JP2002052897A - Method for forming emboss processing mold and emboss processing mold - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for forming an emboss processing mold, capable of reducing the number of processes for performing finish processing using a cutting tool or the like to a large extent or eliminating the same at all, and the emboss processing mold. SOLUTION: In the method for forming the emboss processing mold, a model 1 having a target shape is formed and the shape data in directions X, Y and Z based on the model 1 are collected to be converted to NC processing data and a mold material is subjected to carving processing on the basis of the NC processing data by a NC processing machine. The emboss processing mold is also disclosed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming an embossing die and an embossing die. More specifically, the present invention can faithfully reproduce a product shape when embossing a metal plate or the like.
The present invention relates to an embossing die forming method and an embossing die capable of making a surface of a plate less likely to have a flaw.

[0002]

2. Description of the Related Art Heretofore, a method has been used in which the surface of a metal plate or the like is embossed to form an uneven shape on the surface of the plate, thereby enhancing the aesthetics and strength of the plate material. Such embossing is applied not only to raw materials such as steel plates, aluminum plates, and foils, but also to pre-painted colored steel plates, etc. It is widely used for building interior and exterior materials such as exterior wall materials and interior materials, and interior materials for vehicles.

An embossed plate is formed by passing a pair of embossed rolls formed on the surface by embossing a pattern inverted from a predetermined pattern, or by press-forming using an embossed flat plate. It is manufactured by forming an uneven pattern on the surface. By such an embossing molding method, the embossed plate can be easily designed in various shapes and a high-grade appearance can be obtained. There is a strong demand for embossed boards that increase the depth of irregularities in order to enhance product value, such as emphasizing

As shown in FIG. 2, in an embossing type such as an embossing roll, first, a model having a predetermined shape to be formed on a workpiece is prepared with a plaster type or the like, and used as a sample of a wall covering material or the like (see FIG. 2). 2 (a)). In consideration of the uneven height of the gypsum mold 1, that is, the cross-sectional shape, a tomogram of each height is photographed, and a negative or positive film depicting a contour line pattern is created. By pressing a photoresist film on a substrate to be a mold, and exposing to ultraviolet light through a negative or positive film on which a pattern is drawn, an image having a predetermined pattern is printed, the film is peeled off and developed, and then, A predetermined pattern is formed on the mold surface by etching (FIG. 2B). FIG. 4 shows an upper mold, and FIG.
Represents a lower mold.

[0005]

However, in the conventional embossing plate forming method, as described above, since an etched mold is used, especially in the case of a color steel plate,
There is a problem that the surface is easily scratched. In other words, a smooth surface is not formed on the etched mold surface, which is a mold, due to the chemical reaction peculiar to etching caused by the material structure such as the presence of a crystal grain structure, and is generally formed into a step-like uneven cross-sectional shape. For example, the surface shape is not always easy to control. When the color steel plate 6 or the like to be processed is embossed with an embossing die having such a surface shape (FIG. 2C), fine flaws are generated particularly on a painted surface, which is a portion where clearance is relatively narrow. Cracks and the like occur, and color steel plates warp and warp. For this reason, after the etching, it is necessary to perform finishing work of the mold surface, which requires a great deal of labor and time using a grinding tool such as a luter, and this operation is troublesome.

In view of the above-mentioned problems of the prior art, an object of the present invention is to significantly reduce or eliminate the number of steps for finishing using a grinding tool or the like, and yet to obtain a more faithful three-dimensional shape. An object of the present invention is to provide an embossing die forming method and an embossing die capable of forming reproducible and high-quality products.

[0007]

The above object is achieved by the invention described in each claim. That is, the embossing die forming method according to the present invention is characterized in that a model having a target shape is created, shape data in the X, Y, and Z directions based on the model is sampled, and the sampled data is converted into NC processing data. And engraving the mold material by an NC processing machine based on the NC processing data.

