Punching device and punching method
By grouping punching blades with controlled height differences, the device addresses die deformation and vibration issues, reducing pressure and improving operability in punching operations.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- FINE TEC CO LTD
- Filing Date
- 2022-09-22
- Publication Date
- 2026-05-11
AI Technical Summary
Existing punching devices experience issues with die deformation, vibration, and poor operability due to significant height differences between punching blades, leading to increased pressure requirements and difficulty in workpiece insertion.
The punching device divides punching blades into groups with controlled height differences, ensuring that the height difference between adjacent groups is less than or equal to the workpiece thickness, allowing for sequential contact and reduced pressure on the die, thereby minimizing vibration and facilitating easy workpiece replacement.
This approach reduces die vibration, lowers the required pressure for punching, and enhances operational ease by providing a larger gap for workpiece insertion, thus improving overall device performance.
Smart Images
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Abstract
Description
Technical Field
[0001] The present invention relates to a punching device and a punching method for manufacturing a product by punching a workpiece with a punching blade.
Background Art
[0002] There is known a punching device that forms a hole of a predetermined shape in a workpiece or punches out a predetermined shape from the workpiece. Since the punching device can open a large number of holes at once or punch out a large number of workpieces, it is equipped with a large number of punching blades, and is provided with a die having the same number of holes into which the punching blades fit after punching the workpiece.
[0003] For example, the mold for forming an opening described in Patent Document 1 and the method for forming an opening of an insulating substrate using the same include a first punching member provided with a plurality of columnar punches for opening a predetermined position of the insulating substrate, and a second punching member provided with an opening at a position corresponding to the punch provided in the first punching member. A first punch having a height from a reference plane and a second punch having a height different from that of the first punch are provided. The difference in height between the first punch and the second punch is set to be not less than the thickness of the insulating substrate forming the via hole.
[0004] The method for manufacturing an IC card and the IC card described in Patent Document 2 are such that when punching into a plurality of card forms using a plurality of cutting blades, at least one of the cutting blades starts cutting the card substrate earlier than the other cutting blades, and at least one of the punching speeds of the cutting blades operating simultaneously is different from that of the other cutting blades. In this method for manufacturing an IC card, since the difference in the height of the punches of the punching blades is too large, a punching position deviation occurs when the IC cards commonly distributed in the market are mostly about 760 μm to 800 μm. Therefore, it is preferably 1000 μm or less, and more preferably 500 μm or less. Furthermore, Patent Document 2 illustrates examples of punching blade heights, such as height differences of 500 μm or 250 μm between punching blades, increasing them by 50 μm each to create a total height difference of 100 μm, or increasing them by 150 μm each to create a total height difference of 300 μm. [Prior art documents] [Patent Documents]
[0005] [Patent Document 1] Japanese Patent Publication No. 2002-239991 [Patent Document 2] Japanese Patent Publication No. 2006-218598 [Overview of the Initiative] [Problems that the invention aims to solve]
[0006] The opening-forming mold and the method for forming an opening in an insulating substrate using the same, as described in Patent Document 1, can punch with about half the pressure because the first punch punches first and then the second punch punches. However, in the mold for forming an opening and the method for forming an opening in an insulating substrate using the same described in Patent Document 1, the height difference ΔL between the first punch and the second punch is set to be greater than or equal to the thickness of the insulating substrate in which the via hole is formed. Therefore, for example, if the height difference between the punches is made significantly larger than the thickness of the insulating substrate, when the first punch begins to punch out the workpiece, the pressure causes the second punching member, which corresponds to the die, to begin to bend, and when the first punch finishes punching out the workpiece, the bending returns to its original state. Furthermore, as the second punch begins to punch out the workpiece, the pressure causes the second punching member, which corresponds to the die, to begin to flex, just as with the first punch. As the second punch finishes punching out the workpiece, the flex returns to its original state. Therefore, the die may generate significant noise due to vibrations caused by large amplitudes.
[0007] In the IC card manufacturing method and IC card described in Patent Document 2, the height difference of the punching blades is smaller than the thickness of the workpiece, and the height difference of all the punching blades is also smaller than the thickness of the workpiece. Therefore, before the punching blade that makes contact first punches out the workpiece, the punching blade with the largest height difference also makes contact, so the pressure required to punch out the workpiece cannot be significantly reduced.
