JP2004291157A - Surface grinding apparatus and machining method using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a surface grinding apparatus which accurately and efficiently carries out surface grinding, groove grinding, and cutting-off while maintaining high accuracy with a simple apparatus, and also to provide a machining method using the same. <P>SOLUTION: Heads of a horizontal double-head surface grinding apparatus are provided with different abrasive wheels, and therefore, surface grinding, groove grinding and cutting-off are alternately or continuously carried out without resetting a workpiece on a work table. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【００２６】
【発明の効果】
以上説明したように、本発明によれば、横軸２頭式の研削装置の各頭に、異なる種類の研削砥石を取り付けることにより、平面研削と溝加工、平面研削と切断加工および鏡面研削と溝加工等の異なる２種の研削加工を１台の研削装置で連続して、かつ高精度、高効率で行うことができる。
【図面の簡単な説明】
【図１】Ｅ型フェライトコアを模式的に示す図である。
【図２】従来の縦軸１頭式研削装置による平面研削方法を示す図である。
【図３】従来の横軸１頭式研削装置による平面研削方法を示す図である。
【図４】従来の平面研削−切断の加工方法を示す図である。
【図５】本発明の横軸２頭式研削装置を模式的に示す図である。
【図６】汎用治具を用いたワークの固定方法の例を示す図である。
【図７】本発明の平面研削−溝加工の方法を模式的に示す図である。
【図８】本発明の平面研削−切断加工の方法を模式的に示す図である。
【図９】本発明の平面粗研削−鏡面研削−溝研削の方法を模式的に示す図である。
【符号の説明】
１．Ｅ型フェライトコア
２．基部
３．外脚
３ａ．外脚端面
４．中脚
４ａ．中脚端面
５．作業テーブル
６．ワーク
７．縦回転軸
８．縦軸用研削砥石
９．横回転軸
１０．横軸用研削砥石
１１．平面研削用砥石
１１ａ．鏡面研削用砥石
１２．切断用研削砥石
１３．溝加工用研削砥石
１４．溝
１５．汎用治具
１６．両面テープ
１７．切断ライン[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a surface grinding apparatus and a processing method using the same, and more particularly, to a proposal relating to a horizontal-axis two-head type surface grinding apparatus suitable for processing a ferrite core and a processing method using the same.
[0002]
[Prior art]
Ferrite cores used for various transformers such as power supply circuits and communication equipment, choke coils, and magnetic cores such as noise filters have various shapes such as E type, I type, U type, RM type, PM type and ER type. Among them, an E-type core is a typical example. As shown in FIG. 1, this E-shaped core has a base 1 having two projecting outer legs 2 and a middle leg 3 projecting in the same direction at the center thereof. It is what constitutes.
[0003]
This E-shaped core is generally used in combination with another E-shaped core or an I-shaped core to form a closed magnetic circuit (magnetic circuit) having a “sun” shape. At this time, the outer leg end surface 2a of the E-shaped core is in contact with and faces the end surface of the other core, and the magnetic characteristics of the core are adjusted between the end surface 3a of the middle leg and the end surface of the other core. Therefore, a gap or gap is usually formed. Since the size of the gap has a great influence on the characteristics of the filter and the transformer due to the subtle differences, high dimensional accuracy is required for machining the gap. Furthermore, with the rapid miniaturization of ferrite cores in recent years, not only the gap size but also high processing accuracy has been required for all dimensions.
[0004]
By the way, in order to manufacture an E-type ferrite core, a block larger than a target size is formed in advance in a powder molding process, the block is fired, a grinding process is performed, and the block is cut to obtain a target size. In general, it is formed into a shape (for example, see Patent Document 1). Further, the surface grinding in the above-mentioned processing step is generally performed by using a single-headed horizontal axis (one-axis horizontal axis) or single-headed vertical axis (one axis of vertical axis) surface grinding device.
