JP6837861B2 - A fiber mat cutting device used for helical gears made of fiber reinforced plastic, a method for manufacturing a fiber mat punching blade used for this cutting device, and a method for cutting a fiber mat using a cutting device. - Google Patents

Description

The present invention relates to organic fibers such as aramid fibers (aromatic polyamide fibers), polyimide fibers, PBO fibers, ultrahigh molecular weight polyethylene fibers, polyarylite fibers, carbon fibers, fluorine fibers, PPS fibers, carbon fibers, silicon carbide fibers, and alumina. A cutting device that cuts a fiber mat made by gathering inorganic fibers such as fibers, glass fibers, and metal fibers to a predetermined thickness into a helical gear shape, a method for manufacturing a punching blade used for this cutting device, and a fiber mat. It relates to a cutting method for cutting into a helical gear shape.
In the present specification, the "fiber mat" does not specify the fibers as a non-woven fabric in which a predetermined thickness is assembled without directionality, but is a laminated non-woven fabric of a plurality of sheets, and the fibers are braided by various weaving methods. It is used to mean a material in which a plurality of fiber cloths are laminated, and a material having a predetermined thickness as a three-dimensional fiber structure such as a three-dimensional fiber having a thickness direction thread penetrating the laminated fiber layer in the thickness direction. ..
Further, "fiber mat" is not specified to be composed only of a fiber structure, but is used to include a prepreg formed by adding a thermoplastic resin or a thermosetting resin between fibers.

Fiber reinforced plastic gears reinforced with fiber sheets have been developed. As a method for manufacturing this plastic gear, a method of forming a fiber reinforced plastic into a cylindrical shape and then cutting the outer periphery to form a tooth profile (see Patent Document 1), and a laminated body of reinforcing long fibers and a thermoplastic resin prepreg are used as gears. A method (Patent Document 2) has been developed in which a gear is punched into the shape of a gear.

The method of processing into a cylindrical shape and cutting the outer circumference into a tooth profile has a drawback that the amount of cutting in the cutting process is large and the manufacturing cost is high. The method of manufacturing gears by punching a prepreg into a tooth profile is characterized by easy cutting and efficient mass production.

In the manufacturing method described in Patent Document 2, a punch is used to punch an angled laminate of reinforcing long fibers and a thermoplastic resin prepreg used for a fiber reinforced plastic gear into a tooth profile. The punch is inserted into a through hole provided in the female mold to punch out an angled laminated plate. Cutting with a punch has a drawback that it is difficult to cut a thick angled laminated board into a tooth profile having an accurate outer shape, and in particular, an angled laminated board made of tough reinforcing long fibers such as carbon fiber cannot be cut efficiently. In particular, there is a drawback that the outer shape of a small gear cannot be cut into an accurate tooth shape. In addition, there is a drawback that the running cost becomes considerably high because the outer peripheral edge of the punch is severely damaged at the time of cutting and sufficient durability cannot be realized.

In order to eliminate the drawbacks of the punch, the present inventor manufactured a Thomson blade by bending a metal plate having a tooth tip on the tip edge into a tooth mold. If you use a Thomson blade to place a fiber sheet on a flat cradle and press the tip of the tooth against the fiber sheet to cut it, you can cut a thin fiber sheet that collects fibers that are easy to cut into a tooth mold, but carbon Tough fiber sheets such as fibers and Kevlar fibers cannot be cut repeatedly. In particular, the Thomson blade cannot cut a fiber mat in which tough fibers are thickly laminated. This is because fibers with tough tooth tips cannot be cut, and the metal plate is deformed during cutting to collapse the tooth profile.

Since plastic gears are used in place of metal gears, they are required to have strength comparable to that of metal. In particular, for fiber reinforced plastic gears having a large transmission torque, a fiber mat in which tough fibers are gathered considerably thickly is used. For this reason, a punching blade for cutting a fiber mat for a fiber reinforced plastic gear is required to have an extremely difficult property that a fiber mat in which tough fibers are thickly assembled can be repeatedly cut into an accurate tooth shape.

The present inventor has developed the cutting device shown in FIG. 11 for the purpose of solving the above difficult problems. (See Patent Document 3)

Japanese Unexamined Patent Publication No. 2009-97700 Japanese Unexamined Patent Publication No. 6-114863 Japanese Patent Application No. 2016-196056

The cutting device of FIG. 11 moves toward a pedestal 1 having a cutting section 2 on the upper surface on which the fiber mat 10 is placed and cut, and the cutting section 2 of the pedestal 1 to move the fiber mat 10 of the cutting section 2. A punched blade 3 having a cutting edge 4 for cutting into a gear shape at the tip edge thereof, and a blade driving mechanism 5 for reciprocating the punched blade 3 are provided.

The punching blade of the cutting device of FIG. 11 is shown in FIG. The punched blade 3 includes a tubular toothed blade 3A made of a steel material having a cutting edge 4 at the tip for cutting the fiber mat 10 into a gear shape. The cutting edge 4 of the tooth profile blade 3A is connected to a tooth tip blade 4A for cutting the tooth tip surface of the gear, a tooth bottom blade 4B for cutting the tooth bottom of the gear, a tooth tip blade 4A and a tooth bottom blade 4B, and a gear. It is composed of a tooth surface blade 4C for cutting the tooth surface of the tooth surface.

The above-mentioned cutting device can cut a fiber mat in which tough reinforcing fibers are thickly assembled into an accurate tooth profile by using a punching blade 3, and while repeatedly cutting a large number of fiber mats, a gear having an accurate tooth profile. Realizes the feature that can be punched into the mat.

However, this cutting device has a drawback that it can only manufacture spur gears and cannot manufacture helical gears made of fiber reinforced plastic. Helical gears are often used for various purposes because they have various features that spur gears do not have, for example, they can rotate smoothly to increase the surface pressure strength and further reduce the noise level.

The present invention was developed for the purpose of being able to manufacture a helical gear at low cost, and while using a punched blade that can be mass-produced at low cost, a fiber mat in which reinforcing fibers are thickly assembled can be efficiently and accurately made into a helical gear. It can be cut into the tooth profile of the above, and even if a large number of fiber mats are repeatedly cut, it can be punched into an accurate helical gear tooth profile, and the fiber mat of the helical gear shape used for the helical gear made of fiber reinforced plastic can be cut efficiently. An object of the present invention is to provide an apparatus, a method for manufacturing a punching blade 3 used for the cutting apparatus, and a method for cutting a fiber mat used for a helical gear.

Means for Solving Problems and Effects of Invention

The fiber mat cutting device used for the helical gear made of the fiber reinforced plastic of the present invention has a pedestal 1 having a cutting section 2 on the upper surface for cutting on which the fiber mat 10 is placed, and the cutting section 2 of the pedestal 1. The punched blade 3 having a tooth profile blade 3A having a cutting edge 4 provided at the tip edge for cutting the fiber mat 10 having a cut surface 2 into a helical gear-shaped gear mat 11 and the punched blade 3 are reciprocated. It is provided with a blade drive mechanism 5. The tooth profile blade 3A is connected to a tooth tip blade 4A for cutting the tooth tip circle of the helical gear, a tooth bottom blade 4B for cutting the tooth bottom of the helical gear, and a tooth tip blade 4A and a tooth bottom blade 4B for the helical gear. It has a cutting edge 4 having a tooth surface blade 4C for cutting the tooth surface of the tooth surface. Further, the tooth profile blade 3A has a tooth bottom blade 4B and a tooth surface blade 4C as a tip edge, and a plurality of V grooves 16 extending from the tip edge toward the rear end are provided on the outer peripheral surface at predetermined intervals to provide an inner peripheral surface. The vertical grooves 21 extending from the front end to the rear end and the ridges 22 are alternately provided at predetermined intervals. Furthermore, in the tooth profile blade 3A, the tip edge of the vertical groove 21 is the tooth tip blade 4A, the tip edge between the vertical groove 21 and the ridge 22 is the tooth surface blade 4C, and the tip edge of the ridge 22 is the tooth bottom. The blade is 4B. Further, the tooth profile blade 3A has a protrusion 22 arranged at a position facing the inside of the V groove 16 so that the V groove 16 and the protrusion 22 are tilted at a constant inclination angle with respect to the central axis of the tooth profile blade 3A. It is arranged. The blade drive mechanism 5 includes a rotation mechanism 5A that cuts the fiber mat 10 of the cradle 1 while rotating the punched blade 3 with the central axis of the punched blade 3 as a rotation axis. The blade drive mechanism 5 punches the fiber mat 10 of the cradle 1 while rotating the punched blade 3, and cuts the fiber mat 10 into a helical gear-shaped gear mat 11.

