WO2016017803A1 - Couteau à ultrasons, procédé d'obtention de corps moulé coupé, procédé de coupe de pièce et dispositif de coupe à ultrasons - Google Patents

Couteau à ultrasons, procédé d'obtention de corps moulé coupé, procédé de coupe de pièce et dispositif de coupe à ultrasons Download PDF

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Publication number
WO2016017803A1
WO2016017803A1 PCT/JP2015/071810 JP2015071810W WO2016017803A1 WO 2016017803 A1 WO2016017803 A1 WO 2016017803A1 JP 2015071810 W JP2015071810 W JP 2015071810W WO 2016017803 A1 WO2016017803 A1 WO 2016017803A1
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Prior art keywords
molded body
ultrasonic
knife
cut
cutting
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PCT/JP2015/071810
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English (en)
Japanese (ja)
Inventor
秀治 小池
弘之 堤
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帝人株式会社
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Publication of WO2016017803A1 publication Critical patent/WO2016017803A1/fr

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    • 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
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • 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
    • B26D3/00—Cutting work characterised by the nature of the cut made; Apparatus therefor
    • 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

Definitions

  • the present invention relates to an ultrasonic knife for cutting a molded body containing carbon fiber and a thermoplastic resin, and aims to provide an excellent ultrasonic knife capable of reducing blade wear and breakage and extending the life of the blade. Is.
  • Patent Document 2 A technique of cutting the member to be cut without crushing the member to be cut by moving the cut member along the line to the member to be cut has also been studied (Patent Document 2).
  • Patent Documents 3 and 4 A technique of ultrasonically cutting a fiber fabric or an intermediate material for FRP molding is also known (Patent Documents 3 and 4).
  • the present invention provides an ultrasonic knife that can stably cut a molded body and reduce the replacement frequency of a cutting blade when cutting a molded body containing carbon fibers and a thermoplastic resin.
  • a method for producing a cut molded body by cutting a molded body using the above method is provided.
  • ⁇ 1> The ultrasonic knife whose knife edge angle is 45 degrees or more and less than 90 degrees.
  • ⁇ 2> The ultrasonic knife according to ⁇ 1>, wherein the blade length of the knife is at least twice the thickness of the knife.
  • ⁇ 3> The ultrasonic knife according to ⁇ 1> or ⁇ 2>, wherein the knife edge angle is 45 ° or more and less than 80 °.
  • ⁇ 4> ⁇ 1>- ⁇ 3> A cut molded body comprising a treatment of cutting a molded body containing carbon fiber and a thermoplastic resin by the action of ultrasonic vibration using the ultrasonic knife according to any one of ⁇ 1> to ⁇ 3>. Manufacturing method.
  • ⁇ 5> The method for producing a cut molded article according to ⁇ 4>, wherein the molded article is cut by ultrasonically vibrating an ultrasonic knife.
  • ⁇ 6> ⁇ 4> or ⁇ 5> wherein the angle formed by the length direction of the blade of the ultrasonic knife and the fiber axis surface of the carbon fiber contained in the molded body is in the range of 30 ° to 90 °, and is ultrasonically oscillated.
  • the manufacturing method of the cutting molded object as described in 2.
  • the ultrasonic knife moves in the molded body while cutting the molded body in a direction that forms an angle of 0 ° or more with respect to the direction of ultrasonic vibration ⁇ 4.
  • ⁇ 11> ⁇ 1>- ⁇ 3> A method for cutting a workpiece comprising carbon fiber and a thermoplastic resin, wherein the ultrasonic knife according to any one of ⁇ 1> to ⁇ 3> is used.
  • ⁇ 12> ⁇ 1>- ⁇ 3> An ultrasonic cutting apparatus comprising the ultrasonic knife according to any one of ⁇ 1> and ⁇ 3> and an ultrasonic oscillator.
  • the ultrasonic cutting device according to ⁇ 12> which has a mechanism that vibrates an ultrasonic knife with an ultrasonic oscillator.
  • the ultrasonic knife according to the present invention suppresses the generation of burrs after cutting even if the knife edge angle is obtuse to some extent in order to prevent blade wear, and cuts a molded body containing carbon fiber and thermoplastic resin.
  • the cut molded object excellent in the designability of the cut surface can be obtained.
  • (A) represents a schematic diagram (side view) of the ultrasonic knife
  • (b) represents a schematic diagram of the AA ′ cross section (cross section in the direction perpendicular to the blade length direction) in (a)
  • (C) represents the example of the cross-sectional shape of the direction orthogonal to the length direction of a blade.
