JP2010207865A - Plastic working method and apparatus therefor, and method for manufacturing die - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fine shape array forming method by the plastic working capable of executing the working in a short time. <P>SOLUTION: A plastic working device including: a housing having a space for accommodating a cam 6 therein; a cylindrical or columnar cam arranged in the housing and having at least one projecting part on a side face; a retainer 2 which is fixed to the housing and has an indenter guide hole for accommodating an indenter 1 for executing the plastic working of a workpiece therein; the indenter arranged in the retainer; and a driving device for rotating the cam, is used and a workpiece 3 is arranged opposite to the plastic working device. By performing the simultaneous control of the cam drive and the surface travel of the workpiece by the NC, the driving device is driven to rotate the cam. By intermittently bringing a projecting part 7 formed on the cam surface into contact with the indenter, the indenter is pushed out to the workpiece side, and the pushed-out indenter is press-fitted in the workpiece to form a dent in the workpiece. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a processing method and apparatus for manufacturing a mold for processing a fine shape into a medium such as a sheet or a mold for manufacturing a mold.

  Optical film sheets are used to disperse light emitted from light sources in devices such as flat panel displays. Such an optical film sheet has a fine shape in which, for example, a fine pattern (fine shape array) having a diameter of 100 μm is present in an inverted manner. The fine shape of the optical film sheet is formed by transferring the unevenness of the mold.

  In the flat panel display, a sheet having a fine shape having a large area and excellent light scattering characteristics is required along with the recent increase in screen size and thickness, which is necessary for manufacturing such a sheet. When the concave / convex machining of the mold is performed by a machining method using a laser (Patent Document 1) or a cutting method using a high-speed tool servo (FTS machining method: Patent Document 2), the machining speed is slow. It takes several days. Furthermore, when it processes with the cutting method, there exists a problem that a chip | tip produces and a processed part is impaired.

  Also, in the above cutting method, the tool change during machining for a long time has a problem in machining accuracy, so the life of the cutting tool becomes a problem, the tool clearance angle is limited, There are problems that the depth is limited and that concave processing is impossible in fine shape processing by a combination of continuous groove processing.

  Furthermore, if a long time is required for processing, there is a high possibility that variations in the position size of the processed shape will occur due to external factors such as equipment troubles and earthquakes accompanying changes in environmental temperature during manufacturing. For this reason, when a mold is manufactured by the above-described conventional method, it takes several days for processing, so the yield of finished products is low and not practical.

  On the other hand, rolling is also mentioned as a plastic working method. Rolling is continuously transferred while rotating a groove of a die or a rolling tool. This method is suitable for producing screws, gears, and the like, but is not suitable for processing fine shapes because of a problem in processing accuracy. In addition, since the die and the rolling tool rotate to transfer the shape, wrinkles are likely to occur on the workpiece, which is not suitable for a method of processing a mold for processing a fine shape such as an optical sheet. .

  In addition, the sheet having a fine shape can be used not only for a flat panel display but also for other applications such as an optical memory and a DNA chip, and has been finely processed in a short time at high speed and high accuracy. There is a need for molds.

JP 2004-344957 A JP 2006-123085 A

  With laser and FTS processing methods, the processing speed is slow, the processing shape is limited, chips are generated, the processing time is prolonged, and the device troubles due to external factors reduce the yield. The mold manufacturing efficiency is not very good. Moreover, since there is a problem in accuracy in rolling, it is a problem that it is not suitable for a mold that requires high accuracy such as an optical sheet.

  Accordingly, an object of the present invention has been made to solve the above-described problems, and provides a method for creating a fine shape array by plastic working that can be processed in a shorter time than a conventional processing method.

  Therefore, the plastic working method of the present invention includes a housing having a space for accommodating a cam therein, a cylindrical or columnar cam disposed in the housing and having one or more protrusions on a side surface, and fixed to the housing. A retainer having an indenter guide hole for accommodating an indenter for plastically processing a workpiece, the indenter disposed in the retainer, and a plastic working device including a drive device for rotating the cam. The workpiece is disposed opposite to the plastic working device, the drive device is driven to rotate the cam, and the protruding portion formed on the cam surface and the indenter are intermittently provided. The indenter is pressed out to the workpiece side by bringing it into contact, and the pressed indenter is pressed into the workpiece to form an indentation in the workpiece.

