Machining apparatus and machining method

Abstract

Provided is a machining apparatus capable of improving the life of tools used for machining. A machining apparatus is provided with an emulsion diameter expansion device (3) and a supply device (4). The emulsion diameter expansion device (3) applies negative pressure, shear force, or collision force to a processing fluid (PF) containing emulsion particles to expand the diameter of the emulsion particles. The supply device (4) supplies the processing fluid (PF), in which the particle diameter of the emulsion particles has been expanded by the emulsion diameter expansion device (3), to a processing point (P0), which is a contact point between a workpiece (W) and a tool (1) during machining.

Description

Processing apparatus and processing method

[0001] This disclosure relates to a processing apparatus and a processing method. More specifically, this disclosure relates to a processing apparatus and a processing method for performing processes such as subtractive deformation or cold plastic deformation on a workpiece.

[0002] Methods are known for performing subtractive deformation or cold plastic deformation on a workpiece. These processes yield parts such as intermediate or final components. For example, if the workpiece is a metal material, then the component produced by the process is also a metal material.

[0003] There are three main types of material removal processes: (1) cutting, (2) grinding, and (3) polishing.

[0004] Cutting processes use cutting tools, pressing the cutting edge of the tool against the workpiece to cut it. Examples of cutting processes include threading, milling, turning, and drilling. Grinding processes use grinding wheels, pressing a high-speed rotating grinding wheel against the workpiece to grind it. Examples of grinding processes include surface grinding, cylindrical grinding, and internal grinding. Polishing processes use grinding wheels, bringing the grinding wheel into contact with the workpiece to polish it and finish the surface of the workpiece smoothly. Examples of polishing processes include grinding with abrasive wheels, polishing with abrasive cloth and paper, lapping, tape polishing, buffing, and barrel polishing.

[0005] Cold plastic deformation can be broadly classified into (1) wire drawing, (2) cold drawing, (3) cold extrusion, and (4) cold rolling. The workpieces subjected to cold plastic deformation are metal materials.

[0006] Wire drawing is a process in which a metal material is passed through a die and then drawn out of the die to produce a metal wire. In wire drawing, the die is the tool. Metal wires produced by wire drawing may have a diameter of less than 1 mm, and wire drawing is suitable for producing such extremely fine metal wires. Cold drawing is a process in which a metal material is passed through a die and then drawn out of the die to produce a metal material. In cold drawing, the die is the tool. Metal materials produced by cold drawing include, for example, metal rods or metal tubes.

[0007] Cold extrusion is a method of manufacturing metal materials by using a stem to push the metal material through a die. In cold extrusion, the die acts as the tool. Examples of metal materials manufactured by cold extrusion include metal profiles. Cold rolling is a method of manufacturing metal materials by using work rolls to roll the metal material. In cold rolling, the work rolls act as the tool. Examples of metal materials manufactured by cold rolling include metal sheets, metal wires, metal rods, or metal tubes.

[0008] In these removal or cold plastic deformation processes, the tool comes into contact with the workpiece during the process. Therefore, it is necessary to ensure lubrication between the tool and the workpiece. In particular, the tool wears down or deteriorates due to contact with the workpiece. Consequently, in removal or cold plastic deformation processes, it is required to suppress tool wear and deterioration and improve tool life.

[0009] Regarding removal processes, for example, Japanese Patent Publication No. 2007-331088 (Patent Document 1) describes a machining apparatus. This machining apparatus sprays a cutting fluid containing microbubbles onto the cutting tool and the workpiece to perform the cutting process. Patent Document 1 states that this reduces tool wear.

[0010] Japanese Patent Publication No. 2007-331088

[0011] However, the technology described in Patent Document 1 does not necessarily significantly improve tool life.

[0012] The purpose of this disclosure is to provide a machining apparatus and a machining method that can improve the lifespan of tools used in machining.

[0013] The processing apparatus according to this disclosure comprises an emulsion diameter expanding device and a supply device. The emulsion diameter expanding device applies negative pressure, shear force, or impact force to the processing fluid containing emulsion particles to expand the particle size of the emulsion particles. The supply device supplies the processing fluid, in which the particle size of the emulsion particles has been expanded by the emulsion diameter expanding device, to the processing point, which is the point of contact between the workpiece and the tool during processing.

[0014] The processing method according to this disclosure comprises an emulsion diameter enlargement step and a processing step. The emulsion diameter enlargement step involves applying negative pressure, shear force, or impact force to a processing fluid containing emulsion particles to enlarge the particle diameter of the emulsion particles. The processing step involves supplying the processing fluid, in which the particle diameter of the emulsion particles has been enlarged, to a processing point which is the contact point between the workpiece and the tool, while performing a removal process or cold plastic deformation.

[0015] According to this disclosure, the lifespan of tools used in machining can be improved.

[0016] Figure 1 shows an example of the particle size distribution of emulsion particles in a non-particle size expansion processing fluid. Figure 2 shows an example of the particle size distribution of emulsion particles in a particle size expansion processing fluid. Figure 3 is a schematic diagram showing an example of a processing apparatus in the first embodiment. Figure 4 shows the configuration of an emulsion diameter expansion apparatus equipped with a venturi structure. Figure 5 shows the configuration of an emulsion diameter expansion apparatus equipped with a swirling structure. Figure 6 is a cross-sectional view taken along line VI-VI in Figure 5. Figure 7 shows the configuration of an emulsion diameter expansion apparatus equipped with a collision structure. Figure 8 is a cross-sectional view taken along line VIII-VIII in Figure 7. Figure 9 is a schematic diagram showing an example of a processing apparatus in the second embodiment. Figure 10 is a schematic diagram showing an example of a processing apparatus in the third embodiment.

[0017] In this specification, during subtraction or cold plastic deformation, the portion of the tool in contact with the workpiece, and the portion of the workpiece in contact with the tool, may be referred to as the machining point. In other words, the machining point is the point of contact between the workpiece and the tool. Subtraction or cold plastic deformation may be collectively referred to simply as machining.

[0018] During machining, tools wear down through contact with the workpiece. Tool wear reduces tool life. Furthermore, continuing to use excessively worn tools will reduce the dimensional accuracy of intermediate or final parts manufactured through the process.

[0019] To improve tool life, it is necessary to improve the lubrication between the tool and the workpiece. To achieve this, one might consider supplying cooling water containing fine bubbles to the machining point as a machining fluid (coolant). However, even with the use of cooling water containing fine bubbles, tool life is not necessarily significantly improved.

[0020] Therefore, the inventors considered an alternative method. Specifically, the inventors focused on a water-soluble processing liquid containing emulsion particles and conducted thorough research. Hereinafter, the processing liquid containing emulsion particles may be simply referred to as "processing liquid." Emulsion particles refer to solute (oil) particles that are substantially dispersed in a spherical shape in the processing liquid. For example, emulsion particles are oil particles dispersed in water, which is the solvent, or clumps formed by the aggregation of multiple particles. As a result of the inventors' research, the following was found.

[0021] The processing fluid was subjected to a treatment that increased the particle size of the emulsion particles, and processing was carried out using the processing fluid that had been treated in this way. Such emulsion particle size increase treatment is performed using an emulsion particle size increase device. Specifically, negative pressure, shear force, or impact force is applied to the processing fluid by the emulsion particle size increase device to increase the size of the emulsion particles. When negative pressure, shear force, or impact force is applied to the processing fluid, at least some of the emulsion particles in the processing fluid aggregate or coalesce, and as a result the emulsion particles expand. In this specification, coalescing means that the boundaries between multiple particles disappear, and aggregation means that the boundaries between multiple particles remain. In this specification, the emulsion particle size increase device is also referred to as the "increasing device".

