JP2010036254A - Method for processing carbon fiber material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for processing a carbon fiber material for accurately processing a material including the carbon fiber by machining, well performing processing with high processing surface accuracy and improving the service life of a tool. <P>SOLUTION: In the method, a workpiece W of a material including the carbon fiber is processed. A machine tool in which a table 12 mounted with the workpiece W thereon and a rotatable spindle 19 are constituted to be relatively movable in at least one axial direction is prepared. An electroplated tool 30 having a cylindrical tool body, a cutting blade part formed on an outer periphery of the tool body and an abrasive grain layer fixed with abrasive grains fixed by electrodeposition to a surface of the cutting blade part is mounted on the spindle 19 of the machine tool. While rotating the spindle 19 and relatively moving the spindle 19 and the table 12, the workpiece W is processed by the electroplated tool 30. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for processing a carbon fiber material.

Carbon fiber has excellent wear resistance, heat resistance, thermal stretchability, acid resistance, electrical conductivity, tensile strength, and is lighter than light metals such as aluminum, so it can be used for rockets, aircraft, etc. It is used for everyday tools such as tennis rackets and fishing rods.
However, while having the above-mentioned advantages, it is difficult to process, that is, difficult to process as a disadvantage.

  Therefore, as a product using carbon fiber, a thermoplastic resin is used as a pellet obtained by melting a thermoplastic resin on the surface of the carbon fiber and cutting the coated strand into a predetermined length, or a chopped yarn obtained by cutting the carbon fiber. In many cases, a method is employed in which pellets obtained by melting, kneading, and cutting into a predetermined length are injection molded to obtain a molded product having a predetermined shape (see Patent Document 1).

JP-A-2005-239806

There is a demand for a processing method capable of cutting and polishing the above-described material having carbon fibers by machining.
However, at present, because of the above-mentioned disadvantages, the carbon fiber is left uncut in machining by a general machine tool such as a machining center or a turning center, so that it is hardly performed. In addition, it was difficult to implement from the viewpoint of tool life.

  The object of the present invention is to meet the demands of carbon fiber materials that can process materials containing carbon fibers with high accuracy and good processing surface accuracy by machining, and that can increase tool life. It is to provide a processing method.

  The method for processing a carbon fiber material according to the present invention is a method for processing a carbon fiber material for processing a workpiece made of carbon fiber. The table on which the workpiece is placed and the rotatable main shaft are relatively moved in at least one axial direction. A machine tool configured to be capable of being prepared, and having a cylindrical tool body, a cutting blade portion formed on the outer periphery of the tool body, and an abrasive layer in which abrasive grains are fixed to the surface of the cutting blade portion An electrodeposition tool is attached to the spindle of the machine tool, and the spindle is rotated based on a command from a control device having a machining program for performing machining under a predetermined machining condition for machining the carbon fiber material. In addition, the workpiece is machined by the electrodeposition tool while relatively moving the table and the spindle.

According to this configuration, a machine tool is prepared in which a table on which a workpiece is placed and a rotatable spindle are configured to be relatively movable in at least two directions, and an electrodeposition tool is attached to the spindle of the machine tool. Since the work is processed by the electrodeposition tool while relatively moving the table and the main shaft in a state where the table is rotated, the work made of the material containing carbon fiber can be cut or ground by machining.
Moreover, the electrodeposition tool has a structure having a cylindrical tool body, a cutting blade portion formed on the outer periphery of the tool body, and an abrasive layer in which abrasive grains are fixed to the surface of the cutting blade portion. In addition, the carbon fiber material can be processed with high accuracy and excellent processing surface accuracy, and the tool life can be increased.

