US20060219081A1 - Punch - Google Patents

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Publication number
US20060219081A1
US20060219081A1 US11/390,352 US39035206A US2006219081A1 US 20060219081 A1 US20060219081 A1 US 20060219081A1 US 39035206 A US39035206 A US 39035206A US 2006219081 A1 US2006219081 A1 US 2006219081A1
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US
United States
Prior art keywords
punch
coating film
straight portion
diameter
pits
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/390,352
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English (en)
Inventor
Atsushi Ito
Hikaru Nakamoto
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Brother Industries Ltd
Original Assignee
Brother Industries Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Brother Industries Ltd filed Critical Brother Industries Ltd
Assigned to BROTHER KOGYO KABUSHIKI KAISHA reassignment BROTHER KOGYO KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ITO, ATSUSHI, NAKAMOTO, HIKARU
Publication of US20060219081A1 publication Critical patent/US20060219081A1/en
Priority to US12/605,243 priority Critical patent/US8596105B2/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/02—Perforating by punching, e.g. with relatively-reciprocating punch and bed
    • B26F1/14—Punching tools; Punching dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/16—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass plates with holes of very small diameter, e.g. for spinning or burner nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
    • B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
    • B41J2/01—Ink jet
    • B41J2/135—Nozzles
    • B41J2/16—Production of nozzles
    • B41J2/162—Manufacturing of the nozzle plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
    • B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
    • B41J2/01—Ink jet
    • B41J2/135—Nozzles
    • B41J2/16—Production of nozzles
    • B41J2/1621—Manufacturing processes
    • B41J2/1632—Manufacturing processes machining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
    • B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
    • B41J2/01—Ink jet
    • B41J2/135—Nozzles
    • B41J2/16—Production of nozzles
    • B41J2/1621—Manufacturing processes
    • B41J2/1637—Manufacturing processes molding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
    • B26D7/08—Means for treating work or cutting member to facilitate cutting
    • B26D7/088—Means for treating work or cutting member to facilitate cutting by cleaning or lubricating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49833—Punching, piercing or reaming part by surface of second part
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49833—Punching, piercing or reaming part by surface of second part
    • Y10T29/49835—Punching, piercing or reaming part by surface of second part with shaping
    • Y10T29/49837—Punching, piercing or reaming part by surface of second part with shaping of first part
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T83/00—Cutting
    • Y10T83/929—Tool or tool with support
    • Y10T83/9411—Cutting couple type
    • Y10T83/9423—Punching tool
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T83/00—Cutting
    • Y10T83/929—Tool or tool with support
    • Y10T83/9411—Cutting couple type
    • Y10T83/9423—Punching tool
    • Y10T83/9428—Shear-type male tool

Definitions

  • the invention relates to a punch for use in molding a workpiece.
  • JP Sho. 57-208250 A has disclosed a method of producing an inkjet nozzle from an orifice back sheet and an orifice sheet and a punch used in the method.
  • This method of producing the inkjet nozzle is carried out as follows. A tip end portion of a conical punch is pressed against a sheet placed on a die to thereby form concave portions shaped in accordance with the shape of the tip end of the punch in the sheet. Then, convex portions formed on a surface of the sheet opposite to the surface against which the punch is pressed are ground by a lapping machine to thereby form fine holes in the sheet. In this manner, an orifice back sheet is produced.
  • the invention provides a punch in which lubricant retention capacity is made high enough to suppress the punch from being broken or worn away.
  • a punch for use in molding a workpiece with lubricating oil interposed between the punch and the workpiece includes a straight portion at an end of the punch and a diameter-increasing portion.
  • the straight portion extends in an axial direction.
  • the straight portion includes an end face at an end thereof and a side face.
  • the end surface extends in a radial direction perpendicular to the axial direction.
  • the side surface is connected to the end surface.
  • the diameter-increasing portion is connected to the straight portion.
  • the diameter-increasing portion includes a width in the radial direction, which is identical to that of the straight portion, at a junction between the straight portion and the diameter-increasing portion.
