JP3295061B2 - Surface processing method and surface processing apparatus for ALC panel - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a surface processing method and a surface processing apparatus for an ALC (lightweight cellular concrete) panel.

[0002]

2. Description of the Related Art Conventionally, in order to enhance the design of an ALC panel, it has been widely practiced to cut a linear groove on the panel surface. The cutting method uses a rotary cutting blade that is driven to rotate around an axis perpendicular to the panel surface, and moves the rotary cutting blade or the ALC panel relatively toward the panel surface. Is applied to a predetermined depth of the panel surface from the edge of the ALC panel. However, the design with this straight groove was simple and had little change.

Therefore, as one of means for further improving the design, it is conceivable to apply a design with a stone-like cracking surface, which is widely used for concrete panels and sizing boards, to ALC panels. That is, after forming a linear groove in the ALC panel, for example,
JP-A No. 3514 discloses a technique of "breaking a ridge by colliding a crushing blade with a ridge arranged in a concrete block", and a technique described in JP-A-49-63214. By applying the technique of crushing all or part of the ridges of the concrete block in which the ridges and grooves are alternately arranged by banging a blade there, and breaking the ridges between the grooves, Since the ALC panel is easier to crush than the concrete panel, it is possible to easily form a stone-like cracking surface.

[0004]

However, the method of breaking the ridge after forming the groove as described above has the following problems. If grooves are not formed on the panel surface of the ALC panel in advance, a split skin surface cannot be formed. As described above, the groove is formed by a cutting method using a rotary cutting blade. Two devices, a device for forming a groove and a device for forming a split skin surface, are required, and initial costs and running costs are high, which is not economical. When the number of devices is two, adjustment of each device is required, and productivity is not good. Since a physical impact is applied to the ridge of the ALC panel, which is brittle in terms of strength, cracks occur in the direction from the bottom or side surface of the groove toward the inside of the panel. There is a concern about the occurrence of local physical defects that can lead to such defects.

[0005] An object of the present invention is to solve the above-mentioned problems and to provide an AL
An object of the present invention is to provide a surface processing method and a surface processing apparatus for an ALC panel capable of efficiently forming a band-shaped design concave portion on a panel surface portion of a C panel without generating a physical defect. It is an object of the present invention to provide the most efficient method and apparatus in which a design concave portion including a skin groove portion and a split skin concave portion can be simultaneously formed by a single device.

[0006]

A method of processing a surface of an ALC panel according to the present invention is a non-rotationally driven type surface processing tool (excluding a free-rotation type), which is provided with a cut surface groove as a design concave portion to be formed. It has a substantially U-shaped front shape substantially equal to the cross-sectional shape, and a concave arc-shaped groove bottom cut connecting between a pair of groove inner cutting blades extending obliquely rearward from the upper end to the lower end and the lower end of the groove inner cutting blade. The surface processing tool or the ALC panel is extended in a direction parallel to the panel surface in a band shape to be formed in a state where the surface processing tool having the blade is cut into a predetermined depth of the panel surface of the ALC panel. By relatively moving the cut skin groove in the extending direction, a cut skin groove extending in a band shape is formed on the panel surface.

In the same method, a preceding groove can be formed at a position where the design concave portion is to be formed. Although the preceding groove cutting tool is not particularly limited, a disk-shaped rotary blade can be exemplified.

A surface processing apparatus for an ALC panel according to the present invention is a surface processing apparatus for forming a cutout groove as a design recess extending in a band shape on the panel surface of the ALC panel.
A pair of non-rotation-driven surface processing tools (excluding free-rotation type), each having a substantially U-shaped front shape substantially equal to the cross-sectional shape of the cut skin groove to be formed, and a pair of diagonally rearwardly extending from the upper end to the lower end. A surface processing tool having a groove inner cutting edge and a concave arc-shaped groove bottom cutting edge connecting between lower ends of the groove inner cutting edge, and causing the surface processing tool to bite into a predetermined depth of a panel surface portion. And a mechanism for relatively moving the surface processing tool or the ALC panel in the direction parallel to the panel surface and in the extending direction of the band-shaped cut skin groove to be formed.

In the apparatus, a leading groove cutting tool for forming a leading groove at a position where the design concave portion is to be formed may be provided. Although the preceding groove cutting tool is not particularly limited, a disk-shaped rotary blade can be exemplified.

[0010] The surface processing tool is preferably cut into a predetermined depth of the panel surface from the small face of the ALC panel, but may be cut into a predetermined depth of the panel surface from the surface of the ALC panel. .

The following (1), (2), and (3) can be exemplified as the design recesses extending in a belt shape. In addition, the mode of “extending in a belt shape” may be linear or curved,
The above extension is preferable in terms of processing efficiency and design.

(1) Combination of a cut skin groove and a cut skin recess formed on one side or both sides of the cut skin groove A "cut skin groove" refers to a groove which shows a smooth cut skin without unevenness and roughness. The “split skin concave portion” refers to a concave portion showing a cracked stone-like split skin with uneven roughness. The surface processing tool used in this case is not particularly limited, and a cutting blade having a front shape substantially equal to the widthwise shape of the bottom surface of the cut skin groove to be formed,
An ALC base material having a rake surface for applying a scooping force and a side portion of a tool side portion forming an edge of a bottom surface of the cut skin groove portion can be exemplified. The rake face may be provided straight in the width direction, but is preferably provided so as to be obliquely lowered from the center in the width direction to both left and right sides. Further, it is preferable that the surface machining tool is provided with a lifting portion higher than the rake face at a middle or at an end of the rake face. It is preferable that at least the forefront portion of the lifting portion has a sharp ridge line. When the cut skin groove is formed by the inner surface of the cut skin and the bottom surface of the cut skin, the side part may be a surface having a height.
In the case where the cut skin groove portion is substantially formed of only the bottom surface of the cut skin without the inner side surface of the cut skin, it is preferable that the side portion has substantially no height. In this specification, only the bottom surface of the cut skin which has no inner surface of the cut skin and thus follows the split skin concave portion is included in the category of the "cut skin groove portion". The shapes of the cutting blade, the rake face and the side portion are not particularly limited, and examples include those having a substantially beak shape.