[0008] Furthermore, when punching out multiple products from a workpiece, or when drilling numerous through holes in a workpiece to create a product, multiple punching blades are arranged in a row for punching. In this case, if we consider the height difference of each punching blade, the height difference from the punching blade with the highest tip to the punching blade with the lowest tip is determined by the number of punching blades arranged in the row. Therefore, the more punching blades there are, the larger the overall height difference becomes.
[0009] Because there are height restrictions at the location where the punching machine is installed, even if there is a large difference in height between the punching blades, it is not possible to increase the stroke length and height of the machine without any restrictions. Therefore, when punching blades are lined up from the highest-positioned blade to the lowest-positioned blade, maintaining a height difference, the blade tips gradually approach the workpiece, and in some cases, only a small gap can be secured between the blade tip of the lowest-positioned punching blade and the die. In that case, when the operator manually places the next workpiece onto the die after punching is complete, if the gap between the cutting edge and the die is narrow, it becomes difficult to insert the workpiece onto the die, resulting in poor operability.
[0010] Therefore, the present invention aims to provide a punching device and punching method that can achieve good operability, reduce die vibrations generated during punching, and reduce the pressure required for punching. [Means for solving the problem]
[0011] The punching apparatus of the present invention comprises cylindrical punching blades arranged in a row and a die portion into which the punching blades punch and fit a workpiece, wherein the punching blades are divided into groups with a height difference between every two or more blades in the direction of arrangement of the punching blades, and the height difference between the cutting edge of the group that contacts the workpiece and the cutting edge of the next group that contacts the workpiece is less than or equal to the thickness of the workpiece, and the height difference between the cutting edge of the group that contacts the workpiece and the cutting edge of a group that contacts the workpiece two or more groups after the group that contacted the workpiece is greater than the thickness of the workpiece.
[0012] Furthermore, the punching method of the present invention is characterized by a punching device comprising cylindrical punching blades arranged in a row and a die portion into which the punching blades punch and fit the workpiece, wherein the punching blades are divided into groups with a height difference between every two or more blades in the direction of arrangement of the punching blades, and the height difference between the cutting edge of the group that contacts the workpiece and the cutting edge of the next group that contacts the workpiece is less than or equal to the thickness of the workpiece, and the height difference between the cutting edge of the group that contacts the workpiece and the cutting edge of a group that contacts the workpiece two or more groups after the group that contacted the workpiece is greater than the thickness of the workpiece.
[0013] According to the present invention, since the punching blades are divided into groups with different heights for every two or more blades, the height difference between the punching blade with the highest tip and the punching blade with the lowest tip can be kept small. Therefore, a larger gap can be secured between the blade tip and the die compared to when the height difference of each punching blade is changed individually within the same stroke.
[0014] Furthermore, because the height difference between the cutting edge of the group that contacts the workpiece and the cutting edge of the next group that contacts it is less than the thickness of the workpiece, the next group of punching blades contacts and presses the workpiece before the punching blades have completely punched out the workpiece and finished pressing it against the workpiece. As a result, the next punching blade presses the die while the previous punching blade is pressing against the die. This helps to suppress excessive vibration of the die.
[0015] Furthermore, because the height difference between the cutting edge of the group that contacts the workpiece and the cutting edge of the group that contacts the workpiece two or more steps later is greater than the thickness of the workpiece, a group of cutting edges that has completed punching will appear as each group of punching edges continues to punch. Therefore, since it is possible to avoid a situation where all groups punch the workpiece at once, the pressure on the die can be reduced.
[0016] In the punching operation of the workpiece, the height difference between the cutting edge of the first group that contacts the workpiece and the cutting edge of the second group that contacts it next can be less than or equal to the thickness of the workpiece, and the height difference between the cutting edge of the first group and the cutting edge of the third group that contacts the workpiece after the second group can be greater than the thickness of the workpiece.
[0017] Because the height difference between the cutting edge of the first group and the cutting edge of the third group, which contacts the workpiece after the second group, is greater than the thickness of the workpiece, punching by the cutting edge of the first group is completed by the time the cutting edge of the third group makes contact. Therefore, the situation in which all groups punch out the workpiece at once is avoided, and the pressure on the die can be reduced.