  • the width of the diameter-increasing portion in the radial direction increases with distance from the straight portion. At least one of the end surface and the side surface of the straight portion is formed with a pit.
  • a punch for use in molding a workpiece with lubricating oil interposed between the punch and the workpiece.
  • the punch includes a diameter-increasing portion at an end of the punch.
  • the diameter-increasing portion includes an end surface extending in a radial direction perpendicular to an axial direction of the punch.
  • the width of the diameter-increasing portion increases with distance from the end surface.
  • the end surface of the diameter-increasing portion is formed with a pit.
  • FIG. 1 is a perspective view showing parts of a press die to which a punch according to a first embodiment of the invention is applied.
  • FIG. 2 is an enlarged perspective view of a punch depicted in FIG. 1 .
  • FIG. 3 is an enlarged sectional view showing the structure of the punch depicted in FIG. 2 .
  • FIGS. 4A to 4 D are sectional views successively showing steps of producing the press die.
  • FIGS. 5A to 5 C are sectional views successively showing steps of producing a nozzle plate.
  • FIG. 6 is an enlarged perspective view showing a press die to which a punch according to a second embodiment of the invention is applied.
  • FIGS. 7A to 7 C are sectional views successively showing steps of producing a nozzle plate.
  • FIG. 1 is a perspective view showing parts of a press die using a punch according to a first embodiment of the invention.
  • the press die 1 includes a body portion 2 , and a punch 3 formed at a lower end portion of the body portion 2 so as to be used for molding.
  • the punch 3 of the press die 1 is used for molding a substrate 21 (see FIGS. 5A to 5 C) of a nozzle plate.
  • the body portion 2 has a conical portion 11 tapered off downwards, and a columnar portion 12 extending downwards from a lower end of the conical portion 11 .
  • FIG. 2 is an enlarged perspective view of the punch 3 depicted in FIG. 1 .
  • the punch 3 which is the end portion of the press die 1 , has a truncated cone-shaped taper portion (diameter-increasing portion) 5 connected to a lower end of the columnar portion 12 , and a columnar straight portion 6 connected to a lower end of the taper portion 5 .
  • the punch 3 is integrated with the body portion 2 .
  • the taper portion 5 is formed so that the diameter in the radial direction perpendicular to the axial direction of the punch 3 decreases gradually and linearly as approaching from the lower end of the columnar portion 12 of the body portion 2 toward the upper end of the straight portion 6 of the punch 3 .
  • the straight portion 6 has a circular end surface 6 a, which is in parallel to a direction perpendicular to the axial direction of the punch 3 .
  • the straight portion 6 is shaped like a column so that a discharge port 27 of a nozzle 26 of a nozzle plate 25 can be formed.
  • the diameter and shape of the lower end of the taper portion 5 are identical to those of the upper end of the straight portion 6 .
  • FIG. 3 is an enlarged sectional view showing the structure of the straight portion 6 of the punch depicted in FIG. 2 .
  • the taper portion 5 has the same structure as that of the straight portion 6 shown in FIG. 3 except that no pit 10 is formed in the taper portion 5 .
  • the straight portion 6 has a die member 15 integrated with the body portion 2 , and a hard coating film 16 harder than the die member 15 .
  • the die member 15 functions as a base material of the press die 1 .
  • the die member 15 is formed in such a manner that a die material, which is made of hard metal (cemented carbide) with a Vickers hardness (HV) of 1,500, is mechanically processed into the shape of the die member 15 .
  • HV Vickers hardness
  • the hard metal of the die member 15 is an alloy obtained by sintering a mixture of tungsten carbide, vanadium carbide, titanium carbide, tantalum carbide, chromium carbide and metallic cobalt prepared in predetermined proportions.
