JP3121482U - Ultrasonic machining horn - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an ultrasonic processing horn capable of continuously performing a series of operations from embedding a fiber material into a workpiece to removing irregularities on the workpiece surface without using other tools.
A heating processing section 5 for melting a work surface and embedding a fiber material is provided at the tip of a horn 3, and one of the wedge-shaped finishing processing sections 7 connected to the heating processing section 5 is provided. A step-like step difference 10 is formed on the surface 8 for cutting and removing irregularities generated in the process of embedding the fiber material, and the surface of the workpiece is coated on the other surface 9 of the finishing processing portion 7 by frictional heat. Thus, a flat surface 11 is formed for melting and removing minute irregularities on the workpiece surface.
[Selection] Figure 2

Description

  The present invention relates to an improvement of an ultrasonic processing horn attached to an ultrasonic handpiece used when a fiber material is embedded in a workpiece made of a thermoplastic resin to shape the surface of the workpiece.

  A fiber material having a higher heat resistance temperature than the thermoplastic resin forming the workpiece is placed on the workpiece, and the fiber material is embedded while melting the surface of the workpiece by pressing the fiber material with the horn of an ultrasonic handpiece. A post-processing type fiber embedding method for reinforcing or repairing a workpiece has already been proposed by the present applicants as Patent Document 1.

  Moreover, in this patent document 1, the present applicants, as a horn shape suitable for embedding a fiber material using an ultrasonic handpiece, prevents the displacement of the fiber material or makes the tip of the horn contact the surface of the workpiece. A horn shape having a plurality of projections that are advantageous for the purpose is proposed.

  However, this horn shape is exclusively specialized for fiber material embedding work, and in order to finish the surface of the work after the fiber material embedding has been completed, it is further possible to use a rotary tool called a luter or a minter. It is necessary to remove irregularities on the surface of the workpiece using a coarse file or a coarse file, which leaves certain inconveniences in that various tools are required and it is not always easy to shorten the work time.

Japanese Patent Application No. 2006-001099

  Therefore, the problem of the present invention is to eliminate the above-mentioned inconvenience and use only the ultrasonic processing horn attached to the ultrasonic handpiece to lead to removal of unevenness on the workpiece surface from embedding the fiber material into the workpiece. An object of the present invention is to provide an ultrasonic processing horn capable of continuously performing a series of operations without using other tools.

The ultrasonic processing horn of the present invention is an ultrasonic processing horn to be mounted on an ultrasonic handpiece used when shaping a surface of a work by embedding a fiber material in a work made of a thermoplastic resin, In order to achieve the challenges,
A heating processing portion formed at the tip, and a wedge-shaped finishing processing portion having two surfaces that are in communication with the heating processing portion and gradually increase the separation distance toward the base side,
A plurality of minute protrusions are formed on the heating processing portion, and a step-like step difference is continuously formed on one surface of the wedge-shaped finishing processing portion. A flat surface is formed on one surface.

First, a fiber material having a higher heat resistance temperature than that of the thermoplastic resin is placed on the workpiece made of the thermoplastic resin, and the tip of the ultrasonic processing horn attached to the ultrasonic handpiece driven by the ultrasonic vibrator The fiber material is pressed into the workpiece while the workpiece surface is melted by the frictional heat generated between the work surface and the minute protrusions that contact the workpiece surface by pressing the fiber material at the heating processing part By embedding the fiber material in the workpiece.
Although it depends on the size of the fiber material, in order to embed all the parts in the work, the position of the work melting and the fiber material pushing work using the heating processing part at the tip of the ultrasonic processing horn is changed. Must be repeated many times, and many irregularities are generated on the workpiece surface during this process.
Therefore, in order to remove the unevenness, the surface on the side where the stepped step difference is continuously formed in the wedge-shaped finishing processing portion of the ultrasonic processing horn is pressed against the uneven portion of the workpiece surface, and the stepped shape The ultrasonic processing horn is moved on the workpiece so that the surface of the workpiece is rubbed by the difference in height. The uneven surface of the workpiece surface, in particular the convex portion, is weakened due to some deterioration due to heating, and the step-like step difference vibrates in a direction along the workpiece surface at a high frequency. The tip of the convex part on the workpiece is stepped by moving the ultrasonic processing horn so that the surface on which the step difference is formed is pressed against the uneven part of the work surface and rubs the work surface. It is continuously cut by the rising part of the shape difference.
Then, in order to remove minute irregularities on the workpiece surface that could not be completely removed at this point in time when the workpiece surface became substantially flat, the flat surface of the wedge-shaped finishing processing portion of the ultrasonic processing horn The ultrasonic processing horn is placed on the workpiece by pressing the formed surface against the workpiece surface or rubbing the workpiece surface with the flat surface pressed against the workpiece surface. Move with. Since the flat surface of the finished processing part vibrates in a direction substantially along the workpiece surface at a high frequency, the workpiece surface is melted in a surface layer using frictional heat generated between the flat surface and the workpiece surface. Thus, minute irregularities on the workpiece surface can be removed.
As described above, since the embedding of the fiber material by melting the work surface and the removal of the unevenness generated in the embedding process of the fiber material can be performed with one ultrasonic processing horn, various tools can be used by changing. There is no need, and the working time can be easily reduced.