The fiber mat cutting device used for the above-mentioned fiber reinforced plastic helical gears uses punching blades that can be mass-produced at low cost, and efficiently and accurately even fiber mats with thickly assembled reinforcing fibers. It can be cut into a shape, and even if a large number of fiber mats are repeatedly cut, it can be punched into a gear mat with an accurate helical gear shape.

The above-mentioned cutting device rotates a tooth profile blade 3A having a tooth tip blade 4A, a tooth bottom blade 4B, and a tooth surface blade 4C at the tip edge, which cuts the fiber mat 10 into a helical gear shape. The fiber mat 10 of the cradle 1 is cut while being rotated by the blade drive mechanism 5 having 5A, and the tooth bottom blade 4B and the tooth surface blade 4C are used as the tip edge and the tip edge to the rear end of the tooth profile blade 3A. Multiple V-grooves 16 extending toward The tip edge of the vertical groove 21 is the tooth tip blade 4A, the tip edge between the vertical groove 21 and the ridge 22 is the tooth surface blade 4C, and the tip edge of the ridge 22 is the tooth bottom blade 4B. As a result, the ridges 22 are arranged at positions facing the inside of the V-groove 16, and the V-grooves 16 and the ridges 22 are arranged in a posture of being inclined at a constant inclination angle with respect to the central axis of the tooth profile blade 3A. This is because the tooth profile blade 3A is rotated by the blade drive mechanism 5 to punch out the fiber mat 10 of the cradle 1 and cut the fiber mat 10 into the helical gear-shaped gear mat 11.

The fiber mat cutting device used for the helical gear gradually shallows the V-groove 16 of the tooth profile blade 3A from the cutting edge 4 toward the rear end of the tooth profile blade 3A, and extends from the tooth bottom blade 4B to the rear end of the tooth profile blade 3A. The blade angle (α1) of the tooth bottom line is made larger than the blade angle (α2) of the tooth tip surface from the tooth tip blade 4A to the rear end of the tooth profile blade 3A, and further, the rear end of the tooth bottom blade 4B of the tooth profile blade 3A. The thickness of the portion (W1) can be made thicker than the thickness of the rear end portion (W2) of the tooth tip blade 4A.

The above helical gear has a feature that the tooth bottom blade, which is easily deformed from the shape locally protruding inward, has a tough structure and can surely and effectively prevent the tooth bottom blade from being deformed by the impact at the time of punching. The tooth bottom blade has a shape that locally protrudes inward to cut the tooth bottom of the gear, and is easily deformed by the momentary stress during punching. The tooth bottom blade has the punched fiber mat inside. Since it has a single-edged shape for guiding, as shown in the cross-sectional view of FIG. 6, the center lines (A) on both sides of the tooth tip are inside with respect to the direction in which the cutting edge 4 of the helical gear 3A reciprocates as indicated by the arrow. Inclines to and receives the stress indicated by arrow B during punching. This stress repeatedly acts on the tooth bottom blade 4B every time the fiber mat 10 is cut, causing deformation. When the tooth bottom blade 4B is gradually deformed by the stress acting in the horizontal direction, the punching blade 3 cannot cut a large number of fiber mats 10 into an accurate helical gear shape, but the above tooth profile blade 3A prevents the above harmful effects. It has a feature of realizing excellent durability while cutting a large number of fiber mats 10 into an accurate helical gear shape.

Further, the above punched blade has the above-mentioned unique shape of the tooth profile blade to prevent deformation of the cutting edge due to the stress acting momentarily at the time of punching, so that the tough fibers that are extremely difficult to cut are thickly assembled. The fiber mat can also be cut into an accurate helical gear shape, and the thick fiber mat can be repeatedly cut into an accurate helical gear shape.

The tooth profile blade 3A of the cutting device of the present invention is composed of a blade portion 3a having a cutting edge 4 at the tip edge and a base portion 3b integrally connected to the rear end side of the cutting tool portion 3a. The hardness of the base portion 3b can be made lower than the hardness of the cutting tool portion 3a. This tooth profile blade has a feature that the fiber mat can be punched smoothly with the tooth profile blade because the impact at the time of punching can be absorbed by the buffering action of the base portion having a hardness lower than that of the blade portion. In the tooth profile blade 3A having this structure, the blade portion 3a and the base portion 3b can be made of different steel materials, and the blade portion 3a and the base portion 3b can be connected by a welded structure.

In the cutting device of the present invention, the punching blade 3 is provided with a cylindrical blade 3B, the cylindrical blade 3B is arranged inside the tooth profile blade 3A, a sub cutting edge 4D is provided at the tip edge, and the sub cutting edge 4D is used as the tooth profile blade 3A. The gear mat 11 may be provided with a through hole as a structure in which the cylindrical blade 3B is arranged on the same plane as the cutting edge 4 and fixed to the gear mat 11 to the tooth profile blade 3A. This punched blade has a helical gear shape in outer shape and can cut a gear mat having a through hole in the center. In addition, this punched blade also realizes a feature that the outer peripheral surface and the inner peripheral surface of the cut gear mat can be cut into an accurate shape by reducing distortion.

In the method for manufacturing a punched blade of the present invention, a tooth profile blade 3A is placed on a cutting surface 2 of a cradle 1 and punched on a helical gear-shaped gear mat 11 with a fiber mat 10 used for a helical gear made of fiber reinforced plastic. It is a method of manufacturing, in which the manufacturing process of the tooth profile blade 3A is performed by cutting a steel material into a tubular shape having a predetermined thickness and cutting the fiber mat 10 into a helical gear shape with a cutting edge 4 as a tip edge. It is composed of a cutting step of providing a cutting blade 31, a quenching step of quenching the cutting blade 31 to make a quenching blade, and a polishing step of polishing the hardened blade. The cutting step includes an inner surface cutting step in which the ridges 22 and the vertical grooves 21 are alternately provided in parallel postures on the inner peripheral surface at regular intervals, and an outer surface cutting step in which V grooves 16 are provided on the outer peripheral surface at regular intervals. A V-groove 16 provided in the outer surface cutting process is arranged at a position facing the outer surface of the ridge 22 provided in the inner surface cutting process, and the tip of the V-groove 16 is set as the tooth bottom blade 4B and the tooth surface blade 4C, and between the V-grooves 16. The tooth tip blade 4A is provided on the tooth tip blade 4A, and the ridge 22, the vertical groove 21, and the V groove 16 are further processed into a posture of being inclined at a constant angle with respect to the central axis. Furthermore, the V-groove 16 provided in the outer surface cutting step is made shallower from the tip edge to the rear end so that the blade angle (α1) of the tooth bottom blade 4B is larger than the blade angle (α2) of the tooth tip blade 4A. Further, the thickness of the rear end portion of the tooth profile blade 3A is such that the thickness of the rear end portion (W1) of the tooth bottom blade 4B is made thicker than the thickness (W2) of the rear end portion of the tooth tip blade 4A. To do.