  • (C-1) to (c-5) are, respectively, (c-1) single-sided, (c-2) single-sided, (c-3) double-sided, (c-4) double-sided, (c-5) ) Double-edged on both sides.
  • (C-6) to (c-9) are those in which the shape of the ridgeline of the blade is curved, sawtooth, or recessed in the thickness direction of the blade when the cross section of the blade of the ultrasonic knife with one blade on each side is viewed, and The ultrasonic knife which has a hole which penetrates in the thickness direction of a blade is illustrated.
  • (C) The schematic diagram which drawn the example of the attitude
  • (6A) to (6G) Ultrasonic knives with various edge shapes are illustrated in side views as seen from the thickness direction of the blades.
  • (7A) to (7D) shows an example of an ultrasonic knife viewed from the blade tip direction (equivalent to a plan view), a diagram viewed from the blade tip direction, a diagram viewed from the left side of the blade, and a perspective view. Is.
  • (7A) is equal to a cross-sectional view in a direction perpendicular to the length direction of the blade.
  • the fiber axis surface (two-dimensional plane) and cutting direction (the moving direction of the ultrasonic knife) of the carbon fiber in the molded body (workpiece) to be cut It is a schematic diagram of an example where and are non-parallel. In this figure, the description of the ultrasonic oscillator and the cords connecting the apparatus and the ultrasonic knife are omitted in the same manner as in the above figure, and the body of the body without the blade of the ultrasonic knife is further omitted. The description is also omitted.
  • the manufacturing method (workpiece cutting method) of the cutting molded object of the present invention it is a schematic diagram of an example in which the molded object (workpiece) to be cut is a long sheet.
  • Carbon fiber Any carbon fiber such as polyacrylonitrile (PAN), petroleum pitch, coal pitch, rayon, and lignin can be used as the carbon fiber contained in the molded article of the present invention.
  • PAN-based carbon fibers using PAN as a raw material are preferable because they are excellent in productivity and mechanical properties on an industrial scale.
  • the form of the carbon fiber constituting the molded body is not particularly limited, and may be any of continuous fiber, discontinuous fiber, woven fabric, knitted fabric, and non-woven fabric, and the fiber axes of a plurality of carbon fibers form substantially the same plane. And preferred. In the context of the present invention, this substantially identical plane is referred to as the fiber axis surface.
  • the fiber axis surface is preferably in a two-dimensional plane in the XY direction (hereinafter sometimes abbreviated as a two-dimensional plane (XY direction)) in the molded body.
  • the two-dimensional plane refers to the smallest dimension in the Z-direction in the XYZ coordinate system, that is, the thickness among the dimensions of the molded body in the front-rear, left-right, and vertical directions (three-dimensional directions) As appropriate, it is a plane in the XY direction when the X direction (width) and the Y direction (depth) are set.
  • the molded body when the carbon fiber is layered, it can be said that the molded body has a plurality of fiber axis surfaces.
  • a unidirectional material in which continuous fibers are arranged in one direction to form a sheet may be used.
  • a method for producing the unidirectional material a general method can be used.
  • a unidirectional plastic tape is prepared by a method described in Japanese Patent Application Laid-Open No. 2013-104056, and then laminated to form a molded body. It is also good.
  • the unidirectional material it is possible to use a multi-layered material (for example, alternately laminated in the orthogonal direction) so that the fiber arrangement directions of the respective layers intersect each other, that is, a material having a plurality of fiber axial surfaces.
  • the carbon fibers in the present invention are discontinuous fibers, and are dispersed in a random direction in a two-dimensional plane (XY direction in FIG. 3). May be.
  • the dispersion in a random direction in the two-dimensional plane means that the carbon fibers are randomly distributed in a two-dimensional plane direction of the molded body, not in a specific direction like one direction. Means a state in which it is arranged in a plane without showing a specific directionality.
  • the carbon fibers are dispersed in a random direction in the two-dimensional plane, it is preferable because it is a substantially in-plane isotropic material having no anisotropy in the two-dimensional plane of the molded body.
  • the shaped body can be regarded as containing carbon fibers in the form of an infinite number of fiber axial surface pseudo-laminates.
  • the carbon fiber and the thermoplastic resin fiber or the like may be made into a sheet or a plate by wet papermaking, and the discontinuous carbon fibers are arranged so as to be dispersed and overlapped. It may be a sheet, plate, or mat.
  • the average fiber length of the carbon fibers contained in the molded body is preferably 1 to 100 mm, more preferably 3 to 100 mm, still more preferably 5 to 100 mm, still more preferably 8 mm to 100 mm, particularly preferably 10 to 100 mm, especially 12 to 50 mm is markedly preferred.