  • the mean particle size of carbide in the alloy is equal to or larger than 0.05 ⁇ m and less than 0.3 ⁇ m. For example, if the particle size of carbide in the hard metal is less than 0.05 ⁇ m, the surface area of each powder particle becomes so large that there arises a problem that carbonization of each powder particle is accelerated or the particles are apt to be aggregated. If the particle size of carbide is equal to or larger than 0.3 ⁇ m, carbide particles on the surface of the punch 3 may drop out.
  • the hard coating film 16 has a tungsten (W) coating film 17 formed on the surface of the die member 15 , and a diamond-like carbon (DLC) coating film 18 formed on the surface of the W coating film 17 .
  • the W coating film 17 is formed as an intermediate layer with a thickness of about 0.5 ⁇ m to prevent the DLC coating film 18 from being peeled off from the surface of the die member 15 . This is because bonding force between carbon contained in the DLC coating film 18 and the W coating film 17 is large and bonding force between the W coating film 17 and the die member 15 made of hard metal is large, so that the DLC coating film 18 can be hardly peeled off from the die member 15 in comparison with the case where the DLC coating film 18 is directly formed on the die member 15 made of hard metal.
  • the DLC coating film 18 formed as a surface layer of the hard coating film 16 is lower in friction coefficient and harder than the die member 15 of hard metal.
  • the DLC coating film 18 with a thickness of about 1.5 ⁇ m is formed on the surface of the W coating film 17 .
  • the strength of the DLC coating film 18 can be adjusted on the basis of the hydrogen content of the DLC coating film 18 at the time of forming the DLC coating film 18 .
  • the DLC coating film 18 can be formed as a hard coating film with the Vickers hardness (HV) of from several hundreds to about 8,000 close to the HV of diamond.
  • HV Vickers hardness
  • the DLC coating film 18 with HV of 3,600 harder than the W coating film (HV 430) 17 and the die member (HV 1,500) 15 is formed on the W coating film 17 .
  • the DLC coating film 18 is a coating film very excellent in abrasion resistance and slidability because the friction coefficient of the DLC coating film 18 is about 0.1 or smaller with respect to SUS 430 . For this reason, the life of the punch 3 can be elongated.
  • the thicknesses of the W coating film 17 and the DLC coating film 18 have been shown by way of example.
  • the thicknesses may be smaller or larger than the aforementioned values but the thicknesses may be preferably decided so that durability of the die member 15 is not damaged by a heat-affected layer, which is generated in the surface of the base material affected by heat generated by a focused ion beam method at the time of forming the pits 10 as will be described later.
  • the DLC coating film 18 is harder than the die member 15 , this hardness relation is not always required and it is also an important requirement that the DLC coating film 18 is lower in friction coefficient than the die member 15 . That is, reduction in friction coefficient of the DLC coating film 18 , as well as increase in hardness of the DLC coating film 18 , effectively contributes to longevity.
  • concave pits 10 which are opened outwards so that lubricant can be temporarily reserved in the pits 10 , are formed in the surface of the straight portion 6 of the punch 3 , that is, in the surface of the DLC coating film 18 .
  • an opening of each pit 10 is shaped like a square about 3 ⁇ m on a side.
  • the pits 10 are formed in the end surface 6 a and outer circumferential side surface 6 b of the straight portion 6 but no pit 10 is formed in the outer circumferential side surface of the taper portion 5 .
  • the pits 10 are formed so as not to pass through the DLC coating film 18 . Because the pits 10 do not reach the W coating film 17 in the depth direction as described above, the bottom surface of each pit 10 is relatively far from the surface of the die member 15 . For this reason, heat generated at the time of forming the pits 10 by the focused ion beam method as will be described later can be prevented from being transmitted to the die member 15 . Accordingly, metallic cobalt contained in hard metal of the die member 15 is prevented from being molten by heat. Thus no heat-affected layer is formed as a modified layer, and durability of the die member 15 can be prevented from being deteriorated.