[0022] Furthermore, machining was performed using a machining fluid that had not undergone emulsion diameter expansion treatment. In this specification, a machining fluid that has undergone emulsion diameter expansion treatment may be referred to as a "particle size expansion machining fluid," and a machining fluid that has not undergone such treatment may be referred to as a "non-particle size expansion machining fluid." In machining, when a particle size expansion machining fluid was used, tool life was significantly improved compared to when a non-particle size expansion machining fluid was used.

[0023] Figures 1 and 2 show the volume-based particle size distribution of emulsion particles in the processing fluid. The particle size distribution shown in Figure 1 is an example of the particle size distribution of emulsion particles in a non-particle-enhancing processing fluid. The particle size distribution shown in Figure 2 is an example of the particle size distribution of emulsion particles in a particle-enhancing processing fluid in which tool life was significantly improved.

[0024] As shown in Figure 1, in the particle size distribution of emulsion particles in the non-particle-enhancing processing fluid, the particle size is distributed in the range of approximately 0.07 μm to 1.35 μm, and peaks in relative particle amount (%) appear at particle sizes of approximately 0.15 μm and 0.80 μm. In this case, for the median diameters D10, D50, and D90 of the emulsion particles, D10 is 0.10 μm, D50 is 0.16 μm, and D90 is 0.86 μm.

[0025] In contrast, as shown in Figure 2, the particle size distribution of emulsion particles in the particle size expansion processing fluid is distributed in a range from approximately 0.23 μm to 46.00 μm, with peaks in relative particle amount (%) appearing at particle sizes of approximately 0.32 μm, 0.97 μm, and 13.10 μm. In this case, for the median diameters D10, D50, and D90 of the emulsion particles, D10 is 1.55 μm, D50 is 10.84 μm, and D90 is 28.37 μm. The median diameter D10 (1.55 μm) in the particle size expansion processing fluid is larger than the median diameter D90 (0.86 μm) in the non-particle size expansion processing fluid. Therefore, it can be said that the emulsion particles in the particle size expansion processing fluid are composed of emulsion particles with much larger particle sizes than the emulsion particles in the non-particle size expansion processing fluid.

[0026] In particular, as shown in Figure 2, in the particle size distribution of emulsion particles in the particle size expansion processing fluid, emulsion particles with a particle size of 5.0 μm or larger account for the majority. In the example shown in Figure 2, the volume fraction (percentage) of emulsion particles with a particle size of 5.0 μm or larger relative to the total amount of emulsion particles in the particle size expansion processing fluid is approximately 75%. As is clear from comparing Figure 1 and Figure 2, emulsion particles with a large particle size of 5.0 μm or larger are present in the particle size expansion processing fluid, but are not present at all in the non-particle size expansion processing fluid. In this specification, emulsion particles whose particle size has been expanded by the emulsion size expansion treatment may be referred to as "expanded emulsion particles," and in particular, expanded emulsion particles with a particle size of 5.0 μm or larger may be referred to as "large-size emulsion particles."

[0027] Thus, particle size-expanding processing fluids contain expanded emulsion particles. During removal or cold plastic deformation, the processing fluid is supplied to the processing point, i.e., between the tool and the workpiece. At this time, the emulsion particles in the processing fluid interpose between the tool and the workpiece, acting as a cushion for both the tool and the workpiece. The cushioning effect of these emulsion particles increases with increasing particle size. Therefore, expanded emulsion particles have high cushioning properties. In particular, large-sized emulsion particles have even higher cushioning properties. High cushioning properties of emulsion particles in the processing fluid can suppress excessive contact between the tool and the workpiece. Therefore, when processing is performed using a particle size-expanding processing fluid, the high cushioning properties of the expanded emulsion particles improve lubrication between the tool and the workpiece. As a result, tool life can be significantly improved.

[0028] The processing apparatus and processing method according to the embodiments of this disclosure have been completed based on the above findings.

[0029] The processing apparatus according to this embodiment comprises an emulsion diameter expanding device and a supply device. The emulsion diameter expanding device applies negative pressure, shear force, or impact force to the processing fluid containing emulsion particles to expand the particle size of the emulsion particles. The supply device supplies the processing fluid, in which the particle size of the emulsion particles has been expanded by the emulsion diameter expanding device, to the processing point, which is the contact point between the workpiece and the tool during processing (first configuration).

[0030] In the first configuration of the processing apparatus, the particle size of emulsion particles in the processing fluid is increased by an emulsion diameter increasing device. During processing (removal processing or cold plastic deformation), the particle size increasing processing fluid containing these increased emulsion particles is supplied to the workpiece and tool by a supply device. That is, the particle size increasing processing fluid supplied to the processing point contains increased emulsion particles. Because the increased emulsion particles have high cushioning properties, the lubrication between the tool and the workpiece is increased. Therefore, the first configuration of the processing apparatus can significantly improve tool life.

[0031] The processing apparatus described above preferably further comprises a tank, a circulation pipe, and a pump. The tank stores the processing fluid. The circulation pipe has an inlet end and an outlet end, each of which opens to the processing fluid in the tank. The pump is provided in the circulation pipe and draws the processing fluid from the tank into the circulation pipe from the inlet end, and circulates the processing fluid in the circulation pipe toward the outlet end. In this case, the emulsion diameter expanding device is provided in the circulation pipe, and the supply device is connected to the tank (second configuration).

[0032] In the second configuration of the processing apparatus, a circulation pipe is provided to a tank that stores the processing fluid, and both the inlet and outlet ends of the circulation pipe are open to the processing fluid in the tank. A pump is installed in this circulation pipe. An emulsion diameter expanding device is also installed in the circulation pipe. In this case, the operation of the pump causes the processing fluid to circulate between the tank and the circulation pipe. Therefore, the processing fluid in the tank flows continuously through the expanding device in the circulation pipe. As a result, the density of expanding emulsion particles in the processing fluid in the tank increases. During processing, the particle-expanding processing fluid, in which the density of expanding emulsion particles has increased in the tank, is supplied from the tank to the processing point by a supply device. Therefore, a high cushioning effect due to the expanding emulsion particles is constantly obtained, and as a result, the lubrication between the tool and the workpiece is constantly increased.

[0033] In the processing apparatus relating to the second configuration, preferably, the flow rate L (m³) of the processing fluid in the circulating piping ３ The volume V(m³) of the processing fluid in the tank is equal to the volume V(m³) of the processing fluid in the tank. ３ The relationship between ) satisfies equation (1). In this case, the emulsion particles contained in the processing fluid in the circulating piping preferably include large-sized emulsion particles having a particle diameter of 5.0 μm or more, and the volume fraction of large-sized emulsion particles relative to the total amount of emulsion particles is preferably 1.0% or more (third configuration). 2 < L / V × 100 < 30 (1)

[0034] In equation (1), "L / V × 100" represents the ratio (%) of processing fluid that returns to the tank from the circulation piping per minute to the processing fluid in the tank. That is, "L / V × 100" represents the ratio (%) of particle size expanding processing fluid that flows through the emulsion diameter expanding device and is supplied to the tank per minute to the processing fluid in the tank. Hereinafter, "L / V × 100" may be referred to as the "circulation flow index".

[0035] In the third configuration of the processing apparatus, equation (1) is satisfied. That is, the circulation flow index (L / V × 100) is greater than 2 and less than 30. In short, the circulation flow index is limited, and the amount of particle-expanding processing fluid supplied to the tank by circulation is appropriate.

[0036] Furthermore, in the processing apparatus of the third configuration, in the processing liquid in the circulation pipe, that is, the particle size enlarging processing liquid, the volume fraction of the large-size emulsion particles with respect to the total amount of the emulsion particles is 1.0% or more. In this case, an appropriate amount of large-size emulsion particles is supplied to the tank by circulation.

