JP5005500B2 - Precision roll lathe - Google Patents

Description

  The present invention relates to a precision roll lathe, and more particularly to a precision roll lathe used for processing a roll die for extruding an optical product such as a lens sheet.

  A machine tool for processing a roll includes a roll lathe. A roll lathe is a lathe in which a tool post equipped with a diamond tool is installed on a carriage. The basic usage is to process the circumferential groove while rotating the roll on the headstock and feeding the carriage back and forth (X axis). When machining the axial groove on the roll, the axial groove can be created by feeding the carriage to the left-right direction (Z-axis) while indexing the roll on the headstock (C-axis).

  In recent years, with the advance of machine control technology, ultra-precision machining with a roll lathe has been realized. Recently, a mold used for molding an optical lens has been processed on a roll lathe. As a roll lathe for realizing such ultra-precision machining, the applicant has proposed a precision roll lathe described in Patent Documents 1 to 5.

  This precision roll lathe is equipped with a normal turret and a fly cutter spindle device on the tool swivel, so by using both properly, the roll can be continuously rotated to cut vertical grooves (grooves in the circumferential direction). Of course, it is possible to perform highly accurate processing on the lateral groove (groove in the axial direction) while indexing the roll with a fly cutter.

According to this precision roll lathe, it is possible to realize processing of an ultra-precision roll mold used for extrusion molding of a lenticular lens sheet, a cross lenticular lens sheet, a prism sheet and the like used for a backlight of a liquid crystal panel.
Japanese Patent Application No. 2006-130066 Japanese Patent Application No. 2006-135560 Japanese Patent Application No. 2006-156388 Japanese Patent Application No. 2006-165144 Japanese Patent Application No. 2006-166404

  In this type of roll lathe, ultra-precision machining of a roll mold has a problem that it takes a long time to complete the machining of one roll. Recently, as the size of liquid crystal panels has increased, the rolls have become larger. For example, a lens sheet roll mold having a length of 2 meters is sometimes processed.

  Processing a single groove itself does not take time. In the case of the roll described above, it takes about 1 minute to process one lateral groove in the axial direction. However, in the case of a roll mold for a lens sheet, since each of the grooves is fine, there is a great feature in that an enormous number of grooves must be processed as a whole. In the entire roll, if the number of lateral grooves is 30,000, it takes 30000 minutes, that is, 500 hours, 3 weeks, after processing all the lateral grooves in one roll without interruption.

  Therefore, an object of the present invention is to solve the problems of the prior art, realize a much faster microgroove processing than before, and significantly reduce the processing time per one. Is to provide a precision roll lathe.

  Another object of the present invention is to provide a precision roll lathe to which various functions are added to support roll processing with a remarkably wide range of ultra-precision processing to achieve higher accuracy.

  In order to achieve the above object, a precision roll lathe according to the present invention includes a bed and a spindle that is installed on the bed and has a spindle that rotates the roll while holding one end of the roll as a workpiece with a chuck. A table, a tailstock arranged on the bed opposite to the headstock, and rotatably supporting one end of the roll; and a saddle installed on the bed so as to be movable in the longitudinal direction of the roll A table installed on the saddle so as to be movable in a direction perpendicular to the longitudinal direction of the roll, a guide rail installed on the table and extending parallel to the longitudinal direction of the roll, and a floating state on the guide rail And an air slide device comprising an air slider that holds the diamond bite and a linear motor that drives the air slider. Is shall.

  The air slide device for precision roll lathe according to the present invention is an air slide device that is attached to the tool rest of the roll lathe and moves the cutting tool linearly in the longitudinal direction of the roll at a high speed, the longitudinal direction of the roll A guide rail that extends parallel to the guide rail, an air slider that floats on the guide rail and holds a diamond tool, a linear motor that drives the air slider, and the guide rail, air slider, and linear motor are integrated. And a case to be housed in the housing.

  According to the present invention, it is possible to realize a significantly faster micro-groove processing than before, to significantly reduce the processing time per one, and to further roll processing that significantly increases the ultra-precision processing range. High accuracy and high efficiency can be achieved.

