JPH10156445A - Manufacture of reflecting plate and its device and reflecting plate manufacturing die - Google Patents

Abstract

PROBLEM TO BE SOLVED: To stably manufacture the reflecting plate whose inner surface is an excellent mirror finished surface by coating a specified average thickness of a working liquid on the whole surface of the zone coming into contact with the part being a mirror finished surface in the inner surface of the reflecting plate of the surface of a die and spinning while rotating the material to be worked together with the die. SOLUTION: In order to make the inner surface of the reflecting plate the excellent mirror finished surface, the surface roughness of the zone coming into contact with the part is necessitated to finish to be at least <=0.4μm. A wiping tool 11 is connected to a coating tool 10 with a connecting rod 12 so as to be driven with the coating tool 10. The connecting rod 12 is fixed to an arm, and the arm is copied from the die 1 with a required driving mechanism. The working liquid film 3a is formed on the surface of the die after the coating tool 10 copies, however most of the film thickness is generally specified to be >=0.6μm in average thickness. The working liquid film 3 of >= the same extent as the surface roughness of the die to <=0.6μm in average thickness is successively formed on the surface of the die after the wiping tool 11 copies.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reflector for producing an axially symmetric reflector by spinning, in which a roller is used to press the workpiece against a mold while rotating the workpiece together with the mold. The present invention relates to a method and an apparatus for manufacturing a plate, and a method for manufacturing the reflector and a mold for manufacturing a reflector used in the apparatus, and more particularly to a reflector suitable for spinning a product requiring a good mirror surface on the inner surface. The present invention relates to a method and an apparatus for manufacturing the same and a mold for manufacturing a reflection plate.

[0002]

2. Description of the Related Art FIG. 15 is a partial cross-sectional view showing a roller and a main part of a workpiece during spinning by a reflector manufacturing apparatus for realizing a conventional reflector manufacturing method. In the figure, 1 is a mold for manufacturing a reflection plate, 2 is a workpiece, 3 is a working liquid film, and 5 is a roller. In the conventional spinning process, first, in order to prevent the workpiece 2 from adhering to the mold 1, a working liquid film 3 is manually formed on the surface of the mold that is being rotated by a rotating mechanism (not shown). . That is, the working fluid is impregnated into a tool having excellent liquid impregnating properties, such as work gloves, rags, sponges, etc., and is imitated by the mold 1. The working liquid film 3 is desirably thin and uniform. Therefore, if necessary, of the working fluid applied to the mold surface, the excess working fluid is wiped off using a tool such as a work glove, a rag, a sponge, etc., which is different from the working fluid used for the coating operation, and is thinly applied to the mold surface. Although a uniform working liquid film 3 is formed, this work requires a high degree of skill, and the working liquid film 3 is often thick and non-uniform. Thereafter, once the rotation of the mold 1 is stopped, the workpiece 2 is sandwiched between the molds 1 by a tailstock (not shown), and when the mold 1 is rotated again, the workpiece 2 rotates together with the mold 1. Next, as shown in FIG. 16 (a) or (b) in the document “Rotating” (issued by Corona Co., Ltd. in December 1990), the roller 5 is moved so that the die shape is formed on the workpiece 2. To beat. In addition, the surface of the workpiece 2 is roughened in the process of falling down (plastically deforming).

The workpiece 2 having a roughened surface is pressed by the mold 1 and comes into contact with the mold surface. Since the surface roughness of the mold is generally equal to or less than the surface roughness of a good mirror surface portion of the inner surface of the product, it is sufficiently smooth as compared with the surface roughness of the roughened workpiece 2, which is Transcribed. The reason why the inner surface of the product becomes a mirror surface or a non-mirror surface depends on the film thickness of the working fluid introduced between the mold 1 and the work material 2 when the work material 2 is pressed against the mold 1. This is because the contact state between the surface of the work material and the surface of the mold, which are roughened accordingly, differs, and the degree to which the roughness of the mold surface is transferred to the surface of the work material is different.

[0004]

Since the conventional method and apparatus for manufacturing a reflection plate and the mold for manufacturing the reflection plate are constructed as described above, the inner surface is mirror-finished by spinning of the reflection plate or the like. For a required product, whether or not a good mirror surface can be formed depends on the delicate conditions such as the thickness of the working fluid on the mold surface and the contact state between the workpiece and the mold surface. There is a problem that it is difficult to form a mirror surface.

Further, in order to form a good mirror surface on the inner surface of the product, it is necessary to make the working liquid film formed on the mold surface thin and uniform, but the appropriate value of the film thickness has been clarified. There was a problem that there was not.

Further, the work of applying the working fluid is a manual operation, and the work of applying and wiping the working fluid to a rotating mold is highly dangerous, and it is very difficult to form a thin and uniform working fluid film. There is a problem that the operation requires skill and is not easy for ordinary workers.

Further, in order to obtain a good mirror surface, it is necessary to sufficiently polish the mold surface. However, since the mold surface roughness required for this purpose has not been clarified, the mold surface must be unnecessarily polished. Polishing takes a lot of time, and conversely, using a mold with insufficient mold surface polishing results in a good mirror surface and re-polishing. There was also a problem that needs to be improved.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-described problems, and a method and apparatus for manufacturing a reflector capable of stably manufacturing a reflector having a good inner mirror surface are provided. The purpose is to obtain a mold.

[0009]

According to a first aspect of the present invention, there is provided a method of manufacturing a reflector, comprising: forming a mold having a surface roughness of 0.4 μm or less at least in a region in contact with a mirror surface of an inner surface of the reflector; Applying a working liquid having an average thickness equal to or more than 0.6 μm or less as an average thickness over the entire surface of the mold in contact with at least a portion of the inner surface of the reflecting plate which is to be a mirror surface on the surface of the mold, A spinning process is performed in which the workpiece is pressed against the mold by a roller that moves along the surface of the mold while rotating the workpiece together with the mold.

According to a second aspect of the present invention, there is provided a method of manufacturing a reflector, wherein a working fluid having a kinematic viscosity at 20 ° C. of 40 mm ² / s or less is impregnated into a coating tool having excellent liquid impregnating properties, and then the coating tool is formed. A working fluid application step of pressing the mold against a rotating mold, and pressing a wiping tool having excellent liquid absorbability against the mold to have an average thickness equal to or greater than the surface roughness of the mold 0 A working liquid film forming step of forming a working liquid film of 0.6 μm or less, and pressing the work material against the mold by a roller moving along the surface of the mold while rotating the work material together with the mold. And a spinning process for performing a spinning process for forming by molding.

According to a third aspect of the present invention, there is provided a method of manufacturing a reflecting plate, comprising: converting a working fluid having a kinematic viscosity at 20 ° C. of 40 mm ² / s or less into fine particles having a particle size of 10 μm or less into a rotating mold. A working fluid spraying forming step of spraying to form a working fluid film having an average thickness equal to or greater than the surface roughness of the mold and 0.6 μm or less, and rotating the workpiece together with the mold to the surface of the mold. And a spinning process of performing a spinning process of pressing the workpiece to the mold with a roller that moves along the spinning process.

According to a fourth aspect of the present invention, there is provided a method of manufacturing a reflecting plate, comprising:
The working fluid containing 2 g / l chromic anhydride is used.