[0018] The height difference between the cutting edge of the group in contact with the workpiece and the cutting edge of the next group in contact can be set to be less than the thickness of the workpiece. In this way, when adjacent groups punch out, the punching blades of both groups are in contact with the workpiece, so the punching blades of one group press against the die before the other group's punching blade presses against the die and returns to its original position. Therefore, vibration can be reliably suppressed.
[0019] The group that first contacts the workpiece and the group that last contacts the workpiece can be arranged in order from the first group to the last group to contact the workpiece. By completing the punching and fitting the punching blade into the die part, deformation of the die part can be suppressed. In this state, since the punching blades of adjacent groups will punch the workpiece, the adjacent groups can punch accurately.
[0020] It can be provided with a fixing part for fixing the die part, and the punching blades can be arranged such that groups that contact the workpiece in order from the fixing part side are arranged. Even when pressure is applied by the punching blade, the die part on the fixing part side is difficult to deform. Also, by completing the punching and fitting the punching blade into the die part, deformation of the die part can be suppressed. Therefore, by punching in order from the fixing part side which is difficult to deform, punching while suppressing deformation of the die part by the fitting of the punching blade and the die part, deformation of the die part can be suppressed even when punching the workpiece at a position far from the fixing part side.
[0021] The fixing parts can be formed at both ends in the longitudinal direction of the die part, and the punching blades can be arranged such that groups that contact the workpiece in order from the both ends toward the central part are arranged. If fixing parts are formed at both ends in the longitudinal direction of the die part, by arranging groups that contact the workpiece in order from the both ends toward the central part, deformation of the die part can be suppressed even when punching the workpiece at the central part far from the fixing part side.
Advantages of the Invention
[0022] Since the present invention is divided into groups with a height difference for each of two or more punching blades, a large gap can be secured between the cutting edge of the punching blade at the lowest position and the die part, so that the replacement of the workpiece can be facilitated. Therefore, the present invention can obtain good operability. Also, since the next punching blade presses the die part while the first punching blade presses the die part, large vibration of the die part can be suppressed, and a state where all groups punch the workpiece at once can be avoided, so that the pressure applied to the die part can be reduced. Therefore, the present invention can obtain good operability, reduce the vibration of the die generated during punching, and reduce the pressure for punching.
Brief Explanation of Drawings
[0023] [Figure 1] It is a perspective view showing a punching device according to an embodiment of the present invention. [Figure 2] It is a view of the upper die of the punching device shown in FIG. 1 as seen from the punching blade side. [Figure 3] It is a front view of the upper die shown in FIG. 2. [Figure 4] It is an exploded perspective view of the die plate and the die holder of the lower die shown in FIG. 1. [Figure 5] It is a perspective view of the stripper plate of the punching device shown in FIG. 1. [Figure 6] (A) to (C) are diagrams for explaining the punching state of each group of the punching device shown in FIG. 1. [Figure 7] It is a diagram for explaining another example of the height difference of the group.
Embodiments for Carrying Out the Invention
[0024] The punching device according to an embodiment of the present invention will be described based on the drawings. [[ID=第35]] The punching device 10 shown in FIG. 1 punches circular products from a sheet as a workpiece. The punching device 10 includes an upper die 20, a lower die 30, and a stripper plate 40.
[0025] As shown in FIGS. 1 and 2, the upper die 20 includes a tool holder 21, a guide post 22, and a punching blade 23. The tool holder 21 is a plate that holds the base end portion of the punching blade 23 in a state where the punching blades 23 are aligned. Further, the tool holder 21 is a plate that is pressed by a press machine.
[0026] The guide post 22 is a rod-shaped member that guides the descent of the upper mold 20 by being inserted into the guide hole 32 of the lower mold 30 when the upper mold 20 descends.
[0027] The punching blade 23 shown in Figure 2 is a cylindrical cutting tool (cutter) with a circular cutting edge formed at its tip. In this embodiment, the diameter of the punching blade 23 is 9.0 mm. The punching blades 23 are arranged in a rectangular shape, with rows in the longitudinal direction F1 and rows in the transverse direction F2. Two punching blades 23 are arranged in the transverse direction F2, and 28 are arranged in the longitudinal direction F1.