[0037] In the processing apparatus according to the second or third configuration, preferably, the supply flow rate U (m ３ / min) of the processing liquid supplied to the processing point by the supply device satisfies the formula (2) in relation to the flow rate L (m ３ / min) of the processing liquid in the circulation pipe (fourth configuration). 10 < U / L × 100 < 100 (2)

[0038] In the formula (2), "U / L × 100" indicates the ratio (%) of the supply flow rate of the processing liquid from the tank to the processing point with respect to the flow rate of the processing liquid returning from the circulation pipe to the tank. That is, "U / L × 100" indicates the ratio (%) of the discharge flow rate of the processing liquid discharged from the tank to the processing point with respect to the flow rate of the particle size enlarging processing liquid supplied to the tank through the emulsion diameter enlarging device. Hereinafter, "U / L × 100" may be referred to as the "discharge flow rate index".

[0039] In the processing apparatus of the fourth configuration, the formula (2) is satisfied. That is, the discharge flow rate index (U / L × 100) is greater than 10 and less than 100. In short, the discharge flow rate index is limited, and an appropriate amount of the particle size enlarging processing liquid is accumulated in the tank.

[0040] The processing apparatus according to any one of the first to fourth configurations preferably further includes a recovery device that recovers the used processing liquid used in the processing and returns it to the tank (fifth configuration).

[0041] As described above, during processing, the emulsion particles are interposed between the tool and the workpiece and serve as a cushion for the tool and the workpiece. Therefore, the emulsion particles rupture during processing. As a result, in the used processing liquid, the particle diameter of the emulsion particles has returned to the original particle diameter before the emulsion diameter enlarging treatment is performed.

[0042] In the processing apparatus of the fifth configuration, the used processing liquid used in the processing is returned to the tank by the recovery device. Therefore, the processing liquid can be effectively recycled.

[0043] In the processing apparatus according to any one of the first to fifth configurations, the emulsion diameter enlarging device can include a Venturi structure that applies a negative pressure to the processing liquid. In this case, the Venturi structure includes a passage having a central axis, and the passage includes a reduced-diameter portion, a throttle portion, and an enlarged-diameter portion that are sequentially continuous from the inlet side to the outlet side in the flow direction of the processing liquid. In the Venturi structure, when the area of the cross-section perpendicular to the central axis of the inlet of the reduced-diameter portion is S and the minimum area of the cross-section perpendicular to the central axis of the throttle portion is S1, the ratio "S1 / S" of the minimum area S1 to the area S satisfies the formula (4) (sixth configuration). S1 / S < 3 / 4 (4)

[0044] According to the processing apparatus of the sixth configuration, the emulsion diameter enlarging device includes a Venturi structure, and by this Venturi structure, a negative pressure can be applied to the processing liquid to enlarge the emulsion particles. If the formula (4) is satisfied in the Venturi structure, it becomes possible to more effectively enlarge the emulsion particles.

[0045] In the processing apparatus according to any one of the first to sixth configurations, the emulsion diameter enlarging device can include a swirling structure that applies a shearing force to the processing liquid. In this case, the swirling structure includes a passage having a central axis. In the swirling structure, when the distance that the processing liquid advances in the direction of the central axis in one rotation of swirling is C and the outer diameter of the passage is D, the ratio "C / D" of the distance C to the outer diameter D satisfies the formula (5) (seventh configuration). C / D < 4 (5)

[0046] According to the processing apparatus of the seventh configuration, the emulsion diameter enlarging device includes a swirling structure, and by this swirling structure, a shearing force can be applied to the processing liquid to enlarge the emulsion particles. If the formula (5) is satisfied in the swirling structure, it becomes possible to more effectively enlarge the emulsion particles.

[0047] In the processing apparatus according to the seventh configuration, it is preferable that the rotation of the processing fluid in the swirling structure is 1 / 12 of a rotation or more (eighth configuration).

[0048] According to the eighth configuration of the processing apparatus, the swirling of the processing fluid is 1 / 12 of a rotation or more, which makes it possible to expand the emulsion particles even more effectively.

[0049] In a processing apparatus relating to any one of the configurations from the first to the eighth, the emulsion diameter expanding apparatus may be equipped with a collision structure that imparts a collision force to the processing fluid. In this case, the collision structure includes a passage having a central axis and a plurality of collision parts provided in the passage that collide with the flowing processing fluid. In the collision structure, if A is the area of ​​the cross section perpendicular to the central axis of the passage entrance, and A1 is the total projected area when the faces of the plurality of collision parts facing the passage entrance are projected onto a plane perpendicular to the central axis of the passage entrance, then the ratio of the projected area A1 to the area A, "A1 / A", satisfies equation (6). A1 / A > 15 / 9 (6)

[0050] According to the processing apparatus of the ninth configuration, the emulsion diameter expanding device is equipped with a collision structure, which applies a collision force to the processing fluid to expand the emulsion particles. If equation (6) is satisfied in the collision structure, it becomes possible to expand the emulsion particles more effectively.

[0051] In a processing apparatus relating to any one of the first to ninth configurations, preferably, the emulsion diameter expanding device expands the particle size of emulsion particles in the processing liquid and generates fine bubbles (the tenth configuration).

[0052] In the tenth configuration of the processing apparatus, fine bubbles are introduced into the processing fluid by an emulsion diameter expanding device. Because the fine bubbles are highly charged with zeta potential, excessive expansion of emulsion particles is suppressed in the particle size expanding processing fluid.

[0053] The processing method according to this embodiment comprises an emulsion diameter enlargement step and a processing step. The emulsion diameter enlargement step applies negative pressure, shear force, or impact force to a processing fluid containing emulsion particles to enlarge the particle diameter of the emulsion particles. The processing step performs removal processing or cold plastic deformation while supplying the processing fluid, in which the particle diameter of the emulsion particles has been enlarged, to the processing point, which is the contact point between the workpiece and the tool (11th configuration).

[0054] In the 11th configuration of the machining method, the particle size of the emulsion particles in the machining fluid is increased by the emulsion diameter expansion step. Then, during the machining process, the particle size expansion machining fluid containing these expanded emulsion particles is supplied to the machining point while machining (removal machining or cold plastic deformation) is performed with a tool. At that time, the particle size expansion machining fluid supplied to the machining point contains expanded emulsion particles. Because the expanded emulsion particles have high cushioning properties, the lubrication between the tool and the workpiece is increased. Therefore, the 11th configuration of the machining method can significantly improve tool life. As a result, it becomes possible to manufacture parts with high dimensional accuracy over a long period of time.

[0055] The processing method according to the 11th configuration preferably further includes a storage step in which the processing fluid is stored in a tank before the processing step. In this case, the emulsion diameter expansion step can be repeatedly performed on the processing fluid stored in the tank before the processing step (12th configuration).

[0056] In the 12th configuration of the processing method, an emulsion diameter expansion process is repeatedly performed on the processing fluid stored in the tank before the processing step. This increases the density of expanded emulsion particles in the processing fluid in the tank. During processing, the particle-expanding processing fluid, in which the density of expanded emulsion particles has increased, is supplied from the tank to the processing point. As a result, a high cushioning effect due to the expanded emulsion particles is consistently obtained, and consequently, the lubrication between the tool and the workpiece is consistently increased.

[0057] The processing apparatus and processing method according to this embodiment will be described below with reference to the drawings. In each drawing, the same or equivalent components are denoted by the same reference numerals, and redundant explanations will not be repeated.

[0058] [First Embodiment] In this embodiment, the processing apparatus can be applied to the processing method. The processing method comprises an emulsion diameter expansion step and a processing step. The emulsion diameter expansion step uses an emulsion diameter expansion apparatus to expand the particle size of emulsion particles in a processing liquid containing emulsion particles. The processing step involves bringing a tool into contact with the workpiece to perform removal processing or cold plastic deformation. In the processing step, processing (removal processing or cold plastic deformation) is performed while supplying the processing liquid, in which the particle size of the emulsion particles has been expanded, to the processing point (workpiece and tool).