  • the average fiber length of the carbon fiber is shorter than 1 mm, the role as the reinforcing fiber cannot be sufficiently achieved and sufficient strength may not be obtained.
  • the average fiber length is longer than 100 mm, the fluidity at the time of molding is low, and the desired molded article may not be obtained.
  • the carbon fibers may be composed of carbon fibers having a single fiber length, and carbon fibers having different fiber lengths may be mixed.
  • the average fiber length may be a number average fiber length or a weight average fiber length, but a weight average fiber length is preferred.
  • the length of each discontinuous carbon fiber is substantially the same, and the length is the weight average of both the number average fiber length. It can also be regarded as the fiber length.
  • the volume ratio of carbon fibers contained in the molded body defined by the following formula (1) is not particularly limited, but the carbon fibers are random in a two-dimensional plane. In the case of a dispersed form in any direction, the carbon fiber volume fraction (Vf) in the molded body is preferably 10 to 70 Vol%.
  • Vf 100 ⁇ carbon fiber volume / (carbon fiber volume + thermoplastic resin volume)
  • the carbon fiber volume ratio in the molded body is 10 Vol% or more, desired mechanical properties are easily obtained.
  • the fluidity of the molding material is improved, and a desired shape is easily obtained during molding.
  • a more preferable range of the carbon fiber volume ratio in the fiber reinforced resin material is 20 to 60 Vol%, and a further preferable range is 30 to 50 Vol%.
  • thermoplastic resin for example, vinyl chloride resin, vinylidene chloride resin, vinyl acetate resin, polyvinyl alcohol resin, polystyrene resin, acrylonitrile-styrene resin (AS resin), acrylonitrile-butadiene-styrene.
  • ABS resin acrylic resin, methacrylic resin, polyethylene resin, polypropylene resin, various thermoplastic polyamide resins, polyacetal resin, polycarbonate resin, polyethylene terephthalate resin, polyethylene naphthalate resin, Polybutylene naphthalate resin, Boribylene terephthalate resin, Polyarylate resin, Polyphenylene ether resin, Polyphenylene sulfide resin, Polysulfone resin, Polyethersulfone resin Fat, polyether ether ketone resins, such as polylactic acid-based resin.
  • nylon heat-melting polyamide
  • polycarbonate polyoxymethylene
  • polyphenylene sulfide polyphenylene ether
  • modified polyphenylene ether polyethylene terephthalate
  • polybutylene terephthalate polyethylene naphthalate
  • polyethylene polypropylene
  • polystyrene polymethyl methacrylate
  • AS resin ABS resin
  • preferred thermoplastic resins include polyamide resins such as nylon 6, polybutylene terephthalate resins, polyethylene resins, polypropylene resins, polyacetal resins, polyphenylene sulfide resins, and the like.
  • Nylon which is one of polyamide resins, includes PA6 (also called polycaproamide, polycaprolactam, poly ⁇ -caprolactam), PA26 (polyethylene adipamide) PA46 (polytetramethylene adipamide), PA66 (polyhexamethylene adipamide), PA69 (polyhexamethylene azepamide), PA610 (polyhexamethylene sebacamide), PA611 (polyhexamethylene undecamide) , PA612 (polyhexamethylene dodecanamide), PA11 (polyundecanamide), PA12 (polydodecanamide), PA1212 (polydodecane dodecamide), PA6T (polyhexamethylene terephthalamide), PA6I (polyhexamethylene terephthalamide), PA6I (polyhexamethylene terephthalamide), PA6I (polyhexamethylene terephthalamide), PA6I (polyhexamethylene terephthalamide), PA6
  • the ultrasonic knife in this invention cuts the molded object containing carbon fiber and a thermoplastic resin.
  • the thickness of the molded object that is the object to be cut is not particularly limited, but if it is too thick, the cutting resistance increases, the cutting speed becomes slow, or the blade may be missing.
  • the following is preferable, 3 mm or less is more preferable, and 2 mm or less is most preferable.
  • there is no limitation in particular in the shape of a molded object It can select suitably according to a use, such as not only the thing of the complicated shape which has a three-dimensional shape but flat plate shape, curved plate shape, and corrugated plate shape.
  • the molded product in the present invention is not limited to the molded product that is the final product, but may be an intermediate molded product in the middle of molding, and includes a thermoplastic resin and carbon fiber, and a material that can be cut is a material. However, it corresponds to a molded body.
  • the ultrasonic knife in the present invention has a knife edge angle of 45 ° or more and less than 90 °.