[0028] As shown in Figures 2 and 3, the punching blades 23 have two blades aligned along the short direction F2 with equal cutting edge heights, while the 28 blades aligned along the long direction F1 are divided into groups with varying heights. In this embodiment, the punching blades 23 are divided into 13 groups according to their cutting edge height along the longitudinal direction F1, and into 7 groups according to different cutting edge heights. For example, groups A, B, C, D, E, and F at both ends of the longitudinal direction F1 are divided into two sections each, while group G in the central section is divided into four sections. In this way, each group contains two or more punching blades 23 with the same cutting edge height. In the short direction F2, there are two punching blades 23 side by side, so each group A to F contains 4 blades. Also, group G contains 8 blades.
[0029] Among groups A to F, the height difference of the cutting edge of the punching blade 23 in adjacent groups, for example, A and B, B and C, C and D, D and E, E and F, and F and G, is set to be less than or equal to the thickness of the workpiece sheet. In addition, the height difference of the cutting edge of the punching blade 23 in A and C to G, B and D to G, C and E to G, D and F and G, and E and G is set to be greater than the thickness of the workpiece. In this embodiment, the sheet thickness is 1 mm. Also, the height difference between adjacent groups of cutting edges is 1 mm. Because the height difference between adjacent groups is 1 mm, the height difference between a particular group and the groups inside that group is greater than the 1 mm of the sheet. Therefore, the height difference between the cutting edge of group A, which first contacts the workpiece, and the cutting edge of the last group F is greater than the sheet thickness of 1 mm.
[0030] Therefore, when group A is designated as the first group, the next group to be contacted will be group B. Similarly, the third group to be contacted after the second group will be group C. And when group B is designated as the first group, the next group to be contacted will be group C. Furthermore, the third group to be contacted after the second group will be group D. In this way, as the punching of the punching blade 23 progresses and the first group changes, the second and third groups also shift in order.
[0031] The lower mold 30 shown in Figures 1 and 4 has a die plate 31. The die plate 31 is formed in the shape of an elongated rectangular plate, and through holes 31a are formed at positions below each punching blade 23, functioning as the die portion.
[0032] The stripper plate 40 shown in Figures 1 and 5 has through holes 41a formed in its central portion 41, corresponding to each punching blade 23 (see Figure 1). The stripper plate 40 is connected to both ends 42 that protrude from the upper die 20 and lower die 30 by lifting devices (not shown), so that it lowers when the die is clamped and rises when the die is opened. This action allows the stripper plate 40 to press the workpiece against the lower die 30 during punching.
[0033] A punching method using a punching device according to an embodiment of the present invention configured as described above will be explained with reference to the drawings. The workpiece sheet is placed on the lower mold 30 shown in Figure 1, and positioned below the upper mold 20 and the stripper plate 40. Then, the upper die 20 is lowered, and the punching blade 23 is driven through the stripper plate 40 and brought into contact with the sheet S.
[0034] At this time, as shown in Figure 3, the punching blades 23 of group A, which is the first group, are closest to the sheet and therefore make contact with the sheet first. As shown in Figure 6(A), the height difference between the cutting edges of the punching blades 23 of group A and the punching blades of group B is 1 mm. Since the thickness of the sheet S is 1 mm, as the punching blades 23 descend further, the next punching blade 23 of group B (the second group) makes contact before the punching blade 23 of group A completely punches through the sheet S and fits into the die plate 31. Next, after the punching blade 23 of group A has finished punching, the punching by the punching blade 23 of group B proceeds. Next, as shown in Figure 6(B), the next punching blade 23 of group C (the third group) makes contact before the punching blade 23 of group B completely punches through the sheet S and fits into the die plate 31. Then, as shown in Figure 6(C), the punching by the punching blade 23 of group D begins before the punching blade 23 of group C completely punches through the sheet S and fits into the die plate 31.
