JP2011000667A - Machining apparatus and machining method for high hardness material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a multi-functional machining apparatus and method, relatively easily machining a tool or workpiece made of a high hardness material.SOLUTION: A laser beam machining head 3 and a mechanical machining head 5 are mounted on a headstock 1, a grinding device 15 is attached onto a table 13, and a feed-shaft device relatively movable in the directions of X-, Y-, Z-, B-, and C-axes is disposed between the headstock 1 and the table 13. After a tool material 35 is attached to the table 13 and roughly machined by the laser beam machining head 3, the tool material 35 is attached to a spindle 9 of the mechanical machining head 5 and rotated, a grinding wheel 19 of the grinding device 15 is brought into contact with the tool material 35 while being rotated, and the X-, Y-, Z-, B-, and C-axes are moved to shape and finish a tip cutting edge portion of the tool material 35 to form a blade.

Description

  The present invention relates to a machining apparatus and a machining method for producing a tool made of a high hardness material such as a polycrystalline diamond sintered body (hereinafter referred to as PCD), a cubic boron nitride sintered body (hereinafter referred to as CBN), a cemented carbide, and the like. The present invention relates to a method for processing a workpiece made of a hard material such as cemented carbide or ceramics, or a high hardness and brittle material.

  As materials for tools for cutting and grinding, high-hardness materials such as PCD, CBN, and cemented carbide are known. A tool made of a high hardness material is difficult to manufacture due to its hardness. For example, Patent Document 1 discloses an NC grinder capable of producing a PCD tool. The tool material to be machined is attached to the work spindle, the machining voltage is applied to the disk electrode of the grinding tool, the tool material is roughed by electric discharge machining, and then the grinding voltage is applied with the machining voltage stopped Finishing is performed to produce a tool.

In addition, there is an increasing demand for processing a workpiece made of a high hardness material such as a cemented carbide mold, a ceramic part, or a high hardness and high brittleness material. When a workpiece with high hardness is machined, the tool wears quickly, resulting in an increase in machining time and machining cost.
As a machine tool for processing this high-hardness workpiece, for example, Patent Document 2 discloses a combined processing machine that selectively performs laser processing or machining on a workpiece. It can be used in such a way that rough machining of a workpiece is performed by laser machining and finishing of the workpiece is performed by machining by cutting or grinding.

JP 2003-31535 A JP 2007-83285 A

  As in the technique described in Patent Document 1, the structure in which the tool material is ground after electric discharge machining requires a complicated structure that insulates the anode and the cathode and separates and collects the electric discharge machining liquid and the grinding liquid. There is a problem. Further, Patent Document 2 does not intend to produce a tool made of a high hardness material by laser machining and machining.

  Accordingly, an object of the present invention is to provide a machining apparatus and a machining method capable of easily producing a tool made of a high hardness material such as PCD, CBN, and cemented carbide. Another object of the present invention is to provide a machining method capable of achieving both machining efficiency and tool life when machining a hard material workpiece.

  In order to achieve the above-mentioned object, it is a combined machining apparatus for producing a tool made of a high hardness material by laser machining and machining of cutting or grinding, and a machine having a laser machining head having a laser beam irradiation means and a rotating spindle A head unit having a machining head, a table for mounting a workpiece, three linear directions of X, Y, and Z, an A axis around the X axis, a B axis around the Y axis, and a C around the Z axis A feed shaft device that relatively moves the head unit and the table in two axial directions of the shaft, and a tool that is provided on the table and attached to the rotating spindle of the machining head is shaped and finished with a blade. There is provided a composite processing apparatus including a grinding apparatus that rotationally drives a grinding wheel.

  Further, a tool manufacturing method for manufacturing a tool made of a high hardness material using the composite processing apparatus, wherein a tool material is attached to a table of the composite processing apparatus, and a laser beam irradiated from the laser beam irradiation means is used. The cutting edge of the tool material is roughly machined, the tool material is attached to the rotating spindle of the machining head, and the tool material and the grinding wheel of the grinding device are brought into contact with each other and the relative movement is performed by the feeding device. There is provided a tool manufacturing method in which the tip blade portion of the tool material is shaped and finished to perform a cutting process.

  Further, a tool manufacturing method for manufacturing a tool made of a high hardness material using the composite processing apparatus, wherein a tool material is attached to a rotation main shaft of the machining head, and the laser processing head and the machining head are combined. The tip edge of the tool material is roughly processed by the laser beam irradiated from the laser beam irradiating means and then relatively moved by the feeding device while the tool material and the grinding wheel of the grinding device are in contact with each other. There is provided a tool manufacturing method in which a movement is performed, and a tip edge portion of the tool material is shaped and finished to perform a cutting process.