Hereinafter, an embodiment of a precision roll lathe according to the present invention will be described with reference to the accompanying drawings.
FIG. 1 is a perspective view showing a precision roll lathe according to an embodiment of the present invention from the front, and FIG. 2 is a perspective view showing from the opposite side to FIG. 1 in a state where no roll is installed. .

1 and 2, reference numeral 10 indicates a bed. On the bed 10, a spindle stock 12, a tailstock 14, and a carriage 16 are arranged. The workpiece is a roll-shaped roll W, and is rotatably supported by the headstock 12 and the tailstock 14.
The headstock 12 is disposed at one end of the bed 10 in the longitudinal direction. The headstock 12 includes a main body portion 17, a main shaft 18, a chuck 19 attached to the tip of the main shaft 18, and a servo motor 20 that drives the main shaft 18. The main shaft 18 is supported by a hydrostatic bearing (not shown) built in the main body portion 17. The chuck 19 grips the shaft of the roll W and transmits the rotation of the main shaft 18 to the roll W.

  In the head stock 12, the servo motor 20 that drives the main shaft 18 is configured as a built-in servo motor that directly drives the main shaft 18. The amount of rotation of the main shaft 18 is detected by an encoder. By feeding back the detection signal of this encoder and performing position control and speed control of the spindle 18, the spindle stock 12 has a function as an indexing axis (C axis) for indexing the roll W in the circumferential direction, A function of continuously rotating the main shaft 18 at a constant rotation speed (up to several hundred rotations) is added.

  Next, in FIGS. 1 and 2, the tailstock 14 is arranged on the bed 10 so as to face the headstock 12. A guide surface (not shown) is provided on the upper surface of the bed 10, and the tailstock 14 is movably installed. The tailstock 14 includes a main shaft 24 instead of a conventional general tailstock shaft, and a shaft of the roll W is rotatably supported by a chuck 25 attached to the main shaft 24. The basic structure of the tailstock 14 is the same as that of the headstock 12.

Next, the carriage 16 will be described.
The carriage 16 includes a saddle 26 installed on the bed 10 so as to be movable in the axial direction of the roll W. A table 28 is installed on the saddle 26 so as to be movable in a direction perpendicular to the axial direction of the roll W.

  In the precision roll lathe of the present embodiment, the axis for feeding the saddle 26 is the Z1 axis, and the axis for feeding the table 28 on the saddle 26 is the X axis. In this precision roll lathe, in addition to the X axis and the Z1 axis, the spindle base 12 has a C axis, the cutter swivel 30 provided on the table 28 has a B axis, and Z2 as described in detail below. An axis and a W axis are provided.

  A tool rest 32 is attached on the tool turntable 30. In the case of this embodiment, a normal cutting tool 31 is attached to the tool post 32, and the air slide device 40 can be attached and detached as an attachment.

  Bits 31 are arranged on the tool post 32 at predetermined intervals in the circumferential direction. In this embodiment, four cutting tools 31 and the tool post 32 can be indexed by turning every 60 degrees. As the cutting tool 31, a diamond cutting tool is used in the case of ultra-precision machining.

In the precision roll lathe according to this embodiment, the following air slide device 40 is installed on the tool post 32.
FIG. 3 is a perspective view showing the main body of the air slide device 40. The air slide device 40 is attached to the tool post 32 as an attachment in order to linearly move the diamond tool at a high speed in the longitudinal direction of the roll W and to process the groove in the axial direction with high efficiency.

  The air slide device 40 according to this embodiment is a device that drives an air slider 41 by a linear motor and travels along a guide rail 42 at high speed in a floating state. Is attached through. The air slider 41 travels inside the case 45, and the diamond tool 50 protrudes from a slit 48 formed in the case 45 and moves in this state. Thus, the air slide device 40 is housed in a long box-like case 45 and unitized in advance, and can be attached to or removed from the tool post 32 together with the case 45. When the air slide device 40 is not installed on the tool post 32, it can be processed with the cutting tool 31 as an ordinary tool post 32.