According to a fifth aspect of the present invention, in the method of manufacturing a reflection plate, a region of 1% to 10% of a diameter of the workpiece from an outer edge of the workpiece that rotates together with the mold is defined as a rotation axis of the mold. The method is provided with a workpiece outer edge processing step of turning an angle to 45 ° to 80 ° or 100 ° to 135 °.

According to a sixth aspect of the present invention, there is provided an apparatus for manufacturing a reflection plate, which is formed in a cylindrical shape, an angle between a rotation axis of the reflection plate and a rotation axis of a mold is 120 ° to 150 °, and the material is in contact with a workpiece. When performing the above, the distance between the lower end of the outer peripheral surface of the cylindrical shape and the surface of the mold is kept constant within a range of 3 mm to 10 mm, and a first roller that follows the surface of the mold, and is driven by the first roller to form the cover. A second roller having a curved portion having a radius of curvature of not less than 5 times and not more than 20 times the thickness of the work material in a cross section including the rotation axis, while rotating the work material together with the mold, the work material is formed into a mold. This is provided with a configuration for pressing and molding.

According to a seventh aspect of the present invention, in the apparatus for manufacturing a reflector, the first roller is made of a material having an elastic modulus of 10 ⁵ kgf / cm ² or less, and the second roller is made of a material equal to or more than the first roller. It is made of a material having an elastic modulus.

According to an eighth aspect of the present invention, there is provided an apparatus for manufacturing a reflection plate, wherein the length is equal to or greater than the radial length of a portion of the workpiece to be plastically deformed, and the angle of contact with the workpiece is the rotation axis of the mold. A first roller component having a linear portion of 120 ° to 150 ° in a cross section including the rotation axis, and a curved portion having a radius of curvature of 5 to 20 times the thickness of the workpiece to the rotation axis. And a second roller constituting portion having a cross section including: a roller that moves along the surface of the mold.

According to a ninth aspect of the present invention, in the reflector manufacturing apparatus, the first roller component having a curved portion having a radius of curvature of five times or more the thickness of the workpiece in a cross section including the rotation axis of the roller. And a curved portion having a radius of curvature equal to or smaller than the radius of curvature of the first roller constituting portion in a cross section including the rotation axis of the roller, which is not less than 5 times and not more than 20 times the thickness of the workpiece. And a roller comprising two roller components.

According to a tenth aspect of the present invention, in the apparatus for manufacturing a reflection plate, the first roller constituting part is provided with an elastic modulus of 10 ⁵ kgf / c.
m ² or less, and the second roller component is made of a material having an elastic modulus higher than that of the first roller component.

According to the eleventh aspect of the present invention, the metal mold for manufacturing the reflector has a thermal expansion coefficient of 4.0 × 10 ^{−6 to} 6.5 × 10.
^The thickness of the mold is 0.5 μm at least in a region in contact with the mirror surface of the inner surface of the reflector on the surface of the mold made of a material having a thickness of ^-6 / K
A diamond-like carbon film having a surface roughness of 0.4 μm or less and a thickness of 8 μm or less is formed.

According to a twelfth aspect of the present invention, there is provided a reflecting plate manufacturing die in contact with a base material mainly composed of Fe and at least a part of a die surface made of the base material, which is a mirror surface of an inner surface of the reflecting plate. The thickness formed in the region is 0.5 μm to 8 μm,
A diamond-like carbon film having a surface roughness of 0.4 μm or less, and a thermal expansion coefficient of 4.0 × 10 ^{−6 to} 6.5 × 10 ^−6.
/ K material and an intermediate layer having a thickness of 0.3 μm or more and formed immediately below the diamond-like carbon film.

According to a thirteenth aspect of the present invention, in the metal mold for manufacturing a reflector plate, the surface roughness of at least a region in contact with a mirror surface of the inner surface of the reflector plate is 0.4 μm.
In this case, a base material which is a porous sintered body described below is used.

[0022]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below. Embodiment 1 FIG. FIG. 1 is a view showing the essentials of a mold, a roller, and a workpiece for manufacturing a reflector when spinning is performed in a reflector manufacturing apparatus for implementing the reflector manufacturing method according to Embodiment 1 of the present invention. It is sectional drawing which shows a part. In the figure, 1 is a mold, 2 is a workpiece, 3 is a working liquid film, 5 is a roller, 6 is a rotating shaft of the roller, and the roller 5 is a mold 1
When it comes into contact with the workpiece 2 rotating together with the mold 1, the workpiece 2 rotates together with the mold 1 around the rotation shaft 6. In each step of manufacturing the mold 1, first, for example, a tool steel prepared as a mold base material is subjected to machining such as electric discharge machining, cutting, grinding, polishing, etc., and is processed into a desired shape satisfying required accuracy. . At this time, in order to make the inner surface of the reflector a good mirror surface, it is necessary to finish the surface roughness of at least a region in contact with the mirror surface portion of the inner surface of the reflector to be 0.4 μm or less. If the surface roughness of the area of the mold 1 is larger than 0.4 μm, the workpiece 2 adheres to or sticks to the mold surface, and the mold 1 is chipped, so that a good mirror surface cannot be obtained. Surface roughness may be greater than 0.4 μm on the mold surface in areas where good mirror surfaces are not required.
In addition, alloy tool steel (JI
S: SKD11) and high-speed tool steel (JIS: SKH5)
In 1), it is desirable to perform heat treatment such as quenching and tempering in order to secure sufficiently large hardness and appropriate toughness, and to adjust the hardness to Rockwell hardness HRC of about 58 to 64.

Next, a method of manufacturing a reflector using the mold 1 will be described. First, a working fluid is applied to the surface of the rotating mold 1 in order to prevent the workpiece 2 from sticking to the mold 1. The thickness of the working liquid film 3 formed on the surface of the mold may be equal to or greater than the surface roughness of the mold and equal to or less than 0.6 μm in average thickness at least in a region in contact with a mirror surface of the inner surface of the reflector. desirable. Next, the rotation of the mold 1 is stopped, and the workpiece 2 is pinched by advancing a tail stock (not shown) to the mold 1, and when the mold 1 is rotated again, the workpiece 2 rotates together with the mold 1. Next, when the workpiece 2 is pressed against the mold 1 by the roller 5 and the roller 5 is made to follow the mold 1, a product having a mold shape, that is, a desired shape is obtained. Thereafter, the rotation of the mold 1 is stopped, the tail stock is retracted, and the product is removed from the mold 1.

Next, a method of forming the working liquid film 3 on the surface of the mold will be described with reference to FIG. FIG. 2 is a cross-sectional view showing a method of forming a working liquid film on a die surface. In the drawing, reference numeral 10 denotes an application tool excellent in liquid impregnation, 11 denotes a wiping tool excellent in liquid absorption, and 12 denotes a connecting rod. , 25 are mounting plates for the mold 1, 26
Is a drive shaft of the mold 1, and the wiping tool 11 is the application tool 1.
The application tool 10 is connected to the application tool 10 by a connecting rod 12 so as to follow 0. The connecting rod 12 is fixed to an arm (not shown), and the arm is made to follow the mold 1 by a required driving mechanism. In order to make the film thickness uniform, it is desirable to press at a constant pressure. The direction to be copied is shown by an arrow in the drawing as an example, but is not necessarily limited to this direction. After the coating tool 10 follows, the working liquid film 3a is formed on the mold surface.
m or more in many cases. Subsequently, after the wiping tool 11 follows, the working liquid film 3 having an average thickness equal to or more than the mold surface roughness and 0.6 μm or less is formed on the mold surface.