The tooth profile blade manufactured by the above method can be mass-produced at low cost, and even a fiber mat in which reinforcing fibers are thickly assembled can be efficiently and accurately cut into a helical gear tooth profile, and a large number of fiber mats are repeatedly cut. Even so, it has the characteristic of being able to efficiently cut the helical gear-shaped fiber mat used for the helical gear made of fiber reinforced plastic by punching it into an accurate helical gear tooth profile.

In the method for manufacturing a fiber mat punching blade of the present invention, in the inner surface cutting step, a steel material can be electric discharge machined to provide ridges 22 and vertical grooves 21 on the inner surface. This method is characterized in that the steel material can be efficiently machined and the inner surface can be machined into a helical gear shape.

The cutting method of punching the fiber mat of the present invention into a helical gear-shaped gear mat is to place the fiber mat 10 on the cutting surface 2 of the cradle 1 and use the punching blade 3 to cut the fiber mat 10 into the outer shape of the helical gear. Punch into the gear mat 11. In this cutting method, the tooth surface of the helical gear is cut into the punching blade 3, the tooth tip blade 4A for cutting the fiber mat 10 for the cutting edge 4 of the helical gear, the tooth bottom blade 4B for cutting the tooth bottom of the helical gear, and the tooth surface of the helical gear. A tooth-shaped blade 3A having a cutting edge 4 composed of a tooth surface blade 4C on the tip edge and having a cylindrical shape as a whole is used. As the tooth profile blade 3A approaches the cut surface 2 of the cradle 1, either or both of the tooth profile blade 3A and the cradle 1 are rotated, and the tooth profile blade 3A and the cradle 1 are relatively rotated. The fiber mat 10 is cut into a helical gear-shaped fiber mat 10.

In the above cutting method, while using a punching blade 3 that can be mass-produced at low cost, it is possible to efficiently and accurately cut a fiber mat in which reinforcing fibers are thickly assembled into a helical gear tooth profile, and further a large number of fiber mats can be cut. Even if it is repeatedly cut, it can be punched into an accurate helical gear tooth profile, and the helical gear-shaped fiber mat used for the helical gear made of fiber reinforced plastic can be efficiently cut.

In the method for cutting a fiber mat of the present invention, a blade having all the following configurations A to C can be used for the tooth profile blade 3A used for cutting.
A. The tooth profile blade 3A has a tooth bottom blade 4B and a tooth surface blade 4C as a tip edge, and a plurality of V grooves 16 extending from the tip edge toward the rear end are provided on the outer peripheral surface at predetermined intervals and inside. Vertical grooves 21 and ridges 22 extending in the reciprocating direction from the front end to the rear end are alternately provided on the peripheral surface at predetermined intervals.
B. The tooth profile blade 3A
The tip edge of the flute 21 is a tooth tip blade 4A,
The tip edge between the flute 21 and the ridge 22 is the tooth surface blade 4C,
The tip edge of the ridge 22 is a tooth bottom blade 4B.
C. In the tooth profile blade 3A, the ridges 22 are arranged at positions facing the inside of the V groove 16, and the V groove 16 and the ridges 22 are arranged in a posture of being inclined at a constant inclination angle with respect to the central axis of the tooth profile blade 3A. It becomes.

In the method for cutting the fiber mat used for the helical gear of the present invention, the following blades having the configurations A and B can be used for the tooth profile blade 3A.
A. The V-groove 16 is gradually shallower from the cutting edge 4 toward the rear end of the tooth profile blade 3A.
The blade angle (α1) of the tooth bottom line from the tooth bottom blade 4B to the rear end of the tooth profile blade 3A is larger than the blade angle (α2) of the tooth tip surface from the tooth tip blade 4A to the rear end of the tooth profile blade 3A.
B. In the tooth profile blade 3A, the thickness (W1) of the rear end portion of the tooth bottom blade 4B is thicker than the thickness (W2) of the rear end portion of the tooth tip blade 4A.

The method for cutting the fiber mat used for the helical gear of the present invention comprises connecting the tooth profile blade 3A with a blade portion 3a provided with a cutting edge 4 at the tip edge and an integral structure on the rear end side of the blade portion 3a. A blade composed of the base portion 3b and having a hardness of the base portion 3b lower than the hardness of the blade portion 3a can be used.

The method for cutting the fiber mat used in the helical gear of the present invention is as follows.
For the punching blade 3, a blade having the following configurations A and B can be used.
A. The punched blade 3 includes a cylindrical blade 3B which is concentrically located inside the tooth profile blade 3A and is connected to the tooth profile blade 3A.
B. The cylindrical blade 3B has a sub-edge 4D at the tip edge, and the sub-edge 4D is arranged on the same plane as the blade 4 provided at the tip of the tooth profile blade 3A.

It is a perspective view of the punching blade used for the cutting apparatus which concerns on embodiment of this invention. It is a top view of the punching blade shown in FIG. It is a front view of the punching blade shown in FIG. It is a bottom view of the punching blade shown in FIG. It is sectional drawing which cut along the V groove and the vertical groove of the punching blade shown in FIG. It is sectional drawing which shows the state which the tooth bottom blade of a punching blade cuts a fiber mat. It is a perspective view which shows the state which the metal block is processed into a cylinder, and the cylinder is ground into a tooth profile blade. It is the schematic sectional drawing of the cutting apparatus which punches a fiber mat. It is a schematic cross-sectional view in the radial direction of the gear mat obtained by punching a fiber mat. It is schematic cross-sectional view which shows the state which punches a fiber mat by a punching blade. It is a schematic perspective view of the cutting device for punching a fiber mat which the present inventor developed earlier. It is a perspective view which shows the punching edge of the cutting apparatus of FIG.

Hereinafter, examples of the present invention will be described with reference to the drawings. However, in the examples shown below, a fiber mat cutting device used for a helical gear made of fiber reinforced plastic for embodying the technical idea of the present invention, a method for manufacturing a punching blade used for the cutting device, and a method for manufacturing the punching blade are described. The method for cutting a fiber mat using a punched blade is illustrated, and the present invention does not specify the cutting device, the method for manufacturing the punched blade, and the cutting method below. Further, in order to make it easier to understand the scope of claims, this specification shows the numbers corresponding to the members shown in the examples in "Claims" and "Columns for means for solving problems". It is added to the member. However, the members shown in the claims are by no means specified as the members of the examples.

The cutting device of the present invention cuts a fiber mat into a gear mat of a helical gear. The cut gear mat is used as a reinforcing fiber for plastic helical gears. The gear mat obtained by cutting the fiber mat of the prepreg is made by hardening the plastic under pressure to make a helical gear made of fiber reinforced plastic, and the gear mat without plastic is impregnated with plastic or embedded in plastic. , Mold the plastic and process it into a helical gear made of fiber reinforced plastic. The helical gear made of fiber reinforced plastic in which the gear mat is embedded is a helical gear having a more accurate outer shape by cutting or polishing the outer peripheral surface in a state where the plastic is hardened.

The present invention relates to a device for cutting a fiber mat used for a helical gear made of fiber reinforced plastic, a method for manufacturing a punched blade, and a method for cutting the fiber mat, and is applicable to a device and a manufacturing method for a helical gear. It is not such a thing. Therefore, a method or device for making a fiber-reinforced plastic helical gear by using a gear mat obtained by cutting a fiber mat into a helical gear can be used by a method and a device currently used or will be developed.

Fiber mats used to reinforce helical gears made of fiber-reinforced plastic include organic fibers such as aramid fibers (aromatic polyamide fibers), polyamide fibers, PBO fibers, ultra-high strength polyethylene fibers, and high-strength polyarylate fibers. It is composed of inorganic fibers such as carbon fibers, silicon carbide fibers, alumina fibers, glass fibers, and metal fibers, and these fibers are aggregated to have a predetermined thickness. Further, thermoplastic resin or thermosetting resin is used between the fibers. It is a prepreg made by adding. The fiber mat is a collection of fibers, and the fibers extending in the thickness direction prevent delamination. Therefore, the helical gear made of fiber reinforced plastic in which the fiber mat is embedded as the reinforcing fiber realizes the strength comparable to that of the metal gear.