(2) Cut Surface Groove The surface machining tool used in this case is not particularly limited, and examples thereof include a tool provided with a cutting blade having a front shape substantially equal to the cross-sectional shape of the cut surface groove to be formed. Although the front shape of the cutting blade is not particularly limited, a substantially U-shaped shape, a substantially U-shaped shape, or a substantially V-shaped shape can be exemplified. However, a shape in which the width decreases toward the bottom of the cut skin groove is preferable. It is preferable that the upper end of the cutting blade is protruded above the panel surface when the surface processing tool is cut into a predetermined depth of the panel surface. This is because the panel surface at the upper edge of the cut skin groove is not easily chipped. Preferably, the surface working tool has a rake face following the cutting edge.

(3) Crevice skin concave surface The surface machining tool used in this case is not particularly limited, but a cutting blade having a sharply pointed tip so as not to form a cut skin groove portion, and a scooping force applied to the ALC base material. One having a rake face to be operated can be exemplified. The side part forming the edge of the bottom surface of the cut skin groove part as in the above (1) is not provided.

The processing speed (feed speed of the surface processing tool) in the present invention is not particularly limited,
It is preferably 5.0 m / min, more preferably 0.8 to 3.0 m / min. If it is less than 0.6 m / min, it is not efficient in production, and if it exceeds 5.0 m / min, the energy efficiency is significantly reduced.

It is preferable that the relative movement direction of the surface processing tool or the ALC panel is opposite to the foaming direction at the time of manufacturing the ALC panel. This is because the cracked concave portions are not affected by the roughness of the bubbles in the ALC panel and are not excessively cracked. Generally, in the ALC panel, as the foaming proceeds, the bubbles tend to be coarser in the upper part of the slurry.

[0017]

DESCRIPTION OF THE PREFERRED EMBODIMENTS First Embodiment First, FIGS. 1 to 12 show a first embodiment. ALC of this embodiment
Panel surface processing device, as shown in FIGS.
It comprises a base 10, a tool moving device 20, a preceding grooving tool 30, and a non-rotationally driven surface processing tool 40, 50, 60. Each of these mechanisms will be described in turn. Although the surface processing apparatus in the illustrated example is a small-sized and simple apparatus for simplification of illustration and description, it is needless to say that the configuration can be changed to a large-scale configuration suitable for mass production. Modification examples will be described later.

The base 10 comprises legs 11 and a table 12, on which an ALC panel 1 is placed horizontally with its panel surface 2 facing upward. The table 12 has a panel edge 3 of the ALC panel 1.
Is provided, and a clamper (not shown) for clamping the ALC panel 1 in a state where the ALC panel 1 is in contact with the ruler 13 is provided.

The tool moving mechanism 20 includes a bridge 21 provided on the base 2, a horizontally extending guide bar 22 provided on the bridge 21, and a slider 23 mounted on the guide bar 22.
A movable platen 24 slidably mounted via
And a drive mechanism for the movable platen 24. The movable platen 24 includes a support portion 24a for a leading groove cutting blade on a front end side (right end side in FIG. 2), and a support portion 2 for a surface processing blade on a rear end side (left end side in FIG. 2).
4b. The drive mechanism of the movable platen 24 includes a screw screw 25 rotatably supported in the bridge 21, a female screw member 26 attached to the movable platen 24 and screwed to the screw screw 25, and a motor 27 for rotating the screw screw 25. Become.

The leading groove cutting tool 30 comprises a leading groove cutting blade 31 and a fixture 32 for rotatably mounting the leading groove cutting blade 31. The leading groove cutting blade 31 is a disk-shaped member provided with a cutting edge having an outer peripheral edge that is sharp in a V-shaped cross section.
00 mm. The mounting member 32 is attached to the support portion 24a so as to be vertically adjustable by a screw 34 passing through a long hole 33, so that the depth of the preceding groove cutting blade 31 to the panel surface described later can be adjusted by the vertical position adjustment. It has become.

Non-rotationally driven surface processing tools 40, 50,
As 60 and 70, the following first to fourth examples were implemented. Each of the surface processing tools 40, 50, 60, 70
The supported portion 43 fixed to the upper surfaces of the shank 42, 52, 62, 72 is exchangeably attached to the support portion 24a by a screw.

(I) A surface processing tool 40 of the first embodiment for simultaneously forming a cut skin groove portion and a split skin concave portion on the panel surface at the center of the panel. Surface processing of the first embodiment shown in FIGS. 2 and 3. The tool 40
A blade portion 41 at the tip, a shank 42 supporting the blade portion 41,
And a supported portion 43 fixed to the upper surface of the shank 42. The blade part 41 and the shank 42 in the illustrated example have a height of about 25 m.
Although it is integrally formed from a square bar-shaped tool steel material having an arbitrary length of about 9 mm and a width of about 9 mm, it may be mechanically fixed or brazed. The shank 42 remains the same size as the tool steel, and the blade 41 uses the tool steel
It is processed to have.

A cutting edge A having a blade width of about 9 mm, which forms a substantially arc shape at the front end and the lower end of the tool steel material. The front shape of the cutting edge A is made substantially equal to the widthwise shape of the bottom surface of the cutting groove 4 to be formed. In this case, since the flat cutting groove 4 is formed, the front shape of the cutting blade A is linear. The inclination angle β from the cutting edge A is about 10 degrees (rake angle is about 80 degrees).
Rake surface B diagonally rearward and upward at (degree) The rake surface B may be straight in the blade width direction, but in the present embodiment, it is obliquely lowered from the center in the width direction to the left and right sides. Lifting section C provided at a position in the middle of the rake face B at a central portion in the width direction and higher than the rake face B (in the present embodiment, obliquely rearward and upward at a lifting angle γ larger than the inclination angle β). About 2.5 from the center of blade A to the back
from the point of 1 mm to the point of about 5 mm rearward, a tool with a front end C1 of a triangular cross section (sharp ridge) with a lifting angle γ of about 15 degrees and an obliquely upward direction and a tool from the rear end point of the frontmost part C1 Remaining portion C2 of a trapezoidal cross section (a narrow ridge line) heading obliquely rearward and upward while the lifting angle γ gradually increases from about 15 degrees to about 40 degrees to the upper surface of the steel material.
Consists of The intersection line between the lower end of the lifting portion C and the rake face B forms an opening angle δ rearward as viewed from the plane. Side portions D on the left and right sides of the tool starting from the rear end of the cutting edge A The tip side of the side portion D is in a sharp state (having almost no height) continuously to the cutting edge A, but wraps around to the rear side. The surface gradually becomes higher (for example, up to about 2 mm) to form a surface. This surface may be a vertical surface, but in the illustrated example, it is an inclined surface slightly inclined inward from the lower end toward both sides of the rake surface B thereabove. Approximately 25m behind cutting edge A on the lower surface of tool steel
E escape recess E cut about 1.5 mm upward from the position of m to the whole area behind.