  According to the present invention, the tip edge portion of the tool material made of a high hardness material is rough-processed by the laser beam irradiated from the laser processing head. After that, the rough-processed tool material is mounted on the rotating spindle of the machining head and rotated, and can also be moved relative to each other in the 5-axis direction while being in contact with the grinding wheel driven by the grinding machine provided on the table. The contour of the tip blade portion is shaped and finished into a desired shape by a simple feed shaft device, and further, a cutting process is performed by machining a rake face and a flank face.

  A tool made of a high-hardness material produced by the above-described tool production method is a ball end mill in which a tip edge portion is shaped into a hemisphere and one or more rake faces are formed on the spherical surface. In addition, a tool made of a high-hardness material manufactured by the above-described tool manufacturing method has a cross-sectional shape of the tip blade portion formed in a polygonal shape, and a ridgeline formed by each vertex of the polygonal shape is a longitudinal cross-sectional cut in an arc shape. This is a ball end mill with a blade.

  Further, a workpiece machining method for machining a high-hardness material workpiece using the composite machining apparatus, wherein the tool produced by the above-described tool production method is attached to the rotary spindle of the machining head and attached to the table. Provided is a workpiece machining method in which rough machining is performed on a workpiece with a laser beam emitted from the laser beam irradiation means, and the workpiece is finished with a tool made of a high-hardness material attached to a rotating spindle of the machining head. The

  Using the above-mentioned composite processing machine, the tool manufactured by the above-mentioned tool manufacturing method is mounted on the machining head of the above-mentioned composite processing machine, and a high-hardness material workpiece attached to the table is first irradiated from the laser processing head Then, rough machining is performed, and then machining is performed using a tool of a machining head. High-hardness workpieces can be machined more efficiently by laser machining than by machining, and then machining by cutting or grinding using a tool is performed only for finishing machining with less cutting. If necessary, the workpiece can be further processed with a laser beam irradiated from the laser processing head.

  According to the present invention, even a tool material made of a hard material can be roughed relatively easily by a laser beam emitted from a laser processing head of a composite processing apparatus. Thereafter, the roughened tool material attached to the machining head of the same combined machining apparatus is shaped and sharpened by the cooperative action of the 5-axis feeding device and the grinding device. There is no need for a structure for electric discharge machining-specific insulation or machining fluid separation, and there is an advantage that it is possible to easily switch between laser machining and machining, and to produce a tool made of a hard material with good operability.

  Subsequently, a high-hardness workpiece is attached to the table of the composite processing apparatus, roughing is performed by the laser processing head, and finishing is performed by the machining head equipped with the tool prepared in the previous step. In this way, a series of work steps from tool fabrication to workpiece machining can be performed with a single machining apparatus. A high-hardness material workpiece made of cemented carbide or a high-hardness high brittleness material workpiece made of ceramics can be processed relatively easily by a laser processing head. Thereafter, finishing is performed by a tool attached to the machining head to complete the workpiece processing. Since the machining efficiency of high-hardness workpieces is increased by laser processing and only the finishing process with few cuts is performed by machining to suppress tool wear as much as possible, both machining efficiency and tool life can be achieved.

It is the schematic which shows the structure of the combined processing apparatus by the 1st Embodiment of this invention. It is the schematic which shows the method of producing the tool which consists of a hard material with the compound processing apparatus shown in FIG. 1, (a) shows a roughing process and (b) shows a finishing process, respectively. It is the schematic which shows the front-end | tip blade part of the produced single blade ball end mill. It is the schematic which shows the front-end | tip blade part of the produced multi-blade ball end mill, (a) is a front view, (b) is a bottom view. It is the schematic which shows the front-end | tip blade part of the produced polygonal ball end mill, (a) is a front view, (b) is a bottom view. It is the schematic which shows the structure of the combined processing apparatus by the 2nd Embodiment of this invention.

  Hereinafter, embodiments of a processing apparatus and a processing method for a high hardness material of the present invention will be described with reference to the drawings.