The reason that the lower limit of the average thickness of the film thickness is specified to be substantially the same as the surface roughness of the mold is that if it is less than this, a good mirror surface can be obtained on the inner surface of the reflector, but adhesion and seizure occur,
This is because the aesthetic appearance of the reflection plate is significantly impaired. Further, the upper limit is set to 0.6 μm because if the coating is performed with a film thickness greater than this, adhesion and seizure do not occur, but the thickness of the working fluid introduced between the mold 1 and the workpiece 2 is large. This is because the roughened surface of the workpiece does not sufficiently contact the mold surface, and the surface of the workpiece is not smoothed to a surface roughness required for a good mirror surface.

FIG. 3 shows the state of the mold surface and the working liquid film 3 when the working liquid film 3 having an average thickness approximately equal to the surface roughness of the mold is formed. In the figure, the surface roughness of the mold 1 is represented by Rd.
Then, the thickness of the working liquid film 3 covering the peaks of the unevenness existing on the mold surface is 0.5 Rd, and the thickness of the working liquid film 3 covering the valleys is 1.5 Rd. Also, the reason why the surface roughness of the mold 1 is set to 0.4 μm or less is that the surface roughness transferred to the inner surface of the product is equal to or greater than the surface roughness of the mold 1 serving as a transfer source. The roughness must be less than the surface roughness of the mirror part of the product whose inner surface can be regarded as a mirror surface.As a result of experiments, the surface roughness of the mirror surface part of the product whose inner surface can be regarded as a mirror surface was 0.4 μm or less. The surface roughness was determined in accordance with.

FIG. 4 is a sectional view showing a method of forming a working liquid film when forming a working liquid film by another method. In the figure, reference numeral 15 denotes an outlet, and 16 denotes an atomized working liquid. The working fluid is atomized by using an ultrasonic atomizer, a nozzle, etc. (not shown) so that the particle diameter becomes 10 μm or less, and the atomized working fluid 16 is guided to the outlet 15 and sprayed on the surface of the mold. . The outlet 15 is connected to a drive mechanism (not shown). When the mold 1 is moved while maintaining a constant distance and speed from the surface of the mold, the working liquid film 3 is formed on the surface of the mold. It is desirable that the film thickness of the working liquid film 3 is equal to or more than the surface roughness of the mold and 0.6 μm or less in average thickness. When the particle size of the atomized mist processing liquid 16 exceeds 10 μm, it is very difficult to reduce the thickness of the processing liquid film 3 to an average thickness of 0.6 μm or less.

As described above, according to the first embodiment, the mold surface roughness of the area in contact with the mirror surface of the inner surface of the reflector is 0.4 μm or less (the mirror surface of a product whose inner surface can be regarded as a mirror surface). Or less, which is enough surface roughness to make the inner surface of the product a mirror surface. Further, since the application tool 10 and the wiping tool 11 are made to imitate the mold surface at a constant pressure, it has been extremely difficult (at an average thickness) to apply the wiping liquid by the conventional manual work. It is possible to stably form the working liquid film 3 having a thickness equal to or greater than the roughness and equal to or less than 0.6 μm. The working fluid having a kinematic viscosity of 40 mm ² / s or less at 20 ° C. is used to reduce the thickness of the working fluid film 3 formed on the surface of the mold when applied to the mold 1. It becomes easy to apply to the average thickness. If the kinematic viscosity exceeds 40 mm ² / s, the spreading of the working fluid becomes poor and the coating operation becomes difficult.
When the workpiece 2 is pressed against the mold 1 by the roller 5, the mold 1
It is not preferable in that the amount of the working fluid introduced between the workpiece and the workpiece 2 increases as the kinematic viscosity increases.

When a processing liquid containing 5% or less of triethanolamine or a processing liquid containing 0.1 to 2 g / l of chromic anhydride is used, it is possible to perform anticorrosion treatment on the inner surface of the reflector while molding. it can. The processing method using the above-mentioned processing liquid has an effect that the anticorrosion treatment of the inner surface of the product can be performed while the product is formed, even when applied to spinning of a product that does not require a good mirror surface on the inner surface. If the shape of the mold 1 becomes complicated, it may be difficult to form the working liquid film 3. In that case, a working liquid film may be formed not on the surface of the mold but on the surface of the workpiece on the side in contact with the mold. The workpiece is rotated together with the mold, and a spinning process is performed in which the workpiece is pressed and molded. The formation of the working liquid film is performed by gloves,
4, a method using a tool such as a sponge, a method shown in FIG. 4, a coating tool excellent in liquid impregnation shown in FIG. 2, a method using a wiping tool excellent in liquid absorption, Any of the so-called spin coating methods of forming a working liquid film by dropping a working liquid at a position where the working liquid is rotated at 1,000 rpm to 10,000 rpm (like a record disk) may be used.

Embodiment 2 FIG. FIG. 5 is a cross-sectional view of a plane including a rotation axis of a roller in a manufacturing apparatus for a reflector according to a second embodiment of the present invention. In the figure, 5
Is a roller, 5a is a first roller component, 5b is a second roller component, and the first roller component 5a has a thickness 5 of the workpiece 2 in a cross section including the rotation shaft 6 of the roller. It has a curved portion 5 m having a radius of curvature twice or more, and is made of a material having an elastic modulus of 10 ⁵ kgf / cm ² or less. The second roller component 5b has a radius equal to or smaller than the radius of curvature of the curved portion 5m of the first roller component 5a which is not less than 5 times and not more than 20 times the thickness of the workpiece 2. It has a curved portion 5n and is made of a material whose elastic modulus is equal to or higher than the elastic modulus of the first roller constituting portion 5a. Reference numeral 6 denotes a rotation axis of the roller, and a cross section perpendicular to the rotation axis 6 is a circle. When the roller 5 comes into contact with the workpiece 2 rotating with the mold 1, the roller 5 rotates with the mold 1 around the rotation axis 6.

A method for manufacturing the roller 5 will be described. First, for example, an aramid having an elastic modulus of, for example, 7 × 10 ⁴ kgf / cm ² is used as a base material for the first roller component 5a, and an elastic modulus of, for example, 6 × 10 ⁴ is used for the second roller component 5b.
^{A 6} kgf / cm ² cemented carbide is prepared, machined, and machined into a roughly desired shape. However, the mating surface of the first roller component 5a and the second roller component 5b is processed so that the surface roughness becomes 0.8 μm or less, and both are joined by bolting or bonding. Then, it is finished to a desired shape that satisfies the required accuracy.

Next, a description will be given of a method of manufacturing a reflection plate using the roller 5 configured as described above. In the same manner as described in the first embodiment, the processing liquid film 3
Is formed, and the workpiece 2 is sandwiched between the molds 1 by tail stock and rotated together with the mold 1. Next, the workpiece 2 is pressed against the mold 1 by the roller 5 to cause the roller 5 to follow the mold 1. The first roller constituting portion 5a of the roller 5
And the workpiece 2 is plastically deformed. The surface of the workpiece 2 is roughened as the plastic deformation progresses, but the thickness of the working fluid introduced between the mold 1 and the workpiece 2 is proportional to the surface roughness of the workpiece 2, If the film thickness is too large, the inner surface of the reflector will not be a mirror surface. Subsequently, the second roller component 5b presses the workpiece 2 against the mold 1 and transfers the surface shape (roughness) of the mold 1 to the surface of the workpiece to be abutted.