  • the knife edge angle in the present invention is also referred to as a blade angle, which is a vertex angle of a blade in a cross section perpendicular to the length direction of the blade, and is a blade angle (blade angle) of a portion to be cut in contact with a workpiece.
  • FIG. 1A shows a schematic diagram of the ultrasonic knife of the present invention (a side view of the ultrasonic knife viewed from the thickness direction of the blade).
  • the ultrasonic knife 2 in FIG. 1A has a blade 3.
  • Reference numeral 3-1 denotes the length of the blade of the ultrasonic knife.
  • FIG. 1B shows a schematic diagram of the shape of the AA ′ cross section which is a direction orthogonal to the length (3-1) direction of the blade 3.
  • the apex angle 1 of the blade is the knife edge angle.
  • 3-2 indicates the thickness of the blade of the ultrasonic knife.
  • the cross-sectional shape in the direction orthogonal to the blade length direction is not particularly limited.
  • An example of a cross-sectional shape in a direction perpendicular to the length direction of the blade is shown in FIG. (C-1) to (c-5) are, respectively, (c-1) single-sided, (c-2) single-sided, (c-3) double-sided, (c-4) double-sided, (c-5) ) Double-edged on both sides.
  • (C-6) to (c-9) are those in which the shape of the ridgeline of the blade is curved, sawtooth, or recessed in the thickness direction of the blade when the cross section of the blade of the ultrasonic knife with one blade on each side is viewed, and
  • the ultrasonic knife which has a hole which penetrates in the thickness direction of a blade is illustrated.
  • the knife edge angle is preferably 45 ° or more and less than 80 °, and more preferably 48 ° or more and less than 70 °.
  • a thermoplastic resin molded body not containing carbon fibers is cut with an ultrasonic knife having a knife edge angle of 45 ° or more, a large amount of burrs are generated.
  • the ultrasonic knife is an ultrasonic cutting knife and does not refer to the entire apparatus including the ultrasonic oscillator.
  • the ultrasonic knife of the present invention has a knife blade length that is less than the thickness of the knife from the viewpoint of cutting efficiency, ease of blade preparation, and less restrictions due to the size and shape of the molded object to be cut. It is preferably 2 times or more, more preferably 5 times or more, even more preferably 15 times or more, and particularly preferably 20 times or more. There is no particular upper limit on the length of the blade of the ultrasonic knife / the thickness of the ultrasonic knife (hereinafter sometimes referred to as the blade length / thickness ratio), but from the viewpoint of ease of production and handling If provided, it is more preferably 150 times or less, and particularly preferably 80 times or less.
  • a preferable numerical range of the blade length / thickness ratio can be appropriately selected from the above upper limit value and lower limit value, but is preferably 5 times or more and 150 times or less, more preferably 8 times or more and 150 times or less, The ratio is more preferably 15 times or more and 150 times or less, and further preferably 20 times or more and 80 times or less.
  • the length of the blade refers to the “blade span” (hawatari) in Japanese, that is, the shortest distance between the tip of the blade and the root of the blade. In FIG. That's it.
  • the shape of the ultrasonic knife is not particularly limited, and the knife edge angle and the blade thickness may differ depending on the location of the blade.
  • the shape of the blade edge when the ultrasonic knife is viewed from the thickness direction of the blade is not limited to a straight blade as illustrated in FIG. Or a combination thereof (a part of the cutting edge is linear, the rest is curved, etc.).
  • Various examples of the shape of the cutting edge are illustrated in (6A) to (6G) of FIG.
  • the shape of the ridgeline of the blade may also be linear, sawtooth, curved, or a combination thereof.
  • the blade of the ultrasonic knife may have a hole that penetrates in the thickness direction. Examples of the shape of the edge of the blade when the cross section of the blade of the ultrasonic knife is viewed are illustrated in (C-6) to (C-9) of FIG.
  • the material of the ultrasonic knife of the present invention iron, tungsten, diamond, titanium, aluminum or the like may be used alone, or an alloy such as high speed steel, stainless steel, carbide, duralumin or the like may be used.
  • the ultrasonic knife made of these materials may be one whose surface is further plated or coated.
  • the ultrasonic knife of the present invention is preferably for cutting a carbon fiber composite material.
  • the method for producing a cut molded body of the present invention includes a process for cutting a molded body containing carbon fibers and a thermoplastic resin by the action of ultrasonic vibration using the ultrasonic knife. It is.
  • the knife is preferably subjected to ultrasonic vibration along the length of the knife in the frequency range of 20 to 40 kHz by an ultrasonic generator, and the amplitude is preferably in the range of 10 to 100 ⁇ m, 40 ⁇ m is more preferable. If the frequency is 40 kHz or less, the length of the knife blade can be easily increased, and the ultrasonic knife is excellent.