  The plastic working device of the present invention includes a housing having a space for accommodating a cam therein, a cylindrical or columnar cam disposed in the housing and having one or more protrusions on a side surface, and the housing. A retainer having an indenter guide hole that accommodates an indenter that is fixed and plastically processes a workpiece, the indenter disposed in the retainer, and a drive device that rotationally drives the cam. To do.

  Moreover, the manufacturing method of the metal mold | die of this invention is characterized by performing plastic working with respect to the workpiece which is a preform | base_material of a metal mold | die by the said plastic working method.

  In the processing of fine shapes, high-speed and high-precision processing is possible.

It is a conceptual diagram which shows the press injection with respect to the workpiece in the plastic working method of this invention. It is sectional drawing of the plastic working apparatus of this invention. It is sectional drawing of the plastic working apparatus of this invention. It is a conceptual diagram shown as an example of the indenter of this invention, a in the figure is a front view and b is a left view. It is a conceptual diagram which shows the example of the strip-shaped indenter of this invention, a in the figure is a front view and b is a left view. It is a figure which shows the retainer (A) of the plastic working apparatus of this invention, and the conceptual diagram (B) which expanded the site | part enclosed with the broken-line part in FIG. 6 (A). It is the perspective view (A) of the conceptual diagram which shows a part of cam of this invention, and the expanded view (B) of the conceptual diagram of (A). It is the perspective view (A) of the conceptual diagram which shows a part of cam of this invention, and the expanded view (B) of the conceptual diagram of (A). FIGS. 9B and 9C are conceptual diagrams showing a regular array shape (A) and a dimple array shape (D), respectively. FIGS. FIGS. 9E and 9F are conceptual views of cross sections taken along the single-dot long chain line C in FIG. 9D, respectively. FIG. 10B and FIG. 10C are conceptual diagrams of cross sections taken along the one-dot long chain line in FIG. 10A, respectively. FIG. 10E and FIG. FIG. 11 is a conceptual diagram of a cross section taken along a one-dot long chain line in FIG. 10 (D). It is a perspective view of the conceptual diagram which shows an example of arrangement | positioning of the to-be-processed object and the plastic working apparatus at the time of processing into the cylindrical to-be-processed object of this invention. It is a conceptual diagram which shows an example of arrangement | positioning of the to-be-processed object and a plastic working apparatus at the time of processing into the cylindrical to-be-processed object of this invention. It is a flowchart which shows the process of carrying out regular array processing to a cylindrical workpiece by the plastic working method of this invention. It is a perspective view of the conceptual diagram which shows an example of arrangement | positioning of the to-be-processed object and the plastic working apparatus at the time of processing into the flat plate-shaped to-be-processed object of this invention. It is a conceptual diagram which shows an example of arrangement | positioning of the to-be-processed object and a plastic working apparatus at the time of processing into the flat plate-shaped to-be-processed object of this invention. It is a flowchart which shows the process of carrying out regular array processing to the flat plate-shaped workpiece by the plastic processing method of this invention.

  Therefore, in the plastic working method of the present invention, the indenter inserted into the retainer is intermittently press-fitted into the work piece, not the rolling method in which the unevenness of the rotating die or the rolling tool is continuously transferred to the work piece. Form indentations.

  The plastic working method of the present invention will be described in detail with reference to the conceptual diagrams of FIGS. FIG. 1A shows a conceptual diagram when the indenter 1 is not in contact with the projecting portion 7 of the rotating cam 6 by the rotation driving unit. At this time, the indenter 1 is in a state where no pressure is applied to form an indentation on the workpiece 3.

  Next, FIG. 1B is a conceptual diagram when the cam 6 rotates, the protruding portion 7 of the cam 6 and the indenter 1 come into contact, and the indenter 1 is pressed. The pressed indenter 1 is press-fitted into the workpiece 3 to form an indentation on the workpiece 3.