[0059] As described above, material removal processes can be broadly divided into (1) cutting, (2) grinding, and (3) polishing. Cold plastic working processes can be broadly divided into (1) wire drawing, (2) cold drawing, (3) cold extrusion, and (4) cold rolling. In this embodiment, material removal processes will be taken up, and as an example, cutting will be used to explain the processing apparatus and method, but the same methods can be applied to grinding and polishing.

[0060] [About the processing apparatus] Figure 3 is a schematic diagram showing an example of the processing apparatus of this embodiment. Referring to Figure 3, the processing apparatus 100 is a removal processing apparatus and comprises a tool 1, a fixing jig 2 for fixing the workpiece W, an emulsion diameter expanding device 3, and a supply device 4. The processing apparatus 100 further comprises a tank 5, a circulation pipe 6, and a pump 7.

[0061] Tool 1 is a removal tool for removing material from the workpiece W. If the removal process is cutting, tool 1 is, for example, a cutting tool such as a turning tool, milling cutter, end mill, or drill. If the removal process is grinding, tool 1 is, for example, a grinding tool such as a grinding wheel or brush. If tool 1 is a polishing tool, the polishing tool is, for example, a grinder, sander, or polisher. Fixing jig 2 fixes the workpiece W. Fixing jig 2 is, for example, a chuck. If the removal process is turning, fixing jig 2 fixes the workpiece W so that it can rotate around its axis.

[0062] The material of the workpiece W is not particularly limited. For example, the material of the workpiece W is metal. In this case, the workpiece W is a metallic material. The material of the workpiece W may also be ceramics, glass, or CFRP (carbon fiber reinforced plastic), etc.

[0063] The expanding device 3 expands the particle size of the emulsion particles in the processing liquid PF containing the emulsion particles.

[0064] In this embodiment, the processing fluid PF is stored in tank 5. Tank 5 is a container capable of storing the processing fluid PF.

[0065] Processing fluid PF is a water-soluble processing fluid containing emulsion particles. In a typical example, processing fluid PF is a so-called emulsion-type processing fluid. Processing fluid PF may be a soluble-type processing fluid before the particle size increases. Soluble-type processing fluids are included within emulsion-type processing fluids. A processing fluid containing only particles with a particle size of 0.1 μm or less is called a soluble-type processing fluid.

[0066] Specifically, the processing solution PF contains, for example, water and a surfactant. The surfactant can be any well-known type. The surfactant is, for example, one or more selected from the group consisting of nonionic surfactants, anionic surfactants, amphoteric surfactants, and cationic surfactants.

[0067] Examples of nonionic surfactants include polyoxyethylene alkyl ethers, polyoxyalkylene alkylphenyl ethers, polyoxy(ethylene and / or propylene) alkylphenyl ethers, polyethylene glycol or polyoxyethylene alkyl esters composed of ethylene oxide and higher fatty acids (e.g., 12-18 carbon atoms), and polyoxyethylene sorbitan alkyl esters composed of sorbitan, polyethylene glycol and higher fatty acids (e.g., 12-18 carbon atoms).

[0068] Anionic surfactants include, for example, fatty acid salts, sulfate esters, sulfonates, phosphate esters, and dithiophosphate esters. Amphoteric surfactants include, for example, amino acid type and betaine type carboxylates, sulfate esters, sulfonates, and phosphate esters. Cationic surfactants include, for example, aliphatic amine salts and quaternary ammonium salts.

[0069] The processing fluid PF may contain components other than water and surfactants. These other components may include, for example, extreme pressure additives, rust inhibitors, preservatives, and friction reducers.

[0070] From another perspective, the processing solution PF contains water as a solvent and a solute in the form of emulsion particles. The solute consists of at least one of amines, alcohols, and esters. Examples of amines include disicyclohexylamine and benzylamine. Examples of alcohols include 2-butyl-1-octanol and triethylene glycol monododecyl ether. Examples of esters include fatty acid methyl esters.

[0071] The circulation pipe 6 is provided for the processing fluid PF in the tank 5 and has an inlet end 61 and an outlet end 62. Each of the inlet end 61 and the outlet end 62 opens to the processing fluid PF in the tank 5. Specifically, as shown in Figure 3, the circulation pipe 6 is fixed to the side wall of the tank 5, and the inlet end 61 and the outlet end 62 are spaced apart from each other and open to the processing fluid PF in the tank 5. In this case, the inlet end of the circulation pipe 6, including the inlet end 61, may penetrate the side wall of the tank 5, and the inlet end 61 may be located in the processing fluid PF. Similarly, the outlet end of the circulation pipe 6, including the outlet end 62, may penetrate the side wall of the tank 5, and the inlet end 61 may be located in the processing fluid PF. However, the circulation pipe 6 may not be fixed to the side wall of the tank 5, and the inlet end and outlet end of the circulation pipe 6 may be immersed in the processing fluid PF from above the tank 5.

[0072] Pump 7 is installed in the circulation piping 6. It is the power source for circulating the processing fluid PF in the circulation piping 6. When pump 7 is operated, the processing fluid PF in the tank 5 is drawn into the circulation piping 6 from the inlet end 61, and the processing fluid PF in the circulation piping 6 flows toward the outlet end 62 and is discharged into the tank 5 from the outlet end 62. In this way, the processing fluid PF circulates between the tank 5 and the circulation piping 6.

[0073] The expansion device 3 is installed in the circulation piping 6. Specifically, in the circulation piping 6, the expansion device 3 is installed downstream of the pump 7. Therefore, when the pump 7 is operated, the processing fluid PF in the tank 5 flows continuously through the expansion device 3 in the circulation piping 6.

[0074] The supply device 4 comprises a drive source 41, piping 42, and a nozzle 43. One end of the piping 42 is immersed in the processing fluid PF stored in the tank 5. The other end of the piping 42 is connected to the nozzle 43. The drive source 41 supplies the processing fluid PF from the tank 5 to the nozzle 43 via the piping 42. The drive source 41 is, for example, a pump.

[0075] During the removal process, the nozzle 43 sprays the processing fluid PF and supplies the sprayed processing fluid PF to the workpiece W and the tool 1. Specifically, the nozzle 43 flows the processing fluid PF over the part of the tool 1 that is in contact with the workpiece W, and / or over the part of the workpiece W that is in contact with the tool 1. In other words, when the removal process is being performed, the nozzle 43 flows and supplies the particle-enhancing processing fluid PF to the processing point P0.

[0076] The processing apparatus 100 may further include a recovery device 8. The recovery device 8 recovers the used processing fluid PF used in processing and returns it to the tank 5. Specifically, the recovery device 8 includes a recovery pan 81 and a recovery pipe 82. The recovery pan 81 functions as a receptacle for collecting the processing fluid PF discharged from the nozzle 43, flowing over the processing point P0, and falling down. The recovery pipe 82 is positioned between the recovery pan 81 and the tank 5, connecting the recovery pan 81 and the tank 5. The recovery pipe 82 discharges the processing fluid PF stored in the recovery pan 81 to the tank 5. The recovery device 8 allows the processing fluid PF to be circulated and reused. Note that the processing apparatus 100 does not necessarily have to include a recovery device 8.

[0077] [About the Emulsion Diameter Expanding Device] The emulsion diameter expanding device 3 expands the particle size of emulsion particles in the processing fluid PF. Specifically, the expanding device 3 applies negative pressure, shear force, or impact force to the processing fluid PF. As a result, at least some of the emulsion particles in the processing fluid PF aggregate or coalesce, and as a result, the particle size of the emulsion particles expands. To achieve this function, the expanding device 3 is equipped with a venturi structure, a swirling structure, or an impact structure. The specific structure of the expanding device 3 will be described in detail below with reference to Figures 4 to 8.

