JP2001137975A - Method of manufacturing for punching tool - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provided a method of manufacturing for a punching tool with which a punching tool set and a movable stripper for enabling a fine and high precision punching work are produced. SOLUTION: A shape electrode material 1 and a die material 2 are fixed on a supporting bed 3, a die 2a and a shape electrode 1a are formed by machining through patterns whose shapes and directions are identical with each other by an electric discharge machining using a rod electrode 4 executed upon a die material 2 and a shape electrode material 1. A punch 6a whose sectional form is of the said through pattern is formed by feeding a punch material 6 into a shape material 1a while the electric discharge machining is executed. A tool set where a punch is positioned on a die is produced by moving the punch 6a in a distance and a direction which are determined when the shape electrode 1a and the die 2a are machined.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a punching tool set for performing fine punching and a method for manufacturing a punching tool for manufacturing a movable stripper of the punching tool.

[0002]

2. Description of the Related Art There is an increasing need for processing fine holes such as ink discharge nozzle holes in a print head of an ink jet printer. When processing such micro holes,
When the thickness of the processing portion is smaller than the hole diameter, fine hole processing by punching can be performed at a higher speed than other processing methods such as electric discharge machining. A method for manufacturing a punching tool set including a punch and a die used for such a micron-order punching process is known.

FIG. 4 shows a conventional method of manufacturing the punching tool set. As shown in FIG.
While the punch material 32 attached to the support 31 is lowered while rotating, the wire electric discharge grinding method (WEDG)
The punch 32a is manufactured with submicron accuracy by the method. According to this manufacturing method, a rod-shaped punch having a diameter of 5 to 300 μm can be manufactured.

[0004] Using the punch 32a as an electrode for electric discharge machining, as shown in FIG. 4 (b), a die is manufactured by machining a through hole by fine electric discharge machining on a die material 34. The discharge gap when the pulse discharge energy by the fine electric discharge machining is extremely small as 10 ⁻⁶ to 10 ⁻⁷ J is about 1 to 3 μm, and by using this minute and uniform discharge gap as it is as the clearance for the punching, It is possible to obtain a high-precision punching tool set without shaft deflection.

[0005]

However, after the dies have been subjected to electric discharge machining using the punches as electrodes, FIG.
As shown in the figure above, not only the reduction from the initial length, but also the tip shape is rounded, and it is worn in the radial direction and becomes tapered, so processing using a punch deformed from the initially designed shape Will be done. Even when punching is performed using such a punch, a sharp punched cross section cannot be obtained because the tip end surface of the punch has no edge, and a shape error of a processed product occurs.

In order to solve the above-mentioned problem, when a die is machined with an electrode other than the punch, when the punch and the die are small in size, the punch and the die are positioned so as to obtain a uniform clearance of several microns. Not only is it very difficult, but it also takes a long time for alignment, which causes a decrease in productivity.

Further, when performing punching with a fine-sized punch, a stripper is required in order to prevent the material from being drawn simultaneously with the strip of the punched material. However, a stripper having a minute clearance between the punch and the punch is required. There is also a problem that it is very difficult to manufacture and attach it to a punch.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a punching tool set that enables fine punching with high precision and a movable stripper that can be mounted on a fine punch.

[0009]

According to a first aspect of the present invention, there is provided a method of manufacturing a punching tool for fixing a die material and a mold electrode material on the same plane. A step of forming a die and a mold electrode by machining a through pattern having the same shape and direction with respect to the electrode material by electric discharge machining, and punching material from a direction perpendicular to the flat surface of the mold electrode. Forming a punch having a cross-sectional shape of the through-pattern by feeding while performing electric discharge machining, and the distance and direction connecting any same point on the same through-pattern formed on the die and the mold electrode. The step of moving the punch from the mold electrode to the die produces a tool set in which the punch is positioned on the die.

According to the above manufacturing method, when the same through pattern is formed in the die material and the mold electrode material by electric discharge machining to form the die and the mold electrode, the distance between the respective through patterns formed in both the die and the mold electrode is formed. And the direction is determined. When a punch is formed using the mold electrode, if the punch is moved in the distance and direction determined previously, the punch is positioned at a predetermined position on the die. Further, since the punch is formed to be small by the discharge gap when the electric discharge machining is performed by the through pattern of the mold electrode, the minute discharge gap forms a uniform clearance between the punch and the die.

