding where diameters of shafts change in an order of a small diameter part, a diameter change part, and a large diameter part. The film wrapping processing device is provided with: a workpiece holding part holding the workpiece 100; a processing unit 220 holding the polishing film 202; and a shaft direction swing mechanism swinging the processing unit 220 in the groove in accordance with groove width of the workpiece 100.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a film wrap processing apparatus for polishing a workpiece with a polishing film by NC control.

Background Art

[0002] As a method for polishing a workpiece of a metal part, film wrap processing is known. Film wrap processing is a polishing method using a polishing film having abrasive grains applied to its surface. For example, Patent Document 1 discloses a film wrap processing apparatus in which the workpiece is a ball screw, and the ball groove of the screw shaft of the ball screw is polished with a polishing film. In Patent Document 1, the ball groove is polished by oscillating the screw shaft of the ball screw in the axial direction by an oscillation mechanism.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The cross section of the groove (ball groove) of the ball screw which is the workpiece of Patent Document 1 is semi-circular along the ball rolling therein, and the width and depth of the groove are constant in the axial direction (longitudinal direction). For this reason, by pressing the polishing film against the ball groove of the ball screw with the semi-circular end of the disk-shaped backup roller, such a ball groove can be suitably polished.

[0005] Here, as the workpiece to be processed by film wrapping, in addition to the ball screw of Patent Document 1, an injection molding screw can be mentioned. The injection molding screw has a diameter of the shaft that gradually increases (changes) in the axial direction in order to increase the pressure for extruding the resin for injection molding, and the depth of the groove and the width (pitch) of the bottom of the groove in the axial direction (longitudinal direction) also change. In particular, in the backup roller of Patent Document 1, it is difficult to cope with the change in the width of the groove, and it is difficult to polish the entire range of the bottom of the groove of the injection molding screw.

[0006] Therefore, conventionally, for injection molding screws, workers have performed polishing work manually. Then, there has been a problem that the working time becomes long, leading to a decrease in work efficiency. For manual polishing of one injection molding screw, for example, it takes 2 days for a large one, which has also led to an increase in the manufacturing cost of the injection molding screw.

[0007] In view of such problems, an object of the present invention is to provide a film wrapping processing apparatus that can suitably polish the entire range of the bottom of the groove of an injection molding screw and improve work efficiency by automating complex operations when processing the injection molding screw.

Means for Solving the Problems

[0008] In order to solve the above problems, a typical configuration of the film wrapping processing apparatus according to the present invention is a film wrapping processing apparatus that polishes a workpiece with a polishing film by NC control. The workpiece is an injection molding screw whose diameter of the shaft changes in the order of a small diameter portion, a diameter change portion, and a large diameter portion. The film wrapping processing apparatus includes a workpiece holding portion for holding the workpiece, a processing unit for holding the polishing film, and an axial swing mechanism for swinging the processing unit in the groove according to the width of the groove of the workpiece.

[0009] It is preferable to provide an orthogonal pressing mechanism that presses the processing unit against the workpiece according to the diameter of the axis of the workpiece. In particular, when the diameter-changing portion is a tapered bottom, it is preferable to provide an arc motion mechanism that adjusts the angle of the processing unit so as to be orthogonal to the angle of the bottom of the groove of the diameter-changing portion.

Advantages of the Invention

[0010] According to the present invention, it is possible to provide a film wrap processing apparatus that can suitably polish the entire range of the bottom of the groove of the injection molding screw and improve the working efficiency by automating the complicated work when processing the injection molding screw.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0012] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. The dimensions, materials, and other specific numerical values shown in such embodiments are merely examples for facilitating the understanding of the invention, and do not limit the present invention unless otherwise specified. In the present specification and drawings, elements having substantially the same functions and configurations are denoted by the same reference numerals to omit redundant explanations, and elements not directly related to the present invention are omitted from the illustration or description.

[0013] (Workpiece 100) FIG. 1 is a diagram for explaining a screw for injection molding (hereinafter referred to as workpiece 100) processed by the film wrapping processing apparatus of the present embodiment. FIG. 1(a) is an overall view of the workpiece 100. FIGS. 1(b), 1(c), and 1(d) are partial enlarged views of the workpiece 100.

[0014] The workpiece 100 (screw for injection molding) shown in FIG. 1 is composed of a small diameter portion 110, a diameter changing portion 120, and a large diameter portion 130 in which the diameter of the shaft (diameter of the groove bottom) changes in order. In the workpiece 100, the large diameter portion 130 has the thickest shaft diameter in order to increase the pressure for extruding the resin as the material. Note that the diameter D of the workpiece 100 including the thread is constant in the axial direction.