  • the frequency x amplitude is preferably in the range of 200 to 4000 kHz ⁇ ⁇ m, and more preferably in the range of 700 to 1800 kHz ⁇ ⁇ m. If it is within the above range, for example, even when the feeding speed exceeds 500 mm / sec or more and exceeds 1000 mm / sec at the maximum in cutting the molded body, sharp and smooth cutting can be performed without any trouble such as knife breakage.
  • the ultrasonic knife is connected to an ultrasonic generator, and the molded body is cut by ultrasonic vibration transmitted from the ultrasonic generator to the tip of the knife.
  • a known ultrasonic generator can be used.
  • the output of the ultrasonic generator is not particularly limited, but if an example of the numerical range of the output is given, it is 1 to 4000 W, its upper limit is preferably 800 W, more preferably 500 W, and its lower limit is 10 W. Is preferable, and 100 W is more preferable.
  • the molded body in the process of cutting a molded body containing carbon fiber and a thermoplastic resin by the action of ultrasonic vibration, the molded body is cut by ultrasonically vibrating an ultrasonic knife.
  • the molded body is cut by ultrasonically vibrating an ultrasonic knife.
  • a method is preferable, and a method in which an ultrasonic knife is ultrasonically vibrated in the length direction of the blade to cut the formed body is more preferable.
  • the vibration direction of the ultrasonic knife in the present invention (7 in FIG. 4, 7 in FIGS. 5 (a) and (c)) is not particularly limited, but the angle formed with the fiber axis of the carbon fiber is 30 ° or more and 90 ° or less ( It is preferable to be 8 in FIG. 4 and 8) in FIGS. 5 (a) and 5 (c). In the present invention, the angle is expressed by an acute angle of 90 ° or less.
  • an ultrasonic knife at a position indicated by an angle 8' can be expressed as an obtuse angle as an increase in the angle 8; Is not expressed using an obtuse angle, and the angle between the two directions is also regarded as the angle between the lines, and is represented by a minimum angle, that is, an acute angle. It is preferable that the angle formed by the vibration direction of the ultrasonic knife and the fiber axis surface is 30 ° or more, since roughening of the cut surface and processing burrs are further suppressed.
  • a more preferable angle is 40 ° to 90 °, an even more preferable angle is 40 ° to 80 °, a still more preferable angle is 40 ° to 70 °, and a particularly preferable angle is 45 ° to 60 °.
  • the angle is 90 ° or less (even 90 °)
  • the cut (delamination or carbon fiber is missing) or fine cracks are generated.
  • the angle is less than 90 °, vibration of the molded body during cutting and rubbing between the side surface of the ultrasonic knife and the cut surface of the molded body are less likely to occur. Less and less knife loss.
  • the angle formed by the length direction of the blade of the ultrasonic knife and the fiber axis surface of the carbon fiber contained in the molded body is in the range of 30 ° to 90 °. It is preferable to ultrasonically vibrate.
  • the angle formed by the length direction of the blade of the ultrasonic knife and the fiber axis surface of the carbon fiber contained in the molded body is more preferably 40 ° to 90 °, and more preferably 40 ° to 80 °. More preferably, 40 ° to 70 ° is more preferable, and 45 ° to 60 ° is particularly preferable.
  • the vibration direction of the ultrasonic knife is preferably the same as the length direction of the blade, and it is not necessary that they are completely the same, and the angle formed by the vibration direction and the length direction of the blade is 10 ° or less. Preferably, it is 5 ° or less, more preferably 2 ° or less.
  • the direction of the blade length can also be referred to as the direction of the cutting edge line (knife edge).
  • the molded body to be cut is a carbon fiber contained in the molded body, which is a continuous fiber oriented in one direction or a two-dimensional random dispersion. It is preferably a continuous fiber.
  • the form of the carbon fiber in the present invention is not particularly limited, but the carbon fiber contained in the molded body is dispersed in a random direction within a two-dimensional plane (two-dimensional random dispersion). (Fig. 3).
  • a molded body in which carbon fibers are dispersed in a random direction within a two-dimensional plane is used, some carbon fibers may be oriented three-dimensionally. In this case, the effect of the present invention can be obtained by vibrating within a range of 30 ° or more and 90 ° or less with respect to a fiber axial surface made of approximately 50% carbon fiber.
  • the vibration direction of the preferable ultrasonic knife is preferably 30 ° or more and 90 ° or less with respect to the fiber axis surface of the carbon fiber, so that the fiber axis surface is a two-dimensional plane of the molded body.