(II) The surface processing tool 50 of the second embodiment for simultaneously forming the cut skin groove and the split skin concave portion on the panel surface at the panel edge is a surface processing tool 50 of the second embodiment shown in FIG. A shank 52 for supporting the blade portion 51, and a supported portion fixed to the upper surface of the shank 52 (not shown as in the first embodiment). The blade portion 51 and the shank 52 in the illustrated example are formed integrally from a square rod-shaped tool steel material having a height of about 8 mm, a width of about 8 mm, and an arbitrary length.
It may be mechanically fixed or brazed.
The shank 52 remains the size of the tool steel, and the blade 5
No. 1 is obtained by processing a tool steel material to include the following elements.

The first cutting edge H having a cutting width of about 3.5 mm provided at the tip and the lower end of the tool steel material in the width direction outside (the right side in FIG. 10) has an inclination angle η of about 15 degrees (rake) from the first cutting edge H. Angle about 7
5 °) at the first rake face I going diagonally backward and upward From the end of the first rake face I, the first lifting section J going diagonally backward and upward at a lifting angle θ of about 70 degrees, This is a slope that ends at about 5 mm behind the end of the cutting edge H and passes through the upper surface of the tool steel material. At the lower end on the inner side in the width direction of the tool steel material (the left side in FIG. 10), the second cutting edge K is inclined obliquely rearward from the inner end of the first cutting edge H at an angle of about 57 degrees with the second cutting edge K. κ is about 15 degrees (rake angle is about 7
5 °) and a second rake face L that goes diagonally rearward and upward. From the end of the second rake face L, a second lifting part M that goes diagonally rearward and upward with a lifting angle λ of about 70 degrees, This is a slope that ends at about 17 mm behind the upper edge of the upper edge of the lifting portion J and passes through the upper surface of the tool steel material. Side part N of the tool inner part starting from the rear end of the second cutting edge K The tip side of the side part N is in a sharp state (having almost no height) continuously to the second cutting edge K, The surface gradually increases toward the side to form a surface. This plane is a vertical plane.

(III) A surface processing tool 6 according to the third embodiment for forming a cut groove on the panel surface at the center of the panel.
The surface machining tool 60 of the third embodiment shown in FIG. 14 includes a blade portion 61 at the tip, a shank 62 supporting the blade portion 61, and a supported portion fixed to the upper surface of the shank 62 (the portion of the first embodiment). (Not shown). Although the blade 61 and the shank 62 in the illustrated example are mechanically fixed, they may be brazed or integrally formed. The blade portion 61 is formed by processing a horizontal portion of an L-shaped tool steel material having a height of about 7 mm and a width of about 18 mm to include the following elements.

[0027] At both ends in the width direction of the tool steel material, a pair of groove inner cutting blades P diagonally rearward at a cutting edge angle π of about 40 degrees from the upper end to the lower end, and an inclination angle ρ from each groove inner cutting edge P is about 10 degrees. A pair of rake faces Q diagonally rearward and inward at a rake angle of about 80 degrees. For a groove bottom with a blade width of about 11 mm, forming a concave arc so as to connect between the lower ends of the groove inner cutting edges P at the lower end of the tool steel material. Cutting edge R A rake face S inclined obliquely rearward and upward from the groove bottom cutting edge R at an inclination angle σ of about 20 degrees (rake angle of about 70 degrees).

The front shape formed by the pair of groove inner cutting edges P and the groove bottom cutting edges R is substantially equal to the cross-sectional shape of the cut surface groove portion 4 to be formed. 4, the front shapes of the cutting blades P and R are widened upward and rectangular.

(IV) Surface Processing Tool 70 of Fourth Embodiment for Forming Split Surface Depressions in Panel Surface at Center of Panel The surface processing tool 70 of the fourth embodiment shown in FIG. A shank 72 for supporting the blade portion 71 and a supported portion fixed to the upper surface of the shank 72 (the same as in the first embodiment, not shown). The blade portion 71 and the shank 72 in the illustrated example are integrally formed from a square bar-shaped tool steel material having a height of about 18 mm, a width of about 10 mm, and an arbitrary length, but may be either mechanically fixed or brazed. Good. The blade portion 71 is formed by processing a tool steel material so as to include the following elements.

The cutting edge T whose tip is narrow and narrow so as not to form a cutting skin groove portion has an inclination angle τ of about 20 degrees (rake angle of about 70) from the cutting edge T.
Rake surface U diagonally rearward and upward at (degree) The rake surface U is straight in the blade width direction, but may be obliquely lowered from the center in the width direction to the left and right sides as in the first embodiment. A lifting portion V provided at a position higher than the rake surface U in the width direction central portion in the middle of the rake surface U (in the present embodiment, diagonally rearward and upward at a lifting angle よ り 大 き い larger than the inclination angle τ). About 5m behind the center of T
Starting from point m, the lifting angle υ was set to about 30 degrees. A flank W extending obliquely rearward and upward from the cutting edge A at a clearance angle of about 10 degrees. The left and right sides of the tool only pass through the space after the formation of the split skin concave portion, and the cut skin groove portion as in the first embodiment. It does not work as a side part that forms the edge of the bottom surface of.

Now, a method of forming a band-shaped design concave portion on the panel surface of the ALC panel 1 using the surface processing apparatus configured as described above will be described in the order of steps.

(0) Setting of ALC Panel FIG. 1 shows an initial state.
The LC panel 1 is placed horizontally with its panel surface 2 facing upward, the ALC panel 1 is positioned against a ruler 13 and clamped by a clamper. At this time, the preceding groove cutting tool 30 and the surface processing tool 40 are retracted behind the ALC panel 1. Next, as described below, (1) a cut skin groove portion and a split skin concave portion are simultaneously formed in the panel surface portion at the center portion of the panel, and (2) a cut skin groove portion and the split skin concave portion are formed on the panel surface portion of the panel edge portion. Are simultaneously formed. (1) (2)
May be performed first or may be performed alternately. Alternatively, instead of (1) and (2), (3) a cutout groove is formed in the panel surface at the panel center and panel edges. In addition, instead of (1) and (2), (4) a split skin recess is formed in the panel surface at the center of the panel. The processing speed (feed speed of the surface processing tool) is not particularly limited,
For example, it was 1.2 m / min.