In the carbon fiber material processing method of the present invention, the abrasive layer of the electrodeposition tool is formed by adhering diamond abrasive grains or CBN (cubic boron nitride) abrasive grains to the surface of the cutting edge portion, It is preferable.
According to this configuration, since the diamond abrasive grains or the CBN abrasive grains are fixed to the surface of the cutting edge portion, that is, the diamond abrasive grains or the CBN abrasive grains have high hardness and excellent wear resistance. Therefore, the processing efficiency and processing accuracy of cutting and grinding can be improved, and further the improvement of the tool life can be expected.

In the method for processing a carbon fiber material according to the present invention, the diameter of the electrodeposition tool is 4 to 10 mm, and the rotation speed of the electrodeposition tool is 15000 to 30000 rotations / minute in a range from roughing to finishing. It is preferable that the workpiece is machined under a machining condition in which a cutting amount with respect to the workpiece is 1 to 15 mm and a relative feed speed between the electrodeposition tool and the workpiece is 100 to 4000 mm / min.
Here, regarding the processing conditions, it is preferable to perform processing by appropriately selecting within the above-described range according to the workpiece material. If machining is performed under such machining conditions, the machined surface accuracy can be satisfactorily finished and further increase in tool life can be expected.

In the method for processing a carbon fiber material according to the present invention, the electrodeposition tool is attached to the main shaft via a tool holder, and the tool holder is provided on a holder main body and rotatably provided on the holder main body. A mounting portion, a generator provided in the holder main body and transmitting the rotation of the main shaft through the mounting portion to generate electric power, and an electric power provided from the generator provided in the holder main body and supplied with the electric power It is preferable to include an electric motor that rotates the electrodeposition tool.
According to this configuration, the rotational speed of the electrodeposition tool can be arbitrarily set, and can be set to a rotational speed higher than the rotational speed of the main shaft, so that it can be applied to a machine tool having a low speed of the main shaft.

In the method for processing a carbon fiber material of the present invention, it is preferable that the workpiece is formed of a carbon fiber reinforced resin composite material using carbon fiber as a reinforcing material.
According to this configuration, for example, since the injection-molded carbon fiber reinforced resin composite material can be drilled or formed into a desired shape by machining, the degree of freedom in product design can be improved.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
<Description of machine tools>
FIG. 1 is a front view showing a schematic configuration of a machine tool according to an embodiment of the present invention.
The machine tool of the present embodiment includes a table 12 on which a workpiece W is placed, a main shaft 19 that is supported substantially vertically and rotatably with respect to the table 12, and the table 12 and the main shaft 19 relative to each other in a three-dimensional direction. A relative movement mechanism 10 for movement, a tool exchange mechanism 40 for attaching the tool holder 20 to the tip of the main shaft 19 in a replaceable manner, and a control device 50 for controlling the driving of the tool holder 20 are provided.

The relative movement mechanism 10 includes a base 11 that supports the table 12 so as to be movable in the front-rear direction (X direction), an X drive mechanism 13 that is provided on the base 11 and moves the table 12 in the X direction, and both sides of the base 11. A portal frame 14 provided across the table 12, a saddle 15 provided on the horizontal beam 14A of the portal frame 14 so as to be movable in the left-right direction (Y direction), and the saddle 15 are moved in the Y direction. The Y drive mechanism 16 is composed of a ram 17 provided on the saddle 15 so as to be movable in the vertical direction (Z direction) and having a main shaft 19 inside, and a Z drive mechanism 18 for moving the ram 17 in the Z direction. .
The X drive mechanism 13, the Y drive mechanism 16, and the Z drive mechanism 18 can be configured by a linear motor or the like, and a configuration in which a slider is screwed onto a feed screw shaft can be used.

A specified tool holder is detachably attached to the tip of the main shaft 19 by a tool changing mechanism 40. That is, on the basis of a command from the control device 50, in a state where the saddle 15 is moved to the right end in FIG. 1, a tool changing operation is executed between the spindle 19 and the tool changing mechanism 40, and designated at the tip of the spindle 19 The tool holder is mounted.
For example, in processing a material including carbon fiber, a tool holder 20 having an electrodeposition tool 30 attached to the tip is attached to the main shaft 19.