In the conventional apparatus for manufacturing a reflector by spinning, when the mirror surface of the inner surface of a product is particularly important, the workpiece 2 is sufficiently pressed against the mold 1 by using a tool having a high elastic modulus. The surface roughness of the mold 1 was transferred to the surface of the workpiece to be abutted, and a good mirror surface was obtained. For this purpose, a tool such as a roller made entirely of cemented carbide or a spatula 60 shown in FIG. 6 has been used. However, in this case, since the hardness of the roller or the spatula 60 is harder than that of the workpiece 2, the workpiece 2 may be damaged. Therefore, although the mirror surface of the inner surface of the formed reflector is inferior to the case where the material of the roller is a cemented carbide, the material of the roller is made of resin to prevent the workpiece 2 from being damaged. Either way, roller or spatula 6
Since No. 0 was entirely made of a single material, it was very difficult to achieve both the improvement of the mirror finish and the prevention of damage to the workpiece 2. It is generally said that the radius of curvature of the curved surface portion formed at the roller tip is preferably at least 5 times the thickness of the workpiece 2, but if it is too large, the workpiece 2 is pressed against the mold 1 by the roller. The force required to perform the operation was excessive, and in some cases exceeded the capability of the apparatus. When the workpiece 2 is tilted down, as shown in FIG. 7, when the radius of curvature of the curved surface is small and large, the workpiece 2 has a small radius of curvature.
The radius of curvature of the region along the tip of the roller 5 also becomes smaller.
Therefore, the amount of plastic deformation of the bent portion becomes extremely large locally, so that the workpiece 2 is easily broken or has a rough surface,
This hinders obtaining a good mirror surface.

However, in the second embodiment, in the cross section including the rotating shaft 6 of the roller 5, the first roller constituting portion 5a, which is the portion on which the workpiece 2 is tilted, is at least five times the thickness of the workpiece 2. And the elastic modulus is 10 ⁵ kgf / cm ² or less, so that the amount of the material 2 to be worked up does not become excessive, and the surface of the material to be worked is broken or markedly rough. No scratches. The second roller component 5b, which is a part for pressing the workpiece 2 against the mold 1, is not less than 5 times and not more than 20 times the thickness of the workpiece 2 and the first roller component 5a. Has a curved portion with a radius of curvature equal to or smaller than the radius of curvature, and has an elastic modulus greater than that of the first roller constituting portion 5a. And a good mirror surface can be obtained.

Next, another configuration of the roller will be described with reference to FIG. In the figure, 17 is a roller, 5c is a first roller component, 5d is a second roller component, and 9 is a tailstock. The tail stock 9 is advanced, and the workpiece 2 is sandwiched between the molds 1 and rotated together with the mold 1. In the cross section including the rotating shaft 6 of the roller 17, the first roller constituting portion 5 c has a length equal to or greater than a radial length of a portion of the workpiece 2 to be plastically deformed, and Linear part 5x whose angle with the mold rotation axis is 120 ° to 150 °
And the second roller constituting portion 5d has a curved portion 5y having a radius of curvature of 5 to 20 times the thickness of the workpiece 2.
Having.

In the roller 17 having such a configuration, the first roller constituting portion 5c has, for example, an elastic modulus of 7 × 10 ⁴ kgf /
The aramid of cm ² and the second roller constituting portion 5d were made of a cemented carbide having an elastic modulus of, for example, 6 × 10 ⁶ kgf / cm ² , and the angle between the linear portion 5x and the rotating shaft of the mold was 120 °. Incidentally, the radial length of the portion to plastic deformation of the workpiece 2, as shown in FIG. 9, the radius r ₁ and the mold of the workpiece 2 1
Is the difference from the radius r _{2 of the contact} surface in contact with the workpiece 2. In FIG. 9, the workpiece 2 is sandwiched between the molds 1 by tail stock (not shown).

Next, a description will be given of a method of manufacturing a reflection plate using the roller 17 configured as described above. A working liquid film is formed on the surface of the mold by a method similar to that described in the first embodiment, and the workpiece 2 is sandwiched between the mold 1 by the tailstock 9 and rotated together with the mold 1. Next, the workpiece 2 is pressed against the mold 1 by the roller 17 to cause the roller 17 to follow the mold 1.
First, the first roller component 5c of the roller 17 comes into contact with the workpiece 2, and the workpiece 2 is plastically deformed. The length of the linear portion 5x, which is the portion where the roller 17 comes into contact with the workpiece 2, is equal to or greater than the radial length of the portion of the workpiece 2 that is to be plastically deformed. Since the angle formed by the portion 5x and the mold rotation axis is 120 ° to 150 °, the radius of curvature of the portion of the workpiece 2 along the linear portion 5x of the roller 17 becomes large, and the overturning amount of the workpiece 2 is excessive. And no breakage or noticeable roughening occurs on the surface of the workpiece. Further, since the material is aramid having an elastic modulus of 7 × 10 ⁴ kgf / cm ² , the workpiece 2 is hardly damaged. Subsequently, the second roller component 5 d presses the workpiece 2 against the mold 1. Since the material is a cemented carbide having an elastic modulus of 6 × 10 ⁶ kgf / cm ² , the workpiece 2 can be sufficiently pressed against the mold 1 and the radius of curvature of the curved portion 5y of the second roller constituting portion 5d is reduced. Since it is 5 times or more and 20 times or less of the work material 2, a good mirror surface can be obtained without excessive force for pressing the roller 17.

Next, still another configuration of the roller is shown in FIG. In the figure, the first roller 5g has a cylindrical shape whose cross section perpendicular to the rotation axis is a circle, and the rotation axis is inclined so that an angle between the rotation axis and the mold rotation axis is 120 ° to 150 °, When it comes into contact with the workpiece 2, the surface of the mold is copied so that the distance between the lower end of the cylindrical outer peripheral surface and the surface of the mold 1 is constant at 3 to 10 mm. Reference numeral 5h denotes a second roller which is driven by the first roller 5g, and has a curved portion 5z having a radius of curvature of 5 to 20 times the thickness of the workpiece 2. Here, the angle is 120 °, and the distance is 5 m.
m.

Next, the first roller 5 constructed as described above
The step of spinning using g and the second roller 5h will be described. First, the first roller 5 g contacts the workpiece 2. The first roller 5g functions to tilt the workpiece 2, but is inclined so that the angle between the rotation axis and the mold rotation axis is 120 ° to 150 °, and the first roller 5g contacts the workpiece 2. When performing the molding, the surface of the mold is copied so that the distance between the lower end of the cylindrical outer peripheral surface and the surface of the mold 1 is constant at 3 to 10 mm. Therefore, in a cross section obtained by cutting the first roller 5g by a plane including the rotation axis when the first roller 5g is in contact with the workpiece 2, a linear portion having a rectangular cross section of the first roller 5g, Since the workpiece 2 comes into contact with the side surface of the roller 5g, the radius of curvature of this portion is large, and the angle between the workpiece 2 and the rotating shaft of the mold is 120 ° to 150 °.
The overturning amount does not become excessively large, and the surface of the workpiece does not break or the surface becomes rough. It is desirable that a curved surface 5i be formed at one end of the first roller 5g. If the curved surface portion 5i is not formed, the edge of the end face of the first roller 5g hits the workpiece 2 and the
Roller 5g may be damaged. Also, the second roller 5
The radius of curvature of the curved portion 5z of h is 5 times or more 20 of the workpiece 2
Since it is not more than twice, a good mirror surface can be obtained without an excessive force for pressing the second roller 5h.