(1) Step of Simultaneously Forming a Cut-Skin Groove and a Split-Skin Concavity on the Panel Surface at the Center of the Panel The surface processing tool 40 of the first embodiment is used, but the preceding groove-cutting tool 30 is used. And the case where it is not used (that is, the case where the preceding groove is not preformed at the position where the cut skin groove portion is to be formed), so both cases will be described separately.

(1-1) When the preceding groove is not preformed First, the case where the preceding groove is not preformed will be described.
To do so, the leading groove cutting blade 31 is raised to a height that does not touch the panel surface portion 2 or the leading groove cutting tool 30
So that it does not act on the panel surface.

When the movable platen 24 is advanced by the drive mechanism and moved in a direction parallel to the panel surface, the movable platen 24 is moved as shown in FIG.
As shown in (a2), the cutting edge A of the blade portion 41 of the surface processing tool 40 is moved from the small edge 3 of the ALC panel 1 to the panel surface portion 2.
And cuts the bottom surface 4a of the cut skin of the cut skin groove portion 4 and forms the inner side surface 4b of the cut skin of the cut skin groove portion 4 by the side portion D crushing the ALC base material. . The depth of this bite is not particularly limited,
For example, it was 8 mm. Although the width of the bottom surface 4a is not particularly limited, when the surface processing tool 40 of the first embodiment is used, the width is about 9%.
mm. The height of the inner side surface 4b is determined by the surface height of the side portion D, and is not particularly limited.
Is gradually increased from 0 to about 2 mm, so that the height of the inner side surface 4b is 0.5 to 2 mm. By this biting, the rake face B is moved to the ALC base material 5 on it.
, A scooping force Fb acts.

As shown in FIGS. 4 (b1) and 4 (b2), when the forefront portion C1 and the remaining portion C2 of the lifting portion C higher than the rake face B bite into the panel surface portion 2 in order, the lifting force Fc is applied to the ALC base material 5. Begins to act, and the lifting force Fc eventually becomes dominant over the rake lifting force Fb. Then, when the lifting force Fc exceeds the tensile strength of the ALC base material 5, the ALC base material which is formed in a substantially elliptical shape (its size and shape vary) around the cutting edge A when viewed from a plane. Cracks 6 are formed on the shear surface 5. Also at this time, the formation of the cut skin groove 4 is in progress.

As shown in FIGS. 4 (c1) and 4 (c2), when the lifting portion C further penetrates, the ALC base material 5 separated into a substantially elliptical planar shape by the crack 6 is lifted as a crushed piece 7 and the panel surface The part 2 has a split skin recess 8 formed therein. Further, the cutting blade A, the rake face B and the lifting part C
Repeats the formation of the next cut skin concave portion in the same manner as described above, while forming the cut skin groove portion 4 continuously. In addition, since the escape concave portion E is provided on the lower surface of the blade portion 41, the contact surface between the lower surface and the bottom surface of the cut skin groove portion 4 is small, and the friction is small.
Processing efficiency is improved.

By repeating the above operation, as shown in FIG. 5, the cut skin groove 4 and the split skin recess 8 can be formed simultaneously on the panel surface 2 at the center of the ALC panel 1. Further, in the surface machining tool 40 of the first embodiment, the rake face B of the blade portion 41 is obliquely lowered from the center to both left and right sides, so that the scooping force Fa is dispersed right and left, and the center portion in the blade width direction is formed. Lifting section C higher than rake face B
Is provided, by applying a lifting force Fc suddenly when the lifting portion C is applied from the rake face B, the split skin concave portion 8 can be efficiently formed (
Either one has this effect). Further, since the foremost portion C1 of the lifting portion C has a triangular cross section with a sharp ridge, the formation of the crack 6 is facilitated. However,
In a part where the base material strength is low, the part is broken before a crack is formed. Further, the formed split skin concave portions 8 tend to have an upward R-shape, which is a preferable result in appearance.

Next, four modified examples in which the shape and dimensions of the surface processing tool 40 of the first embodiment were changed were created, and the cut-skin groove 4 and the split-skin recess 8 were simultaneously formed in the same manner as described above. Write the result.

Modification Example 1 shown in FIG. 6A This is an example in which the lengths of the rake face B and the lifting portion C are shortened, and the inclination angles of the rake face B that are lowered to the left and right sides are increased. According to the present example, the amount of cracking at one time was reduced, and the size of the cracked skin concave portion due to one crushed piece was reduced in both the crack length and the crack width. This is considered to be due to excessive dispersion of the scooping force and the lifting force in the left and right directions. Further, the formed cracked concave portions tend to have an upward R-shape, which is a preferable result in appearance. Also,
A cutting edge 4 on the lower surface of the shank 42 for finishing the bottom surface of the cut skin groove.
Because of the provision of 4, the bottom surface of the cut skin groove portion could be finished more finely.

Modification Example 2 shown in FIG. 6B This is an example in which the widths of the cutting edge A and the rake face B are reduced. According to this example, the variation in the amount of cracks at one time became large, and the width of cracks also changed greatly. Further, the formed cracked concave portions 8 tended to form a downward R shape.

Modification 3 shown in FIGS. 7 (a1) and 7 (a2) This is an example in which the lifting portion C of the surface processing tool 40 of the first embodiment is retracted to increase the inclination angle of the rake face B to the left and right sides. According to this example, the amount of a single crack was reduced, and both the crack length and the crack width were reduced. this is,
It is considered that the scooping force and the lifting force are excessively dispersed in both left and right directions. Further, the formed cracked concave portions tend to have an upward R-shape, which is a preferable result in appearance.

Modification 4 shown in FIGS. 7 (b 1) and 7 (b 2) This is an example in which the length of the rake face B and the lifting portion C are shortened, and the length of the rake face B is shortened to widen the opening angle δ. . According to this example, the amount of a single crack was reduced, and both the crack length and the crack width were reduced. This is considered to be due to excessive dispersion of the scooping force and the lifting force in the left and right directions. Further, the formed cracked concave portions tend to have an upward R-shape, which is a preferable result in appearance.

