JP2011011295A - Fine recessed part working method and fine recessed part working machine - Google Patents
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- 238000005520 cutting process Methods 0.000 claims abstract description 75
- 238000003754 machining Methods 0.000 claims abstract description 54
- 238000003672 processing method Methods 0.000 claims description 16
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Abstract
Description
本発明は、非球面レンズアレイ、自由曲面レンズアレイ用金型等の微細凹部が多数配置された金型等を加工するための加工機及び加工方法に関するものである。 The present invention relates to a processing machine and a processing method for processing a mold having a large number of fine recesses such as an aspheric lens array and a free-form lens array mold.
従来、レンズアレイ等のプラスチックレンズはレンズ金型に彫られた微細凹部に樹脂を射出して成形量産している。かかる微細凹部の加工は、ＮＣ旋盤、マシニングセンタ等のＮＣ（数値制御工作機）を用いて加工されている。特許文献１のものは、フレネルレンズの金型に関するものである。このものは、ワークの加工表面に対向して、先端切れ刃が略三角形状のダイヤモンドカッタをマシニングセンタの主軸に取付け、ワーク表面に対し円弧を描くように水平方向に相対移動させる。さらに、主軸を傾斜、揺動させながらダイヤモンドカッタの刃先を加工面に対し、傾斜、揺動させながら、主軸垂直方向に切り込むことにより断面略三角形の円弧溝を切削加工し、同心円状や円弧状の多数の溝を形成してフレネルレンズの金型溝を加工している。この加工方法はシェーパー加工の一種である。 Conventionally, a plastic lens such as a lens array is mass-produced by injecting a resin into a fine recess carved in a lens mold. Such fine recesses are processed using an NC (numerical control machine tool) such as an NC lathe or a machining center. The thing of patent document 1 is related with the metal mold | die of a Fresnel lens. In this case, a diamond cutter having a substantially triangular cutting edge is attached to the main shaft of the machining center so as to face the processing surface of the workpiece, and is relatively moved in a horizontal direction so as to draw an arc with respect to the workpiece surface. Furthermore, while cutting and tilting the spindle, the cutting edge of the diamond cutter is tilted and swung relative to the machining surface, and the arc groove with a substantially triangular cross section is cut by cutting in the direction perpendicular to the spindle. The mold groove of the Fresnel lens is processed by forming a large number of grooves. This processing method is a kind of shaper processing.
一方、多量のレンズ、あるいはレンズアレイを得るためには金型にできるだけ多数のレンズ成形穴（微細凹部）を設けたい。そこで、特許文献２においては、ＮＣ旋盤の主軸先端に所定方向に移動自在なスライドテーブルを設け、このスライドテーブルにワークを固定して旋盤加工により微細凹部を形成している。スライドテーブルにより、ワークの加工すべき微細凹部の中心を主軸と一致するように位置決め固定して、主軸を回転させ、対向するバイトの先端の刃先を加工部に対し主軸方向及び主軸直角方向へ移動させることにより旋盤加工する。これにより、単一の微細凹部を加工するのと同様な旋盤（旋削）加工が行える。次にスライドテーブルを移動させて、次の微細凹部に中心を合わせ、旋盤加工を行う。これを順次行うことにより、多数の微細凹部を所定のピッチで形成するものである。 On the other hand, in order to obtain a large number of lenses or a lens array, it is desirable to provide as many lens molding holes (fine concave portions) as possible in the mold. Therefore, in Patent Document 2, a slide table that is movable in a predetermined direction is provided at the tip of a main spindle of an NC lathe, and a work is fixed to the slide table to form a fine recess by lathe processing. Using a slide table, the center of the fine recess to be machined is positioned and fixed so that it coincides with the main axis, the main axis is rotated, and the cutting edge at the tip of the opposite tool is moved in the main axis direction and the main axis perpendicular direction with respect to the processing part. Lathe processing is done. Thereby, the same lathe (turning) processing as processing a single fine recess can be performed. Next, the slide table is moved so that the center is aligned with the next fine recess and lathe processing is performed. By sequentially performing this, a large number of fine recesses are formed at a predetermined pitch.