Next, FIG. 4 is a view showing the air slider 41 and the guide rail 42 in a state where they are not housed in the case 45 of the air slide device 40.
The guide rail 42 is positioned so as to be parallel to the roll W, and a large roll lathe having a length of about 2 to 3 meters is used so that the large roll lathe can be processed. It is done. Of course, it may be a short rail so that it can accommodate short rolls. The guide rail 42 is a rail having a T-shaped cross section in which the horizontal portion 42a and the vertical portion 42b intersect the T-shape. In this case, the air slider 41 is fitted so as to embrace the horizontal portion 42a from both sides. In addition, on the upper surface of the horizontal portion 42a of the guide rail 42, magnets 46 constituting the stator of the linear motor are arranged at the center in the rail longitudinal direction.

  As shown in FIG. 5, in the guide rail 42, sliding surfaces 43a, 43b, and 43c of the air slider 41 are formed on the upper and lower surfaces and side surfaces of the horizontal portion 42a. Air is ejected from the air slider 41 toward the active surfaces 43a, 43b, and 43c, so that the air slider 41 is slightly lifted from the sliding surfaces 43a, 43b, and 43c. The linear motor movable element 48 is supported by a lower part of the air slider 41 via a cooling block 47 so as to face the magnet 46. Cooling water is supplied to the cooling block 47 to suppress overheating of the mover 48. Such a linear motor constitutes a Z2 axis drive mechanism that moves the air slider 41 and controls its position and speed.

  As shown in FIG. 5, in the air slider 41, a bite holder 49 is attached to the lower part of the side surface facing the roll W via a fine processing unit 44. A diamond tool 50 is mounted on the tool holder 49.

  The microfabrication unit 44 is a device that minutely displaces the position of the cutting edge of the diamond cutting tool 50 in the cutting direction by utilizing minute deformation when a voltage is applied to the piezo element. In this case, the cutting edge of the diamond cutting tool 50 is on the XZ plane including the center line of the roll W, and is moved at the X axis and positioned at an approximate position whether or not the cutting edge contacts the roll W. Therefore, a required voltage is applied by the microfabrication unit 44 to expand the piezo element, and the cutting amount of the diamond cutting tool 50 can be set.

  The air slide device 40 as described above has a structure in which a set of components is housed in a case 45 and attached to the tool post 32, and has both ends supported by legs and a cradle as follows.

  In FIG. 1 and FIG. 6, legs 51 are attached at positions close to both ends of the case 45. Air pads 52 a and 52 b are attached to the lower ends of the leg portions 51. The air pads 52a and 52b are formed of a porous material, and are evacuated through fine holes so that the air pads 52a and 52b can be fixed to a cradle 54 disposed on a bed. Further, when the air slide device 40 is moved in the X-axis direction together with the tool post 32, the air can be slightly floated from the surface of the cradle 54 by ejecting air from the air pads 52a and 52b.

  1 and 2, reference numeral 60 indicates a face suction device. This facet suction device 60 has a W axis synchronized with Z2 of the air slide device 40 as a control axis. The suction port 61 is also disposed near the diamond cutting tool 50 of the air slider 41.

The precision roll lathe according to the present embodiment is configured as described above. Next, its operation and effect will be described.
In the precision roll lathe according to the present embodiment, a usage mode in which the air slide device 40 is attached to the tool post 32 and the roll W is processed, and a usage mode in which the roll is processed as a normal roll lathe without the air slide device 40 being attached, First, the groove processing in the roll axis direction when the former air slide device 40 is attached will be described.
Prior to machining, centering is performed when the roll W is attached to the spindle stock 12 and the tailstock 14. Next, the air slide device 40 installed on the tool post 32 is indexed by the B axis so as to be parallel to the roll W. Thereafter, the cutter swivel 30 together with the table 28 is sent along the X axis and positioned at a position where the distance between the cutting edge of the diamond tool 50 and the roll W becomes substantially zero.