[0015] Specifically, the relationship between the shaft diameter D1 of the small diameter portion 110 shown in FIG. 1(b), the shaft diameter D2 (D2 is not constant) of the diameter changing portion 120 shown in FIG. 1(c), and the shaft diameter D3 of the large diameter portion 130 shown in FIG. 1(d) is "D1 < D2 < D3". The diameter D2 of the diameter changing portion 120 gradually becomes thicker as it approaches the large diameter portion 130 from the small diameter portion 110 in the axial direction of the workpiece 100.

[0016] The fact that the shaft diameter of the workpiece 100 becomes thicker in the order of the small diameter portion 110, the diameter changing portion 120, and the large diameter portion 130 means that the groove depth of the workpiece 100 becomes shallower as it goes from the small diameter portion 110 to the large diameter portion 130. Therefore, the relationship between the groove depth d1 of the small diameter portion 110 shown in FIG. 1(b), the groove depth d2 of the diameter changing portion 120 shown in FIG. 1(c), and the groove depth d3 of the large diameter portion 130 shown in FIG. 1(d) is "d1 > d2 > d3". The groove depth d2 of the diameter changing portion 120 gradually becomes shallower as it approaches the large diameter portion 130 from the small diameter portion 110 in the axial direction of the workpiece 100.

[0017] Also, as described above, along with the change in the depth of the groove, the width of the bottom of the groove also changes. Specifically, the width of the bottom of the groove becomes narrower as the depth of the groove becomes shallower. For this reason, the relationship among the width W1 of the bottom of the groove of the small-diameter portion 110 shown in FIG. 1(b), the width W2 of the bottom of the groove of the diameter-changing portion 120 shown in FIG. 1(c), and the width W3 of the bottom of the groove of the large-diameter portion 130 shown in FIG. 1(d) is "W1 > W2 > W3".

[0018] Furthermore, as described above, in the workpiece 100, the diameter of the shaft and the depth of the groove change in the axial direction at the diameter-changing portion 120. For this reason, in the diameter-changing portion 120, when the bottom is tapered, the angle (tilt angle) of the bottom B2 of the groove also changes. Specifically, as shown in FIGS. 1(b) and 1(d), the bottoms B1 of the grooves of the small-diameter portion 110 and B3 of the grooves of the large-diameter portion 130 are horizontal. On the other hand, as shown in FIG. 1(c), the bottom B2 of the groove of the diameter-changing portion 120 may be horizontal or may be inclined.

[0019] (Processing apparatus 200) FIG. 2 is an overall perspective view of a film wrap processing apparatus (hereinafter referred to as the processing apparatus 200) according to the present embodiment, schematically showing the processing apparatus 200. The processing apparatus 200 of the present embodiment is a machine tool that polishes the groove of the workpiece 100 with a polishing film 202. In particular, the processing apparatus 200 of the present embodiment automatically controls (program control) the polishing process by a computer under NC (Numerical Control) control. By being able to automatically control the polishing operation of the workpiece 100 by the processing apparatus 200 in this way, the processing time required for the polishing process of the workpiece 100 can be shortened and the working efficiency can be improved.

[0020] As shown in FIG. 2, the processing apparatus 200 of the present embodiment includes a work holding unit 210 that holds a work 100 (see FIG. 1(a)), a processing unit 220 that holds a polishing film 202, and a processing base 230 disposed below the processing unit 220. The work holding unit 210 holds the work 100, which is an object to be processed, based on the bed 208. The work holding unit 210 has paired head stocks 110a and tail stocks 110b, and holds the work 100 between these head stocks 110a and tail stocks 110b.

[0021] Further, the work holding unit 210 has a work moving rail 206 provided on the bed 208 and a moving motor (not shown) as a work moving mechanism. Thereby, the head stock 110a, the tail stock 110b, and thus the work 100 can move along the work moving rail 206 in the longitudinal direction (axial direction) of the work 100.

[0022] (Processing Unit 220 and Processing Base 230) FIG. 3 is an overall perspective view of the processing unit 220 and the processing base 230 of FIG. 1. The processing unit 220 is disposed on the processing base 230 fixed to the bed 208, holds the polishing film 202, and presses it against the work 100. Such a processing unit 220 includes a supply reel 222, a take-up reel 224, and a plurality of rollers 226 as a polishing film feeding mechanism.

[0023] By the film feeding mechanism, the polishing film 202 is sent out from the supply reel 222 onto the backup roller 228 via each roller 226. The backup roller 228 is a cylindrical (disk-shaped) member that presses the polishing film 202 against the work 100. The polishing film 202 sent to the backup roller 228 is wound onto the take-up reel 224 as it is consumed by the processing of the work 100. By appropriately moving the consumed polishing film 202 in this way by the film feeding mechanism, it becomes possible to efficiently polish the work 100.