Embodiment 3 FIG. 11 is a sectional view showing a material configuration of a surface layer portion of a mold for manufacturing a reflector according to Embodiment 3 of the present invention. In the figure, 1a is a substrate made of a material containing Fe as a main component, and 40 is a thermal expansion coefficient of 4.0.
An intermediate layer made of a material of × 10 ^{-6 to} 6.5 × 10 ^-6 / K;
41 is a diamond-like carbon film. A method of manufacturing a metal mold for manufacturing a reflector in which the vicinity of the surface layer in a region in contact with a mirror surface of the inner surface of the reflector has the material configuration shown in FIG. 11 will be described. First, for example, tool steel prepared as a mold base material is subjected to mechanical processing such as electric discharge machining, cutting, grinding, and polishing to be processed into a desired shape satisfying required accuracy. At this time, in order to suppress the adhesion and seizure of the workpiece to the die surface during spinning and the occurrence of chipping of the base material 1a, and to prevent local wear and peeling of the diamond-like carbon film 41. It is desirable to finish the surface roughness of the area of the substrate 1a in contact with the product to 0.8 μm or less. In addition,
Alloy tool steel (JIS: S) usually used as base material 1a
KD11) and high-speed tool steel (JIS: SKH51, etc.)
In order to secure sufficiently high hardness and appropriate toughness, it is desirable to perform heat treatment such as quenching and tempering to adjust the Rockwell hardness to a hardness of about 58 to 64 HRC.

Then, after removing the processing powder and processing oil adhering to the surface of the base material by spray cleaning using acetone or the like, a technique such as high energy gas spraying is applied to at least a region in contact with the mirror surface of the inner surface of the reflector. Is used to form a 5 μm thick WC (tungsten carbide) film, for example. Next, the surface of the WC film is polished. At this time, the surface roughness of the diamond-like carbon film 41 formed on the intermediate layer 40 is set to 0.
Since it is necessary to be 4 μm or less, the surface roughness of the area in contact with the mirror surface of the inner surface of the reflector on the surface of the WC coating is 0.1 μm.
It is desirable to finish it to 4 μm or less. Through these steps, the coefficient of thermal expansion is from 4.0 × 10 ^{−6 to} 6.5 × 10
^An intermediate layer 40 made of a material of ^-6 / K is formed.

Next, the processing powder, processing oil and oxide layer adhering to the surface of the substrate 1a and the intermediate layer 40 are removed by acetone ultrasonic cleaning or the like. Next, a diamond-like carbon film 41 having a thickness of 2 μm is formed on at least a region of the mold surface where the intermediate layer 40 is formed by using a method such as a plasma CVD method. In this case, in order to obtain a reflection plate whose desired portion is a mirror surface, the diamond-like carbon film 4 is required.
The surface roughness of the region of the surface 1 in contact with the mirror surface of the inner surface of the reflector must be 0.4 μm or less. Therefore, when the surface roughness of the diamond-like carbon film 41 after formation is 0.4 μm or more, it is finished to 0.4 μm or less by polishing or the like. Diamond-like carbon has both self-lubricating properties and great hardness, and these have an effect of improving the specularity of the inner surface of the formed reflector, but the Vickers hardness reaches 3000 to 5000 and is brittle. Has properties. Therefore, when the thickness of the diamond-like carbon film 41 exceeds 8 μm,
Cracks are generated in the film due to the residual stress in the film, and the diamond-like carbon film 41 is inconsistently scattered. In addition, the thickness of the diamond-like carbon film 41 is set to 0.
If the thickness is less than 5 μm, sufficient abrasion resistance cannot be secured, so that the self-lubricating property of the mold surface is disadvantageously lost at an early stage. Therefore, the diamond-like carbon film 41
Must be 0.5 to 8 μm.

As described above, since diamond-like carbon has a brittle property, it cannot withstand local pressurization during spinning and cracks are generated in the film and the diamond-like carbon film 41 is peeled off. This is more remarkable as the value of the residual stress in the film increases. Therefore, it is important to reduce the residual stress in the diamond-like carbon film 41 in order to obtain a mold capable of stably exhibiting the self-lubricating property and wear resistance of the diamond-like carbon film 41 for a long period of time. Become. The generation of residual stress in the diamond-like carbon film 41 of the mold having the material configuration in the cross-sectional direction shown in FIG.
Temperature rise. That is, the plasma CV belonging to the lowest process temperature (about 150 ° C. to 300 ° C.) class as a method of forming the diamond-like carbon film 41.
Even when the method D is used, the thermal expansion coefficient of the iron-based material is two to three times the thermal expansion coefficient of diamond-like carbon. An extremely large compressive residual stress is generated in the carbon film 41. On the other hand, the middle layer 4
The coefficient of thermal expansion of 0 is between the value of the coefficient of thermal expansion of the substrate 1a and the value of the coefficient of thermal expansion of the diamond-like carbon film 41, and is close to the value of the coefficient of thermal expansion of the diamond-like carbon film 41. By doing so, it becomes possible to greatly reduce the value of the compressive residual stress in the diamond-like carbon film 41 after the film formation is completed. In order to realize this, in the third embodiment, a material having a thermal expansion coefficient of 4.0 × 10 ^{−6 to} 6.5 × 10 ⁻⁶ / K is used as the intermediate layer 40. Cemented carbide was exemplified. However, when the thickness of the intermediate layer 40 is less than 0.3 μm, the effect of reducing the compressive residual stress value is significantly reduced. Therefore, the thickness of the intermediate layer 40 must be 0.3 μm or more.

Embodiment 4 FIG. FIG. 12 is a sectional view showing a material configuration of a surface layer portion of a mold for manufacturing a reflector according to Embodiment 4 of the present invention. In the figure, 51 is a substrate, 52
Is a stoma. Next, a method of manufacturing a reflecting plate manufacturing die according to the fourth embodiment will be described. First, the porous sintered body mainly composed of metal powder prepared as a mold base material is subjected to machining such as electric discharge machining, cutting, grinding and polishing,
Process into a desired shape that satisfies the required accuracy. At this time, in order to make the inner surface of the reflector a good mirror surface, at least the surface roughness of a region in contact with the mirror surface portion of the inner surface of the reflector is 0.4 μm.
It is desirable to finish it below. If the surface roughness of the mold 1 is larger than 0.4 μm, adhesion and seizure of the workpiece 2 to the mold surface, chipping of the mold 1 and the like occur, and a good mirror surface cannot be obtained. Surface roughness may be greater than 0.4 μm on the mold surface in areas where good mirror surfaces are not required. In order to secure sufficiently high hardness and appropriate toughness, the base material 51 is desirably subjected to heat treatment such as quenching and tempering to adjust the hardness to Rockwell hardness HRC58 or more.