[0035] Thus, the height difference between the cutting edge of group A, which first contacts the sheet S, and the cutting edge of group B, which contacts it next, is less than or equal to the thickness of the sheet S. Therefore, before the punching blade 23 of group A punches out the sheet S, the next punching blade 23 of group B contacts and presses against the sheet S. Consequently, the next punching blade 23 presses against the die plate 31 (see Figure 1) while the first punching blade 23 is pressing against the die plate 31. As a result, excessive vibration of the die can be suppressed.
[0036] Furthermore, the height difference between the cutting edge of group A and group C, which contacts the sheet S after group B, is greater than the thickness of sheet S. Therefore, by the time group C makes contact, punching by the cutting edge of group A is complete. Consequently, the situation in which all groups punch out the workpiece at once is avoided, and the pressure on the die plate 31 can be reduced.
[0037] As shown in Figure 3, 14 punching blades are arranged in a row, from group A located at both ends to group G located in the center, ranging from the punching blade 23 closest to the sheet S to the punching blade 23 furthest from the sheet S. For example, if each of the blades has a height difference of 1 mm, a total height difference of 13 mm will be created. In the punching machine 10, the punching blades 23 are divided into groups of two or more blades along the longitudinal direction F1, with a difference in height between each group. In this embodiment, groups A through F contain two blades each, and group G contains four blades without any height difference. Therefore, the height difference between groups A through G is 6 mm.
[0038] Thus, if the position of the upper die is the same, there will be a difference of 7 mm between the cutting edge of the lowest-positioned cutting edge 23 and the die plate 31, whether a height difference is created for every single punching blade 23 or for every two or more punching blades 23.
[0039] Therefore, in the punching device 10, a larger gap can be secured between the cutting edge of the lowest-positioned punching blade 23 (punching blade 23 of group A) and the die plate 31 than when the height difference is varied for each individual blade. As a result, workpiece (sheet) replacement can be easily performed, and good operability can be obtained.
[0040] In this embodiment, as shown in Figure 4, the die plate 31 is fixed at both ends 31b in the longitudinal direction F1 by a fixing portion in which a guide post 22 (see Figure 1) and a guide hole 32 are fitted. Groups A to G (see Figure 3) are arranged in order from the fixing portion side, which is the end 31b side of the die plate 31, toward the center, and contact the sheet S.
[0041] Even when pressure is applied to the workpiece and die plate 31 by the punching blade 23 of group A, the end 31b of the die plate 31 is fitted with the guide post 22 and the guide hole 32, making the die plate 31 less likely to deform. Therefore, by bringing the punching blade 23 into contact with the sheet S sequentially from the end 31b side of the die plate 31, deformation of the die plate 31 can be suppressed. Furthermore, once punching is complete and the punching blade 23 is fitted into the through hole 31a of the die plate 31, the punching blade 23 is supported from the inside of the through hole 31a of the die plate 31. Therefore, the punching blade 23 further suppresses deformation of the die plate 31, so that the die plate 31 is punched sequentially from the end 31b side, and deformation of the die plate 31 can be suppressed even when punching out the central sheet S that is far from the end 31b. Furthermore, since deformation of the die plate 31 can be suppressed, it is possible to prevent the punching blade 23 from colliding with and deforming the die plate 31.
[0042] In this embodiment, the height difference between groups A to G was the same as the thickness of the workpiece (sheet S). However, for example, if the thickness of the workpiece is 1 mm and there are 7 groups, the height difference between adjacent groups can be set to less than 1 mm, such as 0.3 mm as shown in Figure 7. In other words, if the height difference between adjacent groups is 0.3 mm, the height difference between the cutting edge of group A, which first contacts the sheet S, and the cutting edge of group E, which is four groups later, will be greater than the thickness of the sheet S (1 mm). Therefore, by setting the height difference to 0.3 mm, simultaneous cutting is ensured for groups A through D, and by the time group E, the fourth group to come into contact with sheet S, begins punching, group A has already completed punching.
[0043] Similarly, when group F begins punching, group B has already completed punching. Therefore, from the start of punching by group D until the completion of punching by group E, 3 to 4 groups are always pressing down. Consequently, vibration can be reliably suppressed.