(1-2) Preceding Formation of Preceding Groove Next, a case of forming the preceding groove in advance at the position where the cut skin groove is to be formed will be described. For that purpose, the leading groove cutting blade 31
Is adjusted so as to bite into the panel surface 2 by a predetermined depth, so that the surface processing tool 40
To act on. The description of the parts common to the example of FIG. 4 in which the preceding groove is not formed is simplified.

When the movable platen 24 is advanced by the driving mechanism and moved in a direction parallel to the panel surface, as shown in FIG. 2, the leading groove cutting blade 31 hits the panel surface portion 2 and passively rotates. The leading groove 9 having a predetermined depth is formed by biting into the panel surface portion 2. The depth is not particularly limited, but is, for example, 5 mm. The opening width of the leading groove 9 is
Although not particularly limited, it is preferable that the opening width is smaller than the opening width of the cut skin groove portion.

Subsequently, as shown in FIGS. 8 (a1) and 8 (a2), the cutting edge A of the blade portion 41 of the surface processing tool 40 extends from the fore-edge surface 3 of the ALC panel 1 to a predetermined depth of the panel surface portion 2 (see FIG. 4, the bottom surface 4a of the cut skin groove 4 is started to be cut, and the side part D forms the inner side surface 4b of the cut skin groove 4, as in the example of FIG.
At the same time, a scooping force Fb acts on the ALC base material 5 as in the example of FIG.

As shown in FIGS. 8 (b1) and 8 (b2), when the lifting portion C bites into the panel surface 2, the lifting force F
c begins to act, and eventually the lifting force Fc becomes dominant over the rake lifting force Fb. And the lifting force Fc is A
At a point in time when the tensile strength of the LC base material 5 is exceeded, cracks 6 enter the sheared surface of the ALC base material 5 generated around the cutting edge A.
Then, as shown in FIGS. 8 (c1) and 8 (c2), when the lifting portion C further penetrates, the ALC base material 5 separated by the crack 6 is lifted as a crushed piece 7, and the panel surface portion 2 has a split skin concave portion. 8 are formed. At this time, since the leading groove 9 is formed in advance, compared to the example of FIG. 4 in which the leading groove 9 is not formed in advance, the split pieces 7 are formed separately on the left and right sides with the leading groove 9 as a boundary, and As shown in FIG. 9, the amount of a single crack was reduced, and both the crack length and the crack width were reduced, as shown in FIG. 9.

Further, the depth of the preceding groove 9 is 2 mm, 3 m
m, 4 mm, 5 mm, 6 mm, and 7 mm, and the same processing was performed. When the depth was 2 mm and 3 mm, the crack amount / crack length when the left and right split pieces 7 were added was determined.
The crack width was not much different from the example of FIG. 4 in which the preceding groove 9 was not formed in advance, but when the depth became 4 mm or more, the crack amount, crack length, and crack width gradually increased as the depth increased. For example, when the depth was 6 mm, the crack length and the crack width became about half that of the example of FIG.

From this, when the depth of the leading groove 9 is set to be at least 1/2 of the depth of the cut skin groove portion 4, it becomes possible to control the amount of cracks, the crack length and the crack width. It was found that the depth, crack length, crack width and crack width can be reduced as the depth increases. Considering the reason, if it is set to 1/2 or more, a crack is generated from the preceding groove 9 formed in advance by the scooping force Fb and the lifting force Fc given to the ALC base material 5 by the surface processing tool 40, It is considered that the fracture occurred earlier than in the case where the preceding groove 9 was not provided.

As an application described above, the depth, length and width of the crack can be determined by changing the depth of the preceding groove 9 while forming one incision groove 4 and split skin recess 8. Can be made different.

Further, by forming the leading groove 9 in advance, it is possible to eliminate the disadvantage that the groove bottom is excessively deeply cut off when forming the end portion of the cut skin groove portion 4.

(2) Step of Simultaneously Forming a Cut-Skin Groove and a Split-Skin Concavity on the Panel Surface at the Panel Edge The surface processing tool 50 of the second embodiment is used. The pre-groove cutting tool 30 is not used in principle (ie, the pre-groove is not pre-formed), but may be used (ie, the pre-groove is not used).
The leading groove may be preformed).

When the movable platen 24 is advanced by the driving mechanism and moved in a direction parallel to the panel surface, the movable platen 24 shown in FIG.
As shown in (a2), first, the blade portion 5 of the surface processing tool 50 is used.
The first first cutting edge H cuts into a predetermined depth (for example, 8 mm) of the panel surface portion 2 from the small face 3 of the ALC panel 1, and then the second cutting edge K cuts into the bottom surface 4 a of the cut skin groove portion 4. Start processing. Then, as shown in FIGS. 11 (b1) and (b2), when the second cutting edge K finishes biting and the side portion N starts to bite, the side portion N crushes the ALC base material to form the inside of the cut groove portion 4. The side surface 4b is formed.

When the first blade H digs in as described above, a scooping force Fi acts on the ALC base material 5 thereon from the first rake face I, and subsequently from the first lifting portion J to the ALC base material 5. A lifting force Fj acts.

As described above, when the second cutting edge K bites, first, the ALC base material 5 is moved from the second lifting portion M.
Then, a lifting force Fm starts to be applied obliquely upward and inward to the panel at a gentle inclination with respect to the horizontal direction, and then the ALC base material 5 is inclined obliquely upward from the second rake face L to the horizontal direction. And a scooping force Fl acting toward the inside of the panel acts. When the resultant force of the lifting force Fm and the scooping force Fl exceeds the tensile strength of the ALC base material 5, a substantially triangular or substantially semi-elliptical shape (size and shape) around the cutting edges H and K as viewed from a plane. A has a variation.)
Cracks 6 enter the sheared surface of LC base material 5.

As shown in FIGS. 11 (c1) and 11 (c2), when the rake faces I and L and the lifting portions J and M further penetrate, the ALC base material separated into a substantially triangular or substantially elliptical plane by the crack 6 is obtained. 5 is lifted as a crushed piece 7, and a split skin concave portion 8 is formed on the panel surface portion 2. Also, the cutting blades H and K, the rake faces I and L, and the lifting portions J and M
Repeats the formation of the next cut skin concave portion in the same manner as described above, while forming the cut skin groove portion 4 continuously.