According to this configuration, the engraving of the mold material is performed by an NC processing machine (a numerically controlled machine tool, which is used as a concept that includes a machine capable of performing numerical control and automatically working). Thus, the step-like uneven shape peculiar to the etching which is performed in the step (1) does not occur, and the control of the surface shape is much easier than the etching. Therefore, even when embossing a workpiece such as a color steel plate, it is possible to reliably prevent or reduce the occurrence of flaws and the like on the surface thereof, and to perform embossing with a greater uneven depth. However, it is possible to reduce or prevent the occurrence of flaws and the like on the surface of the workpiece. In addition, the correction of the uneven shape can be easily performed not only by the arithmetic means built in the NC processing machine, but also
It is also easy to form an appropriate roundness at the convex portion or the bottom corner portion of the uneven portion by appropriately selecting a processing tool, and it is easy to form a highly accurate and precise mold surface processing. It is also possible to store the NC data once collected by using a storage means. Even when manufacturing a spare mold, it is not necessary to collect data again, and a high precision mold is similarly manufactured. It can be very convenient. In addition, since operations such as changing design dimensions (magnification, enlargement, reduction, repetition, reversal, etc.) including the design depth and size of the product can be performed easily and easily, for example, a size smaller than the product size It is possible to form a processing die capable of manufacturing a product of a sufficiently wide size even by making a model of. As a result, it has been possible to provide an embossing die forming method capable of greatly reducing or eliminating the number of steps for finishing the surface of the die material using a grinding tool or the like.

Preferably, the mold material is a pair of rolls, and the other roll is engraved by NC processing data created by mirror-inverting the collected data.

According to this structure, the NC processing data collected earlier can be easily mirror-reversed by the arithmetic means built in the NC processing machine, and the embossing roll formed and processed in this manner. This is advantageous because it can reliably prevent or reduce the occurrence of flaws and the like on the surface of the workpiece.

When engraving the other roll, it is preferable to use NC processing data that is mirror-inverted taking into account a clearance considering the thickness of the workpiece.

According to this configuration, it is possible to reliably prevent or reduce the occurrence of flaws or the like on the surface of the workpiece even for workpieces having various thicknesses, which is convenient.

A feature of the embossing die according to the present invention is that it is formed by the embossing die forming method according to any one of claims 1 to 3.

According to this configuration, since the surface of the embossed workpiece is unlikely to have flaws, an embossing die capable of greatly reducing or eliminating the number of steps for finishing using a grinding tool or the like. Can be provided.

[0015]

Embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 shows an embossing mold forming method for forming a mold for a wall covering material as an example, and shows the procedure. First, as shown in FIG. 1A, a gypsum mold 1 which is a model having a predetermined concave and convex shape as a target shape is prepared in advance to form a pattern for a wall covering material. In order to collect shape data in the X, Y, and Z directions of the uneven shape formed on the surface of the gypsum mold 1, the digitizer 2 is used to collect point groups in the X, Y, and Z directions regarding the uneven shape of the surface of the gypsum mold 1. Ask for data. The collected point cloud data is processed by arithmetic means, for example, CAD, CAM
Is used to convert to NC processing data. Further, the irregular shape data mirror-inverted from the sampled irregular shape is obtained by calculation. That is, the shape data of the convex type and the concave type are obtained in advance. In this case, since the workpiece is inserted between the convex mold and the concave mold, pressed and molded, the mirror inversion data is added to the emboss clearance considering the thickness of the workpiece. For example, when the thickness of the workpiece is relatively thin, the clearance due to the fitting of the irregularities between the two dies may be small, and when the relatively thick workpiece is exclusively embossed, the clearance is increased. Keep it.

Based on the obtained NC processing data, a separately prepared mold material is engraved using the cutting tool 3 of the NC processing machine (FIG. 2B). Usually, a metal mold is used as the mold material. In this manner, the upper mold 4 and the lower mold 5 are formed, and a workpiece (not shown) such as a color steel plate is disposed between these two molds, and a power source such as hydraulic pressure is used. By pressing with a predetermined pressure, an embossed wall covering having a predetermined uneven shape on the surface is manufactured (FIG. 2C).