<Description of tool holder>
FIG. 2 shows the tool holder 20. The tool holder 20 includes a holder main body 21, a taper shank portion 23 as a mounting portion that is rotatably provided to the holder main body 21 via a bearing 22, and is attached to the tool holder fitting hole 19A of the main shaft 19, and the holder main body. A generator 24 that is provided in the motor 21 and generates power by transmitting the rotation of the main shaft 19 via the taper shank portion 23; and an electric motor 25 that is provided in the holder body 21 and is rotated by the power supplied from the generator 24. And a tool holding portion 26 that is provided on the output shaft 25 </ b> A of the electric motor 25 and holds the electrodeposition tool 30. Although not shown, the holder body 21 is provided with a detent pin that engages with a hole formed in the ram 17 in a state where the tool holder 20 is mounted on the main shaft 19.

Now, in a state where the tool holder 20 is mounted on the main shaft 19 of the machine tool, when the main shaft 19 is rotated at the rotation speed N ₀ , the taper shank portion 23 of the tool holder 20 rotates, and the rotation of the main shaft 19 causes the generator 24 to rotate. Is transmitted to. At this time, since the non-rotating pin is inserted into a fitting hole formed in a non-rotating portion such as a ram, only the tapered shank portion 23 of the tool holder 20 is rotated. Thereby, the generator 24 generates electric power.
When a three-phase synchronous generator is used as the generator 24, three-phase alternating current is generated. Frequency f of the three-phase alternating current generated by the generator 24, the number of poles of the generator 24 and _{P 1,} when the rotational speed of the spindle 19 and _N 0 [rpm], represented by the following formula (1).
_{f = P 1 × N 0/} 120 [Hz] ...... (1)

Therefore, when the main shaft 19 is rotated at the rotation speed N ₀ , three-phase AC power having a frequency f expressed by the above equation (1) is supplied to the motor 25. In the case of using the three-phase induction motor to the motor 25, whereupon the number of poles of the electric motor 25 is P _2, the motor 25 because to 2 / P ₂ rotate in one cycle of 3-phase AC synchronous speed of the motor 25 N ₁ is represented by the following formula (2).
N ₁ = 120 × f / P ₂ [rpm] (2)
Thus, the rotational speed _{N 1} of electroplated tools 30 with respect to the rotational speed _{N 0} of the spindle 19 is represented by the following formula (3).
N ₁ = N ₀ × P ₁ / P ₂ [rpm] (3)

As can be seen from the above equation (3), the rotational speed N ₀ of the main shaft 19 is shifted to the rotational speed N ₁ represented by the above formula (3). As shown by the equation (3), by appropriately setting the ratio of the number of poles P ₁ of the generator 24 and the number of poles P ₂ of the electric motor 25, the rotational speed of the electrodeposition tool 30 with respect to the rotational speed N ₀ of the main shaft 19. It can be seen that the gear ratio of N ₁ can be set arbitrarily.
That is, when it is desired to increase the rotational speed N ₀ of the main shaft 19, the pole number ratio P ₁ / P ₂ is made larger than 1, and when it is desired to decelerate, the pole number ratio P ₁ / P ₂ becomes smaller than 1. Thus, the number of poles P ₁ of the generator 24 and the number of poles P ₂ of the electric motor 25 may be selected in advance.

<Description of electrodeposition tool>
FIG. 3 shows the electrodeposition tool 30. The electrodeposition tool 30 includes a cylindrical tool body 31, a cutting blade portion 32 formed over a predetermined length in the longitudinal direction of the tool body 31 (about half length), and the surface of the cutting blade portion 32. And an abrasive grain layer 33 to which diamond abrasive grains are fixed. In the cutting blade portion 32, a V-shaped groove 34 is formed at a predetermined angle position on the tool body 31 along the axial direction of the tool body 31, and is formed between the V-shaped grooves 34.
Incidentally, in order to manufacture the electrodeposition tool 30, for example, after cutting the cutting blade portion 32 on the tool body 31, an adhesive is applied to the surface of the cutting blade portion 32, and diamond grinding is applied on the adhesive. It is produced by uniformly temporarily bonding the grains and then fixing these diamond abrasive grains by plating.