A gear mat obtained by cutting a fiber mat into a helical gear shape is embedded in plastic without being laminated or laminated and processed into a helical gear made of fiber reinforced plastic. For helical gears with a wide blade width, in other words, a thick helical gear, the blade width can be adjusted by the number of laminated gear mats. Further, thin gear mats can be laminated to form a helical gear having a wide blade width. Therefore, in the helical gear manufactured by laminating gear mats, the number of laminated gears is adjusted by the thickness of the gear mats and the blade width of the helical gears.

The cutting device of FIG. 8 is a device for cutting a fiber mat used for a helical gear made of fiber-reinforced plastic, and this device is a receiver having a cutting section 2 on the upper surface on which the fiber mat 10 is placed and cut by a punching blade 3. The punching blade 3 that moves toward the table 1 and the cutting surface 2 of the cradle 1 and cuts the fiber mat 10 arranged on the cutting surface 2 into a helical gear shape, and the punching blade 3 reciprocate. It is provided with a blade driving mechanism 5 for making the blade drive mechanism 5.

The cradle 1 is a metal plate, and the cut surface 2 is flat. The entire or surface of the cradle 1 may be made of plastic or rubber. As shown in FIG. 1, the pedestal 1 of the metal plate has an elastic sheet 1A laminated on its surface. The elastic sheet 1A is a rubber-like elastic sheet having a thickness of 1 mm to 10 mm. In the cradle 1 on which the elastic sheet 1A is laminated on the upper surface, the cutting edge 4 of the punching tool 3 is brought into close contact with the elastic sheet 1A in a state where the fiber mat 10 is punched by the punching tool 3, or the cutting edge 4 of the punching tool 3 is brought into close contact with the elastic sheet 1A. The cutting edge 11A of the gear mat 11 cut from the fiber mat 10 can be neatly cut by inserting it into the surface of the elastic sheet 1A. However, it is not always necessary to arrange the elastic sheet on the upper surface of the cradle 1, and instead of the elastic sheet, a soft sheet cut by the cutting edge is laminated, or the elastic sheet or the soft sheet is not laminated. It is also possible to punch or cut the fiber mat by bringing the punching blade close to or in contact with the cut surface.

The blade driving mechanism 5 cuts the fiber mat 10 while rotating the punched blade 3 in a horizontal plane. The blade drive mechanism 5 includes a rotation mechanism 5A of the punched blade 3. The blade drive mechanism 5 in the figure includes an upper and lower base 6 for fixing the punched blade 3 and a cylinder 7 for reciprocating the upper and lower base 6 up and down, and the rotation mechanism 5A rotates the upper and lower base 6 in a horizontal plane. The punching blade 3 is fixed in a vertical position on the lower surface of the upper and lower pedestals 6, the rotating mechanism 5A rotates the upper and lower pedestals 6, the cylinder 7 moves up and down, and the fiber mat 10 mounted on the pedestal 1 is placed. The gear mat 11 having a helical gear shape is cut. In the helical gear, the tooth tips on the outer peripheral surface are inclined with respect to the rotation axis. Therefore, the gear mat cut by the punching blade is cut into a helical gear shape in which the tooth tips on the outer periphery are inclined with respect to the rotation axis.

The rotation mechanism 5A rotates the descending upper and lower pedestals 6 in a horizontal plane. The rotation mechanism 5A specifies the rotation position at the vertical position of the upper and lower base 6. The rotation mechanism 5A rotates the punching blade 3 at a rotation position where the cutting edge 4 of the punching blade 3 cuts the fiber mat 10 into a helical gear shape. This is because when the upper and lower bases 6 descend without rotating, the outer shape of the gear mat to be cut becomes the outer shape of the spur gear. The punching blade that descends while being rotated by the rotation mechanism 5A cuts the fiber mat into a helical gear shape, that is, a gear mat having a tooth tip that is inclined with respect to the rotation axis. The rotation mechanism 5A described above rotates the punching blade 3 in a horizontal plane via the upper and lower pedestals 6, but the rotating mechanism rotates the pedestal or both the upper and lower pedestals and the pedestal to form a fiber mat. It can also be cut into a helical gear shape. Therefore, the present invention does not specify the rotation mechanism of the blade drive mechanism as a mechanism for rotating the upper and lower pedestals, but can also be a mechanism for rotating the pedestal or rotating both the pedestal and the upper and lower pedestals. ..

When the upper and lower pedestals 6 descend, the rotation mechanism 5A rotates the upper and lower pedestals 6 so as to have a specific rotation angle with respect to the descending position of the descending upper and lower pedestals 6. The rotation angle at which the rotation mechanism 5A rotates on the lower and lower bases 6, that is, the rotation angle with respect to the lowering distance of the upper and lower bases 6, specifies the inclination angle of the tooth tip of the helical gear. Therefore, the rotation angle at which the rotation mechanism 5A rotates on the upper and lower bases 6, or more accurately, the rotation angle with respect to the descent distance, is set to an angle at which the tip of the gear mat to be cut becomes the inclination angle of the helical gear.

The rotation mechanism 5A of FIG. 8 has a guide convex portion 24 protruding outward in the radial direction from the upper and lower pedestals 6 and the guide convex portion in order to specify the rotation position of the upper and lower pedestals 6 at the lowering position of the upper and lower pedestals 6. A spiral guide 26 having a guide groove 25 for guiding the 24 on the inner surface is provided. The spiral guide 26 is provided with a guide groove 25 on the inner surface. The guide groove 25 has a spiral shape, and guides the guide convex portion 24 here to specify the rotational position of the lowering base 6. The rotation mechanism 5A can adjust the inclination angle of the guide groove 25 with respect to the central axis to adjust the rotation position of the upper and lower base 6 with respect to the lowering position. The inclination angle of the guide groove 25 with respect to the central axis is set to the inclination angle of the cutting edge 4 of the gear mat 11 to be cut. The rotation mechanism 5A in the figure is provided with guide convex portions 24 at positions facing the outer periphery of the upper and lower bases 6, but the rotation mechanism is not shown, but a large number of guide convex portions are provided on the outer periphery, and each guide convex portion is provided. A guide groove for guiding can also be provided in the spiral guide. Further, in the rotation mechanism shown in the figure, a guide convex portion is provided on the upper and lower bases and a guide groove is provided on the spiral guide. However, the guide convex portion is provided on the spiral guide and the guide groove for guiding the guide convex portion is vertically provided. It can also be provided on the outer circumference of the table.

The above-mentioned rotation mechanism 5A guides the guide convex portion 24 to the guide groove 25 in a state where the upper and lower pedestals 6 are lowered, and the guide convex portion 24 moves along the guide groove 25 to move the upper and lower pedestals 6 to the lowering position. The rotation position with respect to can be accurately specified. Further, the rotation mechanism 5A can accurately specify the rotation position of the upper and lower base 6 with respect to the lowering position and cut the gear mat 11 to be cut into an accurate helical gear shape while making it an extremely simple mechanism. The mechanism can be simplified because an actuator such as a motor or a cylinder is not required to rotate the upper and lower bases, and a control mechanism for controlling the actuator is not required. However, the present invention does not specify the rotation mechanism to the above structure. For example, the vertical position of the upper and lower pedestals is detected by a sensor, and the upper and lower pedestals are rotated by an actuator such as a cylinder or a motor at the detection position of the sensor. Needless to say, it can also be a mechanism.

The above-mentioned blade drive mechanism 5 reciprocates the punched blade 3 up and down, sandwiches the fiber mat 10 arranged on the cut surface 2 of the pedestal 1 between the pedestal 1 and the punched blade 3, and has a helical gear shape. Cut into gear mat 11.