[0078] <Venturi Structure> Figure 4 is a longitudinal cross-sectional view of an enlargement device 3 equipped with a venturi structure. Referring to Figure 4, in the enlargement device 3, the venturi structure includes a passage 31 having a central axis CL. The passage 31 is formed, for example, in the internal space of a cylindrical body 30. The processing fluid PF flows through this passage 31 in one direction. The passage 31 includes a diameter-reducing section 311, a constricting section 312, and a diameter-expanding section 313. The diameter-reducing section 311, the constricting section 312, and the diameter-expanding section 313 are continuous in order from the inlet side to the outlet side in the flow direction of the processing fluid PF. The diameter of the diameter-reducing section 311 gradually decreases along the flow direction of the processing fluid PF. The diameter of the constricting section 312 is substantially constant. The diameter of the diameter-expanding section 313 gradually increases along the flow direction of the processing fluid PF.

[0079] When the processing fluid PF flows through the passage 31, negative pressure is applied to the emulsion particles in the processing fluid PF at the constriction section 312. At least some of the emulsion particles subjected to negative pressure will agglomerate or coalesce. As a result, the particle size of the emulsion particles will increase. Thus, in the case of the expansion device 3 equipped with a venturi structure, negative pressure is applied to the processing fluid PF, and as a result, the particle size of the emulsion particles in the processing fluid PF can be increased.

[0080] The magnifying device 3, which has a venturi structure, preferably has the following configuration. Let S be the area of ​​the inlet 311i of the reduced diameter section 311 in a cross section perpendicular to the central axis CL. Let S1 be the minimum area of ​​the constricted section 312 in a cross section perpendicular to the central axis CL. In this case, the ratio of the minimum area S1 to the area S, "S1 / S", satisfies equation (4): S1 / S < 3 / 4 (4)

[0081] If equation (4) is satisfied in the Venturi structure, an appropriate negative pressure is generated in the processing fluid PF. This makes it possible to expand the emulsion particles more effectively. The upper limit of "S1 / S" is preferably 3 / 5. The lower limit of "S1 / S" is not particularly limited, but for example, 1 / 10 is preferred.

[0082] <Swivel Structure> Figures 5 and 6 show the configuration of the expansion device 3 equipped with a swivel structure. Figure 5 shows a longitudinal cross-sectional view of the expansion device 3, and Figure 6 shows a cross-section along line VI-VI in Figure 5. Referring to Figures 5 and 6, the swivel structure in the expansion device 3 includes a passage 31A having a central axis CL. The passage 31A is formed, for example, in the internal space of the cylindrical body 30A. The processing fluid PF flows through this passage 31A in one direction. The inner circumferential surface of the cylindrical body 30A is provided with spirally extending fins 32A. The number of fins 32A may be one or multiple.

[0083] When the processing fluid PF flows through the passage 31A, the processing fluid PF becomes a helical flow due to the fins 32A, and the emulsion particles in the processing fluid PF are subjected to shear force. At least some of the emulsion particles subjected to shear force will aggregate or coalesce. As a result, the particle size of the emulsion particles will increase. Thus, in the case of the expansion device 3 equipped with a swirling structure, a shear force can be applied to the processing fluid PF, and as a result, the particle size of the emulsion particles in the processing fluid PF can be increased.

[0084] The expansion device 3, which has a rotating structure, preferably has the following configuration. Let C be the distance the processing fluid PF travels in the direction of the central axis CL in one rotation. This distance C corresponds to the lead of the spirally extending fin 32A. Furthermore, let D be the outer diameter of the passage 31A. In this case, the ratio of distance C to outer diameter D, "C / D", satisfies equation (5). C / D < 4 (5)

[0085] If equation (5) is satisfied in the swirling structure, an appropriate shear force is generated in the processing fluid PF. This makes it possible to expand the emulsion particles more effectively. The upper limit of "C / D" is preferably 3.0. The lower limit of "C / D" is not particularly limited, but is preferably 2.0, for example.

[0086] Furthermore, by swirling the processing fluid PF at a rate of 1 / 12 or more rotations within the range of the expansion device 3, it becomes possible to expand the emulsion particles even more effectively. The lower limit of the number of swirls of the processing fluid PF is preferably 1 / 4. The upper limit of the number of swirls of the processing fluid PF is not particularly limited, but is preferably 3.0, for example.

[0087] <Collision Structure> Figures 7 and 8 show the configuration of the expansion device 3 equipped with a collision structure. Figure 7 shows a longitudinal cross-sectional view of the expansion device 3, and Figure 8 shows a cross-section along line VIII-VIII in Figure 7. Referring to Figures 7 and 8, the collision structure in the expansion device 3 comprises a passage 31B having a central axis CL and a plurality of collision parts 33B. The passage 31B is formed, for example, in the internal space of the cylindrical body 30B. The processing fluid PF flows through this passage 31B in one direction. The plurality of collision parts 33B are provided within the passage 31B and collide with the flowing processing fluid PF. The plurality of collision parts 33B are provided, for example, on the inner circumferential surface of the cylindrical body 30B. The plurality of collision parts 33B are provided in multiple stages along the central axis CL.

[0088] As the processing fluid PF flows through the passage 31B, the emulsion particles in the processing fluid PF collide with the collision section 33B, and the emulsion particles are subjected to a collision force. At least some of the emulsion particles subjected to the collision force aggregate or coalesce. As a result, the particle size of the emulsion particles increases. Thus, in the case of the expansion device 3 equipped with a collision structure, a collision force is applied to the processing fluid PF, and as a result, the particle size of the emulsion particles in the processing fluid PF can be increased.

[0089] The expansion device 3 equipped with a collision structure preferably has the following configuration. Let A be the area of ​​the cross section perpendicular to the central axis CL of the entrance 31Bi of the passage 31B. Let A1 be the total projected area when the faces 33Ba of the multiple collision parts 33B that face the entrance of the passage 31B are projected onto the plane perpendicular to the central axis CL of the entrance 31Bi of the passage 31B. In this case, the ratio of the projected area A1 to the area A, "A1 / A", satisfies equation (6). A1 / A > 15 / 9 (6)

[0090] If equation (6) is satisfied in the collision structure, an appropriate collision force is generated in the processing fluid PF. This makes it possible to expand the emulsion particles more effectively. The lower limit of "A1 / A" is preferably 2.0. The upper limit of "A1 / A" is not particularly limited, but for example, it is preferably 10.0.

[0091] The expansion device 3 may have one or more structures selected from the group consisting of a venturi structure, a swivel structure, and a collision structure. For example, the expansion device 3 may have a structure that combines a venturi structure and a swivel structure, or a structure that combines a venturi structure, a swivel structure, and a collision structure.

[0092] [Regarding the processing method] The processing method of this embodiment will be described below with reference to Figure 3. As described above, the processing method comprises an emulsion diameter expansion step and a processing step.

[0093] First, the workpiece W is prepared. Specifically, the workpiece W is a material made of metal. When the workpiece W is a metal material, its material may be, for example, carbon steel, alloy steel, Fe-based alloy, Ni-based alloy, Ti-based alloy, Al-based alloy, etc. Here, "X-based alloy" means that the metal element X is contained in 50% or more by mass. Examples of Fe-based alloys are machine structural steel, stainless steel, etc. The prepared workpiece W is fixed to the fixing jig 2 of the removal processing device.