  In FIG. 6, until the air slide device 40 is positioned, air is ejected from the air pads 52 a and 52 b of the leg 51, and the air pads 52 a and 52 b are slightly lifted from the surface of the cradle 54. When the position on the X-axis is determined (indicated by a two-dot chain line), the air pads 52a and 52b are attracted to the cradle 54 by evacuating the air pads 52a and 52b, so that the air slide device 40 can be clamped. . Thus, the movement and clamping operation on the cradle 54 can be smoothly performed using the air pads 52a and 52b.

  Thus, at the position where the air slide device 40 is clamped, the distance between the cutting edge of the diamond cutting tool 50 and the roll W is substantially zero. Subsequently, the air slider 41 is fed along the Z2 axis while the roll W is rotated in order to obtain a processing reference surface, and the entire surface is processed in the processing range of the roll W. By this whole surface processing, the standard of processing is established. The ultra-precision main processing using the diamond tool 50 is performed after that.

  As the ultra-precision main processing, for example, an example in which a fine groove is processed in the axial direction over the entire surface of the roll W will be described. In this case, the air slider 41 is moved at a high speed to process minute grooves one by one in the roll W. When the processing of one groove is completed, the air slider 41 is moved after indexing with the C axis, and the next groove is processed into the roll W. By repeating this, a groove is processed in the entire roll W.

  When fine grooves are machined in the axial direction over the entire roll W, the machining range is widened and the number of grooves is enormous.

  Therefore, according to the precision roll lathe according to the present embodiment, the processing efficiency is improved as follows.

  First, by providing an air slide device 40 that constitutes the Z2 axis together with the Z1 axis that sends the carriage 16 on which the tool rest 32 is placed, the high speed of the air slide device 40 can be fully utilized. ing. That is, since the air slide device 40 constituting the Z2 axis can process the groove while the air slider 41 having the diamond cutting tool 50 travels at a high speed, the carriage 16 on which the tool post 32 is mounted is provided like a conventional roll lathe. Compared with the case where the groove is processed by feeding the wire, the feeding speed is remarkably different.

In fact, the speed of the carriage in a conventional roll lathe is about 15 m / min even if it is fast, but the air slide device 40 can run the air slider 41 at a triple feed rate of 45 m / min. It is.
In addition, the air slide device 40 is not limited to simply a high speed, but is given a straight movement while being suspended in the air slider air, so that the straightness of the movement is high, there is no friction, and the position and speed. There is an advantage that can be controlled with high accuracy.

  Secondly, when a minute groove is processed on the roll W, it is necessary to cut several times with a diamond tool to finish one groove, and conventionally, the cutting edge is cut with the X axis every time it is cut once. It was necessary to adjust the depth of cut as well as the position of.

  In the roll lathe according to the present embodiment, the micromachining unit 44 is provided on the air slider 41, and the diamond cutting tool 50 is attached via the micromachining unit 44, whereby the cutting amount of the diamond cutting tool 50 can be reduced by the voltage applied to the piezo element. Only a small amount can be controlled. For this reason, if the position of the cutting edge of the diamond bite 50 is first determined on the axis, the position of the cutting edge can be finely displaced by the fine processing unit 44 thereafter, and at the same time the accuracy of grooving is improved. The efficiency can be significantly increased by the amount that does not require a very small amount of movement on the X axis.

  In this way, according to the roll lathe of the present embodiment, the efficiency of the ultra-precision machining of the axial groove over the entire surface of the roll W can be significantly improved as compared with the conventional case. In fact, when processing tens of thousands of grooves on a single large roll, it takes about 2 weeks compared to 3 months to 1 month even if it was continuously processed without interruption. It was possible to process with.

  As described above, the example in which the groove in the axial direction is processed in the roll W has been described, but it is needless to say that the fine groove in the circumferential direction can be processed in the entire roll in the roll W by using the air slide device 40. In this case, every time one groove is processed, the air slider 41 is fed in a small amount in the axial direction and the groove processing is repeated.

  In the precision roll lathe of this embodiment, even if the air slide device 40 is removed from the tool post 32, the roll can be processed by the cutting tool 31 of the tool post 32 according to the usage of a normal roll lathe. It is.