<Description of processing method>
In order to process a workpiece W including carbon fiber, for example, a carbon fiber reinforced resin composite material using carbon fiber as a reinforcing material, the workpiece W is fixed on the table 12 and electrodeposition is applied to the spindle 19 of the machine tool. The tool holder 20 equipped with the tool 30 is attached.
In this state, the spindle 19 is rotated by a command from the control device 50 having a machining program for executing machining under a predetermined machining condition for machining the carbon fiber material, and the spindle 19 is rotated in the Y and Z directions. In addition, while the table 12 is selectively moved in the X direction, the electrodeposition tool 30 performs a desired process on the workpiece W.

<Modification>
The present invention is not limited to the above-described embodiments, and modifications, improvements, and the like within the scope that can achieve the object of the present invention are included in the present invention.
In the embodiment, the carbon fiber reinforced resin composite material using carbon fiber as the reinforcing material has been described as the workpiece W. However, the material is not limited to this as long as the material includes carbon fiber.
For example, it may be a composite material of carbon fibers made into long and short fibers and a metal such as aluminum, or a composite material of rubber or wood powder. Further, it may be a flat sheet laminated.

In the embodiment, the electrodeposition tool 30 has an electrodeposition tool having a structure in which a V-shaped groove 34 is formed at a predetermined angular position of the tool body 31 and a cutting edge portion 32 is formed between the V-shaped grooves 34. 30, that is, the electrodeposition tool 30 having a structure in which the cutting blade portion 32 is parallel to the axial direction of the tool body 31 is used, but is not limited thereto.
For example, the electrodeposition tool 30 having a structure in which the cutting blade portion 32 is spirally formed on the outer peripheral surface of the tool main body 31 may be used.

In the said embodiment, although the diamond electrodeposition tool which fixed the diamond abrasive grain to the cutting blade part 32 of the tool main body 31 was used as the electrodeposition tool 30, it is not restricted to this.
For example, a CBN electrodeposition tool may be used in which CBN (cubic boron nitride) is used instead of diamond abrasive grains, and the CBN (cubic boron nitride) is fixed to the cutting edge portion 32 of the tool body 31. Even with a CBN electrodeposition tool, the same effect as the diamond electrodeposition tool described above can be expected.

In the above-described embodiment, the description has been given of the machining apparatus in which the main shaft 19 is configured to be movable in the X direction and the Y direction, and the table 12 on which the workpiece W is placed is configured to be movable in the X direction. I can't.
For example, the main shaft 19 may be configured to be movable in the X, Y, and Z directions, or the table 12 on which the workpiece W is placed may be configured to be movable in the X, Y, and Z directions. . As for the movement axis, any one of the main shaft 19 and the table 12 may be movable in at least one of the X, Y, and Z directions.

  In addition, the specific structure for carrying out the present invention can be appropriately changed to another structure or the like within a range in which the object of the present invention can be achieved.

  In the following examples, a processing machine MPF-2114DS manufactured by Toshiba Machine Co., Ltd. is used as a machine tool, and a TOSNUC-888 model manufactured by Toshiba Machine Co., Ltd. is used as a control device.

<First embodiment>
In the first embodiment, as shown in FIG. 4, a groove (groove with a width of 8 mm) is cut into the workpiece W. The processing conditions are as follows.
Workpiece material: Carbon fiber plate Diameter of electrodeposition tool: 8mm
Rotation speed of electrodeposition tool: 25000rpm
Cutting depth of electrodeposition tool for workpiece: 8mm (Z-direction cutting depth)
Feed rate of electrodeposition tool: 100mm / min
Looking at the processed surface after processing, the raw fibers used as the reinforcing material were cut, and the processed surface accuracy was good.