特許文献１のものは、バイトの先端及び先端近傍の切れ刃形状の全部あるいは一部を転写するシェーパー加工の一種であり、フレネルレンズ等の溝加工に適している。しかし、非球面レンズのような連続面については、シェーパー加工では連続面を考慮していないので、必ずしも適切な加工方法ではない。また、加工時間がかかるという問題があった。 The thing of patent document 1 is a kind of shaper process which transfers all or a part of the front-end | tip of a cutting tool and the cutting edge shape of the front-end | tip vicinity, and is suitable for groove | channel processes, such as a Fresnel lens. However, a continuous surface such as an aspheric lens is not necessarily an appropriate processing method because the continuous surface is not considered in the shaper processing. In addition, there is a problem that processing time is required.
さらに、多数の微細凹部を形成するためには、一つ一つの穴精度はもとより、ピッチ精度が必要である。だが、引用文献１の実施例に記載のマシニングセンタ等の主軸は機械の上方から下方に向かって下向きあるいは斜め下向きに設けられている。このため、主軸の自重による移動、変形、主軸の位置による主軸取付部の変形により、高い精度を望むことは困難であった。さらに、一つのワークに多量の微細凹部加工をする場合、加工途中で、バイトの刃先の摩耗や損傷があった場合、バイトの交換後にも高い精度が必要となる。しかし、マシニングセンタの主軸に交換前と全く同一の状態にバイトを取り付けることは非常に困難である。 Further, in order to form a large number of fine recesses, not only the accuracy of each hole but also the pitch accuracy is required. However, the spindle of the machining center or the like described in the embodiment of the cited document 1 is provided downward or obliquely downward from the upper side to the lower side of the machine. For this reason, it has been difficult to achieve high accuracy due to movement and deformation of the main shaft due to its own weight, and deformation of the main shaft mounting portion depending on the position of the main shaft. Furthermore, when machining a large amount of fine recesses on one workpiece, if there is wear or damage to the cutting edge of the cutting tool during processing, high accuracy is required even after the cutting of the cutting tool. However, it is very difficult to attach the cutting tool to the spindle of the machining center in the same state as before replacement.
一方、特許文献２の加工法においては、主軸に設けられたワークの位置決めをするスライドテーブルにより、微細凹部の加工毎にワークが移動するので、主軸に対する重心も移動する。このため、安定した回転が得られず加工精度が低下する。また、大きなレンズアレイの金型を加工する場合には、ストロークの大きいスライドテーブルを主軸に搭載しなければならず、主軸の先端の搭載重量が大きくなり、さらに、アンバランス量が大きくなり加工精度が低下する。また、微細凹部のピッチ精度を高めるためには、スライドテーブルの移動量をスケールで計測し、制御することが必要になるが、回転する主軸上に位置検出器、スライドテーブル移動用モータを取り付けるとさらに大きくなり、構造も複雑になるという問題があった。 On the other hand, in the processing method of Patent Document 2, the workpiece moves each time the minute recess is processed by the slide table for positioning the workpiece provided on the main shaft, so that the center of gravity with respect to the main shaft also moves. For this reason, a stable rotation cannot be obtained and the machining accuracy is lowered. In addition, when processing a mold with a large lens array, a slide table with a large stroke must be mounted on the spindle, which increases the mounting weight at the tip of the spindle and further increases the unbalance amount. Decreases. In order to increase the pitch accuracy of the fine recesses, it is necessary to measure and control the amount of movement of the slide table with a scale, but if a position detector and a slide table moving motor are mounted on the rotating spindle, There is a problem that the size is further increased and the structure is complicated.
かかる問題点に鑑みて本発明の課題は、旋盤加工と同等の微細凹部加工とし、微細凹部の加工速度、加工精度を上げることである。また、加工時のアンバランスを防止し、さらには工具交換による精度低下を防止して、微細凹部の加工精度、ピッチ精度がよく、バラツキの少ない多数の微細凹部を有する金型を加工する微細凹部加工方法及び加工機を提供することである。 In view of such a problem, an object of the present invention is to make a fine recess processing equivalent to lathe processing, and to increase the processing speed and processing accuracy of the fine recess. In addition, it prevents imbalance at the time of machining, and further prevents deterioration of accuracy due to tool change, and has a fine concave portion for machining a die having a large number of fine concave portions with good precision and pitch accuracy of the fine concave portions and little variation. It is to provide a processing method and a processing machine.