  Further, it is desirable that the stepped step difference provided on one surface of the wedge-shaped finishing processing portion is formed side by side in the longitudinal direction of the horn.

  Since the rising portion of the stepped step difference vibrates in the direction of cutting the tip of the convex portion on the workpiece, the cutting efficiency for the convex portion on the workpiece is improved.

  Furthermore, it is desirable that the heating processing portion at the tip of the ultrasonic processing horn and the flat surface of the finishing processing portion are connected by a smooth curved surface.

  By forming a smooth curved surface at the end of the flat surface of the finish processing part, the tip of the ultrasonic processing horn is inadvertently inserted into the work surface after the embedding of the fiber material and the removal of rough irregularities are completed. Work mistakes are improved, and minute irregularities can be removed without scratching the workpiece surface.

  The ultrasonic processing horn of the present invention is provided with a heating processing portion for melting a workpiece surface and embedding a fiber material at the tip of the horn, and one of the wedge-shaped finishing processing portions connected to the heating processing portion. On the surface, a step-like step difference is formed to cut and remove the irregularities generated in the fiber material embedding process, and on the other surface of the finished processing part, the work surface is melted surface by friction heat Since a flat surface for removing minute irregularities on the workpiece surface is formed, it is possible to perform embedding of the fiber material and removal of irregularities generated during the embedding process of the fiber material with one ultrasonic processing horn. it can.

  Also, since the stepped step difference provided on one surface of the wedge-shaped finishing processing portion is formed side by side in the longitudinal direction of the horn, a convex portion on the workpiece at the rising portion of the stepped step difference The convex part on the workpiece can be cut efficiently by cutting the tip of the workpiece.

  Furthermore, since the flat surface of the heating processing part and the finishing processing part at the tip of the horn are connected by a smooth curved surface, the work surface is not damaged by an inadvertent entry of the tip of the ultrasonic processing horn. Irregularities can be removed.

  Next, the best mode for carrying out the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a simplified perspective view showing an example of an ultrasonic handpiece equipped with an ultrasonic processing horn according to an embodiment to which the present invention is applied.

  The ultrasonic handpiece 1 includes an ultrasonic transducer (not shown) therein, and the ultrasonic processing horn 3 protruding from the handpiece main body 2 is reciprocated in the axial direction by the ultrasonic transducer described above. It has become so.

The ultrasonic processing horn 3 can be attached to and detached from the handpiece main body 2, and various shapes of ultrasonic processing horn, for example, an ultrasonic processing horn for cutting having a cutting edge (not shown). Etc.) can be selectively attached to the handpiece body 2.
In the example of FIG. 1, the entire ultrasonic processing horn 3 is replaced and replaced, but only the tip of the ultrasonic processing horn 3 is formed of a separate member, and only this tip is replaced. It may be a configuration.

  The controller 4 drives and controls the above-described ultrasonic vibrator built in the handpiece body 2 by the V / F conversion method (voltage / frequency conversion method). The handpiece body 2 is also provided with a hand switch 6 for ON / OFF control of the operation of the ultrasonic processing horn.

  Since the structure and function of the ultrasonic handpiece itself are already known, detailed description thereof will be omitted.