[0094] In the emulsion diameter expansion process, an expansion device 3 is used to expand the particle size of the emulsion particles in the processing fluid containing the emulsion particles. Specifically, a pump 7 is activated. As a result, the processing fluid PF in the tank 5 is drawn into the circulation pipe 6 from the inlet end 61, and the processing fluid PF in the circulation pipe 6 flows toward the outlet end 62.

[0095] The processing fluid PF flowing through the circulation pipe 6 passes through the expansion device 3 and is discharged into the tank 5 from the outlet end 62 of the circulation pipe 6. When the processing fluid PF passes through the expansion device 3, negative pressure, shear force, or impact force is applied to the processing fluid PF. As a result, at least some of the emulsion particles in the processing fluid PF aggregate or coalesce, and the particle size of the emulsion particles increases.

[0096] Therefore, the processed liquid PF (particle size expanding processed liquid PF) with enlarged emulsion particles is continuously discharged into tank 5. In this way, the processed liquid PF in tank 5 is replaced by the particle size expanding processed liquid PF, and the particle size expanding processed liquid PF accumulates in tank 5.

[0097] Particle size enlargement processing fluid PF contains dispersed enlarged emulsion particles. In the particle size distribution of emulsion particles in particle size enlargement processing fluid PF, emulsion particles with a particle size of 5.0 μm or larger (large-size emulsion particles) make up the majority. In particle size enlargement processing fluid PF, the volume fraction (percentage) of large-size emulsion particles to the total amount of emulsion particles is, for example, 1.0% or more.

[0098] The volume-based particle size distribution of emulsion particles in the processing fluid PF is determined by an image-based particle size distribution analyzer. Specifically, the processing fluid PF is collected from the circulation piping 6. More specifically, 1 liter of the processing fluid PF flowing in the vicinity of the outlet end 62 of the circulation piping 6 is collected. For the purpose of collecting this processing fluid PF, the circulation piping 6 is provided with a liquid outlet in the vicinity of the outlet end 62. That is, the liquid outlet is located downstream of the expansion device 3 in the circulation piping 6. The collected processing fluid PF is immediately observed with an optical microscope, and the 5 mm ２ Emulsion particles are measured by performing image analysis within the field of view of the area described above. A particle image analyzer (product name: Morphologi 4, manufactured by Spectris Co., Ltd.) can be used as the measuring device. The particle size of the emulsion particles is the equivalent circular diameter of a single particle, or the equivalent circular diameter of a mass formed by the aggregation of multiple particles.

[0099] In the machining process, tool 1 is brought into contact with the workpiece W to perform material removal. Through this material removal process, an intermediate or final part is manufactured. If the workpiece W is, for example, a metal, then the manufactured part will be a metal. If the material removal process is cutting, cutting tool 1 is brought into contact with the workpiece W to perform cutting. If the material removal process is grinding, grinding tool 1 is brought into contact with the workpiece W to perform grinding. If the material removal process is polishing, polishing tool 1 is brought into contact with the workpiece W to perform polishing.

[0100] During the removal process, particle-enhancing processing fluid PF is sprayed from the nozzle 43, and the sprayed processing fluid PF is supplied to the processing point P0. This allows the removal process to be carried out while supplying the processing fluid PF to the processing point P0. During the removal process, processing debris, i.e., chips and shavings, are generated at the processing point P0 of the workpiece W. The generated processing debris is discharged from the part along with the processing fluid PF.

[0101] In this processing method, the particle size of emulsion particles in the processing fluid PF is increased through an emulsion diameter expansion step. During the processing, the particle size expansion processing fluid PF containing these expanded emulsion particles is supplied to the workpiece W and the tool 1, while the tool 1 performs the removal process. At this time, the particle size expansion processing fluid PF supplied to the workpiece W and the tool 1 contains expanded emulsion particles. Because the expanded emulsion particles have high cushioning properties, the lubrication between the tool 1 and the workpiece W is increased. Therefore, the life of the tool 1 can be significantly improved during the removal process. As a result, it becomes possible to manufacture parts with high dimensional accuracy over a long period of time.

[0102] In this embodiment, a circulation pipe 6 is provided to the tank 5 that stores the processing fluid PF, and the inlet end 61 and outlet end 62 of the circulation pipe 6 are open to the processing fluid PF in the tank 5. A pump 7 is provided in this circulation pipe 6. An expansion device 3 is also provided in the circulation pipe 6. In this case, the operation of the pump 7 causes the processing fluid PF in the tank 5 to flow continuously through the expansion device 3 in the circulation pipe 6. As a result, the density of expanding emulsion particles in the processing fluid PF in the tank 5 increases. During processing, the particle-expanding processing fluid PF, in which the density of expanding emulsion particles has increased in the tank 5, is supplied from the tank 5 to the processing point P0 by the supply device 4. Therefore, a high cushioning effect due to the expanding emulsion particles is constantly obtained, and as a result, the lubrication between the tool 1 and the workpiece W is constantly increased.

[0103] In this embodiment, a recovery device 8 is provided to recover the used processing fluid PF used in processing and return it to the tank 5. During processing, emulsion particles are interposed between the tool 1 and the workpiece W, acting as a cushion for the tool 1 and the workpiece W, and burst during processing. As a result, the particle size of the emulsion particles in the used processing fluid PF returns to the original particle size before the emulsion diameter enlargement process. Therefore, the processing fluid PF can be effectively recycled.

[0104] [Preferred Conditions] The preferred conditions in this embodiment are described below.

[0105] <Flow rate L (m³) of processing fluid PF in circulation piping 6 ３ The flow rate L is equal to the volume V (m³) of the processing fluid PF in tank 5. ３ It is preferable that equation (1) is satisfied in relation to ). 2 < L / V × 100 < 30 (1)

[0106] The flow rate L is, for example, the flow rate of the processing fluid PF at the outlet end of the circulation piping 6, including the outlet end 62. The flow rate L can be measured by a known flow meter. The flow meter is, for example, an ultrasonic flow meter.

[0107] In equation (1), as described above, "L / V × 100" is the circulation flow index. If the circulation flow index is too small, the amount of particle size expanding processing fluid PF supplied to tank 5 by circulation will be insufficient. In this case, the increase in the density of expanded emulsion particles in the processing fluid PF in tank 5 will be small. On the other hand, if the circulation flow index is too large, the amount of particle size expanding processing fluid PF supplied to tank 5 by circulation will be excessive. In this case, the increase in the density of expanded emulsion particles in the processing fluid PF in tank 5 will be large, and there is a risk that the emulsion particles will demulsify.

[0108] According to equation (1), the circulation flow index (L / V × 100) is greater than 2 and less than 30. In short, the circulation flow index is limited, and the amount of particle size increasing processing fluid PF supplied to the tank 5 by circulation is appropriate. In equation (1), the lower limit of the circulation flow index (L / V × 100) is preferably 5. The upper limit of the circulation flow index (L / V × 100) is preferably 20.

[0109] <Volume fraction (%) of large-size emulsion particles contained in the machining fluid PF in the circulation pipe 6> In the particle size-expanded machining fluid PF in the circulation pipe 6, it is preferable that the volume fraction of the large-size emulsion particles with respect to the total amount of the emulsion particles is 1.0% or more.

[0110] If the volume fraction of the large-size emulsion particles is too small, the amount of large-size emulsion particles supplied to the tank 5 by circulation becomes too small. In this case, in the machining fluid PF in the tank 5, the increase in the density of the large-size emulsion particles is small. On the other hand, if the volume fraction of the large-size emulsion particles is too large, the amount of large-size emulsion particles supplied to the tank 5 by circulation becomes excessive. In this case, in the machining fluid PF in the tank 5, the increase in the density of the expanded emulsion particles is large, and there is a possibility that the demulsification of the emulsion particles progresses. Therefore, the preferable lower limit of the volume fraction of the large-size emulsion particles is 1.0% so that an appropriate amount of large-size emulsion particles is supplied to the tank 5 by circulation. The lower limit of the volume fraction is more preferably 5.0%. On the other hand, the upper limit of the volume fraction of the large-size emulsion particles is preferably 90.0%.