  Initially, with reference to FIG. 1, the whole structure of the combined processing apparatus by the 1st Embodiment of this invention is demonstrated. A laser machining head 3 and a machining head 5 are fixed to a spindle stock 1 provided so as to be movable in a vertical direction (Z-axis direction) perpendicular to a base (not shown) of a machining apparatus. The laser processing head 3 has a laser beam irradiation means 7 and irradiates a laser beam L downward. The laser beam irradiation means 7 includes a fiber laser that oscillates a laser beam, and a condensing mechanism that guides the oscillated laser beam to a condensing lens and irradiates the workpiece. The description of the fiber laser and the condensing mechanism is omitted here. In addition, it is preferable in terms of processing efficiency to use a laser having a wavelength of 1 to 2 [mu] m, which has a high light absorption rate for diamond.

  A main shaft 9 is rotatably supported on the machining head 5, and the axis of the main shaft 9 faces the Z-axis direction. The main shaft 9 is rotationally driven by driving means (not shown). A cutting tool or a grinding tool is attached to the tip of the main shaft 9. The laser machining head 3 and the machining head 5 are fixed to the headstock 1 so that the optical axis of the laser beam L emitted from the laser machining head 3 and the axis of the spindle 9 of the machining head 5 are parallel to each other.

  The table base 11 provided so as to be movable in two orthogonal biaxial directions (X-axis direction and Y-axis direction) horizontal with respect to the base (not shown) of the processing apparatus is further around the Y-axis around the point O. It is provided so as to be rotatable in the B-axis direction. The table 13 is provided with a table 13 that is rotatable relative to the table 11 in the C-axis direction around the Z-axis. The table base 11 and the table 13 are constituted by, for example, a trunnion type table device having two rotation feed shafts. In this embodiment, the headstock 1 moves in the Z-axis direction and the table 13 moves in the X-, Y-, B-, and C-axis directions. In short, the headstock 1 and the table 13 move in the X-, Y-, Z- and B-directions. The table is fixed, the headstock 1 moves in the X, Y, and Z axis directions, and the machining head 5 rotates in the B axis direction with respect to the headstock 1. The main shaft 9 may be positioned in the C-axis direction. Instead of the B axis, it may have an A axis that rotates around the X axis. In addition, various configurations can be considered for the configuration of the feed shaft device of three linear axes and two rotational axes.

  On the table 13, a work to be processed is attached. Further, a grinding device 15 is provided on the table 13 so as to be attachable / detachable or at a location where the workpiece processing is not hindered. The grinding device 15 includes a rotation driving unit 17 attached on the table 13 and a grinding wheel 19 attached to a rotation shaft of the rotation driving unit 17. The grinding wheel 19 employs a green silicon carbide-based grindstone (hereinafter referred to as GC grindstone), diamond, and CBN abrasive grains that are held and fixed to a wheel by metal bonding or electrodeposition when processing a workpiece of a high hardness material. Is preferred.

  Next, a method for producing a tool made of a high hardness material using the combined machining apparatus of FIG. 1 will be described with reference to FIG. As shown in FIG. 2A, the holder fixture 31 is fixed upward on the table 13. The holder fixture 31 is provided with a tapered hole and clamping means, and can hold and release the tapered shank of the tool holder 33. A chuck for gripping the shank portion of the tool material 35 is provided at the tip of the tool holder 33. In this way, the laser beam L is irradiated from the laser processing head 3 to the tool material 35 mounted upward on the table 13, so that the leading edge portion of the tool material 35 is roughly processed. At that time, the X, Y, Z, B, and C axes are moved as necessary, and the tip edge portion of the tool material 35 is formed into a shape that leaves a finishing allowance.

  The rough-processed tool material 35 is removed from the holder fixture 31 together with the tool holder 33 and attached to the spindle 9 of the machining head 5. The holder fixture 31 on the table 13 is removed, and the grinding device 15 is attached on the table 13 as shown in FIG. When producing a ball end mill, as shown in FIG. 2 (b), the main shaft 9 is rotated, and the B-axis is vertical from the horizontal in a state where the rotating grinding wheel 19 is in contact with the tip edge portion of the tool material 35. First, the tip edge portion is shaped into a hemispherical shape. Next, the rotation of the main shaft 9 is stopped, the B axis and the C axis are positioned at desired angular positions, the rotating grinding wheel 19 is brought into contact with the tip edge portion of the tool material 35, the rake face is processed, and the blade is attached. Do. When producing a grinding tool having a hemispherical tip, the cutting process by machining the rake face may be omitted. In this case, fine particles such as diamond, CBN, and cemented carbide, which are material components of the tool material 35, function as abrasive grains.