<Second embodiment>
In the second embodiment, as shown in FIG. 5, the end face of the workpiece W is ground. The processing conditions are as follows.
Workpiece material: Carbon fiber plate Diameter of electrodeposition tool: 8mm
Number of rotations of electrodeposition tool: 30000 rpm
Cutting depth of electrodeposition tool with respect to workpiece: 0.02 mm (Y-direction cutting depth)
Feed rate of electrodeposition tool: 1000mm / min
Looking at the processed surface after processing, the carbon fiber used as the reinforcing material was cut, and the processed surface accuracy was good.

  The present invention can be used for processing a material containing carbon fiber, for example, a carbon fiber reinforced resin composite material.

1 is a front view showing a schematic configuration of a machine tool according to an embodiment of the present invention. Sectional drawing which shows the tool holder used for the said machine tool. The perspective view which shows the electrodeposition tool used for the said machine tool. The perspective view which shows the processing state of 1st Example. The perspective view which shows the processing state of 2nd Example.

Explanation of symbols

10 ... Relative movement mechanism,
12 ... table,
19 ... Spindle,
20 ... Tool holder,
21 ... Holder body,
23 ... Taper shank part (mounting part),
24 ... Generator,
25 ... Electric motor,
26: Tool holding part,
30 ... Electrodeposition tool,
31 ... Tool body,
32 ... cutting blade part,
33 ... abrasive layer,
W ... Work.

Claims (5)

In the processing method of the carbon fiber material that processes the workpiece of the material containing carbon fiber,
Preparing a machine tool configured such that a table on which the workpiece is placed and a rotatable main shaft are relatively movable in at least one axial direction;
A cylindrical tool main body, a cutting edge portion formed on the outer periphery of the tool main body, and an electrodeposition tool having an abrasive layer in which abrasive grains are fixed to the surface of the cutting blade portion are used as the spindle of the machine tool. attachment,
While rotating the main shaft and relatively moving the table and the main shaft based on a command from a control device having a processing program that executes processing under a predetermined processing condition for processing the carbon fiber material A method for processing a carbon fiber material, wherein the workpiece is processed by the electrodeposition tool. In the processing method of the carbon fiber raw material of Claim 1,
The abrasive layer of the electrodeposition tool is formed by fixing diamond abrasive grains or CBN (cubic boron nitride) abrasive grains on the surface of the cutting edge portion, and a method for processing a carbon fiber material, . In the processing method of the carbon fiber raw material of Claim 1 or Claim 2,
The diameter of the electrodeposition tool is 4 to 10 mm, the rotation speed of the electrodeposition tool is 15000 to 30000 rotations / minute in the range of roughing to finishing, the cutting amount of the electrodeposition tool with respect to the workpiece is 1 to 15 mm, A method of processing a carbon fiber material, wherein the workpiece is processed under a processing condition in which a relative feed rate between the electrodeposition tool and the workpiece is 100 to 4000 mm / min. In the processing method of the carbon fiber raw material in any one of Claims 1-3,
The electrodeposition tool is attached to the spindle via a tool holder,
The tool holder generates a power by transmitting a rotation of the main shaft through the mounting portion provided in the holder main body, a mounting portion rotatably mounted on the holder main body and mounted on the main shaft, and provided on the holder main body. A carbon fiber material processing method, comprising: a generator that performs rotation, and an electric motor that is provided in the holder body and that is supplied with electric power from the generator and rotates the electrodeposition tool. In the processing method of the carbon fiber raw material in any one of Claims 1-4,
The method for processing a carbon fiber material, wherein the workpiece is formed of a carbon fiber reinforced resin composite material using carbon fiber as a reinforcing material.

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