  FIG. 2 shows an example of an ultrasonic processing horn that is used by being attached to the handpiece body 2 when a fiber material is embedded in a workpiece made of a thermoplastic resin to shape the surface of the workpiece.

  The ultrasonic processing horn 3 includes melting of a workpiece made of a thermoplastic resin, embedding of a fiber material into the workpiece, cutting of uneven portions formed on the surface of the workpiece in accordance with the embedding operation of the fiber material, and the cutting It is used for removing minute irregularities that could not be removed by work, and as shown in Fig. 2 (a), the heating process used exclusively when embedding the fiber material in the work piece on the tip In addition, a wedge-shaped finishing processing portion 7 is provided at the tip of the ultrasonic processing horn 3 that communicates with the heating processing portion 5.

  As shown in FIGS. 2 (b) and 2 (e), the finishing processing section 7 as a whole gradually increases the separation distance from the tip of the ultrasonic processing horn 3 toward the base side. A stepped step difference 10 as shown in FIG. 2 (e) is continuously formed on one surface 8 of the finished processing portion 7 among them. On the other hand, a flat surface 11 as shown in FIG. 2 (e) is formed on the other surface 9 of the finishing processed portion 7.

  As shown in FIG. 2 (a), the stepped step difference 10 is engraved side by side in the longitudinal direction of the ultrasonic processing horn 3, that is, the vibration direction of the ultrasonic processing horn 3. An edge portion 12 formed by the rising of 10 is orthogonal to the vibration direction of the ultrasonic processing horn 3.

  In addition, a plurality of minute protrusions 13 for sewing the gaps in the fiber material and making contact with the workpiece surface are formed on the heating processing portion 5 located on the tip surface of the ultrasonic processing horn 3 as shown in FIGS. It is formed as shown in d).

  The minute projections 13 are, for example, minute quadrangular pyramids provided in an array of 2 rows and 5 columns as shown in FIG. 2D. In this embodiment, the height D1 is 0.3 mm, The length D2 of one side of the bottom surface is 0.7 mm, the length D3 of one side of the top surface is 0.2 mm, and the arrangement pitch P in the row and column directions is about 1 mm. Among various fiber materials, it is optimized especially for embedding cloth-like fiber materials. The cloth-like fiber material is held in a state of entering the gap, and the displacement of the cloth-like fiber material with respect to the workpiece surface can be reliably prevented.

  In this way, by forming the relatively sharp micro-projections 13 on the tip surface of the ultrasonic processing horn 3, the cloth-like fiber material is prevented from being displaced, and the cloth-like fiber material forming the surface is obstructed. The tip of the ultrasonic processing horn 3, that is, the heating processing portion 5 is brought into contact with the work surface without being buried, and the cloth-like fiber material can be embedded in the work without giving excessive heat.

  As the shape of the microprojection 13, in addition to a quadrangular pyramid, for example, a quadrangular pyramid, a truncated cone, a cone, a triangular frustum, a triangular pyramid, and the like can be used. The shape of a truncated pyramid or a quadrangular pyramid is particularly suitable.

  As shown in FIG. 2 (e), the connecting portion between the heating processing portion 5 on which the minute projections 13 are formed and the flat surface 11 of the finishing processing portion 7 is a smooth curved surface constituted by an outwardly convex partial arc surface. 14 is connected smoothly.

  Next, an example of repairing and reinforcing a workpiece by embedding a cloth-like fiber material in a workpiece made of a thermoplastic resin that has been torn, such as a cowling of a motorcycle, a bumper of a vehicle, or a polycontainer is taken as an example. The work of embedding the cloth-like fiber material using the melting of the work, the work of cutting the irregularities formed on the work surface due to the work of embedding the cloth-like fiber material, and the minute work that could not be removed by this cutting work A work process related to the unevenness removal work will be briefly described.

  At this time, the cloth-like fiber material embedded in the workpiece should have a heat resistance temperature higher than the thermal deformation temperature of the thermoplastic resin forming the workpiece so that the mechanical and chemical properties are not impaired by the heating during embedding. Choose what you have.

  The heat deformation temperature here is a temperature at which the thermoplastic resin softens to such an extent that the cloth-like fiber material can be embedded, and does not necessarily mean the melting point of the thermoplastic resin itself.

