JP5005501B2 - 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.

  In order to deal with such problems, the present applicant is considering using an air slide device for linearly moving the cutting tool in the longitudinal direction of the roll at a high speed by attaching it to the tool post of the roll lathe.

  When this air slide device is used for precision machining of a roll, how to supply air or electric power to an air slider that reciprocates at high speed becomes a problem. If the cable chain that is bent following the movement is supplied as in the prior art, vibration is generated when the cable chain is deformed, and this vibration causes a problem that the machining accuracy is lowered.

  In addition, the moment when the air slider starts to move or stops, or when the direction changes, the inertial force acts and vibration is generated. At that time, the fact that the vibration greatly reduces the machining accuracy has emerged as a problem to be solved. is doing.

  Therefore, the object of the present invention is to suppress the vibration generated in the air slide device as much as possible when the air slide device is installed on the tool post and perform the ultra-precision machining of the roll, and the ultra-precision machining range is remarkably wide. The purpose of this invention is to provide a precision roll lathe to which various functions are added to support the roll processing with 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 The air slide device includes: an air slider that travels at a position that holds the diamond tool; and a linear motor that drives the air slider; and A moving table that moves in the same direction in synchronization with the air slider, a face suction part supported by the moving table, and a cable that supplies air, cooling water, and electric power to the air slide via the face suction part And a facet suction device including a bundle.

  According to the present invention, when an air slide device is installed on a tool post and ultra-precise machining of a roll is performed, vibration that occurs in the air slide device is suppressed as much as possible, and the ultra-precision machining range is significantly widened. Various functions can be added to assist in making the machining more accurate.

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.

  Next, in FIGS. 1 and 2, reference numeral 60 indicates a face suction device. The face suction device 60 has a W axis that is synchronized with the Z2 axis of the air slide device 40 as a control axis.

  In FIG. 6, the facet suction device 60 includes a moving table 61 and a support arm 62. The moving table 61 moves on the bed in parallel with the moving direction of the air slider 41. In this case, a ball screw is employed as the drive mechanism of the moving table 61, and its control axis is the W axis.

  A support arm 62 is fixed to the moving table 61, and the support arm 62 extends so as to protrude toward the roll W. The suction pipe 63 is supported by the support arm 62. A joint 64 is attached to the suction pipe 63 at a portion bent downward at a right angle from the tip of the support arm 62, and a suction nozzle 65 is connected through the joint 64. The tip of the suction nozzle 65 is positioned near the diamond tool 50.

The end of the suction pipe 63 is connected to the terminal connection portion 66. As shown in FIG. 1, the terminal connecting portion 66 is connected to a cable chain 68 that bends following the movement of the moving table 61. The cable chain 68 includes cables for supplying power to the moving table 61 and the air slide device 40, cooling water piping for supplying cooling water, air piping for supplying air to the air sliding device 40, and cooling water piping. In addition, a vacuum pipe for vacuuming the suction pipe 63 is included.
According to this embodiment, the flexible cable bundle 70 composed of a cable and piping for supplying air, cooling water and electric power to the air slider 41 of the air slide device 40 is attached along the suction pipe 63. The end of the bundle 70 is connected to the air slider 41.

Next, in FIG. 6, reference numeral 80 indicates an NC apparatus. The NC device 80 numerically controls the X axis, Z1 axis, Z2 axis, B axis, C axis, and W axis.
The following control functions are added by the host controller 82 for the Z1 axis for controlling the movement of the saddle 26, the Z2 axis for controlling the air slide device 40, and the W axis for controlling the face suction device 60.

  First, the host controller 82 is configured as a part of the host controller 82 by controlling the W axis controller 83 and the synchronous controller 86 that operates the Z2 axis controller 84 in synchronization with each other by software.

Further, with respect to the Z1 axis and the Z2 axis, the saddle 26 is moved in the direction opposite to the moving direction of the air slider 41 when the air slider 41 of the air slide device 40 starts, stops, and changes its direction, and is generated in the air slider 41. An inertial force correction unit 87 that cancels out the inertial force is configured as a part of the host controller 82, and the Z1 axis control unit 85 and the Z2 axis control unit 84 are controlled as such.
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.
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, and the air slide device 41 is linearly moved while being suspended, so that the straightness of the movement is high, there is no friction, and the position and speed are high. There is an advantage that can be controlled with high accuracy.

  In such an air slide device 40, in order to move the air slider 41 at a high speed, it is necessary to supply power to the linear motor during processing and to continue supplying air and cooling water to the air slider 41.

  In this respect, in this embodiment, a cable for supplying power to the air slide device 40, a cooling water pipe, and an air pipe are connected to the air slider 41 as a cable bundle 70 along the suction pipe 36 of the facet. Yes. Then, the W axis of the face suction device 60 is synchronized with the Z2 axis of the air slide device 40. For this reason, the suction nozzle 65 of the face suction device 60 moves following the movement of the air slider 41, the face generated by the processing is sucked and removed, and the face sticks to the guide rail of the air slider 41. Inconvenience can be prevented.

  Furthermore, since the cable bundle 70 moves not only in accordance with the air slider 41, it is not necessary to connect a cable chain that bends following the air slider 41. For this reason, since the air slider 41 being processed is free from vibration caused by the bending of the cable, the motion straightness and high speed, which are inherent advantages of the air slide device 40, can be utilized to the maximum. .

  Further, regarding vibration that may occur in the air slide device 40, vibration may occur due to inertial force when the air slider 41 starts, stops, or changes direction. For this, a function for canceling the inertial force generated in the air slider 41 with respect to the Z1 axis and the Z2 axis is added, and the inertial force is reduced by moving the saddle 26 in the direction opposite to the moving direction of the air slider 41. Cancels to suppress vibration.

  For example, when the air slider 41 is started, a reaction force of inertia force proportional to the acceleration × mass at that time acts on the tool post 32. If left as it is, this reaction force causes vibration.

  Therefore, inertial forces having the same magnitude as the inertial force generated in the air slider 41 and having opposite directions are generated in the saddle 26 and canceled. That is, if the saddle 26 is moved in the opposite direction at an acceleration such that the acceleration × mass of the air slider 41 and the acceleration × mass of the entire carriage 16 are equal, the inertial force cancels out in both directions.

  In this way, the saddle 26 operates so as to cancel the inertial force, so that the motion straightness and high speed, which are the original advantages of the air slide device 40, can be utilized to the maximum.

  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 slide apparatus was attached.

Explanation of symbols

10 bed 12 spindle stock 14 tailstock 16 carriage 26 saddle 28 table 31 tool 32 tool post 40 air slide device 41 air slider 42 guide rail 44 microfabrication unit 45 case 46 magnet 48 mover 49 tool holder 50 diamond tool 52a, 52b air pad 54 cradle 60 face suction device

Claims (5)

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 moving table that moves in the same direction in synchronization with the air slider of the air slide device, a face suction unit supported by the move table, air, cooling water to the air slide via the face suction part, A face suction device comprising a bundle of cables for supplying power;
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. .   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 2. The precision roll lathe according to claim 1, wherein an axis for moving the slider with the linear motor is a Z2 axis, and an axis for moving a moving table of the facet suction device is a W axis. When the air slider of the air slide device starts, stops, and changes direction, the saddle is moved in a direction opposite to the moving direction of the air slider to cancel the inertial force generated in the air slider. 4. The precision roll lathe according to claim 3 , further comprising inertial force correction means for controlling the shafts in association with each other.   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.

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