[0005]
[Patent Document 1] JP-A-2003-59740
[Problems to be solved by the invention]
In the processing using a single-axis vertical surface grinding device, a workpiece 6 (for example, a ferrite core) as a workpiece is fixed on a table 5 that can be rotated or moved vertically and horizontally, and attached to a vertical rotating shaft 7. Grinding is performed by a grinding wheel 8 as a processing tool (see FIG. 2). Therefore, it is suitable for surface grinding of a work, but it is not possible to perform groove processing for cutting grooves and cutting processing. On the other hand, in the processing by the horizontal-axis single-head type surface grinding device, a groove grindstone 10 that rotates around a horizontal axis (horizontal) rotation axis 9 is used, so that groove processing or cutting processing is possible. However, the width of the grinding wheel used is limited, and generally the maximum width is about 20 mm. Therefore, in the case of performing surface grinding, it is necessary to perform so-called traverse grinding, in which a narrow grinding wheel for groove processing is used to move and grind little by little, and there is a problem that grinding efficiency is significantly reduced. (See FIG. 3). In addition, there is a method in which the surface is ground by using a through-feed type grinding device such as a vertical axis-horizontal axis, a horizontal axis-vertical axis, and the like, and then a groove is formed. However, since the directions of the grindstone shafts are different, the thermal expansion and shrinkage of the grindstone shafts are different directions.
[0007]
Therefore, in order to solve the above problem, it is necessary to perform the surface grinding and the grooving or cutting using a separate grinding device, or to replace the grinding wheel with one grinding device. there were. For example, in the case of performing cutting processing after surface grinding, after performing surface grinding in advance using a horizontal-axis single-head type surface grinding device or a vertical-axis single-head type surface grinding device, the horizontal shaft 1 with a cutting grindstone 11 attached thereto. It is necessary to move the work to a head-type grinding device and perform cutting (see FIG. 4).
[0008]
However, in the above method, work for transferring a work to another device and work for changing a grindstone occur, so that work efficiency is greatly reduced. In addition, there is a problem that a significant decrease in dimensional accuracy is unavoidable due to a difference in accuracy of an apparatus used for processing itself and a change in a reference plane due to attachment and detachment of a work. As a method for solving such a problem, the technique of Patent Document 1 proposes a method using a dedicated jig for fixing a ferrite core. However, this method is intended for a small core, and in order to place a workpiece on the fixing jig, an adhesive work for fixing the ferrite core and the jig, and a method for removing the work. There is a problem that the work efficiency is reduced due to the necessity of the peeling operation of the fixing jig, and that if the dimensional accuracy of the fixing jig is poor, it also affects the product dimensions. In addition, this method lacks versatility because it requires a special four-unit multi-grinding wheel for groove grinding in addition to a fixing jig according to the work.
[0009]
An object of the present invention is to provide a surface grinding apparatus capable of performing high-precision, high-efficiency surface grinding, grooving, and cutting while maintaining high precision using a simple apparatus, and a processing method using the apparatus. It is to propose.
[0010]
[Means for Solving the Problems]
The inventors have conducted intensive studies in order to solve the above-mentioned problems of the prior art. As a result, by using different grindstones for each head of the horizontal axis two-head type surface grinding device according to the processing purpose, surface grinding and grooving, surface grinding and cutting, mirror surface grinding and grooving, etc. It has been found that two types of processing different from each other can be efficiently performed while maintaining high dimensional accuracy.
[0011]
The present invention, which has been developed based on the above knowledge, is a horizontal-axis two-head type surface grinding apparatus including a plurality of processing tools at predetermined intervals along a work moving direction of a work table. A horizontal-axis two-head system, in which different types of processing tools are detachably mounted, and different types of processing are performed sequentially or alternately continuously without replacing a work on a work table. Surface grinding device.
[0012]
In the present invention, it is preferable that a surface grinding wheel and a groove processing wheel are used as the processing tool, or a surface grinding wheel and a cutting wheel are used. Further, it is preferable that the grinding apparatus of the present invention uses a ferrite as a work.
[0013]
Further, the present invention provides a machining method characterized in that different types of machining tools are attached to respective shaft heads of a horizontal-axis two-head surface grinding device so that different machining is performed continuously without replacing a workpiece. suggest.
[0014]
The present invention provides a processing method for continuously performing surface grinding and grooving using a wide surface grinding wheel and a narrow surface grinding wheel as the processing tool, and a wide surface grinding wheel and a cutting wheel as the processing tool. Using a processing method of continuously performing surface grinding and cutting, or using a narrow surface grinding wheel with a coarse grain and a wide surface grinding wheel with a fine grain as the processing tool, rough surface grinding was performed. Thereafter, it is preferable to use any one of the processing methods of continuously performing mirror surface grinding and groove processing.
[0015]
The work in the working method of the present invention is preferably ferrite.
[0016]
BEST MODE FOR CARRYING OUT THE INVENTION
According to the present invention, as shown in FIG. 5, different types of grinding wheels are attached to the respective heads (heads) of a horizontal-axis two-head surface grinding device, and processing is performed using these wheels sequentially or alternately. Thus, the feature is that different processing can be performed by one grinding device without lowering the processing accuracy and the working efficiency.