本発明においては、加工すべきワークの加工面に対してその軸線が垂直になるように設けられた回転主軸と、剣のようなとがった先端切れ刃又は先端が丸コーナーとされた先端切れ刃を有し、前記切れ刃の先端と前記回転主軸の軸線とが一致するように前記軸線に沿って前記回転主軸に取り付けられたバイトと、前記回転主軸を回転させ前記ワーク加工面と前記バイト先端とが前後方向及び前記加工面上下方向及び前記加工面左右方向に相対移動可能とする移動装置と、前記移動装置を制御する制御装置と、を有し、前記ワーク加工面に微細凹部を加工する微細凹部加工方法であって、前記制御装置により、加工すべき微細凹部に対して、前記ワーク加工面を回転することなく、前記回転主軸を連続回転させかつ前記バイト先端のすくい面が常にバイト進行方向になるように前記ワーク加工面と前記バイト先端とを相対移動させながら制御し前記微細凹部を加工する微細凹部加工方法を提供することにより前述した課題を解決した。 In the present invention, a rotating spindle provided so that its axis is perpendicular to the machining surface of the workpiece to be machined, and a tip cutting edge sharpened like a sword or a tip cutting edge whose tip is a round corner And a cutting tool attached to the rotating spindle along the axis so that the tip of the cutting edge and the axis of the rotating spindle coincide with each other, and the workpiece machining surface and the tip of the cutting tool by rotating the rotating spindle And a control device that controls the moving device, and processes a fine recess on the workpiece processing surface. A method for processing a fine recess, wherein the control device continuously rotates the rotating spindle without rotating the workpiece processing surface with respect to the fine recess to be processed, and a rake face at the tip of the cutting tool is provided. And solve the problems described above by providing a micro-concave portion machining method controls while relatively moving the workpiece processed surface and with said byte tip such that the byte traveling direction to process the fine recess.
即ち、本発明においては、ワークの加工面を回転させないので、ワークの加工位置精度、ピッチ精度に対する影響が少なく、また、回転バランスを考慮する必要がない。また、主軸にはバイトが取り付けられるのみであり、構造も簡単であり、取付け、回転バランス調整も容易で、精度を確保し易く、バイト取付後の回転バランスの変化がなく安定した主軸回転を得られる。 That is, in the present invention, since the work surface of the workpiece is not rotated, there is little influence on the work position accuracy and pitch accuracy of the work, and it is not necessary to consider the rotation balance. In addition, only a tool is attached to the spindle, the structure is simple, the mounting and rotation balance can be adjusted easily, accuracy is easily secured, and there is no change in the rotation balance after the tool is installed, resulting in stable spindle rotation. It is done.
特に、移動装置、制御装置により、ワークの加工すべき微細凹部に対して、回転主軸を連続回転させかつバイト先端のすくい面が常にバイト進行方向になるようにワーク加工面とバイト先端とを相対移動させながら制御し微細凹部を加工できるようにしたので、固定されたワークと連続回転するバイトは、あたかも旋盤加工の回転するワークと固定されたバイトと同様の相対運動となり、旋盤加工と同様な条件での加工方法となる。なお、バイト先端の相対移動回転の中心は、加工すべき微細凹部の中心と一致させて、これを加工原点や加工原位置とする。これにより、解析・プログラム等が容易となり、精度も高くなる。 In particular, the workpiece processing surface and the cutting tool tip are moved relative to each other so that the rotating spindle is continuously rotated and the rake face of the cutting tool tip is always in the tool advance direction with respect to the minute recesses to be processed by the moving device and control device. Since the fine recesses can be machined while being controlled, the fixed workpiece and the continuously rotating bite have the same relative movement as the rotating workpiece and the fixed bite of lathe processing, and are similar to lathe machining. It becomes a processing method under conditions. The center of relative movement and rotation of the tip of the cutting tool is made to coincide with the center of the fine recess to be processed, and this is used as the processing origin or the processing original position. This facilitates analysis / programming and increases accuracy.