By repeating the above operation, FIG.
As shown in (1), the cut skin groove 4 and the split skin recess 8 can be simultaneously formed on the panel surface 2 at the panel edge of the ALC panel 1. Although the cut skin groove 4 is open at one side because of the panel edge, such a cut skin groove 4 is also referred to as a “cut skin groove” in the present specification. Further, in the surface machining tool 50 of the second embodiment, when the second cutting edge K bites as described above, the operation timing from the second rake face L is delayed from the timing from the second lifting part M. The cracked concave portion 8 having a large crack amount, crack length and crack width can be efficiently formed. If the action timing of the second rake face L and the second lifting part M is simultaneous or the action of the second rake face L is earlier, the influence of the action force from the second rake face L increases, and the comparison is made. The split skin concave portion 8 is formed at an early stage, and the crack amount, crack length, and crack width tend to decrease.

The surface processing tool 40 of the first embodiment or its modified examples 1 to 4 can be used for the simultaneous formation of the cut skin groove and the split skin recess in the panel surface 2 at the panel edge. As a result of implementation, the split skin depression was formed relatively early because the vertical component of the acting force was large, and the split skin depression was smaller than in the second embodiment.

The above steps (1) and (2) are performed in the ALC panel 1
13 is repeated vertically and horizontally on the panel surface 2 of FIG.
The surface pattern shown in FIG. Then, the following effects can be obtained.

(A) Reduction of total processing time In the method of breaking the ridge after forming the groove as described in the related art and the problem thereof, the AL
Each step of C panel supply → groove processing → ALC panel dispensing is necessary, and ALC
Since each process of panel supply → cracking → dispensing of ALC panel is required, the total processing time is long. On the other hand, according to the present embodiment, each step of supplying the ALC panel → simultaneous formation of the cut skin groove and the split skin recess → dispensing the ALC panel is completed, so that the total processing time is reduced to about half or less. can do.

(A) Reduction of Equipment Cost and Operating Cost Since the cut surface groove portion and the split skin concave portion can be formed simultaneously with a single set of surface processing apparatus, the equipment cost (initial cost) is reduced. In addition, adjustment costs (running costs) can be reduced with a set of devices.

(C) Free change of the pitch between grooves As described above, the surface processing apparatus can be changed to a configuration suitable for mass production. For example, by arranging a plurality of the tool moving devices 20, the preceding groove cutting tool 30, and the surface processing tools 40 and 50 at predetermined intervals, a plurality of the cut skin groove portions 4 and the split skin concave portions 8 can be formed at the same time. . Further, if the interval is configured to be adjustable, the pitch between the grooves can be freely changed only by adjusting the interval. Particularly, the surface processing tools 40 and 50 can be configured to have a narrow width as described above, and a motor for rotational drive occupying a large space is not required. It is also possible to set the pitch between grooves considerably small. Even with the method of breaking the ridge after forming the groove as described in the section of the conventional technology and the problem, it is possible to arrange a plurality of grooving tools and split surface processing tools respectively, and adjust the spacing between them Although not impossible, it is difficult in terms of equipment costs, adjustment costs, and installation space. In addition, as described above, a rotary cutting blade is used to form the groove, and a rotation driving motor that occupies a large space is required. Therefore, when the pitch between the grooves is to be reduced, it cannot be coped with by adjusting the interval, and it is necessary to reciprocate one rotary cutting blade many times.

(D) Free change of crack amount, crack length, and crack width For example, a method of changing the bite amount of the leading groove cutting blade 31 for each blade to adjust the crack amount and the like, and a surface processing tool 40,5
By combining the method of adjusting the amount of bite and the amount of cracking while the processing is being performed at 0, it is possible to form a design with rich expressive power.

(E) No Physical Defect Occurrence In the conventional technique and the method of forming the groove as described in the section of the problem and then breaking the ridge, the side portion of the groove of the ALC panel which is brittle in terms of strength. Will give a physical impact to
In the present embodiment, since such a process is not performed, there is no occurrence of a physical defect associated with a decrease in durability of the panel surface portion and a decrease in panel strength.

(F) Applicability to Thin ALC Panels The thickness of thin ALC panels is usually 35 to 37 mm, but even when digging a cut surface groove on the panel surface, it is necessary to secure a fire resistant upper panel thickness of 30 mm or more. Therefore, the cut skin groove cannot be made too deep. For this reason, in the method of breaking the ridge after forming the groove as described in the section of the related art and the problem thereof, if the groove is shallow, the corner of the ridge is chipped, and the cracked surface having a large crack width. Cannot be formed. However, according to the processing method of the present embodiment,
Even if it is a thin ALC panel and the cut skin groove portion is shallow, it is possible to form a split skin concave portion having a large crack width.

(G) Simultaneous formation of the cut skin groove portion and the split skin concave portion can be progressed not only in a straight line but also in a curved line. (H) The leading groove cutting tool and the surface processing tool are inexpensive due to their simple structures. (G) The width of the cut skin groove can be freely changed by changing the blade width of the surface processing tool.

(3) Method for Forming Cut-Skin Grooves in Panel Surface at Center and Panel Edge Next, only cut-skin grooves are formed in the panel surface at the panel center and panel edges (cut skin). The method of forming no recess will be described. The method uses the surface processing tool 60 of the third embodiment. In principle, the leading groove cutting tool 30 is not used (ie, the leading groove is not preformed).
However, it may be used (that is, the preceding groove may be preformed).

When the movable platen 24 is advanced by the drive mechanism and moved in a direction parallel to the panel surface, the movable platen 24 is moved to the position shown in FIG.
As shown in (a2), the cutting edge P for the inside of the groove of the surface processing tool 60 cuts into the panel surface portion 2 from the fore-edge surface 3 of the ALC panel 1 and starts cutting the inner surface 4b of the cut surface groove portion 4. Subsequently, as shown in FIGS. 15 (b1) and (b2), the groove bottom cutting edge R is provided at a predetermined depth (for example, 8 m) of the panel surface portion 2.
m) to start forming the bottom surface 4a of the cut skin groove 4. In addition, when the upper end of the groove inner side cutting blade P is made to protrude above the panel surface, the panel surface portion at the upper edge of the cut skin groove portion 4 is not easily chipped.