FIG. 1C is a conceptual diagram when the cam 6 further rotates and the tip of the protrusion 7 of the indenter 1 and the cam 6 is not in contact. When the indenter 1 and the projecting portion 7 are not in contact with each other, there is no pressure applied to the indenter 1 for plastic working. Such operations in FIGS. 1A to 1C are repeated to form indentations on the workpiece 3.
In the plastic working apparatus, it is preferable to dispose a plurality of indenters 1. In this case, a large number of indentations can be formed at the same time, which contributes to a significant reduction in working time.

  According to the method of the present invention, the contact time with the workpiece is extremely short, and the processing time can be shortened. For the above reason, the yield of the finished product can be increased. That is, when a very fine shape such as a lens array of a flat panel display suitable for applying the present invention is formed on the surface of a workpiece to be a mold, if a long time is required for pattern formation, The probability of occurrence of changes in environmental temperature and unpredictable earthquakes is increased, and accurate plastic deformation is impaired. Therefore, it is important to complete the mold manufacturing operation in a short time so that accurate plastic deformation is not impaired within the time when the mold manufacturing is completed.

  In addition, when forming a fine shape on the surface of the workpiece by the rolling method, it is necessary to apply the fine shape to the entire surface of the die or rolling tool used for rolling, but according to the method of the present invention, The machining time can be greatly shortened with the number of indentations equal to or less than one row to be processed into the workpiece.

  Further, according to the method of the present invention, there is no limitation on the machining shape due to the fact that the clearance angle of the cutting tool has to be taken into account, unlike cutting. Furthermore, if the shape of the indenter is taken into consideration, concave processing, convex processing, and processing that combines concave and convex are possible.

  Next, the configuration of the plastic working apparatus of the present invention will be described based on FIG. 1 showing the plastic working method and FIGS. 2 and 3 which are conceptual diagrams showing an example of the plastic working apparatus of the present invention. The plastic working apparatus of the present invention includes one or more indenters 1. The retainer 2 is fixed to the housing 13. The retainer 2 is provided with indenter guide holes 2 corresponding to the number of indenters 1 at a highly accurate pitch interval, and the indenter 1 is held in the indenter guide holes 4. In addition, it is preferable that the indenter guide hole 4 is provided with a protrusion 5 that restricts the operation of the indenter 1 so that the indenter 1 does not protrude toward the workpiece and partly protrudes from the indenter guide hole 4. The cam 6 has one or more protrusions as shown in FIG. The cam 6 is supported by a housing 13 by a bearing 10 via a rotary shaft 8 and is rotated by a rotary drive unit 12 such as a servo motor via a joint 11.

  Hereinafter, the indenter, the retainer, the indenter guide hole, the projection, the cam, the projecting portion, the bearing and the rotation driving unit, which are components of the plastic working apparatus of the present invention, and the workpiece will be described in detail.

First, the indenter 1 will be described. An example of a specific shape of the indenter 1 is shown in FIG. Examples of the indenter 1 include a spherical shape, a cylindrical shape, a polygonal column shape, a conical shape, and a fine pattern polygonal shape. The material of the indenter 1 is preferably a material having high hardness, high toughness, and high wear resistance. Specific examples include cemented carbide, diamond, ruby, ceramics, cermet and the like.
It should be noted that a strip-like shape in which indenters are bundled in a line may be used. An example of a strip-shaped indenter is shown in FIG.

  The operating area of the indenter 1 may be limited, and a mechanism may be provided in the indenter 1 or the indenter guide hole 4 so that only the tip of the indenter 1 is pressed into the workpiece 3 without the indenter 1 falling off from the retainer 2.

Examples of the tip shape of the indenter 1 on the side in contact with the workpiece 3 include a concave or convex spherical shape, a cylindrical shape, a polygonal weight such as a triangular weight and a quadrangular weight, a polygonal pillar such as a triangular pillar and a hexagonal pillar, and the like. A combination of multiple types of shapes may also be used. Since the tip shape of the indenter is on the order of millimeters, micros or nanometers, it is preferably processed by laser processing, electron beam processing, etching processing or the like.
Further, it is preferable that the bottom of the indenter with which the protruding portion 7 contacts is a spherical surface or the like.