1 to 5 show a punching blade 3 for cutting the fiber mat 10 into a helical gear shape. The punched blades 3 shown in these figures are a tooth profile blade 3A that cuts the fiber mat 10 into the gear mat 11, and a cylindrical blade 3B that is fixed inside the tooth profile blade 3A and has a through hole in the center of the gear mat 11. And.

The tooth profile blade 3A cuts the fiber mat 10 into a helical gear-shaped gear mat 11, and the cylindrical blade 3B cuts a circular through hole in the center of the gear mat 11. In the tooth profile blade 3A and the cylindrical blade 3B, the cutting edge 4 is arranged on the same plane at the tip edge thereof, and the outer shape of the gear mat 11 and the through hole are punched out at the same time. The gear mat 11 cut by the punching blade 3 is used for a helical gear having a through hole in the center. The punched blade of FIG. 1 cuts a gear mat having a through hole in the center, but the punched blade does not necessarily have a cylindrical blade, and may have a structure of only a tooth profile blade. For punched blades without a cylindrical blade, the gear mat is cut into a helical gear without a through hole in the center. A gear mat having no through hole in the center is used for a helical gear having no through hole in the center, or a central through hole is provided in a later process to process the gear mat into a helical gear shape having a through hole.

The tooth profile blade 3A shown in the figure is not a thin metal plate bent into a tooth profile. The tooth profile blade 3A is manufactured by cutting, grinding, and quenching a metal block 19 having a predetermined thickness. The metal block 19 to be cut is a steel material and has a columnar, cylindrical or thick plate shape. The metal block is cut in the cutting process to obtain a cutting blade 31, and the cutting blade 31 is hardened in the quenching process to obtain a hardened blade. It is manufactured by grinding a hardened blade in the polishing process. In the cutting process, the metal block is electric-discharge machined to be cut into a tubular shape having protrusions 22 and vertical grooves 21 on the inside, and the outside is ground to obtain a cutting tool 31.

The tooth profile blade 3A in the figure includes a blade portion 3a having a cutting edge 4 on the tip edge thereof, and a base portion 3b integrally connected to the rear end side of the cutting edge portion 3a. The tooth profile blade 3A makes the hardness of the base portion 3b lower than the hardness of the blade portion 3a. In this tooth profile blade 3A, the blade portion 3a and the base portion 3b are made of different metals, and the metal of the base portion 3b is made of a metal having a hardness lower than that of the metal of the blade portion 3a. In this tooth profile blade 3A, the cushioning action of the low hardness base portion 3b absorbs the impact at the time of punching. Therefore, the tooth profile blade 3A has a feature that the impact when punching the fiber mat 10 is absorbed by the base portion 3b and the fiber mat 10 can be punched smoothly. In the tooth profile blade consisting of the blade portion and the base portion, the blade portion and the base portion can be made of the same carbon steel, and the hardness of the blade portion can be made higher than that of the base portion in the quenching process.

In the tooth profile blade 3A of FIG. 1, the inner shape of the blade portion 3a is the outer shape of the helical gear shape, and the inner shape of the base portion 3b is larger than the inner shape of the blade portion 3a. The tooth profile blade 3A can smoothly guide the cut gear mat 11 to the base portion 3b. The tooth profile blade 3A makes the height (h) of the blade portion 3a, that is, the axial length of the tooth profile blade 3A, preferably equal to or longer than the thickness of the gear mat 11 to be cut. The blade portion 3a can cut the gear mat 11 into an accurate helical gear shape. This is because the cut gear mat 11 can be guided to the inside of the cutting tool portion. However, the height (h) of the blade portion 3a can be made lower than the thickness of the gear mat 11. This is because the cushioning property of the fiber mat 10 can elastically deform the helical gear shape of the cut gear mat 11 and guide it to the blade portion 3a and the base portion 3b.

In the tooth profile blade 3A of FIG. 1, the height (H) of the base portion 3b is made larger than the height (h) of the blade portion 3a. The tooth profile blade 3A has a large cushioning action of the base portion 3b, and the fiber mat 10 can be smoothly punched into the gear mat 11 with less impact at the time of punching. Another feature is that the base portion 3b can be connected to the upper and lower bases 6 and easily attached to the upper and lower bases 6. Further, since the base portion 3b, which has a larger internal shape than the blade portion 3a, can guide the cut gear mat 11 inward without deforming or slightly deforming the cut gear mat 11, a plurality of cut gears By guiding the mat 11 to the base portion 3b and taking it out smoothly, the fiber mat 10 can be cut efficiently.

The tooth profile blade 3A of FIG. 1 is manufactured by connecting the blade portion 3a and the base portion 3b in an integral structure by a welded structure. The tooth profile blade 3A connected to the integral structure is manufactured by connecting the non-quenched cutting blade and the non-quenched base portion to form an integral structure, and then quenching and grinding. As the steel material to be processed into the blade portion 3a and the base portion 3b, carbon steel having excellent workability is suitable. For carbon steel, the carbon content is adjusted to the optimum value for the application in consideration of the required hardness and brittleness. The tooth profile blade 3A can be made hard by increasing the carbon content. However, since it becomes brittle as the carbon content increases, the carbon content of the steel material processed into the cutting tool portion 3a is, for example, 0.4% or more and 1.4% or less, preferably 0.45% or more. However, it should be 0.7% or less. The base portion 3b is a carbon steel sheet having a lower carbon content than the blade portion 3a, for example, 0.3% or more and 1% or less, preferably 0.4% or more and 0.6% or less of carbon. Use steel plate. However, the cutting tool portion and the base portion can also be made of a steel material having the same carbonization content. In the present specification, the carbon content of the steel material is a mass percent concentration.

In the cutting process, the cutting tool portion 3a is formed into a tubular shape by electric discharge machining of a steel material, and then cut with a grindstone or a file in the grinding process to provide a helical gear cutting edge 4 at the tip to form a cutting cutting tool 31. The cutting blade is connected to the base portion in an integral structure and hardened in the quenching process to obtain a hardened blade, and the hardened blade is further ground to produce the cutting blade. The base portion 3b is manufactured by processing a cylindrical carbon steel plate into a cylindrical shape and cutting the inner surface, or by grinding carbon steel.

FIG. 7 shows a manufacturing process of a tooth profile blade. However, this figure shows a manufacturing process of the blade portion 3a of the tooth profile blade 3A in which the blade portion 3a and the base portion 3b are made of different steel materials and connected to an integral structure. The blade portion 3a manufactured in this step is formed into a tooth profile blade portion 3A by connecting the base portion 3b to an integral structure.
Although not shown, the tooth profile blade can be manufactured by cutting one metal block, but the tooth profile blade manufactured by this method is shown by cutting the inner and outer surfaces of the metal block with the blade in the cutting process. Manufactured as the shape shown in 1.

[Cutting process]
This step includes a cutting step of cutting the inner surface and a grinding step of grinding the outer surface of the cylinder whose inner surface has been machined in the cutting step.

[Cutting process]
In the cutting step, the metal block 19 is electric-discharge machined to form a cylinder 20 having a predetermined thickness. In the electric discharge machining, a wire (not shown) is passed through the metal block 19 and an electric discharge is performed between the wire and the metal block 19 to cut the metal block 19. In electric discharge machining, the wire and the metal block 19 are relatively moved to separate the tubular body 20 from the metal block 19. Vertical grooves 21 and ridges 22 inclined with respect to the central axis are alternately provided in parallel on the inner surface of the tubular body 20 separated from the metal block 19 by electric discharge machining. The tubular body 20 provided with the vertical groove 21 and the ridge 22 on the inner surface has the shape of the inner surface as the outer shape of the helical gear. The flutes 21 and the ridges 22 are inclined with respect to the central axis of the tubular body 20, and the inclination angle is made equal to the inclination angle with respect to the rotation axis of the teeth provided on the outer periphery of the helical gear.