  • the pits 10 may be formed so that a total area of the bottom surfaces of the pits 10 account for 20%-80% of the surface area of the straight portion 6 (i.e. a sum of the area of the end surface 6 a and the area of the outer circumferential side surface 6 b ). If a ratio of the total area of the bottom surfaces of the pits 10 is smaller than 20%, lubricant retention capacity can be hardly improved. If a ration of the total area of the pits 10 is larger than 80%, both lubricant retention capacity and durability of a region where the pits 10 are not formed can be hardly improved because the pits 10 are formed in large part of the straight portion 6 .
  • the pits 10 are formed at higher distribution density in the end surface 6 a of the straight portion 6 than in the outer circumferential side surface 6 b because the end surface 6 a needs high slidability because the end surface 6 a first comes into contact with the substrate 21 at the time of molding the substrate 21 . Accordingly, lubricant retention capacity can be improved while the strength of the punch 3 can be prevented from being lowered. Therefore, slidability, durability and abrasion resistance of the punch 3 can be improved.
  • FIGS. 4A to 4 D are sectional views successively showing steps of producing the press die.
  • a die material made of hard metal is cut into the shape of the body portion 2 and the shape of the punch 3 to thereby prepare the die member 15 .
  • the outer diameter of the die member 15 is determined in consideration of the thicknesses of the W coating film 17 and the DLC coating film 18 , which will be formed later, so that the resultant punch 3 can be fitted to the inner diameter of the discharge port 27 of the nozzle 26 of the nozzle plate 25 .
  • the W coating film 17 and the DLC coating film 18 are formed continuously on the surface of the die member 15 shown in FIG. 4A by an unbalanced magnetron (UBM) sputtering method.
  • UBM unbalanced magnetron
  • sputtering is performed using tungsten (W) as a target to form the W coating film 17 with a predetermined thickness. Thereafter, sputtering is performed using graphite (carbon) as a target while sputtering is performed using W concurrently. On this occasion, the process is shifted so that the rate of sputtering of W decreases gradually and relatively the rate of sputtering of graphite increases gradually as the process advances. That is, a gradient composition layer in which the composition ratio of tungsten to carbon changes continuously is interposed. Finally, sputtering of graphite only is performed.
  • FIG. 4C schematically shows the resulting film structure obtained in this manner.
  • the W coating layer 17 includes the W layer 17 a and the gradient composition layer 17 b. It is noted that detailed structure of the W coating layer 17 is only shown in FIG. 4C but omitted in the other drawings. Also, the W layer 17 a and the gradient composition layer 17 b may be referred to as the W coating layer 17 collectively for the convenience of the description.
  • pits 10 of a fine depth are formed by the focused ion beam method in the end surface 6 a and the outer circumferential side surface 6 b of the straight portion 6 of the punch 3 with respective predetermined distribution densities.
  • liquid gallium is used as an ion source
  • the acceleration voltage and the beam current are set to be 30 KV and 1.3 nA, respectively.
  • the position where each pit 10 will be formed is scanned for about one minute with a focused ion beam 13 having a beam diameter focused into about 10 nm to thereby form the pit 10 in the DLC coating film 18 .
  • This pit forming process is repeated so that pits 10 are formed in the end surface 6 a and the outer circumferential side surface 6 b of the straight portion 6 .
  • production of the press die 1 having the punch 3 with the pits 10 is completed.
  • the depth of each pit 10 formed by the focused ion beam is limited so that thin part of the DLC coating film 18 remains under the bottom portion of the pit 10 . Accordingly, characteristic of the intermediate layer (W film 17 a ) and the gradient composition layer 17 b can be prevented from being deteriorated during the pit forming process, so that the strength of the punch 3 , especially the strength of the straight portion 6 , can be structurally prevented from being lowered.
  • the nozzle plate 25 is provided on the outermost surface of an inkjet head. Nozzles 26 for ejecting ink pressurized by a piezoelectric element or the like are formed in the nozzle plate 25 .
  • FIGS. 5A to 5 C are sectional views successively showing steps of producing the nozzle plate.
  • the substrate 21 is first placed on a die base 20 having a die hole 20 a as shown in FIG. 5A and is fixed and retained thereto.