From the rake face Q and the rake face S to A
When the scooping forces Fq and Fs act on the LC base material 5 and the scooping forces Fq and Fs exceed the tensile strength of the ALC base material 5, the ALC base material 5 generated slightly ahead of the groove bottom cutting edge R is used. Cracks 6 enter the shear plane. Both ends of the crack 6 stop at a pair of rake faces Q when viewed from a plane. FIG.
As shown in (c1) and (c2), when the rake faces Q and S further penetrate, the ALC base material 5 separated into a substantially quadrangular plane by the crack 6 is lifted as a crushed piece 7.

By repeating the above operation, FIG.
As shown in (1), the cut skin groove portion 4 can be formed in the panel surface portion 2 at the panel center portion and the panel edge portion of the ALC panel 1. According to this method, the same effect as the effect in the above (1) can be obtained for the cut skin groove portion 4.

(4) Method of Forming Split-Surface Depressions in Panel Surface at Center Panel Next, a method of forming only split-skin depressions in the panel center part of the panel (not forming cut-skin grooves) will be described. I do. The method uses the surface processing tool 70 of the fourth embodiment. The preceding groove cutting tool 30 may or may not be used as in (1) above. Since the operation and effect when used are the same as those in the above (1), only the case where it is not used will be described here.

When the movable platen 24 is advanced by the driving mechanism and moved in a direction parallel to the panel surface, the movable platen 24 shown in FIG.
As shown in (a2), the cutting edge T of the blade portion 71 of the surface processing tool 70 is shifted from the small edge 3 of the ALC panel 1 to the panel surface 2.
At a predetermined depth (for example, 8 mm as in the example of FIG. 4). By this bite, the rake face U moves from above to ALC
A scooping force Fu acts on the base material 5.

As shown in FIGS. 18 (b1) and 18 (b2), when the lifting portion V higher than the rake face U starts to bite into the panel surface portion 2, the lifting force Fv starts to act on the ALC base material 5, and eventually the scooping force Lifting force Fv becomes more dominant than Fu. And the lifting force Fv is ALC base material 5
When the tensile strength exceeds the tensile strength, a crack 6 is formed in the shearing surface of the ALC base material 5 which is formed in a substantially elliptical shape (its size and shape vary) around the cutting edge T when viewed from a plane.

As shown in FIGS. 18 (c1) and 18 (c2), when the lifting portion V further penetrates, the ALC base material 5 separated into a substantially elliptical planar shape by the crack 6 is lifted as a fragment 7 and the panel surface The part 2 has a split skin recess 8 formed therein.

Since the tip of the cutting edge T is narrow and sharp, and the flank W that starts immediately from the cutting edge T has a clearance angle φ, it does not rub against the ALC. The left and right side portions of the tool only pass through the space after the formation of the split skin concave portions 8 and do not function as side portions as in the first embodiment. For this reason, only the line with the sharpened tip of the cutting edge T appears at the center of the split skin concave portion 8, but no cut skin groove is formed.

By repeating the above operation, FIG.
As shown in (1), a split skin concave portion 8 can be formed in the panel surface portion 2 at the center of the panel of the ALC panel 1. According to this method, the same effect as the effect in the above (1) can be obtained for the split skin concave portion 8.

The present invention is not limited to the above-described embodiment, and may be embodied with appropriate modifications without departing from the spirit of the invention, for example, as described below.

By changing the shape of the rake face and lifting portion, the rake angle, the lifting angle, and the like of the surface processing tool, it is possible to change the shape, the amount of cracks, and the like of the formed split concave portion. Further, the crack direction (downward R / upward R) can also be changed. By changing the shape of the blade portion of the surface processing tool, it is possible to change the cross-sectional shape of the cut skin groove formed.
For example, the bottom surface of the blade is flattened as in the embodiment,
By forming an arc surface, a V-shaped surface, or the like, the bottom surface of the cut skin groove portion can be made flat, or an R surface, a V-shaped surface, or the like can be obtained. FIG. 20 shows the blade portion 41 of the surface processing tool 40 of the first embodiment.
5 is tapered, the rake face B is made to have a two-step inclined structure, and particularly the side part D is shown to be a sharp example having substantially no height. When processing is performed using the surface processing tool 40 of the fifth modification in the same manner as in the above (1), the split skin concave portion 8 is similarly formed, but the cut skin groove portion 4 is substantially formed on the inner surface of the cut skin. And only the bottom surface 4a of the cut skin is provided.

After the surface processing in the above embodiment,
By further processing the cut skin groove portion with a conventional rotary drive type cutter, the design property can be further enhanced. By providing each surface processing tool corresponding to the length direction and the width direction of the panel, all the processing can be performed at once. In the above embodiment, the tool is moved.
The ALC panel can be processed by moving it in a direction parallel to the panel surface. In the above-described embodiment, the movement of the tool is performed by the motor 27, but the tool may be moved by a mechanism using pneumatics and hydraulic pressure. Attach the leading groove cutting blade in front of multiple surface processing tools,
Change the bite amount of the leading groove cutting blade, respectively, and make a difference in the crack amount. The split skin concave portion may be formed only on one side of the cut skin groove portion in the panel surface at the center of the panel. As the blade portion of the surface processing tool used in this case, one having the blade portion of the first embodiment and the other side having the blade portion of the second embodiment or the third embodiment can be exemplified.

[0080]

As described above in detail, according to the present invention, A
It is possible to efficiently form the cut skin groove portion extending in a band shape on the panel surface portion of the LC panel without generating a physical defect.

[Brief description of the drawings]

FIG. 1 is a front view of an ALC panel surface processing apparatus according to an embodiment of the present invention.

FIG. 2 is a perspective view of a main part of the surface processing apparatus.

3A and 3B show a surface processing tool of the first embodiment in the surface processing apparatus, wherein FIG. 3A is a plan view, FIG. 3B is a side view, and FIG.
Is a front view, and (d) is a perspective view of a tip.

FIG. 4 shows the simultaneous formation of a cut skin groove portion and a split skin concave portion by the surface processing tool tool of the first embodiment in the order of progress, and (a1) (a
2) (a3) is a plan view, and (b1), (b2) and (b3) are side views.