Since the uneven shape formed on the surface of the metal mold is finished by the NC machine, a sharp edge is not formed as in the case of etching,
For this reason, the surface of the wall covering material formed by this mold has almost no flaws and the like, and the painted portion of the steel sheet surface is beautiful.

However, in the case of forming an irregular shape with a particularly large depth on the mold surface or forming an extremely fine pattern, it takes too much time to perform all the processing steps using the NC processing machine. If this is the case, a conventional etching method may be added in combination with the above-mentioned processing method as appropriate, or finishing of the mold surface may be added using a grinding tool such as a luter. Even then, as in the prior art,
Compared to performing all the steps of forming the embossing die by etching, the labor required for the operation is significantly less and the operation efficiency is high.
In short, by forming the concave and convex shape of the mold surface mainly by using the NC processing machine, the trouble of the conventional processing method can be greatly reduced, and the processing time or processing labor can be remarkably improved. It is.

[0019]

EXAMPLE In order to form a stripe pattern on the surface of a mold,
The product model was created in a plaster mold. Maximum depth is about 5.0m
m. From this plaster mold, 3 using a digitizer
The dimensional data was collected and converted into NC processing data having a maximum depth of 2.0 mm by an arithmetic unit built in the NC processing machine. Based on the NC processing data, a surface processing was performed on a steel material (SCM) for a mold roll by an NC processing machine. In that case, the tip shape (R10-1.5 m
The processing was performed by changing the feed pitch according to the tip shape using five types of ball cutters having different m).

After the embossing die is manufactured in this manner, the embossing die is used to adjust the surface of the die to a predetermined size (width 30) without any adjustment of the surface of the die.
Emboss processing was performed on a plurality of white color steel plates (0 × length 300 × thickness 0.27 mm).

No flaws, cracks, etc. were found on the surface of the embossed white color steel sheet, and no warping or distortion of the sheet itself could be visually recognized.

[Another Embodiment] (1) In the above embodiment, the upper and lower molds are formed with irregularities on their surfaces, and the workpiece is arranged between these two molds. Although an example of press molding is shown, the mold for forming the uneven shape may be either an upper mold or a lower mold,
The other may be a smooth mold, and the workpiece may be pressed between these two dies to perform embossing.

(2) The embossed pattern may be not only a regular pattern such as a dimple pattern or a houndstooth check, but also an irregular pattern, such as a lace stitch, a pipe woodgrain, a ceramic, a natural stone. Various patterns such as tone can be given.

(3) The model of the uneven shape is not limited to the plaster type, and the material of the model is not particularly limited as long as the shape data can be collected by a digitizer or the like.

[Brief description of the drawings]

FIGS. 1A and 1B are process diagrams showing an embossing mold forming method according to an embodiment of the present invention, in which FIG. 1A is a schematic cross-sectional view showing a state in which shape data is collected from a gypsum mold, and FIG. Sectional view showing a state in which a mold is manufactured using a machine, and (c) a schematic sectional view at the time of embossing.

2A and 2B are process diagrams showing a conventional embossing mold forming method, wherein FIG. 2A is a schematic sectional view of a gypsum mold, FIG. 2B is a sectional view of an etched mold, and FIG. Schematic sectional view

[Explanation of symbols]

 1 model

Claims (4)

[Claims] 1. A model having a target shape is created, shape data in the X, Y, and Z directions based on the model is sampled, the sampled data is converted into NC processing data, and based on the NC processing data. An embossing mold forming method for engraving a mold material with an NC machine. 2. The embossing die forming method according to claim 1, wherein the die material is a pair of rolls, and the other roll is engraved by NC processing data created by mirror-inverting the collected data. 3. The embossing die forming method according to claim 2, wherein, when engraving the other roll, NC processing data is mirror-inverted by taking into account a clearance in consideration of the thickness of the workpiece. 4. An embossing die formed by the embossing die forming method according to claim 1.