  Next, the retainer will be described. An example of the retainer 2 is shown in the conceptual diagram of FIG. The retainer 2 used in the present invention has one or more indenter guide holes 4 and a protrusion 5 that restricts the protrusion of the indenter 1 so that the indenter 1 does not pop out. The shape of the indenter guide hole 4 depends on the shape of the indenter 1.

  It is preferable that the position of the protrusion 5 of the retainer 2 is the end portion on the workpiece side, etc., because the indenter 1 is difficult to drop off and is easy to process. The shape of the protrusion 5 is not particularly limited, such as a columnar shape. The retainer 2 is preferably made of a material having excellent wear resistance, such as carbide, high hardness steel, or ceramic.

  In the plastic working method and the plastic working apparatus of the present invention, the intended shape is not necessarily formed by one working. Therefore, if the plastic processing apparatus processes a specific region and the process until the intended shape is formed is one turn, the processing region that can be processed in one turn is the number of indenters 1 and indenter guide holes 4 and their diameters. And indenter guide hole interval 14. In the case of a regular arrangement, the distance between the centers of adjacent indentations is 1 pitch. And the pitch processed into a to-be-processed object can be adjusted with the indenter guide hole space | interval 14 shown in FIG. 6 (B) which expanded a part of conceptual diagram of the retainer 2 of FIG. 6 (A).

When processing a part of the indentations, or when the distance between adjacent indentations is narrow, the indenter guide hole interval 14 is not one pitch. For example, when the machining shape is a regular arrangement, when the overlap of the indentations is double or when the distance between the indenter guide holes 14 adjacent to each other is two pitches, and when the overlap of the indentations is triple, the indenter guide holes The interval 14 may be 3 pitches. However, when the indenter has a strip shape, it may be different from the above.
Further, the indenter guide hole interval 14 can be made to the limit of manufacturing accuracy and mechanical strength.

  The retainer 2 is preferably fixed to a stable part such as a housing by a method that can be easily replaced. The retainer 2 preferably has a structure that can be easily detached from the outside of the apparatus. By adopting a structure in which the retainer 2 can be easily replaced, not only the indenter 1 accompanying the change of the machining shape and / or the retainer 2 accompanying the change of the pitch can be replaced, but also the indenter 1 that wears when used. Maintenance such as observing wear of the indenter guide hole 4, the protrusion 5, and the cam 6 is facilitated.

  Next, the cam will be described. A conceptual diagram of an example of the cam 6 is shown in FIG. 7A, and a developed view of the cam 6 in FIG. 7A is shown in FIG. A cam 6 having a cylindrical shape of a round cylinder or a cylindrical shape of a round column and having a protrusion 7 on the surface thereof is preferable. High hardness, wear resistance, toughness, etc. are required because the protruding portion of the cam and the indenter contact at high speed. Therefore, examples of the material of the cam include nitrided steel and ceramics.

  It is preferable to press the workpiece 3 with the indenter 1 by (1) indexing and stopping the workpiece (2) continuously running the workpiece. When the workpiece 3 is continuously run to create a shape, the shape of the protrusion 7 of the cam 1 is as shown in the cam 6 of the conceptual diagram of FIG. It is preferable that the two ellipses are opposed to each other so as to minimize the interference between the workpiece 3 and the indenter 1 as much as possible. In consideration of interference between the workpiece 3 and the indenter 1, it is more preferable that the ellipse has a larger ratio than the running speed ratio of the workpiece 3 and the peripheral speed ratio of the cam 6. The shape of the tip of the protruding portion preferably has a shape that takes into account stability during plastic working.

  In addition, the angle formed by the protrusion intersecting with the imaginary line 9 on the cam surface parallel to the rotation axis of the cam 6 is constant, and the angle is 0 ° ≦ θ <180 ° excluding 90 ° (θ = 0 ° is shown in FIG. 7). It is preferable that the protruding portion 7 has an angle (θ) within a range of (equivalent to the conceptual diagram of the cam). This imaginary line 9 is a line represented by a dotted line in FIGS. 8A and 8B which is a conceptual diagram of the cam. FIG. 8A shows a conceptual diagram when the angle of the protruding portion 7 is other than 0 °, and FIG. 8B shows a developed view of a side surface. In the case of θ = 0 ° shown in the conceptual diagram of the cam in FIG. 7, a plurality of indenters 1 are press-fitted into the work piece 3 at a time, so that a large impact is applied to the plastic working apparatus and / or the work piece 3. Therefore, by setting the angle of the protrusion with respect to the imaginary line to 0 ° ≦ θ <180 ° excluding 90 °, the impact applied to the plastic working device or / and the workpiece 3 is reduced, and the durability of the entire device is improved. Is possible.