Next, the state of the interface between the mold 1 and the workpiece 2 during spinning using the mold 1 manufactured as described above will be described. First, the working liquid is impregnated into the base material 51 prior to working. In the fourth embodiment, the volume percentage of the impregnated working fluid was set to about 40%. The spinning process is substantially the same as that described in the first embodiment. The spinning process is performed when the impregnated working fluid is exposed on the mold surface and the working fluid film 3 is formed on the mold surface. I do. The working liquid film 3 preferably has an average thickness equal to or more than the surface roughness of the mold and equal to or less than 0.6 μm. As the spinning process is repeated, the appearance of the working fluid impregnated in advance on the mold surface progresses, and the thickness of the working fluid film 3 formed on the mold surface is equal to the average surface roughness of the mold surface. When the lower surrounding workpiece 2 adheres to the die, the working fluid is again impregnated into the base material 51. Although the working fluid film 3 may be formed by the method described in the first embodiment, the number of operations for forming the working fluid film 3 on the surface of the mold is reduced because the working fluid is exposed from the inside of the mold 1. Can be.

Even if the thickness of the working liquid film 3 formed on the mold surface exceeds the average thickness of 0.6 μm, the base material 51 of the mold 1 is covered with the roller 5 because it is a porous material. Work material 2
Is pressed onto the mold 1, an excess portion of the working fluid introduced between the mold 1 and the workpiece 2 is discharged to the pores 52 connected to the mold surface.

Embodiment 5 FIG. 13 is a cross-sectional view showing main parts of a mold, a roller, and a workpiece during spinning according to Embodiment 5 of the present invention. In the figure, 31 is the outer edge of the workpiece 2 and 32 is burrs. The spinning process is substantially the same as that described in the first embodiment, and only different points will be described. After the workpiece 2 is rotated together with the mold 1, the angle between the outer edge 31 of the workpiece 2 and the area of 1% to 10% of the diameter with the mold rotation axis is 45 ° or more.
Fold it down to 80 or 100-135 degrees.
Subsequently, the workpiece 2 is pressed against the mold 1 by the roller 5 and the roller 5 is pressed.
When the workpiece 2 is made to follow the mold 1, the workpiece 2 is tilted, that is, plastically deformed and formed into a desired shape. When the workpiece 2 is plastically deformed and its shape is created, wrinkles are likely to occur at the outer edge of the workpiece 2, and in some cases, the workpiece 2 is broken. Therefore, conventionally, the surface of the workpiece 2 opposite to the surface in contact with the roller, that is, the surface of the workpiece on the side that becomes the inner surface of the reflection plate is pressed by a backup roller (not shown) to suppress the occurrence of wrinkles. However, the contact of the backup roller with the surface of the workpiece, which is the inner surface of the product requiring a mirror surface, causes the workpiece 2 to be damaged if the hardness of the backup roller is equal to or greater than the hardness of the workpiece 2. When the hardness is smaller than the hardness of the workpiece 2, the backup roller is scraped off by the workpiece 2, and the shavings adhere to the surface of the workpiece 2, that is, the surface that becomes the inner surface of the reflector, so that the workpiece 2 and the mold are removed. 1, which are inconvenient for obtaining a mirror surface. Therefore, to obtain a good mirror surface, a backup roller using a soft material such as a resin is used, and during the processing, the backup roller surface is processed while being wiped with a rag or the like.
Usually, this operation is very dangerous because it wipes the rotating tool by hand.

As a method of tilting the outer edge 31 of the workpiece 2, for example, as shown in FIG. 10, the roller configuration is composed of two rollers, and the rotation axis of the first roller and the die rotation axis are An angle to be formed is set to 100 ° to 135 ° or 45 ° to 80 °, and this is hit against the outer edge of the workpiece to be fell. The area to be overturned is 1% to 1% of the diameter from the outer edge 31 of the workpiece 2.
The reason why 0% is set is that when less than 1%, the rigidity does not sufficiently increase, and when it exceeds 10%, the rigidity is sufficiently increased.
However, this is not preferable from the viewpoint of material yield. In addition, the angle formed with the mold rotation axis is 80.
When it exceeds {} and is smaller than 100 °, the rigidity is not sufficiently increased, and wrinkles are generated on the outer edge 31 of the workpiece 2. When the angle is smaller than 45 °, the roller 5 contacts the outer edge 31 of the workpiece 2 at the time of processing, and the roller is easily damaged. When the angle exceeds 135 °, as shown in FIG. This is because the bent region comes into contact with the mold 1 to form an annular node 4 on the workpiece 2. This section 4 significantly detracts from the aesthetics of the product and is not preferred. The above manufacturing method can also be applied to spinning of a product that does not require a good mirror surface on the inner surface.

[0049]

As described above, according to the first aspect of the present invention, a mold having a surface roughness of 0.4 μm or less at least in a region in contact with a mirror surface of the inner surface of the reflector is used.
A processing liquid is applied to the entire surface of the mold surface in contact with at least a portion to be a mirror surface of the inner surface of the reflector so that the average thickness is equal to or more than 0.6 μm or less of the surface roughness of the mold, and the mold is In addition, a spinning process is performed in which the workpiece is pressed against the mold by a roller moving along the surface of the mold while rotating the workpiece, so that the inner surface of the product is a mirror surface. There is an effect that the board can be manufactured stably.

According to the second aspect of the present invention, after the working fluid having a kinematic viscosity at 20 ° C. of 40 mm ² / s or less is impregnated into the applying tool having excellent liquid impregnating property, the applying tool is rotated. A working liquid application step of impressing and imitating a mold, and a wiping tool having excellent liquid absorbency being impressed against the mold and having an average thickness equal to or greater than the surface roughness of the mold.
A processing liquid film forming step of forming a processing liquid film of 6 μm or less;
It is configured to include a spinning process of performing a spinning process in which the workpiece is pressed against the mold by a roller that moves along the surface of the mold while rotating the workpiece together with the mold. Therefore, the working liquid film formed on the surface of the mold can be stably formed with an average thickness equal to or more than the surface roughness of the mold and equal to or less than 0.6 μm. As a result, the inner surface of the product is mirror-finished. There is an effect that the reflection plate can be manufactured stably.

According to the third aspect of the present invention, the processing liquid is formed into fine particles having a particle size of 10 μm or less and sprayed onto a rotating mold to have an average thickness equal to or more than 0.6 μm of the surface roughness of the mold.
m, and a spinning process of performing a spinning process of pressing the work material against the mold with a roller while rotating the work material together with the mold to form the work fluid film. Because it was configured to have
Since the step of wiping the processing liquid on the mold surface is not required, the processing liquid film can be formed efficiently, and there is an effect that a reflection plate having a mirror inner surface of the product can be manufactured stably and efficiently.

According to the fourth aspect of the present invention, a working fluid containing 5% or less of triethanolamine or 0.1 to 2 g
/ L using a working fluid containing chromic anhydride, and performing a spinning process in which the work material is pressed against the mold by a roller while the work material is rotated together with the mold to form the work material. There is an effect that an anticorrosion function can be provided simultaneously with the formation of the reflection plate.