  • the angle formed by the vibration direction and the two-dimensional plane is preferably 30 ° or more and 90 ° or less.
  • a more preferable angle formed by the vibration direction and the two-dimensional plane is 40 ° to 90 °, an even more preferable angle is 40 ° to 80 °, a further preferable angle is 40 ° to 70 °, and a particularly preferable angle is It is 45 ° -60 °.
  • the carbon fibers are dispersed in a random direction within a two-dimensional plane, and a plurality of carbon fibers have their fiber axes substantially in the same plane, In the plane, it can be said that the fiber axes of the carbon fibers are not oriented.
  • the direction shown to 7 of FIG. 4 is illustrated.
  • the vibration direction preferably coincides with the length direction of the ultrasonic knife.
  • an angle indicated by 8 in FIG. 4 is exemplified.
  • the attitude of the ultrasonic knife is within the range of the direction along the side surface of the cone shown by the dotted line in FIG. It can be set appropriately.
  • the thing of the continuous fiber in which the carbon fiber contained in a molded object orientated to one direction can be used.
  • the vibration direction of the preferable ultrasonic knife described above can be 30 ° or more and 90 ° or less with respect to the fiber axis surface of each carbon fiber.
  • the fiber axis surface formed by these carbon fibers that is, 30 ° or more and 90 ° or less with respect to the two-dimensional plane. It will be preferable.
  • a more preferable angle with respect to the two-dimensional plane is 40 ° to 90 °, an even more preferable angle is 40 ° to 80 °, a further preferable angle is 40 ° to 70 °, and a particularly preferable angle is 45 ° to 60 °. It is.
  • each layer is regarded as a fiber axis surface, that is, a two-dimensional plane.
  • the angular range related to the vibration direction of the ultrasonic knife is the same range.
  • the vibration direction of the ultrasonic knife in the case of cutting a formed body that is a unidirectional material with an ultrasonic knife the direction shown by 7 in FIG. 5C is exemplified.
  • the ultrasonic knife may be vibrated within the range of the conical direction indicated by the dotted lines in FIGS.
  • the ultrasonic knife may move in the molded body while cutting the molded body in a direction that forms an angle of 0 ° or more with respect to the direction of ultrasonic vibration.
  • the ultrasonic knife moves in the molded body while cutting the molded body in a direction that forms an angle of 30 ° or more and 90 ° or less with respect to the direction of ultrasonic vibration, and the angle is 40 ° to 90 °. Is more preferably 40 ° to 80 °, even more preferably 40 ° to 70 °, and particularly preferably 45 ° to 60 °.
  • the fiber axis surface (two-dimensional plane) of the carbon fiber in the molded body and the direction in which the ultrasonic knife moves in the molded body while cutting the molded body (the cutting direction)
  • the angle 8 formed by the fiber axis surface and the vibration direction may be different from the angle 11 formed by the cutting direction and the vibration direction.
  • a molded body containing carbon fiber and a thermoplastic resin is cut to obtain a cut molded body.
  • the carbon fibers and thermoplastic resins contained in the cut molded body include the same carbon fibers and thermoplastic resins as described above.
  • the molded body containing carbon fiber and thermoplastic resin is obtained by molding a molding material containing carbon fiber and thermoplastic resin with a molding die.
  • an object made of a material containing carbon fiber and a thermoplastic resin for example, a mixture of carbon fiber and thermoplastic resin formed into a sheet shape with a heating roller, a 3D printer, a carbon fiber It may be a fusion lump or the like generated due to an apparatus abnormality when manufacturing the reinforced resin or its injection-molded body.
  • the present invention when expressed in terms of a workpiece, which means an intermediate product processed by a tool or a machine, in the manufacturing process, uses the above-described ultrasonic knife of the present invention, carbon fiber, and thermoplasticity.
  • the present invention also relates to a method for cutting a workpiece including resin.
  • a preferred embodiment of the method for cutting the workpiece is the same as that described above with respect to the method for manufacturing the cut molded body.
  • FIG. 9 shows an example of a method of cutting a workpiece including carbon fibers and a thermoplastic resin, which is a long sheet-like material, using an ultrasonic knife.
  • an angle 8 formed by the fiber axis surface of the carbon fiber in the workpiece and the vibration direction of the ultrasonic knife, and an angle 11 formed by the cutting direction and the vibration direction by the ultrasonic knife. is substantially the same.
  • the present invention also relates to an ultrasonic cutting apparatus including the above-described ultrasonic knife of the present invention and an ultrasonic oscillator. It is preferable that the ultrasonic cutting device has a mechanism for vibrating an ultrasonic knife by an ultrasonic oscillator.