  • Lubricating oil functioning as lubricant is applied or sprayed on the whole surface of the straight portion 6 of the punch 3 of the press die 1 so that the lubricating oil is reserved in the pits 10 .
  • lubricant retention capacity of the press die 1 is so high that lubricating oil is not applied or sprayed every time a single press molding cycle is completed. That is, lubricating oil can be applied or sprayed intermittently whenever a number of press molding cycles are completed.
  • the lubricant may be supplied once an hour or once per 3,000 cycles.
  • the substrate 21 is pressed against the punch 3 with such a stroke quantity that the punch 3 does not pierce the substrate 21 .
  • the substrate 21 is press-molded.
  • the DLC coating film 18 having a low friction coefficient, for example, of 0.1 or lower with respect to SUS430 is formed on the surface layer of each of the straight portion 6 and the taper portion 5 of the punch 3 .
  • the lubricating oil is reserved in the pits 10 of the straight portion 6 . Accordingly, friction force acting on the punch 3 from the substrate 21 becomes remarkably small.
  • the independent pits 10 are formed so as to be uniformly distributed in the end surface 6 a of the straight portion 6 of the punch 3 so that higher lubricity can be kept in the end surface 6 a where the contact pressure between the punch 3 and the substrate 21 is maximized. Also, lubricating oil in the pits 10 formed in the end surface 6 a goes round between the substrate 21 and the outer circumferential side surface 6 b because the end surface 6 a comes into contact with the substrate 21 , so that friction force between the outer circumferential side surface 6 b and the substrate 21 is reduced. In addition, the independent pits 10 are formed so as to be uniformly distributed in the outer circumferential side surface 6 b of the straight portion 6 .
  • this molding process is repeated number of times equal to the number of nozzles 26 while the substrate 21 is moved at intervals of a nozzle pitch or at intervals of a nozzle row pitch. In this manner, the substrate 21 is press-molded. Then, as shown in FIG. 5C , after the press molding, the lower surface portion (lower side from the broken line shown in FIG. 5B ) of the substrate 21 inclusive of the convex portion 19 etc. protruding toward a side of the substrate 21 opposite to the press die 1 is ground by a grinding machine or the like to thereby open the ejection port 27 of each nozzle 26 . In this manner, the nozzle plate 25 is completed.
  • the punch 3 can hold lubricating oil.
  • lubricating oil is little by little supplied to the friction surface between the punch 3 and the substrate 21 so that the low friction state can be kept. For this reason, the lubricity between the straight portion 6 and the substrate 21 is kept high.
  • the punch 3 is prevented from being broken and worn away, so that the life of the press die 1 is elongated while the life of the punch 3 is elongated.
  • the pits 10 are formed in the end surface 6 a and the outer circumferential side surface 6 b of the straight portion 6 , the lubricating-oil retained state can be kept for a long time.
  • FIG. 6 is an enlarged perspective view of a press die to which a punch according to a second embodiment is applied.
  • the press die 101 according to this embodiment has a body portion 102 and a punch 103 .
  • the body portion 102 is provided with a columnar portion 112 extending downwards.
  • the punch 103 is formed at a lower end portion of the body portion 102 so as to be used in molding.
  • the punch 103 of the press die 101 is used in molding a substrate 121 into a nozzle plate 125 in the same manner as in the first embodiment.
  • the press die 101 of the second embodiment is substantially the same as the press die 1 except that the straight portion 6 of the punch 3 is not formed in the press die 101 .
  • the punch 103 (functioning as diameter-increasing portion) is shaped like such a taper that the diameter of the punch 103 perpendicular to the axial direction of the punch 103 decreases gradually and linearly as approaching from the lower end of the columnar portion 112 toward the end of the punch 103 .
  • the punch 103 has a circular end surface 103 a, which is in parallel to a direction perpendicular to the axial direction of the punch 103 .
  • Pits 110 identical to the pits 10 are formed so as to be uniformly distributed in the end surface 103 a.
  • no pit 110 is formed in an outer circumferential side surface 103 b of the punch 103 .