  A pallet mounting means is provided on the table 13, and a plurality of pallets such as a pallet having a holder fixture 31, a pallet having a grinding device 15, and a pallet to which a work is attached are prepared in a pallet magazine. By automatically exchanging the pallet with the table 13, the holder fixture 31, the grinding device 15, the workpiece and the like can be selectively attached on the table 13. Further, the holder fixture 31 and the grinding device 15 may be always attached on the table 13. Furthermore, when the tool material 35 is mounted on the table 13, the tool material 35 may be mounted on the table 13 using a mounting tool that directly attaches the tool material 35 without using the holder mounting tool 31 and the tool holder 33.

  Next, in the case of producing a ball end mill with the combined machining apparatus and tool production method of the present embodiment, what kind of tip edge portion is used will be described with reference to FIGS. 3, 4, and 5. In FIG. 3, a flat surface inclined with respect to the axis is processed into a hemispherical tip edge portion to form a rake surface 37. A ridge line between the hemisphere and the rake face 37 is a cutting edge 39, which is a single-edged ball end mill. The machining of the rake face 37 stops the rotation of the main shaft 9, drives the grinding wheel 19 in a state where the B axis and the C axis are positioned at a desired angular position, and moves the grinding wheel 19 from the normal direction of the hemisphere. A predetermined amount may be cut in contact with the material 35.

  In FIG. 4, a plurality of planar rake surfaces 41 are formed on the hemispherical tip edge portion. Similarly, the ridge line between the hemisphere and the rake face 41 is the cutting edge 43. What is necessary is just to repeat the process of each rake face 41 by the method similar to the process of the rake face of a 1-blade ball end mill. At this time, it is preferable to shift the positions of the rake faces 41 in the axial direction from each other. In this way, a multi-blade ball end mill can be produced. FIG. 5 shows that the cross section perpendicular to the axis is hexagonal, and that the ridgeline formed by each vertex of the hexagon forms six arcuate cutting blades 45 in a vertical cross section parallel to the axis. It is the produced ball end mill. In this case, the rotation of the main shaft 9 is stopped, the C-axis is indexed every 60 degrees, and the grinding wheel 19 is rotationally driven at each indexing position, while the tool material 35 is rotated with the X, Z, and B axes. The relative movement of the simultaneous three-axis control may be performed. The cutting blade 45 preferably has a width. Instead of a hexagon, other polygonal shapes can be used. In addition, it is possible to perform shaping finishing processing and blade processing so as to be a square ball end mill or a radius end mill. In addition, since the grinding wheel 19 is worn during the shaping and finishing process, it is necessary to proceed with the processing while measuring the machining dimensions, and to replace the grinding wheel 19 with a new grinding wheel 19 if necessary to increase the processing accuracy.

  With reference to FIG. 6, the overall configuration of a combined machining apparatus according to a second embodiment of the present invention and a method for producing a tool using the combined machining apparatus will be described. A first slider 53 and a second slider 55 are provided on a spindle base 51 that is movable in a vertical direction (Z-axis direction) perpendicular to a base (not shown) of a processing apparatus. The first slider 53 can move in the U-axis direction parallel to the X-axis with respect to the headstock 51, and the second slider 55 can move in the W-axis direction parallel to the Z-axis with respect to the headstock 51. A machining head 57 is attached to the first slider 53 so as to be rotatable in the B1 axis direction around the Y axis, and a laser machining head 59 is attached to the second slider 55 so as to be rotatable in the B2 axis direction around the Y axis. The spindle 61 of the machining head 57 is rotationally driven and has a C-axis function so that feed control in the rotational direction can be performed.

  A table 63 (not shown) of the processing apparatus is provided with a table 63 movably in the X-axis and Y-axis directions, and a grinding apparatus 15 is always attached on the table 63. Furthermore, a mounting space for the workpiece W to be processed is secured on the table 63.

  In the method of manufacturing a tool made of a high hardness material using the composite processing apparatus of the present embodiment, the tool material 35 is attached to the spindle 61 of the machining head 57, and the machining head 57 and the laser processing head 59 are connected to U, W. , B1 and B2 are moved relative to each other in the axial direction, and the leading edge portion of the tool material 35 is roughly processed with the laser beam L. Thereafter, the tip wheel of the tool material 35 is shaped into a desired shape by moving the X, Y, Z, B1, and C axes relative to each other while the rotating grinding wheel 19 of the grinding device 15 is in contact with the rotating tool material 35. After that, the rotation of the spindle 61 is stopped, the tool material is indexed on the C axis, and the blade is machined.

  In the tool manufacturing method according to the first or second embodiment, rough machining of a tool material made of a high-hardness material is performed relatively efficiently by using laser processing, and thereafter, the tool material and the grinding wheel in the five-axis direction are used. By the relative movement means, the front end blade portion can be easily shaped and sharpened.

  The high-hardness workpiece W is mounted on the tables 13 and 63 with the tool created by the tool fabrication method of the first or second embodiment mounted on the spindles 9 and 61 of the machining heads 5 and 57 as they are. First, a laser beam L is irradiated from the laser processing heads 3 and 59 to rough process the workpiece W. Next, the workpiece W is finished by cutting or grinding with a tool attached to the spindles 9 and 61. The high-hardness material workpiece is roughed relatively efficiently by laser processing, and only the remaining minute finishing allowance is removed by cutting or grinding to perform finishing. Since there are few parts to be removed by machining, the tool life is extended. In this way, machining efficiency and tooling can be achieved by using a single combined machining device to carry out the steps from the production of a tool suitable for machining a hard material workpiece to the machining of that workpiece, and using laser machining and machining properly. High-hardness workpieces can be machined with a long life. A YAG laser can be used instead of the fiber laser.

  When processing a mold made of a high hardness material, so-called embossing may be further performed. In that case, a laser beam L is irradiated from the laser processing heads 3 and 59 toward the workpiece W, and the beam irradiation density is adjusted by changing the feed speed of the feed shaft to control the depth of the embossing process. Subtle depth control of laser processing can be easily performed by using a feed function provided in the composite processing apparatus.

DESCRIPTION OF SYMBOLS 1 Spindle table 3 Laser processing head 5 Machining head 7 Laser beam irradiation means 9 Main shaft 11 Table base 13 Table 15 Grinding device 19 Grinding wheel 35 Tool material 37, 41 Rake face 39, 43, 45 Cutting edge L Laser beam

Claims (7)

A composite processing apparatus for producing a tool made of a high-hardness material by laser processing and machining of cutting or grinding,
A head unit comprising a laser processing head having a laser beam irradiation means and a machining head having a rotating spindle;
A table for mounting a workpiece;
Relative movement of the head unit and the table in the three axes of X, Y, and Z linear movement, and the two axes of rotation of the A axis around the X axis, the B axis around the Y axis, and the C axis around the Z axis A feed shaft device,
A grinding device for rotating and driving a grinding wheel that is provided on the table and that shapes and finishes a tool attached to a rotary spindle of the machining head and performs a cutting process;
A composite processing apparatus comprising: A tool manufacturing method for manufacturing a tool made of a high-hardness material using the combined machining apparatus according to claim 1,
A tool material is attached to the table of the composite processing apparatus,
Roughing the tip edge of the tool material with a laser beam emitted from the laser beam irradiation means,
Attach the rough tool material to the rotating spindle of the machining head,
A tool manufacturing method characterized in that the tool material and a grinding wheel of the grinding device are brought into contact with each other and are moved relative to each other by the feeding device, and a tip edge portion of the tool material is shaped and subjected to a cutting process. . A tool manufacturing method for manufacturing a tool made of a high-hardness material using the combined machining apparatus according to claim 1,
A tool material is attached to the rotating spindle of the machining head,
The tip cutting portion of the tool material is roughly machined by a laser beam irradiated from the laser beam irradiation means by relatively moving the laser processing head and the machining head,
After that, the tool material and the grinding wheel of the grinding device are brought into contact with each other, the tool is moved relative to each other, and the tip edge portion of the tool material is shaped and subjected to blade processing. Manufacturing method.   4. The tool manufacturing according to claim 2, wherein the tool made of the high hardness material is a ball end mill in which a tip edge portion is shaped into a hemispherical shape and one or a plurality of rake faces are formed on a spherical surface thereof. Method.   The tool made of the high-hardness material is a ball end mill in which a cross section of a tip blade portion is formed in a polygonal shape, and a ridgeline formed by each vertex of the polygonal shape forms an arcuate cutting blade in a vertical cross section. The tool manufacturing method of Claim 2 or Claim 3. A workpiece machining method for machining a high-hardness material workpiece using the composite machining apparatus according to claim 1,
A tool produced by the method for producing a tool according to claim 2 or 3 is mounted on a rotating spindle of the machining head,
The workpiece attached to the table is subjected to roughing with a laser beam irradiated from the laser beam irradiation means,
A workpiece machining method, wherein the workpiece is finished with a tool made of a high-hardness material mounted on a rotating spindle of the machining head.   A machining method for a workpiece, wherein the high-hardness material workpiece machined by the workpiece machining method according to claim 6 is further subjected to graining with a laser beam emitted from the laser beam irradiation means.

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