[0044] In this embodiment, the height difference between groups was the same, such as 1 mm or 0.3 mm, but different height differences are also acceptable. Furthermore, although the punching blade 23 was formed by a cutter, it may also be formed by a punch.
[0045] In the example shown in Figure 7, the height difference between groups was set to 0.3 mm. Therefore, when group A starts punching, the height difference of the cutting edge becomes 1.2 mm at the fourth group E, which is greater than the thickness of the workpiece (1 mm). Therefore, punching is performed together with the first contacting group A up to the third group D, and by the time group E is punched, group A will have finished being punched.
[0046] For example, if the height difference between groups is equal, and the height difference between groups is greater than 0.5 mm but less than 1 mm, the height difference of the cutting edge from the group that contacts the workpiece to the second group after it will be greater than 1 mm, and therefore greater than the thickness of the workpiece (1 mm).
[0047] In this case, since the height difference of the cutting edge exceeds 1 mm in the second group C after group A, group A will have already been punched out by the time group C is punched out. Furthermore, when the height difference between groups is 1 mm, the situation is as explained using Figure 6.
[0048] Furthermore, if the height difference between groups is less than 0.5 mm, then, similar to the case where the height difference between groups is 0.3 mm, when the cutting edge of a group two or more groups after the group that contacts the workpiece contacts the workpiece, the height difference between the cutting edges will exceed 1 mm, and will exceed the thickness of the workpiece, which is 1 mm. [Industrial applicability]
[0049] This invention is suitable for punching devices that punch out workpieces to produce products, or punch out unwanted portions from workpieces to create products from the workpieces. [Explanation of Symbols]
[0050] 10 Punching machine 20 Upper mold 21. Blade holder 22 Guideposts 23 punching blades 30 Lower mold 31 Die Plates 31a Through hole 31b End 31c Side 32 guide holes 40 Stripper Plates 41 Central part 41a Through hole 42 End F1 Longitudinal Direction F2 Short direction Groups A-G S Seat
Claims
1. It comprises cylindrical punching blades arranged in a row, and a die section into which the punching blades punch and fit the workpiece, In the direction of the arrangement of the punching blades, the two or more punching blades are divided into groups with a difference in height, Among the aforementioned groups, the height difference between the cutting edge of the group that contacts the workpiece and the cutting edge of the next group that contacts it is less than or equal to the thickness of the workpiece. A punching device in which the height difference between the cutting edge of the group that contacts the workpiece and the cutting edge of a group that contacts the workpiece two or more times after the group that contacts the workpiece is greater than the thickness of the workpiece.
2. The punching apparatus according to claim 1, wherein, in the operation of punching out the workpiece, the height difference between the cutting edge of the first group that contacts the workpiece and the cutting edge of the second group that contacts it next is less than or equal to the thickness of the workpiece, and the height difference between the cutting edge of the first group and the cutting edge of the third group that contacts the workpiece next to the second group is greater than the thickness of the workpiece.
3. The punching apparatus according to claim 1 or 2, wherein the height difference between the cutting edge of the group that contacts the workpiece and the cutting edge of the next group that contacts the workpiece is less than the thickness of the workpiece.
4. The punching apparatus according to claim 1, wherein the groups are arranged in order from the group that first contacts the workpiece to the group that last contacts the workpiece.
5. The die portion is provided with a fixing portion for fixing the die portion, The punching apparatus according to claim 4, wherein the punching blades are arranged in groups that contact the workpiece in order from the fixed portion side.
6. The fixing portions are formed at both ends in the longitudinal direction of the die portion. The punching apparatus according to claim 5, wherein the punching blades are arranged in groups that sequentially contact the workpiece from both ends toward the center.
7. In a punching method using a punching device comprising cylindrical punching blades arranged in a row and a die section into which the punching blades punch and fit the workpiece, In the direction of the arrangement of the punching blades, the two or more punching blades are divided into groups with a difference in height, A punching method in which, among the aforementioned groups, the height difference between the cutting edge of the group that contacts the workpiece and the cutting edge of the next group that contacts it is less than or equal to the thickness of the workpiece, and the height difference between the cutting edge of the group that contacts the workpiece and the cutting edge of a group that contacts the workpiece two or more groups after the group that contacts the workpiece is greater than the thickness of the workpiece.