  In general, among thermoplastic resins forming a workpiece, ABS resin has a heat deformation temperature of 93 ° C. to 103 ° C., polypropylene has a heat deformation temperature of 57 ° C. to 63 ° C., polypolycarbonate has a heat deformation temperature of 130 ° C. to 138 ° C., nylon The heat deformation temperature of polyethylene is 67 ° C to 70 ° C, the heat deformation temperature of polyethylene is around 43 ° C, and the melting point (heat resistant temperature) of polyester fiber among the cloth-like fiber materials to be embedded is 255 ° C to 260 ° C, nylon The melting point (heat resistant temperature) of the fiber is 215 to 220 ° C., the carbonization temperature of the aramid fiber (upper limit of the heat resistant temperature) is around 537 ° C. (above, synthetic fiber), the decomposition temperature (heat resistant temperature) of cotton is around 235 ° C., hemp Since the decomposition temperature (heat-resistant temperature) is about 235 ° C. (above, natural fiber), all combinations of these workpieces and cloth-like fiber materials are possible. As other cloth-like fiber materials, for example, those containing fibers such as glass, Kevlar, and carbon are suitable.

  In the case of cloth-like fiber material, it is desirable to select an appropriate one for the weaving method. As the weaving method, those that are less likely to cause inadvertent distortion or thread pull-out when a vertical or horizontal or oblique pulling force is applied, such as thin-leaf non-woven fabrics, plain weaves, multi-woven fabrics, turtle weaving fabrics, and tengu weaves are considered. Among them, the Russell weave in which the warp and the weft are fixed to each other is preferable in that the distortion, the thread dropout, and the like hardly occur.

  When repairing or reinforcing a workpiece made of a thermoplastic resin that has been torn by embedding a cloth-like fiber material in the workpiece, first, the temperature is higher than the thermal deformation temperature of the workpiece 15 in accordance with the breaking condition of the workpiece 15. The cloth-like fiber material 16 having a heat-resistant temperature is cut into an appropriate size, and the cloth-like fiber material 16 is placed on the work 15 so as to straddle the tearing portion 17 of the work 15 as shown in FIG. .

  Next, after setting the frequency, amplitude and the like on the controller 4 side, the hand switch 6 of the ultrasonic handpiece 1 is operated to start the vibration of the ultrasonic processing horn 3 in the axial direction. The micro-projections 13 of the heating processing portion 5 located at the tip are pressed against the cloth-like fiber material 16.

  Since the plurality of minute protrusions 13 press the cloth-like fiber material 16 in such a manner that the minute protrusions 13 enter the gaps between the weaves of the cloth-like fiber material 16, the work 15 resonates and is formed between the work 15 and the cloth-like fiber material 16. Even if the substantial friction coefficient changes from the static friction coefficient to the dynamic friction coefficient, there is no problem that the cloth-like fiber material 16 starts to slip carelessly with respect to the workpiece 15.

  Further, since the minute protrusion 13 enters the gap of the weave of the cloth-like fiber material 16 and comes into contact with the surface of the work 15 so as to sew the gap of the fiber material, the tip surface of the ultrasonic processing horn 3 is attached to the minute protrusion 13. Excessive frictional heat is not generated between the heating processing portion 5 to be formed and the cloth-like fiber material 16, and the mechanical and chemical characteristics of the cloth-like fiber material 16 are caused by overheating of the cloth-like fiber material 16. Problems such as deterioration are also prevented.

  On the other hand, since the tips of the minute protrusions 13 are in direct contact with the surface of the work 15 without being obstructed by the cloth-like fiber material 16, the frictional heat generated between the minute protrusions 13 and the surface of the work 15 is surely secured. In addition, the surface of the workpiece 15 can be melted.

  In this way, the ultrasonic handpiece 1 is operated to melt the workpiece 15, and the cloth-like fiber material 16 is pushed into the workpiece 15 at the tip of the ultrasonic processing horn 3 as shown in FIG. 3. And then embed.

  In this process, the portion of the work 15 around the tearing portion 17 is melted, and the left and right work portions sandwiching the tearing portion 17 are melted together.