  When the angle of the protruding portion 7 is not 0 °, in order to form a regular arrangement as in the case of 0 °, the cam 6 and the work piece 3 are formed in consideration of the indenter guide hole interval 14, the pitch, and θ. It is necessary to perform processing by adjusting the speed ratio of rotation or / and movement.

  In the case where importance is attached to the rotational accuracy of the cam, a hydrostatic bearing or an aerostatic bearing may be applied to the bearing. Moreover, a well-known technique can be used for both the joint and the rotation drive unit.

  Examples of the workpiece 3 to which a fine shape is applied include a cylindrical shape and a flat plate shape. Examples of the surface material of the workpiece 3 include nickel-phosphorus, copper, brass and aluminum. Among these, nickel-phosphorus and copper are preferable because they are excellent in workability and durability. The surface of the work surface is preferably smooth. In addition, it is preferable that the site | part whose surface of the to-be-processed object 3 is not smooth is shaved and smoothed with a diamond tool before or after plastic processing.

  Next, a method for manufacturing a cylindrical or flat plate mold by processing the workpiece 3 using the plastic processing device 15 will be described.

  As an example of the mold manufacturing method of the present invention, a dimple array-shaped plastic working as shown in the conceptual diagram of FIG. 9D will be described. In this case, a method of processing a part of the indentation formed once may be used. However, since the indenter guide holes 4 of the retainer 2 are spaced apart from each other, it is impossible to press-fit the indenters 1 in the same row. Therefore, when processing into a dimple array shape, there is a method in which processing is performed once as shown in the conceptual diagram of FIG. 9A and then shifted by one pitch. 9 (B) and 9 (C) are conceptual diagrams of cross sections taken along the single-dot long chain line A and B in FIG. 9 (A), respectively, and FIGS. 9 (E) and 9 (F) are FIG. 9 (D). It is a conceptual diagram of the cross section in the one-dot long chain line in the inside.

  Further, as a method of manufacturing the mold of the present invention, there is an unprocessed region between the indentations to be processed as shown in the conceptual diagram of the regular array shape in FIG. In some cases, the non-processed region is narrow or the indenter guide hole 4 is too narrow to be processed. In that case, once as in the case of processing into a dimple array shape, once processing as shown in the conceptual diagram of FIG. 10 (A), and processing by shifting by one pitch after processing, the regular array of FIG. 10 (D). Processing of the conceptual diagram of the shape can be performed. 10 (B) and 10 (C) are conceptual diagrams of cross sections taken along the single-dot long chain line in FIGS. 10 (A) and 10 (A), respectively, and FIGS. 10 (E) and 10 (F) are FIG. 10 (D). It is a conceptual diagram of the cross section in the one-dot long chain line in the inside.

  By changing the speed ratio of the rotational speed or movement speed of the workpiece 3 and the rotational speed of the cam 6, the pitch of the formed indentation in the cam rotation direction can be arbitrarily changed. In particular, by accurately NC controlling the pitch, it is possible to easily and quickly form a dimple array shape in which each indentation is superimposed.

  When the cylindrical workpiece 3 is processed using the plastic processing device 15 of the present invention, a plurality of the plastic processing devices 15 of the present invention may be arranged around the workpiece 3. 11 and 12 show conceptual diagrams of examples of the arrangement of the plastic working device 15 and the work piece 3 when the cylindrical work piece 3 is machined. In addition, the processing area | region said below shall mean the area | region processed in 1 turn.