Further, in the method of manufacturing a punching tool according to the second invention of the present application, the stripper material and the mold electrode material are fixed on the same plane, and the stripper material and the mold electrode material are each formed by electric discharge machining. Forming a stripper plate and a mold electrode by processing a penetration pattern having the same orientation, and feeding the punch material from the direction perpendicular to the plane of the plate to the mold electrode while performing electric discharge machining. A step of forming a punch having a pattern in cross-sectional shape, and moving the punch from above the mold electrode onto the stripper plate in a distance and direction connecting any same point on the same through pattern formed on the stripper plate and the mold electrode. And a state in which the punch is inserted into the through pattern so that the tip end surface is located within the thickness of the stripper plate. A manner, is characterized in mounting the movable stripper punch by a step of filling an elastic resin between the side peripheral surface and the stripper plate surface including the base of the punch.

According to the above-described manufacturing method, when the same through-pattern is formed on the stripper material and the mold electrode material by electric discharge machining to form the stripper plate and the mold electrode, the respective through-patterns formed on both are formed. The distance and direction can be determined. When a punch is formed using the mold electrode and the punch is moved in the distance and direction determined previously, the punch is positioned at a predetermined position on the stripper plate. Also, since the punch is formed to be small by the discharge gap when the electric discharge machining is performed by the through pattern of the mold electrode, the minute discharge gap forms a uniform clearance between the punch and the stripper plate. Here, the space between the surface of the stripper plate and the side peripheral surface including the base of the punch is filled with an elastic curable resin and hardened such that the tip end surface of the punch is located within the through pattern of the stripper plate. The elastic resin on the side peripheral surface is peeled off by the operation of inserting the punch toward the die, but the elastic resin sandwiched between the base of the punch and the stripper plate expands and contracts according to the forward and backward movement of the punch, As a movable stripper having a discharge gap as a clearance, a strip of punched material and pull-in of the material are prevented.

In a third aspect of the present invention, there is provided a method for manufacturing a punching tool, comprising: a step of coating a metal layer on a surface of a punch fixed to a support by electroforming; Removing the metal layer covering the side peripheral surface of the punch, and moving the metal layer so as to be peeled from the peripheral surface of the punch so as to be movable with respect to the punch. A movable stripper is mounted on the punch by a step of filling an elastic resin between the metal layer, the punch, and the support in a state where the stripper is pulled out by a desired amount.

According to the manufacturing method, the metal layer formed on the side peripheral surface of the punch is peeled off to form a stripper, and the elastic resin is filled so as to be sandwiched between the support and the metal layer. A stripper is provided with a small clearance to form a movable stripper that moves forward and backward in accordance with the forward and backward movement of the punch. Even with a fine punch, it is possible to mount a movable stripper without requiring mechanical assembly.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the accompanying drawings to provide an understanding of the present invention.
The embodiment described below is an example embodying the present invention, and does not limit the technical scope of the present invention.