The tubular body 20 is separated from the metal block of the steel material by electric discharge machining so that the outer surface thereof has a shape along a cylinder. The tubular body 20 having a columnar outer surface and a helical gear shape on the inner surface is easily machined from a metal block by electric discharge machining. This is because both the inner surface and the outer surface of the tubular body 20 can be machined by relatively moving the metal block and the wire for electric discharge machining. The tubular body 20 is machined by electric discharge machining to have an inner surface shape of a helical gear shape, or, although not shown, an inner surface shape of which increases from the front end to the rear end. Further, the tubular body 20 is electric-discharge-machined into a tapered shape that increases the outer surface shape from the front end to the rear end, or from the front end to the rear end to the same outer shape. The method of discharging a cylindrical or cylindrical metal block into a cylinder is to use a cylindrical or cylindrical metal block equal to the diameter of the cylinder 20 and discharge-process only the inner shape of the cylinder. Can be manufactured.

[Grinding process]
In this step, the outer surface of the tubular body 20 having a cylindrical outer surface is ground, and the outer surface is ground into a taper shape that increases the outer diameter from the front end to the rear end. For a cylinder whose outer surface is tapered by electric discharge machining, the step of grinding the outer surface to taper can be omitted. Further, in this step, the outer surface of the tip portion of the tubular body 20 is ground to obtain a cutting blade 31 having a tooth tip blade 4A at the tip.

The cutting edge 4 of the cutting blade 31 cuts the fiber mat 10 into a helical gear shape, and is a cutting edge that connects the tooth tip blade 4A, the tooth surface blade 4C, and the tooth bottom blade 4B. The tooth tip blade 4A cuts the tooth tip surface portion of the helical gear, the tooth surface blade 4C cuts the tooth surface portion of the helical gear, and the tooth bottom blade 4B cuts the tooth bottom portion of the gear. To do. The cutting edge 4 including the tooth tip blade 4A, the tooth surface blade 4C, and the tooth bottom blade 4B is provided by grinding the outer surface of the tubular body 20.

In the grinding step, the V-groove 16 is ground and provided on the outer surface of the tip of the tubular body 20, and the tooth surface blade 4C and the tooth bottom blade 4B are provided. The V-groove 16 is provided on the outside of the ridge 22 provided on the inner surface of the tubular body 20. The V-groove 16 is provided at a position facing the ridge 22. Since the ridge 22 is inclined with respect to the central axis of the tubular body 20, the V-groove 16 is also inclined with respect to the central axis. In the V-groove 16, both sides of the tip edge are the tooth surface blades 4C, and the groove bottom portion is the tooth bottom blade 4B. Since the groove bottom of the V-groove 16 has the cutting edge 4 as the tooth bottom blade 4B, the groove bottom can be curved with a predetermined radius of curvature as shown in FIG. 7, or may have a predetermined width (not shown). .. The V-groove 16 has a shape that gradually becomes shallower from the front end to the rear end of the tubular body 20, and the blade angle of the tooth bottom blade 4B is made larger than the blade angle of the tooth tip blade 4A.

FIG. 5 is a cross-sectional view of the V-groove 16 cut in the longitudinal direction. This figure shows the cross-sectional shapes of the tooth tip blade 4A and the tooth bottom blade 4B. In this figure, the solid line shows the cross-sectional shape of the tooth bottom blade 4B cut along the longitudinal direction of the V-groove 16, and the chain line shows the cross-sectional shape of the tooth tip blade 4A cut along the longitudinal direction of the vertical groove 21. There is. The blade angle of the tooth bottom blade 4B becomes larger than the blade angle of the tooth tip blade 4A by making the V-groove 16 shallow from the tip to the rear end. As shown in the front view of FIG. 3, the tooth profile blades 3A of FIGS. 1 and 3 do not extend the V groove 16 to the rear end (lower end in the drawing), and the tooth bottom blade 4B is provided on the inner surface of the tubular body 20. Since it is provided in the protruding portion, the thickness (W1) of the rear end portion of the blade portion 3a provided with the tooth bottom blade 4B is the thickness of the rear end portion of the blade portion 3a provided with the tooth tip blade 4A. Thicker than (W2). This unique structure is extremely important in the realization of the tooth profile blade 3A having excellent durability. This is because, in the punching process of the fiber mat 10, the deformation distortion of the tooth bottom blade 4B protruding inward is prevented and the durability is improved.

In the blade portion 3a of the tooth profile blade 3A shown in FIGS. 1 to 5, the V groove 16 is gradually made shallower toward the rear end, and the thickness (W1) of the rear end portion of the portion provided with the tooth bottom blade 4B is further increased. By making the thickness (W2) of the rear end portion of the portion provided with the tooth tip blade 4A larger, the inclination angle of the tooth bottom line 17 from the tooth bottom blade 4B to the rear end of the blade portion 3a which is the tooth profile blade 3A. That is, the blade angle (α1) of the tooth bottom blade 4B is made larger than the blade angle (α2) of the tooth tip blade 4A, which is the inclination angle from the tooth tip blade 4A to the rear end of the tooth profile blade 3A.

Further, the tip portion of the cutting edge 4 is ground on the outer surface with a width of 1 mm to 5 mm from the tip edge, the blade angle is gradually increased toward the tip, and the finishing angle of the tip of the cutting edge 4 is 10 degrees or more. Durability can be improved by setting the temperature to 15 degrees or less, more preferably 15 degrees or more and 45 degrees or less. Further, the cutting tool portion 3a can be processed into a tapered shape in which a part of the inner surface surface of the tubular body 20 is ground to gradually increase the inner shape from the tip end to the rear end end.

[Connecting process between cutting tool and base]
The cutting blade 31, which is the blade portion obtained in the grinding process, has a base portion 3b connected to the rear end in an integral structure without quenching. The base portion 3b is manufactured by cutting or grinding the inner surface of a tubular carbon steel plate. In the tooth profile blade 3A, the inner shape of the base portion 3b is made larger than the inner shape of the blade portion 3a. The inner shape of the base portion 3b connected to the cutting blade 31 to be the cutting tool portion can be increased, and the inner shape can be gradually increased from the front end to the rear end. In this tooth profile blade 3A, the ridge 22 provided on the base portion 3b can be lowered from the tip toward the rear end so that the inner shape of the rear end can be made larger than the tip, so that the cut gear mat 11 can be smoothed. It can be guided to the inside of the base portion 3b, and the cut gear mat 11 can be smoothly separated from the rear end of the tooth profile blade 3A.

[Quenching process]
In a state where the cutting tool 31 that is not hardened and the base portion 3b are connected to the integral structure, the cutting tool 4 is hardened in order to harden it. In the quenching step, the HRC hardness of the cutting edge 4 is 62 or more, preferably about 65. The hardness of the cutting edge 4 can be made hard to prolong the life, but if it is too hard, it becomes brittle and easily damaged during punching. Therefore, the quenching step is quenching so that the HRC hardness of the cutting edge 4 is higher than 62, preferably higher than 64, and lower than 72, preferably lower than 66. The hardness of the cutting edge 4 after quenching is controlled by the carbon content and the quenching temperature. The quenching temperature can be raised to increase the hardness of the cutting edge 4, and the temperature can be lowered to lower the hardness. For example, carbon steel having a carbon content of 0.6% can be used as the steel material of the cutting tool portion 3a, the quenching temperature can be set to 780 ° C to 950 ° C, and the HRC hardness can be set to the range of 62 to 72. The tooth profile blade 3A having an HRC hardness of 65 after quenching has a carbon content of 0.6% and a quenching temperature of 850 ° C.

[Polishing process]
The hardened blade is finally finished and polished to obtain a sharp cutting edge 4. In particular, in the grinding process, the outer surface of the tip portion of the cutting edge 4 is polished to adjust the finishing angle to the optimum value.

