JP3115382B2 - Honeycomb core stepping method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in a step-forming method for a metal honeycomb core used as a structural material of an automobile, an aircraft or the like.

[0002]

2. Description of the Related Art Conventionally, when processing a step portion on a honeycomb core, grinding or cutting is performed using a ball end mill or other dedicated tools. As a ball end mill used for such step forming, for example, a ball end mill described in Japanese Utility Model Application Laid-Open No. 63-193613 is known, and this tool has a diamond abrasive grain on a hemispherical tool tip. Are formed by multiple electrodeposition. On the other hand, as a special tool, for example, Japanese Utility Model Application Hei.
No. 7, there is a disk-shaped cutter having cutting edges along the circumference, as proposed by the present applicant. This tool has a nitride layer formed by ion implantation on the bottom surface of the cutter in order to prevent the blade of the cutter from burning and the honeycomb core from being welded.

[0003]

However, the processing of the honeycomb core has a problem of difficulty in cutting due to the specific shape of the honeycomb, and this point is particularly apparent in the stepping processing. That is, when cutting is performed using a conventional tool, for example, a cutter disclosed in Japanese Utility Model Application No. 1-145597, it is very difficult to cut a stepped portion having an R smaller than the radius of the cutter, It has been pointed out that the shallow stepped portion has a problem in that the cutting edge has a poor biting property with respect to the honeycomb core. In addition, there is a problem that it takes a very long time to process due to the difficulty of cutting the honeycomb core, which is common to both cutting and grinding.
In addition, there are many process elements that increase the working time as a whole, such as special measures to fix the honeycomb core using polyethylene glycol or the like to counter the force applied to the workpiece from the tool. Therefore, an object of the present invention is to solve the problems of the above-described conventional technology and to provide a honeycomb core stepping method suitable for shortening the processing time of a honeycomb core and processing a stepped portion having a fine shape. Aim.

[0004]

In order to achieve the above object, the present invention provides a preforming step of positioning and pressing a honeycomb core in a mold in which uneven portions are developed in a net-like or wavy manner, and a step in which the mold is removed. And a main forming step of positioning the preformed honeycomb core on a mounting jig and pressurizing the honeycomb core again.

[0005]

According to the present invention, the step is formed by the main forming only in the deformed portion of the honeycomb core deformed by pressing against the uneven portion of the preforming die, so that the crash portion spreads to the inside of the honeycomb. And a processed product having good internal quality can be obtained.

[0006]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a honeycomb core according to an embodiment of the present invention; FIG. 2 is a plan view of a jig used to carry out the method of the present invention, and FIG. 3 is a sectional view taken along line AA in FIG. In this embodiment, the jig 1 is used with a press machine,
A stepped portion is formed on a honeycomb core W used as a structural member of an aircraft.

In FIGS. 2 and 3, reference numeral 2 denotes a base, and a rectangular recess 3 is formed in the center of the base 2, and the depth of the recess 3 is applied to the honeycomb core W. It is designed to match the step size. In this embodiment, as the material of the base 2, an aluminum material is employed so that the concave portion 3 can be processed by the chemical milling method. However, when the concave portion 3 is processed by means such as machining. In this case, another material such as iron can be used for the base 2. A stopper block 4 for restricting the operation of the press machine is fastened to each of the four corners of the base 2 by bolts or the like. 5 is attached. These stopper blocks 4 also serve to set the step size of the honeycomb core W. In this embodiment, iron (S48C, RC25 to RC30) is used as a material, and a set of four is formed by milling. Are simultaneously processed to make the block heights uniform. Also,
A core locating block 6 made of aluminum material is fixed to the inside of the stopper block 4 on the base 2 at four places by bolts or the like. The core locating block 6 is used to hold the honeycomb core W and the preforming die 7. It is a member for positioning. In this embodiment, a notch 8 is provided on one side of the preforming die 7, and the core locating block 6, which is intentionally shifted in position and fixed to the notch 8, is combined to set the preforming die 7. The direction is not misunderstood.

The preforming die 7 is made of an aluminum plate corresponding to the outer peripheral shape of the honeycomb core W. In the set state, the peripheral edge portion corresponding to the outside of the concave portion 3 forms a net-like unevenness. A stainless steel wire mesh 9 is spread via an adhesive. In this case, the mesh of the wire mesh 9 is smaller than the size of the honeycomb cells of the honeycomb core W. Depending on the use of the honeycomb core to be processed or the like, the metal plate 9 may be knurled or grooved on a suitable metal plate to develop the mesh-like irregularities in the same manner. Processing such as corrugated processing, wire-shaped processing on a metal plate in the same way, and even processing with razor-shaped blades when the preforming amount is large, etc. Can be changed appropriately according to the embodiment.

Next, an embodiment of a processing method using the jig configured as described above will be described with reference to FIG. FIG. 1A shows a processing method of the preforming, and FIG.
(B) shows the working method of the main forming, and FIG. 1 (c) shows the honeycomb core W after the working. In the figure, reference numeral 10 indicates an upper press of the press machine, and reference numeral 11 indicates a lower press. Table 1 shows actual molding data. Table 1 Item formed form Conditions _pressurized preform 40 (ton) present molding 80 (ton) Core Size 0.3 m × 0.3 m core Material Aluminum 5052 CORE cell size 3.1 × 1/8 × 07N core thickness 9. 53 mm wire mesh size 0.25 (in DIA) 16 × 16 MESH First, the preforming will be described. First, the jig 1 fixed on the lower press 11 is spread on the preforming mold 7 with an epoxy-based adhesive. The honeycomb cores W are placed on the wire mesh 9 and the core locating blocks 6, which are not shown in FIG. In this case, it is preferable that the thickness of the wire netting 9 is smaller than the step size S, and the preforming amount is about half of the step size S. However, when it is difficult to set a half of the S dimension in the size of the wire mesh or the like (this example corresponds to the example), the shim 5 is appropriately stacked on the stopper block 4, and thereby the upper press 10 during the preforming is formed. Can be provided with a function such that the amount of preforming is reduced to half of the step size S. After preparing for preforming as described above,
The upper press 10 is lowered, and the honeycomb core W
Press. By performing such preforming, the portion of the honeycomb core W that is pressed against the wire mesh 9 is crushed and deformed so as to be turned up as indicated by reference numeral 12 in FIG.