FIG. 1 shows a step-by-step method of manufacturing a punching tool set according to the first embodiment. An example of manufacturing a punching tool set including punches and dies for punching a long hole shape as a punching pattern. It shows. The manufacturing method will be described below in the order of the steps shown in FIGS. (First Step) As shown in FIG. 1A, a mold electrode material 1 and a die material 2 are fixed at predetermined positions on an XY plane of a support 3 formed of a conductive material. Tungsten or brass is suitable as the mold electrode material 1 and cemented carbide or sintered diamond is suitable as the die material 2, but is not limited thereto. At a predetermined position of the support 3 to which the mold electrode material 1 and the die material 2 are fixed, a space is formed on the back surface thereof. Further, the support base 3 is configured to be capable of positioning in the X-axis direction. (Second Step) As shown in FIG. 1B, the rod electrode 4 connected to the fine discharge pulse generator 5 is fed in the Z-axis direction with the position A on the X coordinate of the mold electrode material 1 as a starting point. The mold electrode 1a having a through-hole-shaped through pattern is formed by advancing the workpiece and performing electrical discharge machining while moving it in the X-axis direction to a width corresponding to the longitudinal width of the elongated hole. The electric discharge machining using the rod electrode 4 can obtain a fine pattern with a submicron accuracy of 5 to 300 μm in diameter and an aspect ratio of about 10 by reverse electric discharge machining using a tungsten wire as a material. (Third Step) As shown in FIG.
The rod electrode 4 is positioned directly above the position B on the X coordinate of the die material 2 by the movement in the axial direction. Type electrode material 1
With the same processing size as that of the above, electric discharge machining is performed while feeding the rod electrode 4 in the Z-axis direction starting from the position B and moving it in the X-axis direction to a width corresponding to the longitudinal width of the elongated hole. As a result, a die 2a having a long hole-shaped through pattern is formed. By this step, the elongated hole having the same shape is formed in the mold electrode 1a and the die 2a in a state where the longitudinal direction thereof coincides with the X-axis direction. (Fourth Step) As shown in FIG. 1 (d), a bar-shaped punch material 6 having a bottom area sufficiently larger than the size of the elongated hole formed in the mold electrode 1a is positioned on the position A, When the discharge pulse generator 5 is connected and discharge machining is performed while feeding in the Z-axis direction, a rod-shaped punch 6a having a cross section of the contour of the elongated hole formed in the mold electrode 1a is formed. The cross-sectional size of the punch 6a is formed smaller than the size of the elongated hole by an amount corresponding to the discharge gap. Further, as the punch material 6, a cemented carbide or sintered diamond is suitable. The positioning of the punch material 6 on the position A is as follows.
The bottom surface of the punch material 6 may cover the entire long hole. (Fifth Step) As shown in FIG. 1E, after the punch 6a is pulled out from the mold electrode 1a, the support 6 is moved in the X-axis direction to position the punch 6a on the die 2a. This moving distance is the same as the moving distance of the bar electrode 4 determined at the time of shifting from the second step to the third step, that is, the distance from the position A to the position B. This punch 6
By moving a into the die 2a, the punch 6a having a clearance corresponding to the discharge gap is positioned with respect to the long hole formed in the die 2a, and a punching tool set can be obtained.

In the above steps, the case where the punching pattern is a long hole has been described. However, by performing electric discharge machining of the die electrode material 1 and the die material 2 by the rod electrode 4 in a desired shape, an arbitrary punching pattern can be formed. And a punching tool set having the same.

Next, a second embodiment will be described.
The present embodiment shows a method of manufacturing a movable stripper for preventing a material from being drawn simultaneously with a strip of a punched material when performing a punching process with a fine punch.

Instead of the die material 2 in the method for manufacturing a punching tool set shown in FIG.
1 is fixed on the support 3 and the first to fifth steps described above are performed.
By the process, the punch 6a and the stripper plate 11a as shown in FIG. 2 are manufactured. By this processing, a state where the punch 6a can be inserted with a uniform clearance into the stripper plate 11a on which the through pattern is formed is obtained. As the stripper material 11, it is desirable to use a high-hardness metal such as a cemented carbide so as not to cause abrasion.

As shown in FIG. 2, the punch 6a is inserted until its tip surface reaches about half the thickness of the stripper plate 11a, and the punch 6a is inserted into the stripper plate 11a from the periphery including the step 6b generated when the punch 6a is formed. The area up to the surface is filled with the curable resin 12 and cured. The curable resin 12 is suitably a room-temperature-curable silicone rubber, but is not limited to this as long as it is an elastic material that can be compressed beyond the punching stroke of the punch 6a after curing.

By inserting the punch 6a formed as described above into the die, the curable resin 12 adhered to the side peripheral surface of the punch 6a is peeled off.
Is compressed between the step portion 6b of the punch 6a and the stripper plate 11a and is restored by the retraction of the punch 6a from the die, so that the stripper plate 12 acts as a movable stripper.

Since the structure of the movable stripper does not require mechanical assembly, it is possible to realize a movable stripper having a very small discharge gap as a clearance when forming a punch even with a fine punch 6a. With this movable stripper, the punched material can be reliably stripped even at the time of the punching process of the fine hole, and the punching process that does not draw in the material can be performed.