[0111] <Supply flow rate U (m ３ / min) of the machining fluid PF by the supply device 4> The supply flow rate U preferably satisfies the formula (2) in relation to the flow rate L (m ３ / min) of the machining fluid PF in the circulation pipe 6. 10 < U / L × 100 < 100 (2)

[0112] The supply flow rate U is the flow rate of the machining fluid PF supplied to the machining point P0 (the workpiece W and the tool 1) by the supply device 4. The supply flow rate U can be calculated by measuring the volume of the machining fluid PF ejected from the nozzle 43 per unit time.

[0113] In equation (2), as described above, "U / L × 100" is the discharge flow rate index. If the discharge flow rate index is too small, the amount of particle size-enhancing processing fluid PF accumulated in tank 5 will be excessive. In this case, there is a risk that the emulsion particles in the processing fluid PF in tank 5 will demulsify. On the other hand, if the discharge flow rate index is too large, the amount of particle size-enhancing processing fluid accumulated in tank 5 will be insufficient.

[0114] According to equation (2), the discharge flow rate index (U / L × 100) is greater than 10 and less than 100. In short, the discharge flow rate index is limited, and the amount of particle size increasing processing fluid PF accumulated in tank 5 is appropriate. In equation (2), the lower limit of the discharge flow rate index (U / L × 100) is preferably 20. The upper limit of the discharge flow rate index (U / L × 100) is preferably 80.

[0115] [Example of operation of processing apparatus 100 in processing method] <Operation example 1> In the emulsion diameter expansion process, the pump 7 is operated to circulate the processing liquid PF to the expansion apparatus 3. This adjusts the emulsion particles contained in the processing liquid PF in the tank 5 to an appropriate particle size. After adjustment, the pump 7 is operated continuously and the processing process is carried out using the adjusted processing liquid PF. That is, the emulsion diameter expansion process and the processing process proceed simultaneously. At that time, the used processing liquid PF used in processing is collected in the tank 5. If the processing liquid PF decreases due to evaporation or scattering, new processing liquid PF is replenished in the tank 5. This keeps the volume V of the processing liquid PF in the tank 5 constant.

[0116] <Operation Example 2> In Operation Example 2, the used processing fluid PF is not collected in the tank 5. In this case, the amount of processing fluid PF in the tank 5 decreases as the processing progresses. Therefore, the pump 7 controls the flow rate L of the processing fluid PF in the circulation piping 6. Furthermore, new processing fluid PF is replenished in the tank 5, and the volume V of the processing fluid PF in the tank 5 is kept constant.

[0117] [Second Embodiment] Figure 9 is a schematic diagram showing an example of the processing apparatus 100A in the second embodiment. The processing apparatus 100A differs from the processing apparatus 100 of the first embodiment in that it is used for cold plastic deformation of the workpiece WA. In this case, the material of the workpiece WA is metal.

[0118] Referring to Figure 9, the processing apparatus 100A is a cold plastic working apparatus. Specifically, the processing apparatus 100A is a wire drawing apparatus. The processing apparatus 100A comprises a tool 1A, a drawing device 9, and an enlargement device 3.

[0119] Tool 1A is a plastic deformation tool for drawing a workpiece WA. The workpiece WA is a metal wire. Tool 1A is a die. In this embodiment, tool 1A will also be referred to as die 1A in the following description.

[0120] Die 1A has a through hole in the center. Die 1A may have a well-known configuration. The through hole of die 1A includes, for example, an approach and reduction section, a bearing section, and a back relief section, in order from the inlet side to the outlet side of die 1A. The inner diameter of the approach and reduction section decreases from the inlet side to the outlet side of die 1A. The approach and reduction section introduces the workpiece WA, which is a metal wire, into die 1A and reduces the diameter of the workpiece WA. The inner diameter of the bearing section is constant. The inner diameter of the bearing section corresponds to the die diameter. The bearing section restrains the workpiece WA and keeps the outer diameter of the workpiece WA constant. The inner diameter of the back relief section increases from the inlet side to the outlet side of die 1A. The back relief section prevents damage to die 1A from the reduced diameter of the workpiece.

[0121] The drawing device 9 draws the workpiece WA from the die 1A. The drawing device 9 includes an unwinding device 91, a winding device 92, and a support reel 93. The unwinding device 91 unwinds the coiled workpiece WA. The winding device 92 draws the workpiece WA, which has been unwinded from the unwinding device 91 and passed through the die 1A, from the die 1A. The winding device 92 further winds the metal material produced by drawing from the die 1A into a coil. The support reel 93 is positioned on the entry and / or exit sides of the die 1A and supports the workpiece WA during the wire drawing process and the metal material produced by the wire drawing process. The drawing device 9 does not necessarily include the support reel 93.

[0122] The drawing device 9 is not limited to the above configuration. The drawing device 9 may have any configuration other than the above, as long as it is configured to draw the workpiece WA from the die 1A.

[0123] The expansion device 3 has the same configuration as in the first embodiment. However, in this embodiment, the nozzle 43A of the supply device 4 is positioned on the inlet side of the die 1A. During wire drawing, the nozzle 43A sprays the processing fluid PF and adheres the sprayed processing fluid PF to the surface of the workpiece WA before it passes through the die 1A.

[0124] Even with the processing method of this embodiment, similar to the first embodiment, the high cushioning properties of the expanded emulsion particles enhance the lubrication between the tool (die) 1A and the workpiece WA. Therefore, the lifespan of the tool 1A can be significantly improved in cold plastic working.

[0125] [Third Embodiment] The processing apparatus used in the processing method of this embodiment, that is, the cold plastic deformation apparatus, is not limited to the processing apparatus 100A shown in Figure 9. Figure 10 is a schematic diagram showing an example of the processing apparatus 100B in the third embodiment. The processing apparatus 100B differs from the processing apparatuses 100 and 100A of the first and second embodiments in that it is used for cold rolling of the workpiece WB. In this case, the material of the workpiece WB is metal.

[0126] Referring to Figure 10, the processing apparatus 100B is a cold rolling machine. The processing apparatus 100B includes a tool 1B and an enlargement device 3.

[0127] Tool 1B is a plastic working tool for cold rolling a workpiece WB. The workpiece WB is a metal plate. Tool 1B is a pair of work rolls. In this embodiment, tool 1B will also be referred to as work roll 1B in the following description.

[0128] Each of the pair of work rolls 1B is supported by a corresponding support roll 10. The expanding device 3 has the same configuration as in the first embodiment. However, in this embodiment, the nozzle 43B of the supply device 4 is positioned on the inlet side of the pair of work rolls 1B. During cold rolling, the nozzle 43B sprays processing fluid PF between the work rolls 1B, causing the sprayed processing fluid PF to adhere to the surface of the workpiece WB passing between the work rolls 1B.

[0129] The processing method of this embodiment also produces the same effects as the second embodiment described above.

[0130] Figure 10 shows a processing apparatus (cold rolling apparatus) 100B when the workpiece WB is a metal plate. However, in this embodiment, the workpiece WB may also be a metal wire, a metal rod, or a metal tube. In these cases, a caliber is formed on a pair of work rolls, and a hole is formed by the pair of work rolls. When the workpiece WB is a metal wire, a metal rod, or a metal tube, the cold rolling apparatus may include three or more work rolls. When the cold rolling apparatus includes three work rolls, each work roll is arranged at a 120° pitch around the central axis of the workpiece WB. In this case, a hole is formed by the three work rolls. When the cold rolling apparatus includes four work rolls, each work roll is arranged at a 90° pitch around the central axis of the workpiece WB. In this case, a hole is formed by the four work rolls.