According to the invention described in claim 5, the angle between the outer edge of the workpiece rotating with the mold and the axis of rotation of the mold from 1 to 10% of the diameter to the mold rotation axis is 45 ° to 80 ° or 100 ° to 100 °. The outer edge processing step of the workpiece to be tilted to 135 °;
A spinning process for performing a spinning process of pressing and molding the workpiece to the mold with a roller while rotating the workpiece together with the mold, so that the inner surface of the product is a reflecting plate having a mirror surface Has the effect of being able to be manufactured stably.

According to the sixth aspect of the present invention, the rotary shaft is formed in a cylindrical shape, and its rotation axis is inclined such that an angle between the rotation axis and the mold rotation axis is 120 ° to 150 °. A first roller that follows the surface of the mold so that the distance between the lower end of the outer peripheral surface of the cylindrical shape and the surface of the mold is constant at 3 to 10 mm, and the workpiece is driven by the first roller, A roller comprising a second roller component having a curved portion having a radius of curvature not less than 5 times and not more than 20 times the thickness of the first member while rotating the workpiece with a mold.
And the second roller perform the spinning process in which the workpiece is pressed against the mold to form the workpiece. Without causing breakage or noticeable skin roughness
In addition, the force for pressing the roller against the mold is not excessive, and there is an effect that a reflector having a mirror-finished inner surface can be manufactured stably.

According to the seventh aspect of the present invention, the first roller is made of a material having an elastic modulus of 10 ⁵ kgf / cm ² or less, and the second roller is made of a material having an elastic modulus higher than that of the first roller. With this configuration, the workpiece can be sufficiently pressed against the mold without damaging the workpiece, and thus there is an effect that a reflector having a mirror inner surface of the product can be stably manufactured.

According to the eighth aspect of the present invention, in the section including the rotation axis of the roller, the length is equal to or greater than the radial length of the portion of the workpiece to be plastically deformed and when the workpiece comes into contact with the workpiece. Angle between the mold rotation axis and 120 °
A roller comprising a first roller component having a linear portion of 50 ° and a second roller component having a curved portion having a radius of curvature of 5 to 20 times the thickness of the workpiece. Since the spinning process is performed such that the roller is moved along the surface of the mold while rotating the workpiece with the mold, and the workpiece is pressed against the mold to form the workpiece. In addition, the amount of the material to be processed does not become excessive, the material to be processed is not broken or the surface becomes rough, and the force for pressing the roller against the mold does not become too large. There is an effect that the board can be manufactured stably.

According to the ninth aspect of the present invention, in the cross section including the rotation axis of the roller, the first roller component having a curved portion having a radius of curvature of five times or more the thickness of the workpiece is provided. A second roller component having a curved portion having a radius of curvature equal to or smaller than the radius of curvature of the first roller component which is not less than 5 times and not more than 20 times the thickness of the workpiece. It has a roller, and is configured to perform a spinning process in which the workpiece is pressed against the mold by a roller that moves along the surface of the mold while rotating the workpiece together with the mold, thereby forming the workpiece. The overturning amount of the work material does not become excessive, the work material does not break or noticeable surface roughness does not occur, and the force for pressing the roller against the mold does not become excessive, and the inner surface of the product has a mirror-like reflection plate. There is an effect that it can be manufactured stably.

According to the tenth aspect of the present invention, the first roller is made of a material having an elastic modulus of 10 ⁵ kgf / cm ² or less, and the second roller is made of a material having an elastic modulus higher than that of the first roller. With this configuration, since the workpiece can be sufficiently pressed against the mold without damaging the workpiece, there is an effect that a reflection plate having a mirror inner surface of the product can be stably manufactured.

According to the eleventh aspect of the present invention, a base material made of a material having a coefficient of thermal expansion of 4.0 × 10 ^{−6 to} 6.5 × 10 ⁻⁶ / K, and a mold made of the base material A diamond-like carbon film having a thickness of 0.5 to 8 μm formed at least on a surface of the surface in contact with a portion to be a mirror surface of the inner surface of the reflector, and at least a portion of the diamond-like carbon film to be a mirror surface of the inner surface of the reflector. Surface roughness of contact area is 0.4
μm or less, so that local wear and peeling of the diamond-like carbon film occurs during spinning, adhesion and seizure to the surface of the die of the workpiece, the base material of the die This has the effect of stably forming a reflector having a mirror-finished inner surface while preventing breakage.

According to the twelfth aspect of the present invention, the base material containing Fe as a main component and the thickness of 0.5 to 0.5% formed at least in the region in contact with at least the mirror surface of the inner surface of the reflector on the surface of the mold.
An 8 μm diamond-like carbon film, and a 0.3 μm thick film formed of a material having a thermal expansion coefficient of 4.0 × 10 ^{−6 to} 6.5 × 10 ⁻⁶ / K and formed directly under the diamond-like carbon film The diamond-like carbon film has the above-mentioned intermediate layer, and the surface roughness of at least a region of the diamond-like carbon film which is in contact with a mirror surface of the inner surface of the reflector is set to 0.4 μm or less. Can be reduced, and the diamond-like carbon film can be prevented from peeling off, so that there is an effect that a reflecting plate having a mirror inner surface of a product can be formed stably.

According to the thirteenth aspect of the present invention, the base material is a porous sintered body containing metal powder as a main component, and the surface roughness of at least a region in contact with a mirror-finished portion of the inner surface of the reflection plate is set to 0. Since the thickness is set to 4 μm or less, even if the average thickness of the working fluid film on the mold surface is less than the same level as the roughness of the mold surface, the working fluid previously impregnated into the porous sintered body is not As a result, it is possible to prevent the work material from sticking to the surface of the mold and to stably form a reflector having a mirror-finished inner surface.

[Brief description of the drawings]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view illustrating a method of manufacturing a reflector, a mold, a roller, and a workpiece when a spinning process is performed in a reflector manufacturing apparatus that implements a reflector manufacturing method according to Embodiment 1 of the present invention; It is sectional drawing which shows a principal part.

FIG. 2 is a cross-sectional view showing a method for forming a working liquid film of a reflector manufacturing apparatus for implementing the reflector manufacturing method according to Embodiment 1 of the present invention;

FIG. 3 is an explanatory view showing a state of a mold surface and a working liquid film when a working liquid film having the same average thickness as the mold surface roughness is formed.

FIG. 4 is a cross-sectional view showing another method of forming a working liquid film of the reflector manufacturing apparatus for realizing the reflector manufacturing method according to Embodiment 1 of the present invention;

FIG. 5 is a cross-sectional view showing a roller used in a reflector manufacturing apparatus according to a second embodiment of the present invention.

FIG. 6 is a partial perspective view of a spatula used for spinning processing in the related art for explaining spinning processing of a reflecting plate manufacturing apparatus according to Embodiment 2 of the present invention.

FIG. 7 is an explanatory diagram comparing a case where the radius of curvature of the roller curved surface is small and a case where the roller is tilted by the roller in the spinning process of the reflecting plate manufacturing apparatus according to the second embodiment of the present invention.

FIG. 8 is an explanatory diagram showing another configuration of the roller in the spinning process of the reflecting plate manufacturing apparatus according to the second embodiment of the present invention.

FIG. 9 is an explanatory diagram showing a portion of a workpiece to be plastically deformed in spinning processing of a reflector manufacturing apparatus according to Embodiment 2 of the present invention;

FIG. 10 is an explanatory view showing a cylindrical first roller and a second roller in spinning processing of a reflecting plate manufacturing apparatus according to Embodiment 2 of the present invention.