また、請求項２に記載の発明においては、前記加工すべき微細凹部が前記加工すべきワークの加工面に多数設けられている微細凹部加工方法とした。ワークは回転しないので、多数の微細凹部の加工にあたって高精度ピッチでの加工が可能である。 According to a second aspect of the present invention, there is provided a fine recess processing method in which a large number of the fine recesses to be processed are provided on the processing surface of the workpiece to be processed. Since the workpiece does not rotate, it is possible to process with a high precision pitch when processing a large number of fine recesses.
また、請求項３に記載の発明においては、前記バイト先端をＲ形状とし、前記バイトの切れ刃先端を前記加工すべき微細凹部の外側から中心に向かって螺旋状に相対移動させて加工するので、より旋盤加工と同様な加工を実現できる。 Further, in the invention according to claim 3, since the tip of the cutting tool has an R shape, and the tip of the cutting edge of the cutting tool is processed by being relatively moved spirally from the outside of the fine recess to be processed to the center. Therefore, it is possible to realize the same processing as lathe processing.
さらに、請求項４に記載の発明においては、前記回転主軸の連続回転速度を１〜５００ｒｐｍとし前記微細凹部を加工するようにしたので、制御も容易で、精度も高く加工面を良好とすることができる。より好ましくは、５〜１００ｒｐｍである。また、請求項５に記載の発明においては、前記ワーク加工面に直径換算で０．５ｍｍ〜１０ｍｍの微細凹部を多数加工する微細凹部加工方法としたので、相対移動にかかる振動の影響の少ない範囲での加工とすることができる。より好ましくは微細凹部は直径換算で１〜５ｍｍである。 Furthermore, in the invention described in claim 4, since the fine recesses are machined by setting the continuous rotation speed of the rotating spindle to 1 to 500 rpm, the control is easy, the accuracy is high, and the machining surface is good. Can do. More preferably, it is 5 to 100 rpm. Moreover, in the invention according to claim 5, since it is a fine recess processing method for processing a large number of fine recesses of 0.5 mm to 10 mm in diameter on the workpiece processing surface, the range is less affected by vibrations on relative movement. It can be processed with. More preferably, the fine recess is 1 to 5 mm in terms of diameter.
さらに、請求項６に記載の発明においては、水平テーブル上に設けられ加工すべきワークの加工面を前記水平テーブルに垂直になるように保持するワーク保持部と、前記保持部のワーク加工面に対向して前記水平テーブル垂直方向に設けられた主軸台と、前記主軸台に前記水平テーブルと水平かつ前記ワークの加工面と垂直になるように支持された回転主軸と、剣のようなとがった先端切れ刃又は先端が丸コーナーとされた先端切れ刃を有し、前記切れ刃の先端と前記回転主軸の軸線とが一致するように前記軸線に沿って前記回転主軸に取り付けられたバイトと、前記回転主軸を回転させ前記ワーク加工面と前記バイト先端とが前後方向及び前記加工面上下方向及び前記加工面左右方向に相対移動可能とする移動装置と、前記移動装置を制御する制御装置と、を有し、前記ワーク加工面に微細凹部を多数加工する微細凹部加工機であって、前記制御装置により、多数の内の一つの加工すべき微細凹部に対して、前記回転主軸を連続回転させかつ前記バイト先端のすくい面が常にバイト進行方向になるように前記ワーク加工面と前記バイト先端とを相対移動させながら制御し前記微細凹部を加工可能にされている微細凹部加工機を提供することにより前述した課題を解決した。 Furthermore, in the invention described in claim 6, a workpiece holding portion that is provided on a horizontal table and holds a machining surface of a workpiece to be machined so as to be perpendicular to the horizontal table, and a workpiece machining surface of the holding portion. A headstock provided opposite to the horizontal table in the vertical direction, a rotating spindle supported on the headstock so as to be horizontal to the horizontal table and perpendicular to the processing surface of the workpiece, and sharp like a sword A cutting edge having a tip cutting edge or a tip cutting edge whose tip is a rounded corner, and a cutting tool attached to the rotating spindle along the axis so that the tip of the cutting edge and the axis of the rotating spindle coincide with each other; A moving device that rotates the rotation main shaft to enable relative movement of the workpiece machining surface and the cutting tool tip in the front-rear direction, the machining surface vertical direction, and the machining surface left-right direction, and controls the movement device A fine recess processing machine that processes a large number of fine recesses on the workpiece processing surface, and the control device rotates the rotation of one of the multiple micro recesses to be processed. Micro recess processing that allows the micro recess to be processed by controlling the workpiece processing surface and the tool tip to move relative to each other so that the spindle is continuously rotated and the rake face of the tool tip is always in the tool advance direction. The above-mentioned problems were solved by providing a machine.