  • the pits 110 are not formed in the outer circumferential side surface 103 b formed as an inclined surface as described above, traces of the pits 110 do not remain on the molded surface of the substrate 121 when each nozzle 126 is formed in the substrate 121 by the press die 101 .
  • the punch 103 has a die member 115 integrated with the body portion 102 , and a hard coating film 116 harder than the die member 115 .
  • the die member 115 is formed in such a manner that a die material made of chromium-molybdenum steel (SCM 415 ) with HV 200 is mechanically processed into the shape of the die member 115 and then carburized and hardened.
  • the hard coating film 116 has a chromium (Cr) coating film 117 formed on the surface of the die member 115 , and a DLC coating film 118 formed on the surface of the Cr coating film 117 .
  • the Cr coating film 117 is formed to have a thickness of about 0.5 ⁇ m in the same manner as the W coating film 17 .
  • the DLC coating film 118 formed as a surface layer of the hard coating film 116 is a coating film with HV 800 harder than the die member 115 made of chromium-molybdenum steel.
  • the DLC coating film 118 with a thickness of about 1.5 ⁇ m is formed on the surface of the Cr coating film 117 .
  • the punch 103 is made of materials different from the materials of the die member 15 and the hard coating film 16 in the first embodiment but the punch 103 has substantially the same effect.
  • the hard coating film 116 is not necessary harder than the die member 115 as in the case of the punch 3 according to the first embodiment.
  • the hard coating film 116 may be lower in friction coefficient than the die member 115 , for example, the friction coefficient of the hard coating film 116 may be 0.1 or lower with respect to SUS 430 .
  • the press die 101 can be produced substantially in the same manner as the press die 1 according to the first embodiment. That is, a die material made of chromium-molybdenum steel is mechanically processed into the shape of the body portion 102 and the shape of the punch 103 and then carburized and hardened to thereby prepare the die member 115 . On this occasion, the outer diamter of the die member 115 is determined in consideration of the thicknesses of the Cr coating film 117 and the DLC coating film 118 , which will be formed later, so that the resultant punch 103 can be fitted to the inner diameter of each nozzle. Then, the Cr coating film 117 and the DLC coating film 118 are formed continuously on the surface of the die member 115 by an unbalanced magnetron (UBM) sputtering method.
  • UBM unbalanced magnetron
  • the Cr coating film 117 and the DLC coating film 118 In the case of forming the Cr coating film 117 and the DLC coating film 118 , after sputtering is performed using Cr as a target to form the Cr coating film 117 having a predetermined thickness, sputtering is performed using graphite (carbon) as a target while sputtering is performed using Cr concurrently. On this occasion, the process is shifted so that the rate of sputtering of Cr decreases gradually and the rate of sputtering of graphite increases gradually as the process advances.
  • the DLC coating film 118 is formed on the surface of the Cr coating film 117 . Also in this embodiment, a gradient composition layer including Cr and carbon is interposed between the Cr coating film 117 and the DLC coating film 118 as described above but not shown in FIG. 3 .
  • Pits 110 having such a fine depth that the pits 110 do not pass through the DLC coating film 118 and that a heat-affected layer modified by heat is not generated in the surface of the die member 115 are formed in the end surface 103 a of the punch 103 by the focused ion beam method in the same manner as in the first embodiment.
  • the pits 10 are formed in the end face 103 a at a predetermined distribution density. In this manner, production of the press die 101 having the punch 103 formed with the pits 110 is completed.
  • the nozzle plate 125 is the same as the nozzle plate 25 .
  • FIGS. 7A to 7 C are sectional views successively showing steps of producing the nozzle plate.
  • the substrate 121 is first placed on a die base 20 having a die hole 20 a as shown in FIG. 7A and is fixed and retained thereto.
  • Lubricating oil functioning as lubricant is applied or sprayed on the whole surface of the punch 103 of the press die 101 so that the lubricating oil is reserved in the pits 10 formed in the end surface 103 a.