Next, a third embodiment will be described. This embodiment shows another configuration of the movable stripper, and FIG. 3 shows its manufacturing process in order. (First Step) As shown in FIG. 3A, the surface of the fine-diameter punch 22 fixed to the insulating support 21 is
The metal layer 23 is formed by electroforming. The punch 22 is formed of a high hardness metal such as a cemented carbide. Further, as the electroformed metal material, nickel or nickel-iron alloy which can obtain relatively high hardness is suitable. (Second Step) As shown in FIG. 3B, the metal layer 23 formed on the bottom surface of the punch 22 is removed by means of electric discharge machining or the like, and the tip surface of the punch 22 is exposed. (Third Step) As shown in FIG. 3C, the metal layer 23 is pulled out from the punch 22 so as to be peeled off. The drawing distance is adjusted to a desired movable distance as a stripper.
If a sacrificial layer is provided by etching on the surface of the punch 22 before electroforming in order to facilitate the separation of the metal layer 23 from the punch 22, the metal layer 23 can be removed from the punch 22 without applying unnecessary force. Can be withdrawn. (Fourth Step) As shown in FIG. 3C, the side peripheral surface of the punch 22 exposed from the metal layer 23, the bottom surface of the support 21, and the side peripheral portion of the portion of the metal layer 23 that covers the punch 22. Is surrounded by a curable resin 24 so as to cover and fill, and is cured. The curable resin 24 is suitably a room-temperature-curable silicone rubber, but is not limited to this as long as it is an elastic material that can be compressed beyond the punching stroke of the punch 22 after curing.

Through the above steps, a movable stripper in which the metal layer 23 is fixed to the support 21 via the curable resin 24, which is an elastic body, is obtained. Since the manufacture of the movable stripper does not require mechanical assembly, an extremely small clearance can be realized even if the punch 22 has a fine diameter. Further, the punch 22 having the movable stripper, when punching a fine hole in a punching material together with a die (not shown), can reliably strip the punching material and perform high-precision punching without drawing in the punching material. .

[0025]

As described above, according to the present invention, a punching tool set which is a combination of a punch and a die for punching a fine through hole can be manufactured with high precision. In addition, a movable stripper that strips a punched material at the time of punching with a fine punch and prevents the material from being pulled in can be manufactured without requiring mechanical assembly.

[Brief description of the drawings]

FIG. 1 is a process chart showing steps of a method for manufacturing a punching tool set according to a first embodiment in the order of (a) to (e).

FIG. 2 is a sectional view showing a configuration of a movable stripper according to a second embodiment.

FIG. 3 is a process chart showing the steps of a method for manufacturing a movable stripper according to a third embodiment in the order of (a) to (c).

FIG. 4 is a process diagram showing a manufacturing process of a punching tool set according to the related art.

[Explanation of symbols]

 Reference Signs List 1 type electrode material 1a type electrode 2 dice material 2a dice 4 bar electrode 5 fine discharge pulse generator 6 punch material 6a punch 11 stripper material 11a stripper plate 12 curable resin (elastic resin) 21 support 22 punch 23 metal layer 24 curing Resin (elastic resin)

Claims (3)

[Claims] 1. A die material and a die electrode material are fixed on the same plane, and the die material and the die electrode material are processed by electric discharge machining to form through patterns having the same shape and the same direction. Forming a punch having a cross-sectional shape of the through pattern by feeding a punch material to the mold electrode from a direction perpendicular to the plane of the plate while performing electrical discharge machining; Moving the punch from the die electrode to the die in a distance and direction connecting the same point on the same through pattern formed on the die electrode and the die electrode to produce a tool set in which the punch is positioned on the die. A method for manufacturing a punching tool. 2. A stripper in which a stripper material and a mold electrode material are fixed on the same plane, and the stripper material and the mold electrode material are processed by electric discharge machining to form through patterns having the same shape and direction. Forming a plate and a mold electrode; and forming a punch having a cross-sectional shape of the through pattern by feeding a punch material from the direction perpendicular to the flat surface of the mold electrode while performing electrical discharge machining on the mold electrode. Moving the punch from the mold electrode onto the stripper plate in a distance and direction connecting any same point on the same through pattern formed on the stripper plate and the mold electrode; Inserted into the penetration pattern so as to be within the thickness of the plate, and the side peripheral surface including the base of the punch and the stripper plate A method for manufacturing a punching tool, comprising: attaching a movable stripper to a punch by a step of filling a gap between the punch and a surface with an elastic resin. 3. A step of coating the surface of the punch fixed to the support with a metal layer by electroforming, a step of removing the metal layer covering the front end surface of the punch, and coating the side peripheral surface of the punch. Moving the metal layer away from the punch side peripheral surface to make it movable with respect to the punch, and drawing the metal layer to the punch tip surface side by a desired amount, and supporting the metal layer, the punch and A method for manufacturing a punching tool, comprising: attaching a movable stripper to a punch by a step of filling an elastic resin between the punch and a tool.