即ち、本発明加工機においては、ワークの加工面を水平テーブルに垂直になるように保持するワーク保持部にワークを取付け（固定し）、ワークは回転させないので、ワークの加工位置精度、ピッチ精度に対する影響が少なく、また、回転バランスを考慮する必要がなく、剛性も高い。さらに、主軸台を水平テーブルに垂直に取付け、垂直な加工面に対向してバイト及び主軸を水平に配置したので、主軸の剛性が高く、重力による主軸の軸方向への移動、変形がほとんどない。これにより、高い剛性のもとに、移動装置、制御装置により、ワークの多数の内の一つの加工すべき微細凹部に対して、回転主軸を連続回転させかつバイト先端のすくい面が常にバイト進行方向になるようにワーク加工面とバイト先端とを相対移動させながら制御し微細凹部を加工できるようにしたので、精度の高い旋盤加工と同様な条件での多数の微細凹部加工が可能な微細凹部加工機となった。 That is, in the processing machine of the present invention, the work is mounted (fixed) on the work holding part that holds the work surface of the work so as to be perpendicular to the horizontal table, and the work is not rotated. In addition, there is no need to consider the rotational balance and the rigidity is high. In addition, the headstock is mounted vertically on a horizontal table, and the tool and spindle are horizontally arranged facing the vertical machining surface, so that the rigidity of the spindle is high and there is almost no movement or deformation in the axial direction of the spindle due to gravity. . As a result, the rotating spindle is continuously rotated and the rake face at the tip of the cutting tool is always advanced by a moving device and a control device with a high rigidity against one of the fine recesses to be machined. Since the workpiece machining surface and the cutting tool tip are moved relative to each other and controlled so that fine recesses can be machined, fine recesses that can be processed into many fine recesses under the same conditions as high-precision lathe machining It became a processing machine.
本発明においては、ワークの加工面を回転させず、バイトを主軸側に取付連続回転させ、バイト先端のすくい面が常にバイト進行方向になるようにワーク加工面とバイト先端とを相対移動させながら制御し微細凹部を加工し、固定されたワークと連続回転するバイトがあたかも旋盤加工の回転するワークと固定されたバイトと同様の相対運動とし、旋盤加工と同様な条件での加工方法としたので、旋盤加工と同等の微細凹部加工が可能となり、加工速度、加工精度、ピッチ精度も良好な微細凹部を有するレンズ用金型等の加工に適したものとなった。 In the present invention, without rotating the work surface of the workpiece, the tool is attached and continuously rotated on the spindle side, and the work machining surface and the tool tip are moved relative to each other so that the rake face of the tool tip is always in the tool advancement direction. Because it controlled and processed the fine recesses, the fixed work and the continuously rotating tool had the same relative movement as the rotating work and the fixed tool of lathe processing, and the processing method was the same as the lathe processing. As a result, it is possible to perform fine recess processing equivalent to lathe processing, and it is suitable for processing a lens mold having a fine recess with good processing speed, processing accuracy, and pitch accuracy.