Next, the main forming will be described. After the above preforming is completed and the upper press 10 is raised, the honeycomb core W is taken out from the preforming mold 7 and the preforming mold 7 is removed from the base 2. Remove. Then, the honeycomb core W is positioned on the base 2 again as shown in FIG. 1B, and then the upper press 10 is lowered to press the honeycomb core to perform the main forming. As a result, as is apparent from a comparison between FIG. 6 showing the honeycomb core W after the main forming and FIG. 5 described above, the edge 13 of the honeycomb cell including the crushed portion 12 deformed by the preforming is bent. , The stepped portion 14 is processed. As described above, since a large number of ruptured portions 12 are formed in advance by preforming, the stepping process is performed only on the portions deformed by the preforming, and the crush portion spreads to other portions. It is possible to perform processing that is prevented and maintains quality. Here, FIG. 8 is a diagram showing a honeycomb core panel using the honeycomb core W subjected to the step processing as described above.
In the honeycomb core W processed by the above-described method, when the outer plates 17a to 17d are bonded using an epoxy-based adhesive, the outer plate 17c bonded to the stepped portion has a stepped portion bent. Therefore, there is an advantage that the adhesion becomes strong and the panel becomes high quality. FIG. 7 schematically shows a cross section of the honeycomb core W in which a step is formed by directly forming the main body without performing the preforming. However, if the preforming is not performed, the inside of the cell may be deformed. I understand. As described above, in the present embodiment, since the honeycomb core can be pressed quickly and continuously by using a press machine for pressurizing the honeycomb core, the processing efficiency can be greatly improved as compared with the conventional cutting or grinding processing. improves.

Next, an example of carrying out the method of the present invention using a roller molding machine will be described with reference to FIG. The embodiment using this roller forming machine is preferably applied when the size of the honeycomb core W to be subjected to the stepping process is large and it is difficult to apply a press machine. The jig used in the second embodiment has basically the same configuration as the jig of the first embodiment. Hereinafter, the same components will be described with the same reference numerals.

FIG. 4A shows a preforming step. First, a honeycomb core W is placed on a wire mesh 9 of a preforming die 7.
, And a shim 5 is superimposed on the molding amount adjustment block 4 as necessary, and a cover plate 15 is further mounted thereon. Thereafter, the jig and the entire honeycomb core W are pressed between the pressing rollers 16a to 16c of the roller forming machine. In this case, the interval between the pressing rollers 16a and 16b and the pressing roller 16c is appropriately adjusted in order to apply an appropriate pressing force. Pressure rollers 16a to 16c
, The honeycomb core W is pressurized to complete the preforming. Thereafter, the cover plate 15, the honeycomb core W, the shim 5, and the preform 7 are once removed. Thereafter, in this molding, as shown in FIG. 4B, the honeycomb core W is set again on the base 2 and the pressure rollers 16a to 16
c and pressurized to end.

In the above, an embodiment using a press machine and a roller forming machine as the means for applying pressure has been described. For example, when a honeycomb core having a small area is processed, an alternative pressurizing means is used. As a means, it is also possible to perform manual processing using a hammer, a wooden stick or the like. When pressure is applied by such manual processing, stepped processing of a small shape, which could not be conventionally handled by cutting, grinding, or the like, can be finished with high accuracy.

[0014]

As is apparent from the above description, according to the present invention, a preforming step of positioning and pressing a honeycomb core on a mold having irregularities formed in a net or wavy shape, and a step of removing the mold. The stepped portion is machined in the honeycomb core in a two-stage process of positioning the preformed honeycomb core on the jig for attaching and processing and positioning the honeycomb core again to apply pressure. In addition to maintaining good internal quality, it is possible to perform efficient processing in a short time by applying a press machine, roller forming machine, etc., and it can sufficiently cope with processing small and shallow stepped parts Such an effect is provided.

[Brief description of the drawings]

FIG. 1 is a process explanatory view showing an embodiment in which a stepping method of a honeycomb core according to the present invention is performed using a press machine.

FIG. 2 is a plan view of a jig used in the stepping processing method of the present invention.

FIG. 3 is a sectional view taken along line AA of FIG. 2;

FIG. 4 is a process explanatory view showing one embodiment in which a step forming method of a honeycomb core according to the present invention is performed using a roller forming machine.

FIG. 5 is a perspective view of a honeycomb core after completion of preforming.

FIG. 6 is an explanatory view of the honeycomb core after the step processing.

FIG. 7 is an explanatory view of a honeycomb core that has been subjected to stepping processing without undergoing preforming.

FIG. 8 is a cross-sectional view of a panel in which an outer plate is bonded to a honeycomb core after step processing.

[Description of Signs] 1 jig 2 base 3 concave portion 4 stopper block 5 shim 6 core locating block 7 preforming die 9 wire mesh 10 upper press 11 lower press 12 crushed portion 14 stepped portion W honeycomb core

Claims (1)

(57) [Claims] 1. A preforming step of positioning and pressurizing a honeycomb core in a mold in which uneven portions are developed in a net-like or wavy manner, and a honeycomb core having been preformed on a stepping jig from which the mold has been removed. A step of forming a honeycomb core, comprising: a main forming step of positioning and pressing again.