[0024] Note that the backup roller 228 may be configured with a metal central portion where a rotation axis (not shown) is provided, but it is preferable that at least the outer peripheral portion is formed of a soft material (e.g., urethane). By using a soft material for the material, appropriate flexibility can be obtained, and the polishing film 202 can be uniformly and efficiently brought into contact with the workpiece 100.

[0025] The processing base 230 causes the processing unit 220 to perform a predetermined operation (moves the processing unit 220 in a predetermined direction) according to the type of processing of the workpiece 100. Therefore, as a feature of the processing apparatus 200 of the present embodiment, the processing base 230 has an axial swing mechanism, an orthogonal direction pressing mechanism, and an arc motion mechanism.

[0026] The axial swing mechanism swings the processing unit 220 in the axial direction of the workpiece 100 within the groove according to the width of the groove of the workpiece 100. Specifically, as shown in FIG. 3, the axial swing mechanism includes two swing rails 242, an input shaft 244 from a swing motor, and a swing feed screw 246.

[0027] When swinging the processing unit 220 by the axial swing mechanism, the swing feed screw 246 is rotated by the input shaft 244 from the swing motor. As a result, the processing unit 220 moves in the direction of arrow A1 (see FIG. 3) along the swing rail 242, and the backup roller 228 and thus the polishing film 202 reciprocate within the range of the groove of the workpiece 100.

[0028] FIG. 4 is a schematic diagram for explaining the axial swing mechanism. FIG. 4(a) illustrates the case of polishing the bottom B1 of the groove of the small diameter portion 110, and FIG. 4(b) illustrates the case of polishing the bottom B3 of the groove of the large diameter portion 130. For convenience of explanation, the polishing film 202 is not shown in FIGS. 4(a) and (b). Also, the dimensional ratio is exaggerated for easier understanding of the difference as compared with FIG. 1.

[0029] In the small-diameter portion 110 shown in Fig. 4(a), the width of the bottom B1 of the groove is wide. Therefore, the backup roller 228 swings in the groove with a traverse amount T1 (swing width) to polish the bottom B1 of the groove. On the other hand, in the large-diameter portion 130 shown in Fig. 4(b), the width of the bottom B3 of the groove is narrow. Therefore, the backup roller 228 swings in the groove with a traverse amount T3 larger than the traverse amount T1 (swing width) to polish the bottom B3 of the groove. Thus, according to the processing apparatus 200 of the present embodiment, it is possible to suitably polish the entire range of the bottoms of grooves having different widths with one backup roller 228 without using a plurality of backup rollers having different sizes.

[0030] The orthogonal direction pressing mechanism presses the processing unit 220 against the workpiece 100 according to the diameter of the axis of the workpiece 100. Here, the orthogonal direction is a direction orthogonal to the axial direction of the workpiece 100, that is, a direction of approaching and separating from the workpiece 100. Specifically, as shown in Fig. 3, the orthogonal direction pressing mechanism includes two pressing rails 252, a pressing motor 254 (see Fig. 2), and a pressing feed screw 256.

[0031] When the processing unit 220 is pressed against the workpiece 100 by the orthogonal direction pressing mechanism, the pressing motor 254 rotates the pressing feed screw 256. As a result, the processing unit 220 moves in the direction of arrow A2 (see Fig. 3) along the pressing rail 252, and the processing unit 220 and thus the backup roller 228 are pressed against the workpiece 100.

[0032] Fig. 5 is a schematic diagram for explaining the orthogonal direction pressing mechanism. Fig. 5(a) illustrates the case of polishing the bottom B1 of the groove in the small-diameter portion 110, and Fig. 5(b) illustrates the case of polishing the bottom B3 of the groove in the large-diameter portion 130. For convenience of explanation, the polishing film 202 is not shown in Figs. 5(a) and (b).

[0033] In the small-diameter portion 110 shown in Fig. 5(a), the diameter D1 of the shaft is thin and the depth d1 of the groove is deep. On the other hand, in the large-diameter portion 130 shown in Fig. 5(b), the diameter D3 of the shaft is thick and the depth of the groove is shallow. For this reason, in the small-diameter portion 110 and the large-diameter portion 130, the position (pressing position) in the orthogonal direction where the backup roller 228 presses the bottom of the groove is different. Therefore, in the processing apparatus 200 of the present embodiment, the pressing position of the backup roller 228 is adjusted by the orthogonal direction pressing mechanism. Thereby, even when the diameter difference of the shaft is absorbed and the diameter of the shaft changes, it is possible to surely press the bottom of the groove.