  • this molding process is repeated number of times equal to the number of nozzles 126 while the substrate 121 is moved at intervals of a nozzle pitch or at intervals of a nozzle row pitch. In this manner, the substrate 121 is press-molded. Then, as shown in FIG. 7C , after the press molding, the lower surface portion (lower side from the broken line shown in FIG.
  • the punch 103 can hold lubricating oil.
  • the lubricity between the punch 103 and the substrate 121 is kept high.
  • friction force generated when the punch 103 is pressed against the substrate 121 and when the punch 103 is pulled out from the substrate 121 can be reduced so that the punch 103 is prevented from being broken and worn away.
  • the life of the press die 101 is elongated while the life of the punch 103 is elongated.
  • the punch 103 according to the second embodiment is shaped like a taper, there is little place of stress concentration compared with the punch 3 according to the first embodiment. For this reason, the life of the punch 103 is elongated more greatly.
  • the pits 10 , 110 have such a depth that the pits 10 , 110 does not pass through the DLC coating film 18 , 118 and does not reach the W coating film 17 , the Cr coating film 117 .
  • the pits 10 , 110 may have such a depth that the pits 10 , 110 pass through the DLC coating film 18 , 118 and reaches the W coating film 17 , the Cr coating film 117 and the die member 15 , 115 .
  • each pit has a depth in a range of from about 0.1 times to about 5 times as much as the thickness of the oil film.
  • the depth of each pit is not smaller than 0.1 times as much as the thickness of the oil film, lubricant retention capacity can be improved.
  • the depth of each pit is not larger than 5 times as much as the thickness of the oil film, supply characteristic of the lubricant reserved in the pits can be improved.
  • only one pit 10 , 110 may be formed.
  • the punch may have a taper portion equivalent to the taper portion 5 , a straight portion equivalent to the straight portion 6 , and a curved surface portion smoothly connecting the taper portion and the straight portion to each other.
  • the punch may have a curved surface portion (diameter-increasing portion) in place of the taper portion 5 so that the curved surface portion has a diameter tapered off toward the straight portion 6 and an outer circumferential side surface provided as a smooth curved surface.
  • the pits are preferably formed only in the straight portion. According to this configuration, the same effect as in the first embodiment can be achieved.
  • the punch may have only a curved surface portion (diameter-increasing portion), which has a diameter tapered off toward its end surface and has an outer circumferential side surface provided as a smooth curved surface. Also in this case, the pits may be formed only in the end surface. According to this configuration, the same effect as in the second embodiment can be achieved.
  • the first embodiment has been described on the case where the pits 10 are formed both in the end surface 6 a of the straight portion 6 and in the outer circumferential side surface 6 b of the straight portion 6 , the pits 10 may be formed in either surface. In this case, if the pits 10 are formed in the end surface 6 a, friction force between the substrate and the punch can be further reduced than the case where the pits 10 are formed in the outer circumferential side surface 6 b.
  • lubricating oil may be applied or sprayed on the surface of the substrate 21 , 121 before the punch 3 , 103 is pressed against the substrate 21 , 121 to perform press molding.
  • the lubricating oil supplied to the substrate 21 , 121 is put in the pits 10 , 110 so that the lubricity between the substrate 21 , 121 and the punch 3 , 103 is kept high.
  • the pits are formed by a focused ion beam method
  • the pits may be formed by laser etching using a femtosecond laser, an excimer laser, an ultraviolet laser or the like.
  • the pits may be formed by etching such as plasma etching.
  • the hard coating film 16 , 116 is not essential and may be eliminated in accordance with the shape of the die and the metal material of the die member.
  • the pits may be directly formed in the surface of the die member having the straight portion in its end or directly formed in the end surface of the die member having the taper portion in its end side.
  • the die member 15 according to the first embodiment is made of hard metal containing carbide with a mean particle size, which is equal to or larger than 0.05 ⁇ u and less than 0.3 ⁇ m.
  • the ground surface (the surface) is excellent, and cracking serving as a start point of rupture hardly occurs. Accordingly, the hard coating film 16 may not be formed.