  Further, although depending on the interval between the weaves of the cloth-like fiber material 16, the thermoplastic resin melted on the surface of the work 15 is relatively formed between the heating processing unit 5 located at the tip of the ultrasonic processing horn 3 and the work 15. The cloth-like fiber material 16 is pressed against the non-melting portion located at a deep position, and the cloth-like fiber material 16 exudes to the front side of the cloth-like fiber material 16 so as to sew the gap of the texture of the cloth-like fiber material 16 by this pressure. 15 is surely taken into the interior.

  What can be embedded by pressing the ultrasonic processing horn 3 once is an area portion that is equal to or slightly larger than the area of the heating processing portion 5 that forms the tip surface of the ultrasonic processing horn 3. In order to embed the entire cloth-like fiber material 16 in the work 15, it is necessary to repeatedly perform the same pressing operation as described above while shifting the tip position of the ultrasonic processing horn 3.

  Finally, when the above-described pressing operation is performed on the entire region of the cloth-like fiber material 16, the embedding operation of the cloth-like fiber material 16 is finished, but ultrasonic processing is performed in a state where the workpiece 15 is melted. As a result of the operation of causing the tip of the horn 3 to enter the surface of the work 15 is repeated for each part on the work 15, a large number of irregularities 18 as shown in FIG. 4 are formed on the surface of the work 15, for example. .

  Therefore, in order to remove the irregularities 18, first, the attitude of the ultrasonic machining horn 3 is changed as shown in FIG. 4, and the tapered surface 8 of the finishing machining portion 7 on the side where the stepped step difference 10 is formed is formed. Ultrasonic machining while making the surface substantially parallel to the surface of the work 15, pressing the tapered surface 8 against the uneven portion 18 on the surface of the work 15 and rubbing the surface of the work 15 with a stepped step difference 10. The horn 3 is moved along the surface of the workpiece 15.

The step-like step difference 10 vibrates at a high frequency along the longitudinal direction of the ultrasonic processing horn 3, and the tapered surface 8 forming the step-like step difference 10 is substantially on the surface of the workpiece 15. Since the ultrasonic machining horn 3 is moved by rubbing the surface of the work 15 with the taper surface 8, the tip of the convex portion on the work 15 has a step-like step difference 10. The edge portion 12 is continuously cut.
At this time, the relationship between the convex portion on the workpiece 15 and the edge portion 12 is equivalent to the relationship between the object to be cut and the flat file in normal metalworking, and the convex portion on the workpiece 15 is subjected to frictional heat accompanying ultrasonic vibration. In this case, the edge portion 12 is cut by the same principle of operation as that of cutting using a file. Since the uneven portion 18 on the workpiece 15, particularly the convex portion raised from the surface, is deteriorated and made brittle by heating when the cloth-like fiber material 16 is embedded, the tapered surface 8 becomes uneven on the surface of the workpiece 15. It can be cut off very easily by a simple operation of pressing against the portion 18 and rubbing the surface of the workpiece with the stepped difference 10.

Then, when the surface of the workpiece 15 becomes substantially flat, the attitude of the ultrasonic processing horn 3 is changed as shown in FIG. The taper surface 9 of the finishing processing portion 7 on the side on which the flat surface 11 is formed is made substantially parallel to the surface of the work 15 so that the uneven surface of the work 15 is pressed by the flat surface 11. Level 15 surfaces flat.
At this time, the surface of the work 15 and the flat surface 11 oscillating ultrasonically rub against each other to generate frictional heat, and the surface of the work 15 is melted in a surface layer by this frictional heat, thereby removing minute irregularities on the work 15. However, the flat surface 11 of the finishing processing unit 7 vibrates in a direction substantially along the surface of the workpiece 15, and the heating processing unit 5 is pressed against the surface of the workpiece 15 from the normal direction. Since no strong vibration is applied as in the case of the above, the amount of heat generated on the work 15 is moderately limited, and excessive melting of the work 15 is prevented.

  When the surface of the work 15 is leveled by pressing the irregularities on the flat surface 11, a small amount of resin melted on the surface layer of the work 15 is pushed aside from the surface of the work 15 and the contact surface of the flat surface 11. In some cases, the tool mark 19 as shown in FIG.