[0034] The arc motion mechanism adjusts the angle of the processing unit 220 with respect to the axial direction of the workpiece 100. Thereby, the pressing direction of the processing unit 220 is adjusted so as to be orthogonal to the angles of the bottoms B1 to B3 of the grooves in the diameter change portion (see Fig. 1). Specifically, as shown in Fig. 3, the arc motion mechanism includes two arc rails 262, an arc motor 264, and an arc feed screw 266.

[0035] When the processing unit 220 is moved in an arc (swivel motion) by the arc motion mechanism, the arc feed screw 266 is rotated by the arc motor 264. Thereby, the processing unit 220 moves in the direction of arrow A3 (see Fig. 3) along the arc rail 262, and the processing unit 220 is inclined with respect to the axial direction of the workpiece 100 so as to be orthogonal to the bottom of the groove.

[0036] Fig. 6 is a schematic diagram for explaining the arc motion mechanism, and illustrates a case where the bottom of the groove near the boundary between the diameter change portion 120 and the large-diameter portion 130 in the case of being tapered is polished. For convenience of explanation, the polishing film 202 is not shown in Fig. 6.

[0037] As shown in FIG. 6, in the large-diameter portion 130, the diameter D3 of the shaft is constant, and the bottom B3 of the groove is parallel to the axial direction. Therefore, by bringing the backup roller 228 of the processing unit 220 into contact with the work 100 in a direction perpendicular to the axis of the work 100, the entire bottom B3 of the groove can be polished. On the other hand, the bottom B2 of the groove in the diameter-changing portion 120 is inclined with respect to the axial direction of the work 100 in the case of a tapered shape. Even if the backup roller 228 of the processing unit is brought into contact with the bottom B2 of such a groove in a direction perpendicular to the axis of the work 100, the entire bottom B2 of the groove cannot be polished.

[0038] Therefore, in the processing apparatus 200 of the present embodiment, the processing unit 220 is inclined with respect to the axial direction of the work 100 by the arc motion mechanism, and the backup roller 228 is brought into contact with the bottom B2 of the groove so as to be perpendicular thereto. Thereby, the entire bottom B2 of the groove inclined with respect to the axial direction can be suitably polished.

[0039] As described above, according to the film wrap processing apparatus according to the present invention, by combining the axial swing mechanism, the orthogonal direction pressing mechanism, and the arc motion mechanism and performing NC control, the groove of the injection molding screw can be automatically polished. In this way, it is possible to reduce the manual work by the operator, shorten the working time, improve the working efficiency, and reduce the manufacturing cost.

[0040] As described above, the preferred embodiments of the present invention have been described with reference to the accompanying drawings. Needless to say, the present invention is not limited to such examples. It is obvious that those skilled in the art can conceive of various modification examples or correction examples within the scope described in the claims, and it is naturally understood that they also belong to the technical scope of the present invention.

Industrial Applicability

[0041] The present invention can be used for a film wrap processing apparatus that polishes a work with a polishing film by NC control.

Explanation of Signs

[0042] D1…Diameter of the shaft, B1…Bottom of the groove, d1…Depth of the groove, W1…Width, D2…Diameter of the shaft, B2…Bottom of the groove, d2…Depth of the groove, W2…Width, D3…Diameter of the shaft, B3…Bottom of the groove, d3…Depth of the groove, W3…Width, 100…Workpiece, 110…Small-diameter part, 120…Diameter-changing part, 130…Large-diameter part, 200…Processing device, 202…Polishing film, 206…Workpiece moving rail, 208…Bed, 210…Workpiece holding part, 220…Processing unit, 222…Supply reel, 224…Take-up reel, 226…Roller, 228…Backup roller, 230…Processing base, 242…Swinging rail, 244…Input shaft from the swinging motor, 246…Swinging feed screw, 252…Pressing rail, 254…Pressing motor, 256…Pressing feed screw, 262…Arc rail, 264…Arc motor, 266…Arc feed screw

Claims

【Claim 1】 In a film wrapping processing apparatus for polishing a workpiece with a polishing film by NC control, the workpiece is an injection molding screw in which the diameter including the thread is constant in the axial direction, and the diameter of the shaft and the width of the groove change in the order of a small diameter portion, a diameter change portion, and a large diameter portion, the diameter change portion is tapered and the bottom of the groove is inclined with respect to the axial direction of the workpiece, the film wrapping processing apparatus includes a workpiece holding portion for holding the workpiece, a processing unit for holding the polishing film, an axial swing mechanism for swinging the processing unit in the groove according to the width of the groove of the workpiece, a perpendicular direction pressing mechanism for pressing the processing unit against the workpiece according to the diameter of the shaft of the workpiece, and an arc motion mechanism for adjusting the angle of the processing unit so as to be perpendicular to the angle of the bottom of the groove of the diameter change portion, characterized in that the film wrapping processing apparatus is provided with the arc motion mechanism.

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