[0017]
First, in the present invention, once the work is fixed to the work table, the subsequent processing such as surface grinding, grooving, cutting, etc. is continuously performed, without being removed, as it is It is performed in the state of. Therefore, processing can be performed while maintaining high dimensional accuracy without causing a decrease in dimensional accuracy due to attachment and detachment. For this purpose, it is preferable to mount a work on a work table beforehand by machining a reference surface and mounting the work on the work table with the reference surface as a back surface. As a method of fixing to the work table, for example, a method using a magnet, a method of bonding with a wax or the like using a versatile jig, or a method using a freezing chuck can be used, and there is no particular limitation. . However, in the case of processing in which cutting is performed, it is preferable to use a versatile jig and fix the jig and the work with double-sided tape (see FIG. 6).
[0018]
Further, in the grinding device according to the present invention, since the rotation axis of the grinding wheel is the horizontal axis, the processing is performed using the outer peripheral surface of the grinding wheel. Therefore, it is preferable to use a wide grinding wheel for surface grinding and a narrow grinding wheel for grooving and cutting. For example, a grinding wheel used for processing a small product such as a ferrite core is a wide grinding wheel having a width of more than 20 mm, preferably about 50 mm for surface grinding, and a narrow width of 20 mm or less for groove processing. It is preferable to use a grinding wheel having a width of 2 mm or less. Further, the grain size of the grindstone may be appropriately determined according to the processing purpose. For example, a grindstone of about # 170 is used for rough grinding of a ferrite core, and a grindstone of # 800 or more is used for mirror grinding. Is preferred.
[0019]
In the present invention, the above-mentioned grinding wheel is appropriately selected according to the processing application, and is attached to each head of the two-head apparatus, so that the work fixed on the work table can be continuously processed without detaching and attaching. Therefore, it is possible to perform grinding with high dimensional accuracy and high production efficiency.
[0020]
Although the above description of the present invention has been focused on the processing of ferrite cores, the present invention is not limited to processing ferrite cores, but also processing metals, such as iron, aluminum, and copper, and silicon and ceramics. It is not necessary to limit the work material. The material of the grinding wheel can be a diamond wheel, a CBN wheel, a general grinding wheel, or the like, and is not particularly limited.
[0021]
【Example】
Next, embodiments of the present invention will be described with reference to the accompanying drawings.
(Example 1) A grindstone having an outer diameter of 200 mm, a width of 50 mm and a grain size of # 170 as a surface grinding wheel and a grindstone of an outer diameter of 200 mm, a width of 5 mm and a grain size of # 170 were used as a surface grinding wheel in a two-axis horizontal grinding machine. Attach a grindstone and, for a ferrite core with a thickness of 10 mm, a width of 40 mm, and a total length of 500 mm, follow a surface grinding process with a grinding allowance of 1 mm, and then make a groove of 5 mm in width and 1 mm in depth in the center in the width direction and in the length direction. (See FIG. 7). Note that all of the above grindings were performed by creep grinding in which the grinding was performed in one pass at a low speed of 1.0 m / min. During the processing, the ferrite core as the work was not attached or detached.
[0022]
(Example 2) A grinding wheel having an outer diameter of 200 mm, a width of 50 mm, and a grain size of # 170 as a surface grinding wheel, and a grinding wheel having an outer diameter of 200 mm, a width of 1 mm, and a grain size of # 170 as a surface grinding wheel. Is mounted on a ceramic plate having a thickness of 5 mm, a width of 40 mm, and a length of 500 mm, followed by a surface grinding process with a grinding allowance of 1 mm, and a width of 1 mm, a cutting depth of 5 mm, and a center in the width direction in the length direction. The cutting process was performed continuously (see FIG. 8). Note that all of the above grindings were performed by creep grinding in which the grinding was performed in one pass at a low speed of 0.2 m / min. The ceramic plate as the work was fixed to a general-purpose jig using a double-sided tape, and the ceramic plate was not attached or detached during the processing.