[0131] The processing method relating to this disclosure will be described in more detail below with reference to examples. However, the processing method relating to this disclosure is not limited to the following examples.

[0132] The removal process was performed using the processing apparatus shown in Figure 3. Specifically, a hot-forged product was prepared as the workpiece, and drilling and finish reaming were performed on this workpiece. The material of the workpiece was low-Mn steel. The main elements contained in the workpiece were, by mass%, C: 0.31%, Si: 0.24%, Mn: 1.49%, and P: 0.019%. In this example of the present invention, the flow rate L of the processing fluid in the circulating piping was set to 0.043 (m³). ３ The particle size increasing processing fluid was supplied to the tool with a flow rate L of the processing fluid in the circulation piping set to zero, and a non-particle size increasing processing fluid was supplied to the tool. The volume V of the processing fluid in the tank was 1 (m³). ３ )

[0133] In both the present invention example and the comparative example, the lifespan of the drill used for drilling and the lifespan of the reamer drill used for finish reaming were investigated. The lifespan of each drill was defined as the total number of holes drilled at the point when the tool became worn and machining became impossible. In drilling, the drill lifespan of the present invention example was 109% of that of the comparative example. In finish reaming, the drill lifespan of the present invention example was 133% of that of the comparative example. In short, in both drilling and finish reaming, using a particle size expanding processing fluid as in the present invention example improved tool life.

[0134] The embodiments of this disclosure have been described above. However, the embodiments described above are merely examples for implementing this disclosure. Therefore, this disclosure is not limited to the embodiments described above, and the embodiments described above can be modified as appropriate without departing from the spirit of this disclosure.

[0135] For example, the expansion device 3 may be located in the piping 42. That is, the circulation piping 6 may be omitted, and the expansion device 3 may be located inside the supply device 4. However, it is preferable that the expansion device 3 is located in the circulation piping 6, as shown in Figure 3. If the expansion device 3 is located in the circulation piping 6, the density of the expanded emulsion particles in the processing fluid PF in the tank 5 will increase.

[0136] The expansion device 3 may be configured to expand the particle size of emulsion particles in the processing fluid PF and generate fine bubbles. Since fine bubbles are highly charged with zeta potential, excessive expansion of emulsion particles is suppressed in the particle size expansion processing fluid PF. In a typical example, the expansion device 3 does not have an air supply mechanism to introduce gas from the outside into the processing fluid PF. In this case, the expansion device 3 generates dissolved oxygen in the processing fluid PF as fine bubbles by applying negative pressure, shear force, or impact force to the processing fluid PF. In this case, the expansion device 3 does not take in air from the outside to generate fine bubbles. Therefore, a special air supply mechanism is not required. Since the processing fluid PF is prone to deterioration when air is introduced from the outside, it is preferable to use an expansion device 3 without an air supply mechanism. However, the expansion device 3 may be equipped with an air supply mechanism.

[0137] 100, 100A, 100B: Processing equipment 1, 1A, 1B: Tools 3: Emulsion diameter expansion device 4: Supply device 5: Tank 6: Circulation piping 7: Pump 8: Recovery device P0: Processing point W, WA, WB: Workpiece

Claims

1. A machining apparatus comprising: an emulsion diameter expanding device that applies negative pressure, shear force, or impact force to a machining fluid containing emulsion particles to expand the particle size of the emulsion particles; and a supply device that supplies the machining fluid, in which the particle size of the emulsion particles has been expanded by the emulsion diameter expanding device, to a machining point which is the contact point between the workpiece and the tool during machining.

2. A processing apparatus according to claim 1, further comprising: a tank for storing the processing liquid; a circulation pipe having an inlet end and an outlet end, each of which opens to the processing liquid in the tank; and a pump provided in the circulation pipe for drawing the processing liquid in the tank from the inlet end into the circulation pipe and for circulating the processing liquid in the circulation pipe toward the outlet end, wherein the emulsion diameter expanding device is provided in the circulation pipe, and the supply device is connected to the tank.

3. The processing apparatus according to claim 2, wherein the flow rate L (m³) of the processing fluid in the circulation piping ３ The volume V(m³) of the processing fluid in the tank is equal to the volume V(m³) of the processing fluid in the tank. ３ A processing apparatus that satisfies equation (1) in relation to ), wherein the emulsion particles contained in the processing fluid in the circulation piping include large-sized emulsion particles having a particle diameter of 5.0 μm or more, and the volume fraction of the large-sized emulsion particles to the total amount of emulsion particles is 1.0% or more. 2 < L / V × 100 < 30 (1) 4. The processing apparatus according to claim 2, wherein the supply flow rate U(m) of the processing fluid supplied to the processing point by the supply device ３ / min) is the flow rate L (m) of the processing fluid in the circulation piping. ３ A processing device that satisfies equation (2) in relation to ( / min). 10 < U / L × 100 < 100 (2) 5. A processing apparatus according to claim 2, further comprising a recovery device for recovering the used processing liquid used in processing and returning it to the tank.

6. A processing apparatus according to any one of claims 1 to 5, wherein the emulsion diameter expanding apparatus comprises a venturi structure that applies negative pressure to the processing fluid, the venturi structure comprises a passage having a central axis, the passage includes a diameter reduction section, a constricted section, and a diameter expansion section that are continuous in order from the inlet side to the outlet side in the flow direction of the processing fluid, and in the venturi structure, when the area of ​​the cross section perpendicular to the central axis at the inlet of the diameter reduction section is S, and the minimum area of ​​the cross section perpendicular to the central axis at the constricted section is S1, the ratio of the minimum area S1 to the area S, "S1 / S", satisfies equation (4). S1 / S < 3 / 4 (4) 7. A processing apparatus according to any one of claims 1 to 5, wherein the emulsion diameter expanding device comprises a swirling structure for applying the shear force to the processing fluid, the swirling structure comprises a passage having a central axis, and in the swirling structure, when the distance the processing fluid travels in the direction of the central axis in one rotation is C and the outer diameter of the passage is D, the ratio of distance C to outer diameter D, "C / D", satisfies equation (5). C / D < 4 (5) 8. A processing apparatus according to claim 7, wherein in the swirling structure, the swirling of the processing fluid is 1 / 12 of a rotation or more.

9. A processing apparatus according to any one of claims 1 to 5, wherein the emulsion diameter expanding apparatus comprises a collision structure that applies the collision force to the processing fluid, the collision structure includes a passage having a central axis and a plurality of collision parts provided in the passage that collide with the flowing processing fluid, and in the collision structure, if A is the area of ​​the cross section perpendicular to the central axis of the entrance of the passage, and A1 is the total projected area when the faces of the plurality of collision parts facing the entrance of the passage are projected onto the plane perpendicular to the central axis of the entrance of the passage, then the ratio of the projected area A1 to the area A, "A1 / A", satisfies formula (6). A1 / A > 15 / 9 (6) 10. A processing apparatus according to any one of claims 1 to 5, wherein the emulsion diameter expanding device expands the particle size of the emulsion particles in the processing liquid and generates fine bubbles.

11. A machining method comprising: an emulsion diameter enlargement step of applying negative pressure, shear force, or impact force to a machining fluid containing emulsion particles to enlarge the particle diameter of the emulsion particles; and a machining step of performing a removal process or cold plastic deformation while supplying the machining fluid, in which the particle diameter of the emulsion particles has been enlarged, to a machining point which is a contact point between the workpiece and the tool.

12. A processing method according to claim 11, further comprising a storage step of storing the processing liquid in a tank before the processing step, and repeatedly performing the emulsion diameter expansion step on the processing liquid stored in the tank before the processing step.

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