  A plurality of methods for manufacturing the mold by processing the dimple array shape of FIG. 9D on the cylindrical workpiece 3 by the mold manufacturing method of the present invention will be described based on the flowchart of FIG. To do. The flowchart in FIG. 13A is a basic process for performing dimple array processing. When the workpiece 3 is cylindrical, the workpiece 3 and the cam 6 of the plastic working device 15 rotate to form an indentation, and the workpiece 3 rotates to move the machining surface. The rotation direction of the workpiece 3 may be the same as or opposite to the rotation direction of the cam 6. When plastic working is performed without rotating the workpiece 3, the plastic working device 15 may be moved along the surface of the workpiece, and the moving (rotating) direction may be either clockwise or counterclockwise. Absent.

First, steps of the flowchart in FIG. 13A will be described. When the plastic processing device 15 processes the workpiece 3 once, processing in a regular array shape as shown in FIG. 9A is performed (step 1). In the processing of the adjacent dimple array, it is necessary to process by overlapping a part of the indentation by shifting by one pitch. Therefore, a step (step 2) of shifting the plastic working device 15 by 1 pitch in the Z-axis direction after step 1 is necessary. After step 2, the workpiece 3 is further processed once (step 3), and the dimple array shape as shown in FIG. 9D is applied. In this case, step 1 to step 3 are one turn. The plastic working device 15 is moved to an unprocessed region (step 4), and all the processed surfaces of the workpiece 3 are processed to manufacture a mold.
When two or more plastic processing apparatuses 15 are used and each plastic processing apparatus 15 processes a different processing area, the process is the same as the flowchart of FIG.

  Next, steps in the flowchart of FIG. 13B will be described. When two plastic working apparatuses 15 are used and the second plastic working apparatus 15 is machined by shifting one pitch with respect to the Z-axis direction with respect to the first plastic working apparatus 15 as shown in FIG. There is also a method in which only one step 5 shown in the flowchart of FIG. Even with this method, the machining time can be reduced to about half compared to the case where only one plastic working device 15 is used.

  Further, when machining a shape in which the pitch of the machining shape is sufficiently larger than the indenter diameter and the indenter guide hole interval 14 is 1 pitch, only one step 5 in the flowchart of FIG. In this case, the processing is performed by omitting steps 2 and 3 in the flowchart of FIG. In addition, even if the machining shape is different from the dimple array shape of FIG. 9D, the machining can be performed by the same or similar process as the process described in the flowchart of FIG.

  14 and 15 show examples of arrangement of the plastic working device 15 and the work piece 3 when the flat work piece 3 is machined using the plastic working device 15 of the present invention. Usually, in this configuration, the plastic working device 15 is installed on the upper support column, the flat plate as the work piece 3 is fixed to a stage movable in the XY directions, and the plastic working device 15 is movable in the Z directions. It is. The movement of the table is preferably controlled with high accuracy.

  A plurality of methods for manufacturing a die by processing the flat plate-shaped workpiece 3 into the regular array shape of FIG. 10D by the plastic processing method of the present invention will be described based on the flowchart of FIG. When the workpiece 3 is a flat plate, the workpiece 3 moves, the cam of the plastic working device 15 rotates to form an indentation, and the plastic working device 15 moves to move the work surface. The moving direction of the plastic working device 15 may be either on the XY plane. When plastic working is performed without moving the plastic working device 15, the workpiece 3 may be moved, and the movement may be in any direction on the XY plane.

First, the steps in the flowchart of FIG. When the plastic working device 15 moves in the X-axis direction, when the workpiece 3 moves from end to end in the X-axis direction, processing like the regular array shape of FIG. 10A is performed (step 6). When the pitch of the shape to be machined is narrow and the intended shape cannot be machined only in step 6, it is necessary to machine the plastic working device 15 by shifting it by one pitch in the Y-axis direction. Therefore, after step 6, the plastic working apparatus is shifted by 1 pitch in the Y-axis direction (step 7). After step 7, the workpiece 3 is processed once more from end to end in the X-axis direction (step 8), and the processing like the regular array shape of FIG. 10D is performed. In this case, step 6 to step 8 are one turn. The plastic working device 15 is moved to an unprocessed area (step 9), and all the processed surfaces of the workpiece 3 are processed to manufacture a mold.
When two or more plastic processing apparatuses 15 are used and each plastic processing apparatus 15 processes a different processing area, the process is the same as the flowchart of FIG.