  As described above, the precision roll lathe according to the present invention has been described with reference to the embodiment in which the Z2 axis is added by attaching the air slide device, but the present invention is not limited to this embodiment, and from the beginning. You may make it comprise Z2 axis | shaft fixedly.

It is the perspective view which represented the precision roll lathe by one Embodiment of this invention from the front. It is the perspective view which represented the precision roll lathe by one Embodiment of this invention from the back surface. It is a perspective view which shows the external appearance of the air slide apparatus used with the precision roll lathe by one Embodiment of this invention. It is a perspective view which shows the air slider and guide rail of the air slide apparatus of FIG. The figure which shows the side surface of an air slider. The side view of the tool post with which the air slider apparatus was attached.

Explanation of symbols

10 bed 12 headstock 14 tailstock 16 carriage 26 saddle 28 table 31 tool 32 tool rest 40 air slide device 41 air slider 42 guide rail 44 micro-processing unit 45 case 46 magnet 48 mover 49 tool holder 50 diamond tool 52a, 52b Air pad 54 cradle

Claims (10)

Bed and
A headstock having a spindle installed on the bed and providing rotation to the roll while holding one end of the roll as a workpiece;
A tailstock arranged on the bed facing the headstock and rotatably supporting one end of the roll;
A saddle installed on the bed movably in the longitudinal direction of the roll;
A table installed on the saddle movably in a direction perpendicular to the longitudinal direction of the roll;
A guide rail installed on the table and extending in parallel with the longitudinal direction of the roll; an air slider that floats on the guide rail and holds a diamond tool; and a linear motor that drives the air slider; An air slide device comprising:
A precision roll lathe characterized by comprising:   2. The precision roll lathe according to claim 1, wherein the table is provided with a swivel having a tool rest to which a plurality of cutting tools are fixed, and the air slide device is disposed on the tool rest. .   2. The precision according to claim 1, wherein the air slide device includes a microfabrication unit that finely displaces the position of the cutting edge of the diamond tool in a cutting direction by expansion and contraction when a voltage is applied to the piezo element. Roll lathe.   On the table, the swivel base is moved at right angles to the longitudinal direction of the roll, the axis for positioning the air slide device at the processing position is the X axis, the axis for moving the saddle in the longitudinal direction of the roll is the Z1 axis, and the air 3. The precision roll lathe according to claim 2, wherein an axis for moving the slider by the linear motor is a Z2 axis, and a turning axis of the swivel base is a B axis.   The precision roll lathe according to claim 2, wherein the air slide device is configured as an attachment that is detachably attached to the tool post. An air slide device that is attached to a tool post of a roll lathe and moves a cutting tool linearly in the longitudinal direction of the roll at a high speed,
A guide rail extending parallel to the longitudinal direction of the roll;
An air slider that floats on the guide rail and holds a diamond tool;
A linear motor for driving the air slider;
An air slide device for exclusive use with a precision roll lathe , comprising: a case for integrally housing the guide rail, the air slider, and the linear motor .   7. The air slide for exclusive use with a precision roll lathe according to claim 6, further comprising fine processing means for finely displacing the position of the cutting edge of the diamond tool in the cutting direction by expansion and contraction when a voltage is applied to the piezo element. apparatus.   The guide rail is composed of a horizontal portion into which the air slider is fitted and a T-shaped rail having a T-shaped vertical portion, and a linear motor magnet is arranged in the longitudinal direction in the center on the upper surface of the horizontal portion. 7. A precision roll lathe dedicated air slide device according to claim 6, wherein sliding surfaces on which the air slider slides by air are formed on both sides of the magnet array. Legs attached to the case and supporting the air slide device horizontally;
A cradle that slidably supports the legs,
The air slide device for exclusive use with a precision roll lathe according to claim 6, further comprising:   An air pad for ejecting and sucking air is attached to the lower end of the leg portion, and the air slide device can float and slide the surface of the cradle by ejecting air from the air pad. The air slide device for precision roll lathe according to claim 9, wherein the air slide device can be fixed and clamped at an arbitrary position by vacuum suction.

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