The tooth profile blade 3A is manufactured by the above process. In the cylindrical blade 3B, an elongated carbon steel plate is curved along the cylinder, both ends are welded to form a cylinder, and the tip portion is ground to form a cutting edge 4. After the above, it is hardened, and after the quenching, it is further finished and polished. The cylindrical blade 3B is made of a carbon steel plate of 2 mm to 5 mm. The carbon steel sheet is curved and processed into a cylindrical shape in the pre-quenching step, and a circular sub-cutting edge 4DD is provided at the tip edge. The cylindrical carbon steel sheet is provided with a circular sub-blade edge 4DD by grinding the inner surface of the tip portion.

The cylindrical blade 3B has a shape in which the blade angle gradually increases toward the sub-edge 4DD, and prevents the sub-edge 4DD from being damaged by the impact at the time of punching. In the cylindrical blade 3B in which the blade angle is gradually increased toward the tip, the finishing angle of the tip affects the durability and cutting ability. Therefore, the finishing angle of the cylindrical blade 3B is preferably 15 degrees or more and 60 degrees or less, and optimally about 30 degrees. The cylindrical blade 3B is hardened so that the HRC hardness of the cutting edge 4 is equivalent to that of the tooth profile blade 3A.

The cylindrical blade 3B is fixed to the tooth profile blade 3A via the connecting metal fitting 23. The connecting metal fitting 23 is fixed by welding to the rear ends of the cylindrical blade 3B and the tooth profile blade 3A, the cylindrical blade 3B is arranged at a concentric position of the tooth profile blade 3A, and the cutting edge 4 of the cylindrical blade 3B and the tooth profile blade 3A is placed. Place on the same plane. In the punched blade 3 of FIG. 4, four connecting metal fittings 23 are radially fixed between the cylindrical blade 3B and the tooth profile blade 3A. One end of the connecting metal fitting 23 of FIG. 4 is welded and fixed to the outside of the cylindrical blade 3B, and the other end is inserted into a fitting recess provided in the tooth profile blade 3A and fixed by welding. The rear end faces of the connecting metal fitting 23, the cylindrical blade 3B, and the tooth profile blade 3A are arranged on the same plane. The punched blade 3 cuts the fiber mat 10 by pressing the rear end surface on which the connecting metal fitting 23, the cylindrical blade 3B, and the tooth profile blade 3A are arranged on the same plane with the blade driving mechanism 5.

The cutting device of FIG. 8 provided with the above punching blade cuts the fiber mat used for the helical gear of the fiber reinforced plastic into the helical gear shape in the following steps.
[Process of setting the fiber mat on the cradle]
The upper and lower pedestals 6 are lifted by the cylinder 7, and the punching blade 3 fixed to the lower surface of the upper and lower pedestals 6 is arranged in the raised position. In this state, the punching blade 3 is arranged away from the cradle 1.
The fiber mat 10 is placed on the cut surface 2 of the cradle 1. An elastic sheet 1A is laminated between the fiber mat 10 and the cut surface 2.

[Descent of the punched blade]
Push down the upper and lower base 6 with the cylinder. Since the upper and lower pedestals 6 descend while rotating in the horizontal plane, the punching blade 3 cuts the fiber mat 10. At this time, since the punching blade 3 descends while rotating, the fiber mat 10 is cut into a helical gear shape by the cutting edge 4. The cutting edge 4 of the punching blade 3 cuts the fiber mat 10 into the helical gear-shaped gear mat 11, and then further cuts into the elastic sheet to surely cut the fiber mat 10.

Since the punched blade 3 has the cylindrical blade 3B fixed inside the tooth profile blade 3A, the tooth profile blade 3A cuts the outer shape of the gear mat 11 into a helical gear shape, and the cylindrical blade 3B has a through hole in the center of the gear mat 11. Is provided. Since the tooth profile blade 3A and the cylindrical blade 3B have the cutting edge 4 arranged in the same plane, both the tooth profile blade 3A and the cylindrical blade 3B cut the fiber mat 10 and cut it into the gear mat 11. At the time of cutting, the tooth profile blade 3A descends while rotating, cuts the outer shape of the gear mat 11 into a helical gear shape, and cuts a through hole in the gear mat 11 while rotating the cylindrical blade 3B. Since the cylindrical blade 3B that provides a through hole in the gear mat 11 while rotating rotates in the circumferential direction, the cutting edge 4 moves in the circumferential direction in the through hole to ensure a clean penetration in the center of the gear mat 11. Open a hole.

The cylindrical blade 3B is fixed inside the tooth profile blade 3A, and the fiber mat 10 is cut at the same time by both the tooth profile blade 3A and the cylindrical blade 3B. The punched blade 3 makes the gear mat 11 to be cut into an accurate helical gear shape. Can be cut. This is because the fiber mat 10 is sandwiched between the tooth profile blade 3A and the cylindrical blade 3B and cut into a helical gear shape having a through hole in the center. When the elastically deformable fiber mat 10 is punched with a punching blade 3 and cut into a helical gear shape without a through hole, the outer peripheral surface is deformed into a shape having a recess in the center and cut as shown in (1) of FIG. Tends to be. This is because, as shown by the chain line in FIG. 10, the punching blade 3 is in a state of crushing the fiber mat 10 and is cut in a state where the upper surface is projected and greatly curved. On the other hand, when the fiber mat 10 is cut by the punched blade 3 in which the cylindrical blade 3B is fixed inside the tooth profile blade 3A, both the tooth profile blade 3A and the cylindrical blade 3B are made of fibers as shown by the solid line in FIG. Since it is pressed against the surface of the mat 10 and cut, the height of the curved and protruding portion between the tooth profile blade 3A and the cylindrical blade 3B is reduced, and the surface is cut in a state of being almost flat, and FIG. 9 shows. As shown in (2), the recesses in the central portions of the outer peripheral surface and the inner peripheral surface can be made smaller. This realizes a feature that both the outer peripheral surface and the inner peripheral surface of the cut gear mat can be cut into a more accurate helical gear shape.

[Process of taking out the cut gear mat]
The cut gear mat 11 is inserted between the tooth profile blade 3A and the cylindrical blade 3B. The upper and lower pedestals 6 are raised by the cylinder, the punched blade 3 is raised by the upper and lower pedestals 6, and the gear mat 11 inserted inside the punched blade 3 is extracted from the punched blade 3.
The fiber mat 10 is cut into the gear mat 11 by repeating the above steps.

1 ... Cradle 1A ... Elastic sheet 2 ... Cut surface 3 ... Punched blade 3A ... Toothed blade 3a ... Blade part 3b ... Base part 31 ... Cutting blade
3B ... Cylindrical blade 4 ... Blade edge 4A ... Tooth tip blade 4B ... Tooth bottom blade 4C ... Tooth surface blade 4D ... Sub blade edge 5 ... Blade drive mechanism 5A ... Rotation mechanism 6 ... Upper and lower base 7 ... Cylinder 10 ... Fiber mat 11 ... Gear mat 11A ... Cutting edge 16 ... V groove 17 ... Tooth bottom line 18 ... Outer line 19 ... Metal block 20 ... Cylinder 21 ... Vertical groove 22 ... Convex 23 ... Connecting bracket 24 ... Guide convex part 25 ... Guide groove 26 ... Spiral guide

Claims (12)