  Next, the process of the flowchart in FIG. When two or more plastic working apparatuses 15 are provided, the time required for plastic working can be shortened. When two plastic working apparatuses 15 are used, the second plastic working apparatus is shifted by one pitch with respect to the X-axis direction with respect to the first plastic working apparatus 15, and only one step 10 is used for one turn. There are cases. When two plastic working devices 15 are used, the machining time can be reduced to about half compared to the case where only one plastic working device 15 is used.

  Further, when machining a shape in which the pitch of the machining shape is larger than the indenter diameter and the indenter guide hole interval 14 is 1 pitch, only one step 10 is made in the flowchart of FIG. In this case, it is possible to perform one turn of machining only in step 10 of FIG. In addition, even if the processing shape is different from the regular arrangement of FIG. 10, the processing can be performed by the same or similar process as the process described in the flowchart of FIG.

  In addition, in the case where the workpiece 3 is either a cylindrical shape or a flat plate shape, even when processing a shape in which a part of the indentation is overlapped, if the indenter is a strip-shaped indenter, one plastic processing device 15 It is also possible to process one turn in one step.

  It is preferable that the movement direction of the flat workpiece 3 can be arbitrarily moved with respect to any of the X, Y, and Z axes. By controlling the rotation speed, the rotation direction, the movement direction, and the movement speed, a spiral shape or a geometric pattern can be applied. Further, the rotational speeds of the cam 6 and the cylindrical workpiece 3 may be either constant or variable.

Example 1
As a basic embodiment, a method for plastic working a dimple array on a cylindrical workpiece 3 will be described. Since the width of the retainer 2 is narrower than the width of the workpiece 3, the retainer 2 is pressed into a plurality of times to form indentations.

  A method of plastic working a continuous dimple array as shown in FIG. 9D using a spherical indenter 1 having a diameter of 1 mm for a cylindrical workpiece 3 will be described. FIG. 11 is a perspective view of a conceptual diagram of the plastic working device 15 and the workpiece 3 when producing a cylindrical mold. The workpiece 3 and the plastic working device 15 are arranged in parallel. The workpiece 3 is rotated by a servo motor to sequentially change the workpiece surface. The rotation of the workpiece 3 is synchronized with the rotation of the servo motor for driving the cam using a rotation driving unit such as a servo motor.

  The indenter 1 of the plastic working apparatus 15 of Example 1 is 50, the rotation of the cam 1 is 1000 rpm, the protrusions of the cam are 6 parts at equal intervals, the indentation diameter is 0.1 mm, the pitch is 0.0866 mm, and the indentation depth Will be described in the form of forming an indentation of 4 μm. The workpiece 3 has a cylindrical shape with a diameter of 300 mm and a trunk length of 800 mm.

  When the cam 6 and the workpiece 3 rotate and the workpiece 3 rotates once, an indentation as shown in FIG. 9A is formed on the workpiece 3. Next, the workpiece 3 is shifted by one pitch in the Z-axis direction, and an indentation is formed on the workpiece again. When the press-fitting for the second rotation was completed, the indentation shown in FIG. 9D was formed on the workpiece.

  When the process was repeated and an indentation was press-fitted throughout, the surface of the workpiece 3 was given a continuous fine shape indent in FIG. 9 (D), and a mold was manufactured. Since the current FTS method can process only about 500 pieces / second, it takes about 100 hours to process the workpiece 3 of the first embodiment. In the method and apparatus of the present invention, processing of 5000 pieces / second is possible in the form of Example 1, and the entire processing is completed in about 10 hours. In the form of Example 1, processing can be performed in about 1/10 of the time of the current FTS method.

  Furthermore, since it is easy to further increase the working efficiency by installing two or more plastic processing devices 15 so as to surround the workpiece 3 as shown in the conceptual diagram of FIG. 12 and increasing the number of indenters 1, The workpiece 3 of Example 1 can be processed within a few hours.

(Example 2)
A method of plastic working a flat workpiece 3 by using a square columnar indenter with a regular quadrangular pyramid whose one side is 1 mm and whose tip 1 is convex will be described.
Also in this embodiment, since the width of the retainer 2 is narrower than the width of the workpiece 3 as in the first embodiment, one row of fine patterns is formed in a plurality of times.