[0023]
(Example 3) A grinding wheel having a 200 mm outer diameter and a width of 50 mm and a grain size of # 800 as a flat mirror-surface grinding wheel and a grinding wheel for coarse grinding having an outer diameter of 200 mm and a width of 10 mm and a grain size were placed on a two-axis horizontal grinding machine. Attach a grindstone of # 170, first perform rough surface grinding with a rough grinding wheel on a 10 mm thick, 45 mm wide, 100 mm long ferrite plate, and then perform total grinding using a mirror grinding wheel. Mirror surface grinding with an allowance of 10 μm is performed, and subsequently, using the previously used coarse grinding wheel, groove processing for forming a groove having a width of 10 mm and a depth of 1 mm in the center in the width direction and the length direction is continuously performed. (See FIG. 9). The rough grinding was performed by creep grinding at a feed rate of 2 m / min, the mirror grinding was performed by plunge grinding at a feed rate of 20 m / min, and the groove processing was performed by creep grinding at 1.0 m / min in one pass. Also, during this processing, the ferrite plate as the work was not attached or detached.
[0024]
Table 1 shows the time required for grinding in Examples 1 to 3 in comparison with the prior art. As is clear from this table, by using the grinding apparatus and the processing method of the present invention, the processing can be performed with a short working time of 1/3 to 1/10 and with high processing accuracy as compared with the conventional method. It can be carried out.
[0025]
[Table 1]

[0026]
【The invention's effect】
As described above, according to the present invention, different types of grinding wheels are attached to the respective heads of a horizontal-axis two-head type grinding machine, so that surface grinding and grooving, surface grinding and cutting, and mirror grinding can be performed. Two different types of grinding, such as grooving, can be performed continuously, with high precision, and high efficiency by a single grinding device.
[Brief description of the drawings]
FIG. 1 is a diagram schematically showing an E-type ferrite core.
FIG. 2 is a view showing a surface grinding method using a conventional vertical single-head grinding device.
FIG. 3 is a view showing a surface grinding method using a conventional horizontal-axis single-head grinding apparatus.
FIG. 4 is a view showing a conventional surface grinding-cutting processing method.
FIG. 5 is a diagram schematically showing a horizontal-axis two-head grinding apparatus of the present invention.
FIG. 6 is a diagram illustrating an example of a method of fixing a work using a general-purpose jig.
FIG. 7 is a view schematically showing a method of surface grinding and grooving according to the present invention.
FIG. 8 is a diagram schematically illustrating a method of surface grinding and cutting according to the present invention.
FIG. 9 is a view schematically showing a method of surface rough grinding-mirror surface grinding-groove grinding of the present invention.
[Explanation of symbols]
1. 1. E-type ferrite core Base 3. Outer leg 3a. Outer leg end face4. Middle leg 4a. Middle leg end face5. Work table6. Work 7. 7. Vertical rotation axis Vertical grinding wheel 9. Horizontal rotation axis10. 10. Grinding wheel for horizontal axis Surface grinding wheel 11a. Mirror grinding wheel 12. 12. Grinding wheel for cutting 13. Grinding wheel for groove processing Groove 15. General-purpose jig16. Double-sided tape 17. Cutting line

Claims (9)

In a horizontal-axis two-head type surface grinding device equipped with a plurality of processing tools at predetermined intervals along the work moving direction of the work table, different types of processing tools can be attached to and detached from each shaft head. A horizontal-axis two-head type surface grinding apparatus characterized in that different types of processing are performed sequentially or alternately continuously without mounting a work on a work table. The surface grinding device according to claim 1, wherein a surface grinding wheel and a groove processing wheel are used as the processing tools. The surface grinding device according to claim 1, wherein a surface grinding wheel and a cutting wheel are used as the processing tool. The surface grinding device according to claim 1, wherein the work is ferrite. A machining method characterized in that different machining tools are attached to respective shaft heads of a horizontal-shaft two-head surface grinding device to perform different machining continuously without replacing a workpiece. A wide surface grinding wheel is mounted on one shaft head and a narrow surface grinding wheel is mounted on the other shaft head of the two horizontal shaft type surface grinding device. Surface grinding with a wide surface grinding wheel and narrow surface grinding A machining method characterized by continuously performing groove machining with a grinding wheel without replacing the work. A wide surface grinding wheel is attached to one head and a cutting wheel is attached to the other head of the two-axis horizontal surface grinding device, and the work is replaced by surface grinding with a wide wheel and cutting with a cutting wheel. Processing method characterized in that the processing is carried out continuously without using any method. A coarse-grained, narrow-width surface grinding wheel is attached to one head of the horizontal-axis dual-head surface grinding device, and a fine-grained, wide-surface grinding wheel is attached to the other head. A machining method comprising, after rough surface grinding, continuously performing mirror surface grinding with a wide-grain grindstone having a fine grain size and groove machining with a narrow grindstone having a coarse grain size without replacing the workpiece. The processing method according to any one of claims 5 to 8, wherein the work is ferrite.

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