A pedestal having a cutting surface on the upper surface for cutting on which a fiber mat is placed, and a cutting edge that moves toward the cutting surface of the pedestal and cuts the fiber mat of the cutting surface into a helical gear-shaped gear mat. A punched blade having a tooth profile blade provided in
It is equipped with a blade drive mechanism that reciprocates the punched blade.
The tooth profile cuts the tooth surface of the gear by being connected to the tooth tip blade that cuts the tooth tip circle of the gear, the tooth bottom blade that cuts the tooth bottom of the gear, and the tooth tip blade and the tooth bottom blade. Has a cutting edge with a tooth surface blade to
Further, the tooth profile blade has the tooth bottom blade and the tooth surface blade as the tip edge, and a plurality of V-grooves extending from the tip edge toward the rear end are provided on the outer peripheral surface at predetermined intervals, and the inner circumference thereof. The surface is provided with flutes and ridges extending in the reciprocating direction from the front end to the rear end alternately at predetermined intervals.
Furthermore, the tooth profile blade
The tip edge of the flute is the tooth tip blade,
The tip edge between the flute and the ridge is the tooth surface blade,
The tip edge of the ridge is used as the tooth bottom blade.
Further, in the tooth profile blade, the ridges are arranged at positions facing the inside of the V groove, and the V groove and the ridges are tilted at a constant inclination angle with respect to the central axis of the tooth profile blade. Arranged and
Further, the blade drive mechanism includes a rotation mechanism that cuts the fiber mat of the cradle while rotating the punched blade with the central axis of the punched blade as a rotation axis.
A fiber mat cutting device used for a helical gear made of fiber reinforced plastic having a structure in which the blade driving mechanism punches and cuts the fiber mat of the cradle while rotating the punched blade. A fiber mat cutting device used for a helical gear made of a fiber reinforced plastic according to claim 1.
The V-groove gradually becomes shallower from the cutting edge toward the rear end of the tooth profile.
The blade angle (α1) of the tooth bottom line from the tooth bottom blade to the rear end of the tooth profile blade is larger than the blade angle (α2) of the tooth tip surface from the tooth tip blade to the rear end of the tooth profile blade.
Further, the tooth profile blade is fiber-reinforced so that the thickness (W1) of the rear end portion of the tooth bottom blade is thicker than the thickness (W2) of the rear end portion of the tooth tip blade. A fiber mat cutting device used for plastic helical gears. A fiber mat cutting device used for a helical gear made of a fiber reinforced plastic according to claim 1 or 2.
The tooth profile blade
A cutting tool portion having the cutting edge provided on the tip edge,
It consists of a base portion that is integrally connected to the rear end side of the blade portion.
A fiber mat cutting device used for a helical gear made of fiber reinforced plastic, wherein the hardness of the base portion is lower than the hardness of the cutting tool portion. A fiber mat cutting device used for a helical gear made of a fiber reinforced plastic according to claim 3.
A fiber mat used for a fiber reinforced plastic helical gear, wherein the blade portion and the base portion are made of different steel materials, and the blade portion and the base portion are connected by a welded structure. Cutting device. A fiber mat cutting device used for a helical gear made of a fiber reinforced plastic according to any one of claims 1 to 4.
The punched blade is arranged inside the tooth profile blade and has a cylindrical blade that cuts a through hole in the gear mat.
The cylindrical blade has a sub-edge on the tip edge, and the sub-edge is arranged on the same plane as the blade provided at the tip of the tooth profile and is fixed to the tooth profile. A fiber mat cutting device used for helical gears made of. A method for manufacturing a fiber mat punching blade having a tooth profile blade that is placed on the cut surface of a cradle and punched into a helical gear-shaped gear mat.
The manufacturing process of the tooth profile blade
A cutting process in which a steel material is formed into a tubular shape having a predetermined thickness, and a cutting edge for cutting the fiber mat into a helical gear shape is provided at the tip edge thereof.
The quenching process of quenching the cutting blade to obtain a quenching blade, and
It consists of a polishing process for polishing the hardened blade.
The cutting process comprises an inner surface cutting process in which ridges and vertical grooves are alternately provided in a parallel posture on the inner peripheral surface at regular intervals, and an outer surface cutting process in which V grooves are provided on the outer peripheral surface at regular intervals.
A V-groove provided in the outer surface cutting step is arranged at a position facing the outer surface of the convex strip provided in the inner surface cutting step, and the tip of the V-groove is used as a tooth bottom blade and a tooth surface blade between the V-grooves. With a tooth tip blade
Further, the ridge, the vertical groove, and the V groove are processed so as to be inclined at a constant angle with respect to the central axis.
Furthermore, the V-groove provided in the outer surface cutting step is made shallower from the tip edge toward the rear end so that the blade angle (α1) of the tooth bottom blade is larger than the blade angle (α2) of the tooth tip blade. Further, the thickness of the rear end portion of the tooth profile blade is such that the thickness of the rear end portion of the tooth bottom blade (W1) is thicker than the thickness of the rear end portion of the tooth tip blade (W2). A method for manufacturing fiber mat punching blades used for helical gears made of fiber reinforced plastic, which is characterized by being processed. A method for manufacturing a fiber mat punching blade used for a helical gear made of a fiber reinforced plastic according to claim 6.
A method for manufacturing a fiber mat punching blade used for a helical gear made of a fiber reinforced plastic, wherein the inner surface cutting step is an electric discharge machining of a steel material to provide ridges and flutes on the inner surface. A cutting method in which a fiber mat used for a fiber reinforced plastic helical gear is placed on the cut surface of a cradle, and the fiber mat is punched into the outer shape of the helical gear with a punching blade to cut the fiber mat.
The punched blade is provided with a tooth tip that cuts the fiber mat from the cutting edge of the helical gear, a tooth bottom blade that cuts the tooth bottom of the helical gear, and a tooth surface blade that cuts the tooth surface of the helical gear. Using a cylindrical tooth-shaped blade provided on the tip edge,
As the tooth profile is brought closer to the cut surface of the cradle, either or both of the tooth profile and the cradle are rotated, and the tooth profile and the cradle are relatively rotated to obtain the above. A method for cutting a fiber mat used for a helical gear made of a fiber reinforced plastic, which comprises cutting a fiber mat in the shape of a helical gear. The method for cutting a fiber mat used for a helical gear according to claim 8.
A method for cutting a fiber mat used for a helical gear, which comprises using a blade having all the following configurations A to C for the tooth profile blade.
A. The tooth profile blade has the tooth bottom blade and the tooth surface blade as the tip edge, and has a plurality of V-grooves extending from the tip edge toward the rear end on the outer peripheral surface at predetermined intervals and has an inner peripheral surface. Is provided with flutes and ridges extending in the reciprocating direction from the front end to the rear end alternately at predetermined intervals.
B. The tooth profile blade
The tip edge of the flute is the tooth tip blade,
The tip edge between the flute and the ridge is the tooth surface blade,
The tip edge of the ridge is used as the tooth bottom blade.
C. In the tooth profile blade, the protrusions are arranged at positions facing the inside of the V groove, and the V groove and the protrusions are arranged in a posture in which the protrusions are inclined at a constant inclination angle with respect to the central axis of the tooth profile blade. Become. The method for cutting a fiber mat used for a helical gear according to claim 9.
A method for cutting a fiber mat used for a helical gear, which comprises using a blade having the following configurations A and B for the tooth profile blade.
A. The V-groove gradually becomes shallower from the cutting edge toward the rear end of the tooth profile.
The blade angle (α1) of the tooth bottom line from the tooth bottom blade to the rear end of the tooth profile blade is larger than the blade angle (α2) of the tooth tip surface from the tooth tip blade to the rear end of the tooth profile blade.
B. In the tooth profile blade, the thickness (W1) of the rear end portion of the tooth bottom blade is made thicker than the thickness (W2) of the rear end portion of the tooth tip blade. A method for cutting a fiber mat used for a helical gear according to any one of claims 8 to 10.
The tooth profile includes a blade portion having the cutting edge provided on the tip edge and a base portion integrally connected to the rear end side of the cutting tool portion, and the hardness of the base portion is defined as the hardness of the blade portion. A method of cutting fiber mats used in helical gears, which is characterized by the use of blades that are lower than. A method for cutting a fiber mat used for a helical gear according to any one of claims 8 to 11.
A method for cutting a fiber mat used for a helical gear, which comprises using a blade having the following configurations A and B for the punched blade.
A. The punched blade includes a cylindrical blade that is concentrically located inside the toothed blade and is connected to the toothed blade.
B. The cylindrical blade has a sub-edge at the tip edge, and the sub-edge is arranged on the same plane as the blade provided at the tip of the tooth profile blade.

Images