  FIG. 15 is a conceptual diagram showing an example of the arrangement of the plastic working device 15 and the workpiece 3 when producing a flat plate mold. The workpiece 3 and the plastic working device 15 are arranged in parallel. There are two plastic working devices 15, and the workpiece 4 moves on the XY plane and moves on the workpiece surface. The movement of the workpiece is precisely controlled by NC control. The arrangement of the plastic working apparatus is an adjacent form as shown in FIG. The two plastic working apparatuses are arranged at a position shifted by 1 pitch in the Y-axis direction. If it arrange | positions in the position shifted | deviated 1 pitch in the Y-axis direction, the process of 1 turn can be performed only by processing the to-be-processed object 3 once to the X-axis direction from end to end.

  The indenter 1 of the plastic working apparatus 15 of Example 2 is 50 pieces, the rotation of the cam 6 is 1000 rpm, the protrusions of the cam 6 are 6 strips, the indentation diameter is 0.1 mm, the pitch is 0.1 mm, and the indentation depth is 4 μm. This will be described in the form of forming the indentation. The workpiece 1 is assumed to be a flat plate of 1500 mm × 850 mm.

When the workpiece rotates and the workpiece 3 moves from end to end in the X-axis direction, an indentation having a continuous shape as shown in FIG. 10D is formed on the workpiece 3, and one turn is completed.
Next, the processing region was shifted to the non-processing region and processed in the same manner, and a fine shape indentation shown in FIG. 10D was formed in all the processing regions on the surface of the workpiece to manufacture a die.

  As a result, even when the flat workpiece 3 is used, the machining time can be greatly reduced as compared with the FTS method. Further, in Example 2, since two plastic working devices 15 were used for one workpiece, the mold could be machined in about half the time compared to Example 1.

DESCRIPTION OF SYMBOLS 1 ... Indenter 2 ... Retainer 3 ... Workpiece 4 ... Indenter guide hole 5 ... Protrusion 6 ... Cam 7 ... Projection part 8 ... Rotating shaft 9 ... Virtual wire 10 ... Bearing 11 ... Joint 12 ... Rotation drive part 13 ... Housing 14 ... Indenter guide hole spacing 15 ... Plastic working device 16 ... Prop 17 ... Workpiece 18 ... Stand

Claims (8)

A housing having a space for accommodating a cam therein, a cylindrical or columnar cam disposed in the housing and having one or more protrusions on a side surface, and a work piece fixed to the housing. Using a retainer having an indenter guide hole that accommodates an indenter to be plastically worked, the indenter disposed in the retainer, and a plastic working device provided with a drive device that rotationally drives the cam,
Arrange the work piece facing the plastic working device,
The driving device is driven to rotate the cam, and the indenter is intermittently brought into contact with the protrusion formed on the cam surface to cause the indenter to be pressed out to the workpiece side. ,
An indentation is formed in a work piece by press-fitting the pressed indenter into the work piece.   The plastic working apparatus according to claim 1, wherein the indenter and / or the retainer includes a protrusion that restricts movement of the indenter in a guide hole of the retainer.   The plastic working method according to claim 1, wherein the workpiece is cylindrical or flat.   4. The plastic working method according to claim 1, wherein an indentation having an arbitrary pitch is formed by controlling the rotation ratio in NC synchronization with the rotation of the workpiece and the cam. 5.   A method for producing a mold, comprising performing plastic working on a workpiece which is a base material of a mold by the plastic working method according to claim 1. A housing having a space for accommodating a cam therein;
A cylindrical cam disposed in the housing and having one or more protrusions on a side surface;
A retainer having an indenter guide hole that is fixed to the housing and accommodates an indenter that plastically processes a workpiece;
The indenter disposed in the retainer;
A plastic working device comprising a drive device for rotationally driving the cam.   The plastic working apparatus according to claim 6, wherein the material of the indenter is ceramics, cemented carbide, ruby or diamond. The angle (θ) formed between the protrusion and the imaginary line on the cam surface parallel to the rotation axis of the cam is constant and within a range of 0 ° ≦ θ <180 ° (excluding 90 °). The plastic working apparatus according to claim 6 or 7, characterized in that: