JP2016087659A - Manufacturing method of integrated molding roller, cutter and integrated molding roller - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a novel method for manufacturing an integrate molding roller which can be adapted to a fine louver shape which is difficult in processing by a normal tool such as an end mill, and can accurately mold a fin shape and a louver shape.SOLUTION: A process for cutting a recessed groove 15 being a cutting blade 14 at each tooth face of a tooth part 11 of an external peripheral face of an integrated molding roller 1 by using an acute-angled blade 3 of a cutting tool 4 has: a first process for cutting the groove 15 up to a depth shallower than a groove depth by using a wide-angled blade 31 having a molding angle α larger than a groove angle which is formed of an erecting wall 14b and an inclined part 14c of a slant blade 14a; and a second process for cutting the groove up to the groove depth of the groove by using a shape-transferred blade 32 having a molding angle β which coincides with the groove angle.SELECTED DRAWING: Figure 3B

Description

  The present invention relates to an integral molding roller for molding a corrugated fin with a fine louver for a small heat exchanger, and more particularly to a method and a cutting apparatus for machining a cutting edge portion for forming a fine louver on an integral molding roller. .

  A corrugated fin constituting a heat exchanger for a vehicle, for example, a heater core, is generally bent into a corrugated fin shape and cut into a louver shape using a forming device having a pair of forming rollers. To form a predetermined shape. The pair of forming rollers has a cylindrical gear shape, and has an uneven portion that meshes with each other on the outer peripheral surface, and a thin plate of fin material is passed between them to form a louvered fin shape. In the method described in Patent Document 1, a first processing device provided with a large number of blades for forming louver slits on the outer peripheral surface of a cylindrical roller, and a large number of convex portions for louver bending on the outer peripheral surface of a gear-shaped roller. A corrugated fin with a louver is manufactured by combining a second processing apparatus provided with a louver.

  In addition, there is a pair of gear-shaped rollers in which a concave and convex portion corresponding to the fin shape and a cutting edge portion corresponding to the louver shape are formed so that the fin and the louver can be processed simultaneously. 10A and 10B are detailed examples of a conventional forming roller, which is configured as a laminated roller 200 in which a predetermined number of gear-shaped flat plates 201 are stacked in the axial direction. In the figure on the right, the outer periphery of the flat plate 201 to be the laminated roller 200 is formed with crests and troughs for processing the fins in the circumferential direction alternately, and these crests and troughs are Superimposed to match the axial direction. In the laminated roller 200, the outer peripheral surface of each flat plate 201 excluding both axial end portions and the intermediate portion is an acute cutting blade 202 inclined in the axial direction. As shown in the left figure, a pair of laminated rollers 200 is provided. The fins 203 are sandwiched between the cutting blades 202 with the rollers 200 facing each other, and are cut up into a louver shape.

JP2013-139042A

  In the conventional laminated roller 200, a disk-shaped flat plate 201 base material is processed into a gear shape by a known grinder, and the outer peripheral surface is ground into a cutting blade 202 shape inclined in the axial direction, and a positioning reference hole is formed. It is assembled using and fixed with bolts. For this reason, it is necessary to process a large number of flat plates into a predetermined gear shape and then stack them in a predetermined order with their circumferential positions aligned, which not only increases the number of manufacturing processes but also increases the time required for assembly adjustment. The production cost increases. In addition, there is a risk of inaccuracy due to chip biting. Accordingly, the present inventors have studied to replace the laminated roller with a cylindrical block-shaped roller outer periphery with a cutting tool to form a gear-shaped integrally formed roller having a cutting edge portion.

  However, with the downsizing of the heater core part, the corrugated fin corrugated shape is reduced and the fin surface louver becomes finer, so the corresponding cutting edge part also becomes finer. Has been found to have limitations. FIG. 9 (left figure) shows an example of the shape of the cutting edge part for forming the louver. For example, when the end mill is processed when the groove pitch is about 0.9 mm, the tool diameter to be used is about φ0.2 to 0.6 mm. It becomes. However, in recent years, further miniaturization of corrugated fins has been demanded. When the groove shape of the cutting edge portion for forming the louver becomes, for example, about 1/3 as shown in FIG. It is difficult to manufacture itself (diameter φ0.05 mm or less). Or since the rigidity of the tool used falls remarkably, it was not realistic.

  The object of the present invention is to cope with a louver shape that is difficult to cut with a tool such as an end mill, and has a cutting edge portion for forming a fine louver on an outer peripheral tooth portion, so that a fin shape and a louver shape can be simultaneously formed. The object is to realize a new method and apparatus for efficiently manufacturing a moldable integral molding roller with high dimensional accuracy.

Invention of Claim 1 of this invention has the tooth part which formed the peak part and trough part which followed a fin shape on the outer peripheral surface of a cylindrical body alternately, and makes each fine tooth surface of this tooth part into a fine louver shape. A manufacturing method of an integrally formed roller for forming a corrugated fin with a fine louver, in which a cutting blade portion is integrally formed,
The cutting blade portion is arranged in parallel in the axial direction of the tooth surface, and is formed between a large number of convex swash blades composed of a standing wall portion and an inclined portion, and a large number formed between the adjacent standing wall portion and the inclined portion. Consists of grooved grooves,
When cutting the groove part by moving a cutting bite provided with an acute angle blade for grooving at the tip in the groove longitudinal direction,
A first step of cutting to a depth shallower than the groove depth of the groove portion using a wide-angle blade having a molding angle larger than the groove angle formed by the adjacent standing wall portion and the inclined portion as the acute angle blade;
And a second step of cutting to the groove depth of the groove portion using a shape transfer blade having a molding angle that matches the groove angle formed by the adjacent standing wall portion and the inclined portion as the acute angle blade. To do.

In the invention according to claim 2 of the present invention,
The first step is a roughing step of cutting off the remaining allowance between the wide-angle blade and the side wall portion.
The second step includes a middle processing step of scraping off the remaining margin formed in the first step with the shape transfer blade, and a finishing step of scraping off the surface along the groove shape with the shape transfer blade. Have

  In the invention according to claim 3 of the present invention, the cutting edge portion has a groove pitch of the plurality of concave groove portions of 0.9 mm or less and a groove depth of 0.5 mm or less.

  In the invention according to claim 4 of the present invention, the groove angle is 40 to 70 °, and the wide-angle blade is an acute-angle blade having a forming angle of 80 ° or more.

The invention according to claim 5 of the present invention is
The outer peripheral surface of the cylindrical body has teeth that are alternately formed with ridges and valleys along the fin shape, and cutting edges along the fine louver shape are integrally formed on each tooth surface of the teeth, A cutting device for an integrated molding roller for forming a corrugated fin with a fine louver,
The cutting blade portion is arranged in parallel in the axial direction of the tooth surface, and is formed between a large number of convex swash blades composed of a standing wall portion and an inclined portion, and a large number formed between the adjacent standing wall portion and the inclined portion. Consists of grooved grooves,
A roller support unit that rotatably holds the integral molding roller and can be stopped at an arbitrary position;
A cutting tool that can be arbitrarily operated in the vertical direction and the horizontal direction with respect to the tooth surface serving as the processing surface of the integrated molding roller is provided, and an acute angle blade for grooving provided at the tip of the cutting tool is arranged in the longitudinal direction of the groove. A cutting unit that moves and cuts the groove.
The acute angle blade has a forming angle larger than the groove angle formed by the adjacent standing wall portion and the inclined portion, and is formed of a wide angle blade for cutting to a depth shallower than the groove depth of the groove portion, and the adjacent standing wall portion and the inclined portion. A shape transfer blade having a forming angle that matches the groove angle formed and for cutting to the groove depth of the groove portion is used.

  The invention according to claim 6 of the present invention includes the cutting edge portion in which the groove portion is cut by the manufacturing method according to any one of claims 1 to 4 or the cutting apparatus according to claim 5. This is an integral forming roller for forming a corrugated fin with a fine louver.

  In the cutting method of the present invention, a large number of groove portions arranged in the axial direction are cut on the outer peripheral tooth surface of a gear-shaped integral molding roller to form a cutting edge portion for forming a fine louver. At this time, as the two types of sharp blades of the cutting tool, a shape transfer blade corresponding to the angle of the groove portion formed by the standing wall portion and the inclined portion and a wide angle blade having a larger molding angle are used. The rough shape of the groove is cut while the chipping is suppressed by roughly machining the stress applied to the blade edge by roughing. Next, the portion left uncut by the wide-angle blade is gradually scraped off in a second step using the shape transfer blade, and finished into a predetermined shape. Since the shape transfer blade cuts off only a part of the standing wall portion side left uncut by the wide-angle blade, the stress applied to the blade tip is small, and high-precision grooving can be performed without causing chipping.

  Therefore, it is possible to accurately process a cutting blade portion made up of a large number of oblique blades on the tooth portion of the integral molding roller. Therefore, the moldability and reliability of the integral molding roller can be greatly improved, and a corrugated fin having a fine louver with a desired shape can be easily molded.

It is a schematic diagram for demonstrating the manufacturing process of the fine louver fin for heat exchangers. It is a whole perspective view of a pair of integral molding rollers for molding a fine louver fin. It is the AA sectional view showing the partial enlarged view and louver shape of the fine louver fin which were processed. FIG. 4 is a front view of the integral molding roller and a partially enlarged perspective view thereof. It is the elements on larger scale of the tooth | gear part of an integral molding roller. It is the elements on larger scale of the cutting blade part formed in the tooth | gear part of an integral forming roller, and it is a B arrow line view of FIG. 2B. It is the elements on larger scale of the integral molding roller for demonstrating the cutting method of this invention. In the cutting method of this invention, it is a schematic diagram for demonstrating the cutting process using a wide angle blade and a shape transfer blade. It is a figure which shows the relationship between the shaping | molding angle of an acute angle blade in the cutting method of this invention, a process shape, and a stress vector. It is a figure which shows the relationship between the shaping | molding angle of an acute angle blade, a vector angle, and a stress index. It is a schematic diagram for demonstrating the chipping which arises at the time of the total type cutting by a shape transfer blade. 1 is an overall schematic sectional view of a cutting apparatus according to the present invention. It is typical sectional drawing for demonstrating the detailed example of the cutting process by the cutting method of this invention. It is a figure which shows the example of a process shape and evaluation result of the integral molding roller which cut by applying this invention. It is a schematic diagram for demonstrating the example of the shape of the cutting-blade part of the integral forming roller which can apply this invention. It is a partial expanded sectional view which shows the structure of the conventional lamination type forming roller. It is a partial expansion perspective view which shows the structure of the conventional lamination type forming roller.

  Hereinafter, the present invention will be described in detail with reference to the drawings. FIG. 1A shows a series of steps for manufacturing a fine louver fin (corrugated fin with a fine louver) 2 used in a small heat exchanger such as a heater core, and the present invention shows an integrated molding roller 1 used in a roller molding step. To be processed. In FIG. 1B, a pair of integral forming rollers 1 are cylindrical gear-shaped, each having a tooth portion 11 for forming a fin on the outer peripheral surface, and forming opposing tooth portions 11 so as to be able to mesh with each other. A thin fin material 2 ′ that passes between them is processed into a predetermined fin shape. The fin material 2 ′ is a metal coil material such as aluminum, and the roll-shaped fin material 2 ′ is fed out by a known uncoiler and continuously supplied between the pair of integrally formed rollers 1 that rotate synchronously. The tooth portion 11 of the integral molding roller 1 is provided with a cutting edge portion 14 for louver processing, and the corrugated fin type fine louver fin 2 with louver and the louver 21 cut-and-raise processing are simultaneously performed as shown in FIG. 1C. Do.

  In the fine louver fin 2 of the present embodiment, a large number of fine louvers (fine louvers) 21 are juxtaposed at a predetermined louver angle θ in the corrugated slope width direction, and one of the louver fins 2 has a central flat portion in the width direction as a boundary. The louver 21 is arranged in a symmetrical manner in which the direction of inclination of the louver 21 is different between the other side and the other side. Next, the fine louver fin 2 that has been corrugated by the integral molding roller 1 and has the louver 21 formed thereon is pressed between the pair of straightening rollers 100 in a substantially perpendicular direction to correct the uneven shape (correction process). ) Further, the shape is adjusted by pressing in the traveling direction between the pair of brake shoes 101 (shaping step).

  2A and 2B show the detailed shape of the integral molding roller 1, and the tooth portion in which the inside of the cylindrical block body is the connecting hole 10 of the rotation drive shaft, and the crests 12 and the troughs 13 are alternately formed on the outer peripheral surface. 11. The tooth portion 11 integrally forms a cutting edge portion 14 having a large number of ridged oblique blades 14a for cutting and raising the louver 21 on each tooth surface, with the side surface connecting the peak portion 12 and the valley portion 13 being a tooth surface. ing. Each oblique blade 14a is a long and narrow acute blade having a substantially triangular cross section, and extends from the vicinity of the peak of the peak portion 12 to the vicinity of the bottom portion of the valley portion 13 along the tooth surface. As shown in FIG. 2C, a large number of the slant blades 14a of the cutting blade portion 14 are arranged in parallel at a predetermined pitch in the roller axis direction (left and right direction in the figure), and each slant blade 14a is a substantially vertical standing wall. It is comprised by the part 14b and the inclination part 14c. The large number of slant blades 14a correspond to the large number of louvers 21 of the fine louver fins 2, and are arranged symmetrically with different inclination directions in the left half part and the right half part in the drawing with the central flat part as the center.

  In the pair of integral molding rollers 1, the inclination directions of a large number of oblique blades 14 a are set so that the cutting blade portions 14 that face each other at the time of molding are engaged with each other. Thereby, in the roller molding process, the integral molding roller 1 rotates and the tooth portions 11 mesh with each other, whereby the fine louver fin 2 is bent into a waveform along the peak portion 12 and the valley portion 13, and at the same time, the fine louver fin A number of slanting blades 14a of the cutting edge portion 14 located opposite to each other 2 shear the fin material with the top portion of the standing wall portion 14b as a fulcrum, and twist it along the inclined portion 14c.

  In order to form a large number of louvers 21 of the fine louver fins 2 with high precision in this roller forming step, the slewing blades 14a of the cutting blade portion 14 also have extremely high dimensional accuracy in the integrated molding roller 1. Required. For this reason, the integral molding roller 1 integrally forms a large number of oblique blades 14a to be the cutting blade portions 14 with the side surfaces of the tooth portions 11 by the cutting method of the present invention, which will be described in detail later. That is, by cutting the acute concave groove 15 surrounded by the standing wall 14b and the inclined portion 14c on the side surface of the tooth portion 11 at a predetermined pitch in the axial direction, a fine shape of a desired shape is formed between the adjacent grooves 15. Many slant blades 14a are formed.

  Specifically, as shown in FIG. 3A, a cutting bit 4 having an acute angle blade 3 for grooving at the tip is used and is perpendicular to a substantially horizontal workpiece surface (tooth surface of the tooth portion 11). To place. And the formation position of the groove part 15 is cut | disconnected with the acute angle blade 3 made into the corresponding shape, and it is set as a predetermined groove shape by moving substantially horizontally in a groove | channel longitudinal direction. By repeating this operation, a large number of groove portions 15 arranged in the axial direction, that is, a large number of oblique blades 14a, are formed integrally with the tooth surface to form a cutting blade portion 14. Here, in the integral molding roller 1 as an object of the present invention, since the groove portions 15 have a minute pitch, the corresponding cutting tool 4 is also minute, and the sharp blade 3 at the tip is stressed and easily damaged ( Chipping). Therefore, in the present invention, as the acute angle blade 3 for grooving, two types of blades shown in FIG. 3B are sequentially used, and efficient machining is performed stepwise to realize highly accurate grooving.

  FIG. 3B is a basic process of the cutting method according to the present invention. In the first process, the groove angle of the final processed shape (groove portion 15) is selected in order to suppress chipping among the two types of acute angle blades 3. In the second step, the shape transfer blade having a forming angle β (β <α <90 °) matched with the groove angle in order to make the wide-angle blade 31 having a wider forming angle α into a final processed shape in the second step. 32 are used respectively. The wide-angle blade 31 and the shape transfer blade 32 are made of a known super hard material, have a predetermined blade thickness in the processing direction (feed direction), ensure rigidity, and have a reference surface whose upper side surface is substantially perpendicular to the processing surface. As 33, positioning of the blade edge is facilitated. The wide-angle blade 31 has a cutting edge shape that protrudes in a substantially triangular shape below the reference surface 33, and both blade surfaces (left and right side surfaces in the figure) are inclined with respect to the reference surface 33 so that the load applied to the cutting edge is substantially uniform. To do. The shape transfer blade 32 has a vertical blade surface following the reference surface 33 on the upright wall portion 14b side.

  At this time, when the wide-angle blade 31 is pulled from the front side to the back side of the drawing together with the cutting tool 4 that moves forward, the standing wall portion 14b side of the groove portion 15 is left uncut and a remaining margin is formed. Therefore, the shape transfer blade 32 is attached to the cutting bit 4 in place of the wide-angle blade 31 at a position where the groove depth is shallower than the final processing shape, and subsequently, cutting is performed to a predetermined groove depth, and the remaining allowance is reduced. You can scrape off and transfer the blade shape.

  Here, the setting method of the forming angle α of the wide-angle blade 31 and the forming angle β of the shape transfer blade 32 will be examined with reference to FIGS. In FIG. 4A (left figure), when the forming angle of the acute angle blade 3 is increased with respect to the groove portion 15 which is a processed shape, the remaining margin portion formed on the standing wall portion 14b side of the groove portion 15 increases. Further, the contact surfaces of the two blade surfaces of the acute angle blade 3 and the processing portion (the standing wall portion 14b side or the inclined portion 14c side) change depending on the forming angle, and the magnitude and direction of the stress vector acting on the blade edge of the acute angle blade 3 change ( (Right figure). Therefore, these relationships were examined and shown in FIG. 4B. In the figure, the vector angle is the inclination angle of the stress vector with respect to the cutting direction (vertical direction) of the acute angle blade 3, and the stress index is the case where the molding angle of the acute angle blade 3 coincides with the groove angle (molding of the shape transfer blade 32). The angle β) was set as the stress index = 1, and the magnitude of the stress was relatively evaluated.

  FIG. 4B shows the relationship between the forming angle of the acute blade 3, the vector angle, and the stress index. Here, the groove angle of the groove 15 is set to 54 °, and the forming angle of the acute blade 3 is increased in increments of 5 °. In addition, the presence or absence of chipping when the cutting process was performed using each test piece was examined. As shown in the figure, as the forming angle increased, the vector angle gradually decreased, the stress index decreased rapidly, and became substantially constant (about 0.8) near 79 °. Further, no chipping was observed in the region exceeding 79 °. Thus, it can be seen that by reducing the vector angle, the stress bias during the cutting process is alleviated and the risk of chipping is reduced.

  Accordingly, the two types of acute angle blades 3 have an effect of suppressing chipping by increasing the forming angle α of the wide angle blade 31 used in the first step as much as possible. Preferably, the wide-angle blade 31 is an acute-angle blade having a forming angle α of 80 ° or more, and is set so that the remaining margin is minimized within a predetermined range where the stress index is small. The shape transfer blade 32 shape used in the second step is determined according to the specifications of the cutting blade portion 14 of the integral molding roller 1. For example, the groove angle of the groove portion 15 is in the range of about 40 to 70 °, and the forming angle β of the shape transfer blade 32 is set to coincide with this.

  In this way, when the groove 15 is cut with the fine acute angle blade 3, the wide angle blade 31 is used to cut a part of the groove 15 in advance in the first step, and then in the second step. By using the shape transfer blade 32, the shape of the blade can be accurately transferred without causing chipping. On the other hand, as shown in FIG. 5, when the entire shape was cut with only the shape transfer blade 32 without using the wide-angle blade 31, chipping occurred in the cutting edge (left side in the drawing) on the standing wall portion 14 b side. This is because the cut shape of the shape transfer blade 32 is asymmetric with respect to the cut direction, and the contact surface is small on the standing wall portion 14b side of the blade edge and large on the inclined portion 14c side, resulting in stress imbalance. I guess that.

  6 and 7 show a configuration example of the cutting apparatus 5 to which the present invention is applied and a preferable example of the machining process. In FIG. 6, the cutting apparatus 5 includes a roller support unit U <b> 1 that mounts the integral molding roller 1 on the outer periphery of the rotation drive shaft 51 and supports the rotation in the horizontal direction as an axial direction. A disc-shaped pressing plate 52 is attached to the front end side of the rotary drive shaft 51 to prevent the surface vibration of the integral molding roller 1, and the rotary drive shaft 51 is rotated to a predetermined processing position on the rear end side. The index mechanism 53 to be stopped is attached. A cutting unit U2 is provided above the integral molding roller 1, and the cutting tool 4 in FIG. 3 is held by a tool holder 54 and arranged in the vertical direction. The acute angle blade 3 at the tip is opposed.

  The tool holder 54 is fixed to the outer periphery of the processing head 56 having the reference bar 55, and can be arbitrarily operated in the horizontal direction and the vertical direction integrally with the processing head 56 by a driving unit (not shown). Further, the position of the cutting edge of the cutting tool 4 can be accurately determined by measuring the relative position (XY direction and Z direction) with respect to the reference bar 55. The cutting tool holder 54 has a plurality of adjusting bolts that protrude into a rectangular tube and come into contact with the outer periphery of the cutting tool 4 to facilitate adjustment of the cutting edge. At this time, the wide-angle blade 31 or the shape transfer blade 32 to be the acute-angle blade 3 can be moved in the longitudinal direction of the groove at an arbitrary cutting depth and feed rate to be cut into a desired groove shape.

  Preferably, as shown in FIG. 7, a roughing process (1) which is a first process using a wide-angle blade 31 and a middle machining process (2) which is a second process using a shape transfer blade 32. And the three-step processing which combined finishing process (3) is performed. First, in the roughing process (1), a processing portion indicated by hatching in the drawing is gradually cut using the wide-angle blade 31 with respect to the tooth portion 11 of the unprocessed integrated molding roller 1 to follow the blade shape. Grooves are formed. At this time, in the wide-angle blade 31, both blade surfaces (left and right blade surfaces in the figure) are inclined with respect to the cutting direction (vertical direction), and a load is applied relatively evenly to the contact surface with the work surface. That is, chipping due to stress concentration can be suppressed by scraping off a portion where a uniform load is applied and leaving only a portion where stress is applied. The width of the groove to be formed is slightly smaller than the width of the groove 15 to be processed, and an uncut portion that becomes a remaining portion is generated around the groove, particularly on the side of the standing wall 14b.

  In the intermediate machining step (2), among the remaining portions after the rough machining step (1), the machining portion indicated by hatching in the figure is gradually cut using the shape transfer blade 32 to form a groove along the blade shape. To do. At this time, the shape transfer blade 32 is inclined only on one blade surface (right blade surface in the drawing) with respect to the cutting direction (vertical direction). Since the part has been scraped off, the stress applied to the blade surfaces when the remaining part is cut is relatively small. That is, the finishing process step (3) is effectively performed by scraping off the portion where the stress does not increase and processing to the extent that the remaining margin is slightly provided around the groove.

  In the finishing process (3), the remaining portion after the intermediate machining process (2) is cut using the shape transfer blade 32. Since the remaining allowance portion that becomes the processing portion is left so that the stress applied to both blade surfaces (left and right blade surfaces in the drawing) becomes substantially equal, the remaining blade is cut again with the same blade and all the remaining allowance is removed. By the three-stage machining using these two types of blades, the shape of the groove 15 can be machined with high accuracy while reducing stress and suppressing chipping.

  In order to confirm the effect of the present invention, the integrated molding roller 1 was cut according to the three-stage machining steps (1) to (3) of FIG. 7 using the cutting device 5 of FIG. FIG. 8 shows the processed shape and the evaluation results. In the integral molding roller 1, the indicated dimensions of the cutting edge portion 14 are such that the pitch P between adjacent slant blades 14a: 0.3 mm (required crossing ± 0.004 mm), and the groove portion 15 depth D: 0.17 mm (required crossing ± 0.002 mm), and the angle γ of the groove 15 is 54 ° (required crossing ± 5 ′). As the acute angle blade 3 of the cutting tool 4, a wide angle blade 31 (forming angle α: 84 °) and a shape transfer blade 32 (forming) Angle β: 54 °) was used. As a result, as shown in the table in the figure, the measured values (pitch P: 0.299 to 0.302 mm, depth D: 0.168 to 0.171 mm, angle γ: 53.99 °) of each part are as follows: All were within the required intersection (evaluation: ◯).

  When the stress vectors in the three-stage machining steps (1) to (3) were examined, in the rough machining step (1) using the wide-angle blade 31, the vector angle was 17.92 ° and the stress index was 0.787. . In the intermediate machining step (2) using the shape transfer blade 32, the vector angle is 35.03 ° and the stress index is 0.444, and the vector angle is large, but the stress is reduced. In the finishing machining step (3), The vector angle 2.717 ° and the stress index 0.405 are greatly reduced, and it can be seen that cutting can be effectively performed. Furthermore, when the fine louver fin 2 having a large number of louvers 21 is formed by the manufacturing process of FIG. 1 using the obtained integral forming roller 1, the louver angle (average value) is within a desired range. It was found to have sufficient practicality.

  As described above, according to the cutting method and the cutting device of the present invention, the fine cutting edge portion 14 of the integral molding roller 1 is manufactured with high molding accuracy by using the transfer method by total die cutting. Can do. In other words, a combination of two types of blades serving as the acute-angle blade 3 of the cutting tool 4 can eliminate stress unevenness and suppress chipping, and is an integral forming roller corresponding to the fine louver 21 shape that has been difficult in the past. 1 can be realized. Specifically, as shown in FIG. 9 (left figure), the present invention provides a cutting edge portion 14 having a groove portion 15 having a groove pitch P of about 0.9 mm or less and a groove depth D of about 0.5 mm or less. It is applied and preferably particularly effective for cutting the fine cutting edge portion 14 having a groove pitch P of 0.5 mm or less, for example, about 0.3 mm.

  When the groove shape (groove pitch P: 0.9 mm ± 5 μm, groove depth D: 0.5 mm, bottom R: 0.2 mm or less) shown in FIG. 9 (left figure) becomes smaller, processing by the conventional method is performed. Becomes difficult. For example, as shown in FIG. 9 (right figure), the groove shape refined to one third size (groove pitch P: 0.3 mm ± 5 μm, groove depth D: 0.15 mm, bottom R: 0.05 mm or less) However, not only is it difficult to produce a usable end mill (tool diameter φ0.05 mm or less), but workability deteriorates due to a significant decrease in rigidity. Even in such a case, by using the cutting method of the present invention, cutting can be performed with high productivity.

  The present invention is not limited to the heater core exemplified in the above embodiment, and is applied to an integral forming roller for manufacturing a corrugated fin with a fine louver used in a small heat exchanger, and cuts a fine cutting edge portion with high accuracy. it can. Further, the integral molding roller manufactured by the method or apparatus of the present invention is capable of molding a corrugated fin with a fine louver in which a large number of louvers are cut and raised with high precision by a fine cutting edge part. Contributes to improving the performance of small heat exchangers.

U1 Roller support unit U2 Cutting unit 1 Integrated molding roller 11 Tooth portion 12 Mountain portion 13 Valley portion 14 Cutting edge portion 14a Oblique blade 14b Standing wall portion 14c Inclined portion 15 Groove portion 2 Fine louver fin 21 Fine louver 3 Sharp angle blade 31 Wide angle blade 32 Shape Transfer blade 4 Cutting tool

Claims (6)

It has a tooth part (11) in which a peak part (12) and a valley part (13) along the fin shape are alternately formed on the outer peripheral surface of the cylindrical body, and each tooth face of the tooth part has a fine louver (21) shape. A manufacturing method of an integral forming roller (1) for forming a corrugated fin (2) with a fine louver, in which a cutting edge portion (14) along which it is formed is formed,
The cutting blade portion is arranged in parallel in the axial direction of the tooth surface, and includes a plurality of ridged slant blades (14a) constituted by the standing wall portion (14b) and the inclined portion (14c), and the adjacent standing wall portion and the inclined surface. Consisting of a number of concave groove portions (15) formed between the portions,
When cutting the groove part by moving a cutting tool (4) provided with an acute angle blade (3) for grooving at the tip in the groove longitudinal direction,
A first step of cutting to a depth shallower than the groove depth of the groove portion using a wide-angle blade (31) having a molding angle (α) larger than the groove angle formed by the adjacent standing wall portion and the inclined portion as the acute angle blade;
A second step of cutting to the groove depth of the groove part using the shape transfer blade (32) having a forming angle (β) matched to the groove angle formed by the adjacent standing wall part and the inclined part as the acute angle blade; A method for producing an integral molding roller. The first step is a roughing step of cutting off the remaining allowance between the wide-angle blade and the side wall portion.
The second step includes a middle processing step of scraping off the remaining margin formed in the first step with the shape transfer blade, and a finishing step of scraping off the surface along the groove shape with the shape transfer blade. The manufacturing method of the integral molding roller of Claim 1 which has these.   3. The method of manufacturing an integral molding roller according to claim 1, wherein the cutting blade portion has a groove pitch of the plurality of concave groove portions of 0.9 mm or less and a groove depth of 0.5 mm or less.   4. The method of manufacturing an integral molding roller according to any one of 3 and 4, wherein the groove angle is 40 to 70 °, and the wide angle blade is not an acute angle blade having a molding angle of 80 ° or more. It has a tooth part (11) in which a peak part (12) and a valley part (13) along the fin shape are alternately formed on the outer peripheral surface of the cylindrical body, and each tooth face of the tooth part has a fine louver (21) shape. A cutting device for an integrally formed roller (1) for forming a corrugated fin (2) with a fine louver, in which a cutting edge portion (14) along which it is formed is formed,
The cutting blade portion is arranged in parallel in the axial direction of the tooth surface, and includes a plurality of ridged slant blades (14a) constituted by the standing wall portion (14b) and the inclined portion (14c), and the adjacent standing wall portion and the inclined surface. Consisting of a number of concave groove portions (15) formed between the portions,
A roller support unit (U1) that rotatably holds the integral molding roller and can be stopped at an arbitrary position;
A sharp cutting blade (3) provided with a cutting bit (4) that can be arbitrarily operated in the vertical and horizontal directions with respect to the tooth surface that is the processing surface of the integral molding roller, and provided at the tip of the cutting bit (3) ) In the longitudinal direction of the groove, and a cutting unit (U2) for cutting the groove portion,
Adjacent to the wide-angle blade (31) having a forming angle (α) larger than the groove angle formed by the adjacent standing wall portion and the inclined portion and cutting to a depth shallower than the groove depth of the groove portion. An integral forming roller having a forming angle (β) that matches the groove angle formed by the standing wall portion and the inclined portion, and using a shape transfer blade (32) for cutting to the groove depth of the groove portion Cutting equipment.   An integral forming roller for forming a corrugated fin with a fine louver, comprising the cutting edge portion in which the groove portion is cut by the manufacturing method or cutting device according to any one of claims 1 to 5.

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