JPH10202382A - Manufacture of die by diagonally cut layer structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To omit finishing processes by handwork to be followed thereafter, to largely reduce the time and labor required for manufacturing a die and to realize the inexpensive die by manufacturing the die of a diagonally cut layer assembly. SOLUTION: Diagonal cutting, matched the die contour forming a free curved surface every the plate thickness from a thin plate stock, is successively executed with the laser beam machine connected to the CAD prepared the die contour forming the free curved surface and the contour linelike slice shape, and those are layered and assembled in the contour line shape with bolt-tightening or bonding, thereafter polishing by handwork is applied.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a technique for manufacturing a mold having a complicated three-dimensional curved surface called a free-form surface.

[0002]

2. Description of the Related Art Die machining is not a simple one such as planar machining, but is a complicated three-dimensional curved surface machining which is generally called a free-form surface. A machining method usually performed on a mold having these free-form surfaces includes a machining center.
Using a machine tool such as the above, a cutting process (roughing-medium processing-finishing) of a shape material is performed by a ball end mill, and thereafter, a process of finishing by manual polishing is performed.

[0003] However, the method of cutting with a machine tool involves many disadvantages, such as taking a lot of time for each of the above-mentioned steps, deforming due to machining conditions and tool diameter, and displacing the shape due to wear of the tool. . Therefore, it is indispensable to finally make up for it by hand polishing and finishing, but this manual work requires more time and years of skill, and is a major bottleneck in die machining.

Further, it is almost impossible to machine a deep groove having a free-form surface, a deep hole as seen in a rubber mold, a complicated groove, or the like due to a restriction of a ball end mill shape. There are also limitations on the processing form.

[0005] In order to solve such difficulties caused by the end milling, a so-called lamination mold manufacturing method has been proposed. In this method, a thin metal plate is vertically cut by a laser processing machine, and they are laminated in a stepped shape by bolting or bonding.
The squaring operation is performed by a grinder, and then (b) a step of polishing and finishing with sand paper and paste or the like is performed.

However, in the conventional method of manufacturing a laminated mold, since the latter half is performed by hand as described above, the end mill requires much labor and skill, and is not allowed to make any mistakes. This is the same as the finishing process after the cutting process, and has not been implemented as a popularized technique.
In addition, since the squaring operation is required, there remains a difficulty that machining such as a deep groove having a free-form surface and a complicated groove is impossible.

[0007]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned circumstances of the conventional mold making technology, and is based on a ball end mill using a machine tool which has been generally practiced so far. The cutting process is basically based on the method of manufacturing a laminated mold, and the laser connected to CAD is used.
Using a processing machine, slant cutting that matches the contour of the mold that forms a free-form surface for each sheet thickness is sequentially performed from a thin sheet material, and they are stacked in a contour shape by bolting or bonding, and assembled, and the slant-cut laminated structure With this mold, the subsequent manual finishing process can be minimized.

[0008]

In order to achieve the above object, the present invention includes the following steps as shown in FIGS. Performs slant cutting in order from the thin sheet material to match the contour of the mold that forms a free-form surface for each sheet thickness (a, b, b)
C). Next, they are laminated and assembled in a contour shape by bolting or bonding (d). Note that FIG. 2 shows an assembling mode by bonding. Finally, there is a method of manufacturing a mold with a slant-cut laminated structure, which is obtained by manual polishing (FIG. 3).

The slant cutting from the thin plate material described in the above (a) to (c) is performed by connecting the die contour forming the free-form surface and the CAD for forming the contour slice shape thereof.
This is a method for manufacturing a mold having an inclined-cut laminated structure performed by a processing machine.

[0010] The method of manufacturing a mold using the oblique cutting lamination structure of the present invention is configured as described above, and is used when laminating and assembling cutting plates, that is, Figs. 1 (d) and 2 (d). ), A mold having a free-form surface (before scribing) is used. Therefore, deflection due to machining conditions and tool diameter, which is a problem in the conventional cutting process using a ball end mill, and tool bending. A product having high shape accuracy can be obtained without fear of shape deformation due to friction or the like.

Further, unlike the state of middle processing or vertical cutting and laminating with a ball end mill having a stepped step, the subsequent manual work of squaring and finishing can be omitted. The time required for mold production can be greatly reduced. Although the last scribing is indispensable, the labor is greatly reduced, and there is almost no loss due to a work error. Thus, the cost of the mold can be reduced.

Since there is no need for squaring and finishing, as shown in FIGS. 4 and 5, it is easy to form deep grooves having a free-form surface and deep-spread holes found in rubber molds. New developments that can be made are also possible.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view showing the present invention in the order of steps.

FIG. 2 is a schematic side view showing the present invention in the order of steps (only a plate material is a vertical side view).

FIG. 3 is a side view of a mold having an inclined-cut lamination structure subjected to lamination assembly and polishing according to the present invention.

FIG. 4 is a side view of a mold having an oblique cut lamination structure having a deep intermediate groove that has been laminated and polished according to the present invention.

FIG. 5 is a side view of a mold having an oblique cut lamination structure having a deepened hole that has been laminated and polished according to the present invention.

Claims (2)

[Claims] 1. A thin plate material is sequentially cut obliquely in accordance with the contour of a mold forming a free-form surface for each plate thickness, and these are stacked and assembled in a contour line by bolting or bonding. A method of manufacturing a mold with an oblique cut lamination structure, characterized by being obtained by polishing. 2. The oblique cutting lamination according to claim 1, wherein the oblique cutting from the thin plate material is performed by a laser processing machine connected to a CAD having a mold contour forming a free-form surface and its contour sliced shape. Manufacturing method of mold by structure.