  • Unitika KE435-POG is a carbon fiber (Tenax STS40 manufactured by Toho Tenax Co., Ltd., average fiber diameter of 7 ⁇ m) that is cut into an average fiber length of 16 mm and distributed in a random direction in a two-dimensional plane so as to have an average basis weight of 270 g / m 2.
  • PA6 A flat composite material 1 having a carbon fiber volume ratio (Vf) of 35% and a thickness of 1 mm was produced by sandwiching between 5 sheets of cloth and pressing at 260 ° C. and 2.5 MPa. The obtained composite material 1 was heated at 280 ° C. for 2 minutes using an IR heater to obtain a heat-softened sheet 1. Thereafter, the heat-softening sheet 1 was sandwiched between an upper mold and a lower mold to form a flat molded body 1. The molding conditions were a mold temperature of 100 ° C. and a pressure of 15 MPa for 1 minute.
  • a molded body was prepared in the same manner as the molded body 1 except that polycarbonate (Teijin Limited: L-1225Y) was used instead of Unitika KE435-POG (PA6) used in the molded body 1. Obtained.
  • polycarbonate Teijin Limited: L-1225Y
  • PA6 Unitika KE435-POG
  • Carbon fiber (Tenax STS40-24KS manufactured by Toho Tenax, fiber diameter 7 ⁇ m, tensile strength 4000MPa) is laminated with PA6 film (Unitika Emblem ON 25 ⁇ m thickness), and 32 layers are stacked alternately at 0 ° and 90 ° in the fiber direction (carbon The composite material 3 was produced by heating and compressing at 260 ° C., 2 MPa, 20 minutes, and the fibers were alternately 0 ° 90 °, symmetrical lamination, carbon fiber volume ratio (Vf) 47%, 1 mm thickness. The obtained composite material 3 was molded in the same manner as the composite material 1 to obtain a flat molded body 3.
  • PA6 film Unitika Emblem ON 25 ⁇ m thickness
  • the unidirectional molding material was cut into a size of 400 mm ⁇ 400 mm, dried with a hot air dryer at 120 ° C.
  • the molded body 6 is the same as the composite material 1 except that the carbon fiber is replaced with glass fiber EX-2500 (average fiber diameter 15 ⁇ m) fiber manufactured by Nippon Electric Glass Co., Ltd., and the basis weight is adjusted so that Vf is 35%. Was made.
  • the molded body 1 is made of cemented carbide with a knife edge angle of 50 ° (angle 1 in FIG. 1B), a blade length (length 3-1 in FIG. 1) of about 25 mm, and a thickness of 1 mm.
  • the ultrasonic knife is operated in the length direction of the blade under the conditions of output 200 to 400 W, vibration frequency 40 kHz, amplitude 10 to 40 ⁇ m.
  • the molded body was cut by ultrasonic vibration to obtain a cut molded body.
  • the cutting speed was 300 mm / second.
  • the angle formed by the length direction of the blade of the ultrasonic knife and the two-dimensional plane (XY direction) of the molded body at the time of cutting was 90 °.
  • This angle is also an angle in a direction in which the ultrasonic knife moves while cutting the molded body with respect to the direction of ultrasonic vibration.
  • Example 2 The ultrasonic wave is the same as in Example 1 except that the angle formed by the length direction of the blade of the ultrasonic knife and the two-dimensional plane (XY direction) of the molded body (angle 8 in FIG. 4) is 45 °.
  • the molded body was cut using a knife to obtain a cut molded body. The results are shown in Table 1.
  • Example 3 The ultrasonic wave is the same as in Example 1 except that the angle formed by the length direction of the blade of the ultrasonic knife and the two-dimensional plane (XY direction) of the molded body (angle 8 in FIG. 4) is 30 °.
  • the shaped body was cut using a knife. The results are shown in Table 1.
  • Example 4 The molded body was cut using an ultrasonic knife in the same manner as in Example 1 except that the molded body 2 was used. The results are shown in Table 1.
  • Example 5 The molded body was cut using an ultrasonic knife in the same manner as in Example 1 except that the molded body 3 was used. The results are shown in Table 1.
  • Example 6 The molded body was cut using an ultrasonic knife in the same manner as in Example 1 except that the molded body 4 was used. The results are shown in Table 1.
  • Example 7 The molded body was cut using an ultrasonic knife in the same manner as in Example 1 except that an ultrasonic knife having a knife edge angle of 75 ° was used. The results are shown in Table 1.
  • Example 1 The molded body was cut using an ultrasonic knife in the same manner as in Example 1 except that an ultrasonic knife having a knife edge angle of 23 ° was used. The results are shown in Table 1.