FIG. 11 is a cross-sectional view showing a material configuration of a surface layer portion of a mold for manufacturing a reflector according to Embodiment 3 of the present invention.

FIG. 12 is a cross-sectional view illustrating a material configuration of a surface layer portion of a mold for manufacturing a reflector according to Embodiment 4 of the present invention.

FIG. 13 is a cross-sectional view showing main parts of a mold, a roller, and a workpiece during spinning according to Embodiment 5 of the present invention.

FIG. 14 is an explanatory diagram showing a state where an annular node is formed at an outer edge portion of a workpiece during spinning according to Embodiment 5 of the present invention.

FIG. 15 is a partial cross-sectional view showing a main part of a mold, a roller, and a workpiece for manufacturing a reflector at the time of spinning by a conventional reflector manufacturing method and a reflector manufacturing apparatus for realizing the method; is there.

FIG. 16 is an explanatory diagram showing a state in which a die shape is formed by roller movement on a workpiece during spinning processing in the document “Rotation processing” (issued by Corona Co., Ltd. in December 1990).

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Die, 1a, 51 base material, 2 work materials, 3 working liquid films, 5, 17 rollers, 5a, 5c 1st roller component parts, 5b, 5d 2nd roller component parts, 5g 1st roller , 5h Second roller, 5m, 5n, 5y, 5z
Curved part, 5x linear part, 10 application tool, 11 wiping tool, 40 intermediate layer, 41 diamond-like carbon film.

 ──────────────────────────────────────────────────続 き Continued from the front page (72) Inventor Seiji Matsuda 5-1-1, Ofuna, Kamakura City, Kanagawa Prefecture Inside Mitsubishi Electric Lighting Co., Ltd.

Claims (13)

[Claims] 1. A mold having a surface roughness of at least 0.4 μm or less in a region in contact with a portion to be a mirror surface of the inner surface of the reflector, and contacting at least a portion of the inner surface of the mold to be a mirror surface of the inner surface of the reflector. Applying a working liquid having a thickness equal to or greater than the surface roughness of the mold at an average thickness of 0.6 μm or less over the entire surface of the region, and moving a roller along the mold while rotating the workpiece together with the mold, A method of manufacturing a reflecting plate for performing spinning processing in which the workpiece is pressed against the mold with a roller to form the workpiece. 2. A kinematic viscosity at 20 ° C. of 40 mm ² / s
A working fluid application step of impregnating the application tool having excellent liquid impregnating property with the following working fluid and then pressing the application tool against a rotating mold, and a wiping tool excellent in liquid absorbability. A working liquid film forming step of forming a working liquid film having an average thickness equal to or greater than the surface roughness of the mold and not more than 0.6 μm by pressing against the mold, and rotating the workpiece together with the mold; 2. A reflecting plate according to claim 1, further comprising: a spinning process of performing a spinning process of pressing a workpiece onto the mold with a roller moving along a surface of the mold. Production method. 3. A kinematic viscosity at 20 ° C. of 40 mm ² / s
The following processing fluid is formed into fine particles having a particle size of 10 μm or less and sprayed onto a rotating mold to form a processing fluid film having an average thickness equal to or greater than the surface roughness of the mold and 0.6 μm or less. A spray forming step, and a spinning process of performing a spinning process of pressing the work material against the mold with a roller moving along the surface of the mold while rotating the work material together with the mold. The method for manufacturing a reflector according to claim 1, further comprising: 4. The method according to claim 1, wherein the working fluid contains 5% or less of triethanolamine or 0.1 to 2 g / l of chromic anhydride.
The method for producing a reflection plate according to the above item. 5. An angle between the outer edge of the workpiece rotating with the mold and an area of 1% to 10% of the diameter of the workpiece with the mold rotation axis is 45 ° to 80 ° or 100 ° to 135 °. The method for manufacturing a reflector according to any one of claims 1 to 4, further comprising a step of processing an outer edge of a workpiece to be bent to the angle (゜). 6. A reflecting plate manufacturing apparatus for performing a spinning process in which a workpiece is pressed against a mold by a roller moving along the surface of the mold while rotating the workpiece together with the mold. The roller is formed in a cylindrical shape, an angle between a rotation axis thereof and a mold rotation axis is 120 ° to 150 °, and a lower end of the cylindrical outer peripheral surface and a mold surface when contacting a workpiece. A first roller that imitates the surface of the mold with the distance between the first roller and the second roller being constant within a range of 3 mm to 10 mm;
An apparatus for manufacturing a reflector, comprising: a second roller having a curved portion having a radius of curvature of 0 or less in a cross section including a rotation axis. 7. The first roller has an elastic modulus of 10 ⁵ kgf / c.
m ² consists of the following material, reflector apparatus for manufacturing the second roller according to claim 6 comprising a material of the elastic modulus of more than the first roller. 8. A reflecting plate manufacturing apparatus for performing a spinning process in which a workpiece is pressed against a mold by a roller moving along the surface of the mold while rotating the workpiece together with the mold. The roller has a rotating portion having a length equal to or greater than a radial length of a portion of the workpiece to be plastically deformed and an angle of contact with the workpiece being 120 ° to 150 ° with respect to the mold rotating shaft. And a second roller component having a curved portion having a radius of curvature of 5 to 20 times the thickness of the workpiece in a section including the rotation axis. An apparatus for manufacturing a reflection plate, comprising: 9. A reflecting plate manufacturing apparatus for performing a spinning process in which a workpiece is pressed against a mold by a roller that moves along the surface of the mold while rotating the workpiece together with the mold. A first roller component having a curved portion having a radius of curvature of at least five times the thickness of the workpiece in a cross section including the rotation axis of the roller; And a second roller component having a curved portion having a radius of curvature equal to or smaller than the radius of curvature of the first roller component in a cross section including the rotation axis of the roller. Reflector manufacturing equipment. 10. The first roller component has an elastic modulus of 10 ⁵ k.
gf / cm ² less made of a material the second roller component is the first roller component or more elastic modulus reflector apparatus for manufacturing made of a material according to claim 8 or claim 9, wherein the. 11. The thermal expansion coefficient is 4.0 × 10 ^{−6 to} 6.5.
A base material made of a material of × 10 ^-6 / K, and a diamond-like member having a thickness of 0.5 μm to 8 μm formed at least on a surface of a mold made of the base material in contact with a portion to be a mirror surface of the inner surface of the reflector. 11. The method according to claim 1, wherein the diamond-like carbon film has a carbon film, and has a surface roughness of 0.4 μm or less in a region in contact with at least a portion of the inner surface of the reflector that is a mirror surface. A mold for manufacturing the reflection plate according to any one of the preceding claims. 12. A base material containing Fe as a main component and a material having a thermal expansion coefficient of 4.0 × 10 ^{−6 to} 6.5 × 10 ⁻⁶ / K, which is formed immediately below a diamond-like carbon film. The mold for manufacturing a reflector according to claim 11, further comprising an intermediate layer having a thickness of 0.3 µm or more. 13. The base material is a porous sintered body containing metal powder as a main component, and has a surface roughness of 0.4 μm or less at least in a region in contact with a mirror surface of the inner surface of the reflector. The mold for manufacturing a reflector according to any one of claims 1 to 10.