FIG. 5 is a perspective view showing the ALC panel after processing of FIG. 4;

FIG. 6A is a perspective view illustrating a surface processing tool according to a first modification of the first embodiment, and FIG. 6B is a perspective view illustrating a surface processing tool according to a second modification.

FIGS. 7 (a1) and (a2) are perspective views showing a surface processing tool of Modification 3 of the first embodiment, and FIGS. 7 (b1) and (b2) are Modification 4;
It is a perspective view which shows the surface processing tool of FIG.

FIG. 8 shows the simultaneous formation of a cut skin groove portion and a split skin concave portion by the preceding groove cutting tool and the surface processing blade of the first embodiment in the order of progress;
(A1) (a2) (a3) is a plan view, (b1) (b2)
(B3) is a side view.

FIG. 9 is a perspective view showing the processed ALC panel of FIG. 8;

10A and 10B show a surface processing tool of a second embodiment in the surface processing apparatus, wherein FIG. 10A is a perspective view, FIG. 10B is a side view,
(C) is a sectional view taken along line cc of (b).

FIG. 11 shows the simultaneous formation of a cut skin groove portion and a split skin concave portion by the surface working tool tool of the second embodiment in the order of progress, and (a1)
(A2) (a3) is a plan view, (b1) (b2) (b3)
Is a side view.

FIG. 12 is a perspective view showing the ALC panel after processing of FIG. 11;

FIG. 13 is a plan view showing the ALC panel after processing of FIG. 4 or FIG. 8 and FIG. 12;

14A and 14B show a surface processing tool of a third embodiment in the surface processing apparatus, wherein FIG. 14A is a perspective view, FIG.
(C) is a front view, and (d) is a sectional view taken along line dd of (b).

FIGS. 15A and 15B show machining of the cut surface groove portion by the surface machining tool tool of the third embodiment in the order of progress, wherein (a1), (a2), and (a3) are plan views, and (b1), (b2), and (b3) are side views. is there.

FIG. 16 is a perspective view showing the ALC panel after the processing of FIG. 15;

FIG. 17 shows a surface processing tool of a fourth embodiment in the surface processing apparatus, wherein (a) is a plan view, (b) is a side view,
(C) is a front view.

FIGS. 18A and 18B show machining of the cut surface groove portion by the surface machining tool tool of the fourth embodiment in the order of progress, wherein (a1), (a2), and (a3) are plan views, and (b1), (b2), and (b3) are side views. is there.

FIG. 19 is a perspective view showing the ALC panel after processing of FIG. 18;

20A and 20B show a surface processing tool of Modification 5 of the first embodiment, where FIG. 20A is a plan view, FIG. 20B is a side view, FIG. 20C is a front view, and FIG. D line sectional view, (e) is (a)
FIG. 5 is a sectional view taken along line ee of FIG.

FIG. 21: AL after machining by the surface machining tool of Modification 5
It is a perspective view which shows C panel.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ALC panel 2 Panel surface part 3 Panel small face 4 Cut skin groove part 4a Bottom surface 4b Inner surface 5 ALC base material 6 Crack 7 Cracked piece 8 Split skin concave part 9 Leading groove 10 Base 11 Leg 12 Table 13 Ruler 20 Tool moving mechanism 30 Leading groove cutting tool 31 Leading groove cutting blade 40, 50, 60, 70 Surface processing tool A Cutting blade B Rake surface C Lifting part C1 Foremost part C2 Remaining part D Side part E Escape recess H First cutting edge I First rake face J First lifting part K Second cutting edge L Second rake face M Second lifting part N Side part P Groove inside cutting edge R Groove bottom cutting edge S Rake face T Cutting edge U Rake face V Lifting part W Flank

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-11-148198 (JP, A) JP-A-11-254417 (JP, A) JP-A-2000-301522 (JP, A) (JP, U) Japanese Utility Model Showa 60-154487 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) B28D 1/00 B28D 1/24 B28B 11/08

Claims (7)

(57) [Claims] 1. A non-rotationally driven surface processing tool (excluding a free-rotation type), which has a substantially U-shaped front shape substantially equal to the cross-sectional shape of a cut-skin groove as a design recess to be formed.
A surface processing tool including a pair of groove inner cutting blades extending diagonally rearward from the upper end to the lower end and a concave arc-shaped groove bottom cutting blade connecting between the lower ends of the groove inner cutting blades is provided on a panel surface of an ALC panel. By moving the surface processing tool or the ALC panel in a direction parallel to the panel surface and in the extending direction of the band-shaped incision groove to be formed in a state where the surface cutting tool or the ALC panel is cut into a predetermined depth of the portion. A method of processing a surface of an ALC panel, wherein a cutout groove extending in a band shape is formed on the panel surface. 2. The method for processing a surface of an ALC panel according to claim 1, wherein a preceding groove is formed in advance at a position where the cut skin groove is to be formed. 3. A non-rotationally driven surface processing tool (excluding a free-rotation type), comprising: a non-rotationally driven surface processing tool for forming a cut surface groove as a design recess extending in a band shape on a panel surface of an ALC panel. A concave arc shape connecting between a pair of groove inner cutting blades diagonally rearward from an upper end to a lower end and a lower end of the groove inner cutting blade having a substantially U-shaped front shape substantially equal to the cross-sectional shape of the cut skin groove portion to be cut. A surface processing tool having a groove bottom cutting edge, and the surface processing tool or the ALC panel in a direction parallel to the panel surface in a state where the surface processing tool is cut into a predetermined depth of the panel surface. A surface processing apparatus for an ALC panel, comprising: a mechanism for relatively moving, in the extending direction, a band-shaped cut skin groove portion to be formed. 4. The AL according to claim 3, further comprising: a leading groove cutting tool for forming a leading groove at a position where the cut skin groove is to be formed.
Surface processing equipment for C panel. 5. The surface processing method or surface processing of an ALC panel according to claim 1, wherein the surface processing tool cuts into a predetermined depth of a panel surface portion from a small surface of the ALC panel. apparatus. 6. The panel according to claim 1, wherein an upper end of the cutting blade is protruded above the panel surface when the surface processing tool is cut into a predetermined depth of the panel surface. A surface processing method or a surface processing apparatus for an ALC panel as described in the above. 7. The surface processing method or surface processing apparatus for an ALC panel according to claim 1, wherein the surface processing tool has a rake face following the cutting blade.