  • Example 2 The molded body was cut using an ultrasonic knife in the same manner as in Example 1 except that an ultrasonic knife having a knife edge angle of 17 ° was used. The results are shown in Table 1.
  • Example 3 The molded body was cut using an ultrasonic knife in the same manner as in Example 1 except that an ultrasonic knife having a knife edge angle of 95 ° was used. The results are shown in Table 1.
  • Reference Example 2 The molded body was cut using an ultrasonic knife in the same manner as in Reference Example 1 except that an ultrasonic knife having a knife edge angle of 23 ° was used. The results are shown in Table 1.
  • the ultrasonic knife for cutting a molded body containing the carbon fiber and the thermoplastic resin of the present invention has a significantly longer blade life than conventional ones, and is produced in large quantities, particularly represented by automobiles and home appliances. It is suitable for use.
  • the matrix may be used for cutting a molded body of a material other than the thermoplastic resin, for example, a carbon fiber reinforced material such as a thermosetting resin or rubber.
  • Knife edge angle of ultrasonic knife 1 Knife edge angle of ultrasonic knife 2 Ultrasonic knife 3 Blade of ultrasonic knife 3-1 Length of blade of ultrasonic knife 3-2 Thickness of blade of ultrasonic knife 4 Including carbon fiber and thermoplastic resin Molded body (workpiece) 5 Discontinuous carbon fiber 6 Planned cutting part 7 Vibration direction of ultrasonic knife 8, 8 ′ Angle formed by fiber axial plane ⁇ 2-dimensional plane (XY direction) ⁇ of carbon fiber and ultrasonic knife vibration direction 9 Unidirectional carbon fiber 10 Direction in which the ultrasonic knife moves through the molded body while cutting the molded body (cutting direction) 11 Angle of cutting direction with respect to vibration direction of ultrasonic knife

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  • Life Sciences & Earth Sciences (AREA)
  • Forests & Forestry (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Reinforced Plastic Materials (AREA)
  • Nonmetal Cutting Devices (AREA)

Abstract

La présente invention a pour but de fournir un couteau à ultrasons (2) qui peut couper, en ce qui concerne la coupe d'un corps moulé qui comprend une fibre de carbone et une résine thermoplastique, de façon stable le corps moulé et qui peut réduire la fréquence de remplacement d'une lame de coupe. La présente invention a également pour but de fournir un procédé pour utiliser ledit couteau pour couper un corps moulé et obtenir un corps moulé coupé. L'invention concerne un couteau à ultrasons (2) qui présente un angle de bord de couteau (1) égal ou supérieur à 45°, mais inférieur à 90°.
PCT/JP2015/071810 2014-08-01 2015-07-31 Couteau à ultrasons, procédé d'obtention de corps moulé coupé, procédé de coupe de pièce et dispositif de coupe à ultrasons WO2016017803A1 (fr)

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JP2014157674A JP2017196667A (ja) 2014-08-01 2014-08-01 超音波ナイフ、及びこれを用いて切断成形体を製造する方法

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JP2019038087A (ja) * 2017-08-29 2019-03-14 株式会社アドウェルズ 切断装置
JP6489626B1 (ja) * 2017-09-28 2019-03-27 Ａｃｓ株式会社 カッティング装置の制御方法
CN114311044A (zh) * 2022-03-14 2022-04-12 常州纳捷机电科技有限公司 一种碳纤维层合板的自动切割方法

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KR102440156B1 (ko) * 2020-12-24 2022-09-08 주식회사 에스알아트 적층 필름의 초음파 절단 및 실링 장치 및 그 방법
KR102486943B1 (ko) * 2021-03-26 2023-01-11 주식회사 삼연기술 탄소섬유 강화 플라스틱 제조용 탄소섬유 재단장치

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JPH029735A (ja) * 1988-06-27 1990-01-12 Central Glass Co Ltd 板ガラス間に介在する中間膜端部の切断除去方法ならびにその装置
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Publication number Priority date Publication date Assignee Title
JP2019038087A (ja) * 2017-08-29 2019-03-14 株式会社アドウェルズ 切断装置
JP6489626B1 (ja) * 2017-09-28 2019-03-27 Ａｃｓ株式会社 カッティング装置の制御方法
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CN114311044A (zh) * 2022-03-14 2022-04-12 常州纳捷机电科技有限公司 一种碳纤维层合板的自动切割方法
CN114311044B (zh) * 2022-03-14 2022-05-27 常州纳捷机电科技有限公司 一种碳纤维层合板的自动切割方法

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