  • the pits may be formed in the surface of the straight portion 6 of the die member 15 .
  • the DLC coating film 18 , 118 is formed as a surface layer of the press die 1 , 101 .
  • a hard coating film such as a CrN coating film may be formed in place of the DLC coating film so long as the hard coating film is harder than the die member to make contribution to abrasion resistance and reduction in friction force.
  • the die member 15 , 115 is made of the alloy (hard metal) obtained by sintering the mixture of tungsten carbide, vanadium carbide, titanium carbide, tantalum carbide, chromium carbide and metallic cobalt prepared in the predetermined proportions.
  • the die member 15 , 115 may be made of another hard material such as high speed metal.
  • lubricant of nanolevel particles may be used.
  • particles of silicon oxide (with a diameter of from about 10 nm about 40 nm), titanium oxide (with a diameter of about 20 nm), aluminum oxide (with a diameter of about 10 nm) or the like can be used.
  • the invention has been described on the case where the invention is applied to a punch of a press die for forming nozzles of a nozzle plate of an inkjet head.
  • the invention may be applied to other various press dies such as a press die for lead frame of semiconductor and a press die for molding parts of a sawing machine or a car.
US11/390,352 2005-03-29 2006-03-28 Punch Abandoned US20060219081A1 (en)

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JP2005094691A JP4341572B2 (ja) 2005-03-29 2005-03-29 ポンチ及びインクジェットヘッドのノズル形成用ポンチ

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US11685133B2 (en) * 2017-02-20 2023-06-27 Etgar Marcus Digital systems and processes for cutting and creasing corrugated cardboards

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EP2036630B1 (de) * 2007-09-14 2013-01-16 Feintool Intellectual Property AG Verfahren und Vorrichtung zum Schmieren von Werkzeug und Werkstück beim Schneiden
JP5433356B2 (ja) * 2009-09-16 2014-03-05 日本航空電子工業株式会社 金型及び金型表面の加工方法
JP6604701B2 (ja) * 2012-11-19 2019-11-13 株式会社Ｕａｃｊ 拡管プラグ及び金属管の拡管方法
CN103552273B (zh) * 2013-10-11 2016-01-20 广东东睦新材料有限公司 一种粉末冶金模具的防磨损润滑冲头结构
CN105234645B (zh) * 2015-10-14 2017-11-24 南京航空航天大学 一种亲疏复合织构化刀具表面的制备方法
GB2572016A (en) 2018-03-16 2019-09-18 Maxwell Wade Colin Vacuum plate
CN114274249B (zh) * 2021-12-24 2024-02-02 厦门华天华电子有限公司 一种fpc模具冲头的加工方法
WO2023148899A1 (ja) * 2022-02-03 2023-08-10 日本製鉄株式会社 鋼材、自動車部品、せん断加工装置及び鋼材の製造方法

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US2797595A (en) * 1954-04-02 1957-07-02 American Screw Co Method of hobbing recess-forming punches
US3461195A (en) * 1965-06-04 1969-08-12 Carlo Sebastiani Spraying method and apparatus to lubricate punch surfaces of tabletting machines
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US20030122900A1 (en) * 2001-12-03 2003-07-03 Seiko Epson Corporation Method of manufacturing nozzle plate, nozzle plate manufactured by the method and liquid jetting head provided with the nozzle plate
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Publication number Priority date Publication date Assignee Title
US11685133B2 (en) * 2017-02-20 2023-06-27 Etgar Marcus Digital systems and processes for cutting and creasing corrugated cardboards

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US20100037672A1 (en) 2010-02-18
JP2006272391A (ja) 2006-10-12
CN1840260A (zh) 2006-10-04
CN100525948C (zh) 2009-08-12
EP1707285A1 (en) 2006-10-04
EP1707285B1 (en) 2012-06-06
US8596105B2 (en) 2013-12-03
JP4341572B2 (ja) 2009-10-07

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