  In such a case, as shown in FIG. 6, the ultrasonic processing horn 3 is slightly stood up, and the surface of the work 15 is lightly rubbed with the curved surface 14 at the tip of the flat surface 11. By moving the processing horn 3, the swell of the outer periphery of the tool mark 19 is melted to scrape excess molten resin with the curved surface 14, and at the same time, on the workpiece 15 encountered in the moving process of the ultrasonic processing horn 3. By absorbing the excess molten resin in the relative concave portions, it is possible to remove the minute irregularities.

  When slight streaks are formed on both sides of the moving path of the ultrasonic processing horn 3 when the mark tool 19 is removed, the curved surface 14 between the heating processing portion 5 and the flat surface 11 is necessary. This means that the surface is pressed against the surface of the work 15 with a stronger force. Therefore, it is preferable to move the ultrasonic processing horn 3 so as to slide on the work 15 with the force removed.

  As described above, the ultrasonic processing horn 3 of this embodiment includes the heating processing portion 5 for melting the surface of the work 15 and embedding the cloth-like fiber material 16, and the step used for rough cutting of the convex portion. The taper surface 8 formed with the step difference 10 and the taper surface 9 formed with the flat surface 11 for finishing are integrally provided, and these portions are sequentially used to embed the cloth-like fiber material 16 to the workpiece 15. It is possible to carry out a series of work processes up to the shaping of the surface of the machine, so it is not necessary to continue the work by changing rotating tools such as a ruter and a mini-tutter or a file for roughing, and the time required for substantial work It is possible to greatly reduce the setup time required for the preparation of tools and tools and the time required for clean-up.

  As described above, as an example, the case where the thermoplastic resin workpiece 15 that has been torn by embedding the fabric fiber material 16 in the workpiece 15 is repaired and reinforced is described. You may make it embed | buy in the workpiece | work 15, and also in this case, it is possible to utilize this horn 3 for ultrasonic processing.

It is the perspective view which simplified and showed about an example of the ultrasonic handpiece which equipped with the horn for ultrasonic processing of one Embodiment to which this invention was applied. FIG. 2A is a plan view, FIG. 2B is a side view, and FIG. 2C is a microscopic view of a heating processing portion at the tip of the ultrasonic processing horn. FIG. 2D is a conceptual diagram showing the arrangement of the projections, FIG. 2D is an enlarged view of the heating processing portion at the tip of the ultrasonic processing horn, and FIG. 2E is the ultrasonic processing horn. It is the partial side view which expanded and showed the front-end | tip part. It is the figure which simplified and showed about the example of the mounting condition of the cloth-like fiber material with respect to a workpiece | work, and the embedding work of a cloth-like fiber material. It is the figure which simplified and showed about the cutting operation of the uneven | corrugated | grooved part formed with the embedding operation | work of a cloth-like fiber material. It is the figure which simplified and showed about the operation | work for planarizing the fine uneven | corrugated part which was not able to be removed by cutting operation. It is the figure which simplified and showed about the planarization operation | work using the smooth curved surface between the process part for heating, and a flat surface.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Ultrasonic handpiece 2 Handpiece main body 3 Ultrasonic processing horn 4 Controller 5 Heating processing part 6 Hand switch 7 Finishing processing part 8, 9 Taper surface 10 Step-like step difference 11 Flat surface 12 Edge portion 13 Small protrusion 14 Smooth curved surface 15 Work piece 16 Cloth-like fiber material 17 Rupture point 18 Concavity and convexity 19 Tool mark

Claims (3)

A horn for ultrasonic processing that is attached to an ultrasonic handpiece used when a fiber material is embedded in a workpiece made of a thermoplastic resin to shape the surface of the workpiece,
A heating processing portion formed at the tip, and a wedge-shaped finishing processing portion having two surfaces that are in communication with the heating processing portion and gradually increase the separation distance toward the base side,
A plurality of minute protrusions are formed on the heating processing portion, and a step-like step difference is continuously formed on one surface of the wedge-shaped finishing processing portion. A horn for ultrasonic processing, characterized in that a flat surface is formed on one surface.   2. The ultrasonic processing horn according to claim 1, wherein the stepped step difference is formed side by side in the longitudinal direction of the horn.   The ultrasonic processing horn according to claim 1 or 2, wherein flat surfaces of the heating processing section and the finishing processing section are connected by a smooth curved surface.

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