また、請求項２に記載の発明においては、ワークは回転せず、多数の微細凹部の加工にあたって高精度ピッチでの加工が可能なので、加工速度、加工精度、ピッチ精度も良好な多数の微細凹部を有するレンズアレイ用金型等の加工に適したものとなった。 In the invention described in claim 2, since the workpiece does not rotate and machining of a large number of fine recesses is possible at a high precision pitch, a large number of fine recesses having good processing speed, processing accuracy, and pitch accuracy. It became suitable for processing of molds for lens arrays having
また、請求項３に記載の発明においては、バイト先端をＲ形状とし、外側から中心に向かって螺旋状に相対移動させて旋盤加工と同様な加工としたので、加工精度の高い、滑らかな微細凹部加工方法を提供でき、量産にも適したものとなった。さらに、請求項４に記載の発明においては、連続回転速度を１〜５００ｒｐｍとし、最適な回転数として加工面を良好とすることができ、よりレンズアレイ用金型に適したものとなった。また、請求項５に記載の発明においては、直径換算が０．５ｍｍ〜１０ｍｍの微細凹部の加工であれば、振動の影響の少ない範囲での加工となり、精度も高いものとなる。 Further, in the invention according to claim 3, since the tip of the cutting tool has an R shape and is relatively moved spirally from the outside toward the center, the same processing as lathe processing is performed. A recess processing method can be provided, which is suitable for mass production. Furthermore, in the invention described in claim 4, the continuous rotation speed can be set to 1 to 500 rpm, the processing surface can be made favorable as the optimum rotation speed, and the lens array mold is more suitable. Further, in the invention according to claim 5, if the processing of a fine recess having a diameter conversion of 0.5 mm to 10 mm is performed, the processing is performed in a range where the influence of vibration is small, and the accuracy is high.
さらに、請求項６に記載の発明においては、ワークの加工面を水平テーブルに垂直に固定し、位置精度、ピッチ精度への影響を少なくし、加工面に対向して水平に配置された回転主軸にバイトを取り付け、剛性を高め、軸方向への移動、変形がほとんどなく、主軸及びバイトの構造も簡単で、回転バランスの変化がなく安定した主軸回転を得られるので、アンバランスがなく工具交換や加工による精度低下を防止するものとなった。また、ワーク側は回転部を持たないのでワークを主軸に取り付ける場合に比べ大きさの制限も少ないものとなった。工具の交換による精度低下も少ないので、多数の微細凹部の加工途中、微細凹部間での工具交換が容易であり、微細凹部間のバラツキも小さなものとなり、多量、多種、さらには複雑な微細凹部を有するワーク、さらにはより大きなワークを加工できるものとなった。 Furthermore, in the invention described in claim 6, the work spindle of the work is fixed to the horizontal table vertically, the influence on the position accuracy and pitch precision is reduced, and the rotary spindle arranged horizontally facing the work face. A tool is attached to the tool to increase rigidity, there is almost no movement or deformation in the axial direction, the spindle and tool structure are simple, and stable spindle rotation can be obtained with no change in rotation balance. And accuracy reduction due to machining. In addition, since the work side does not have a rotating part, the size is less limited than when the work is attached to the spindle. Since there is little decrease in accuracy due to tool replacement, it is easy to change tools between micro-recesses during machining of a large number of micro-recesses, and the variation between micro-recesses is small, resulting in a large number, variety, and complex micro-recesses. It has become possible to machine a workpiece having a larger diameter and a larger workpiece.
このように高い剛性を与えると共に、回転主軸を連続回転させかつバイト先端のすくい面が常にバイト進行方向になるようにワーク加工面とバイト先端とを相対移動させながら制御し微細凹部を加工することにより旋盤加工と同様な条件での加工となるようにしたので、旋盤加工と同等の微細凹部加工が可能となり、加工速度、加工精度、ピッチ精度も良好で、バラツキの少ない多数の微細凹部を有するレンズアレイ用金型等の加工に適したものとなった。 In addition to giving high rigidity in this way, it is possible to continuously rotate the main spindle of rotation and control the workpiece machining surface and the tip of the tool so that the rake face at the tip of the tool is always in the direction of tool movement, thereby processing the fine recess. Since the machining is performed under the same conditions as lathe machining, it is possible to process fine recesses equivalent to lathe machining, and the machining speed, machining accuracy and pitch accuracy are good, and there are many fine recesses with little variation. It became suitable for processing of molds for lens arrays.
本発明の実施の形態について、図を参照して説明する。図１は本発明の実施の形態を示す微細凹部加工機の模式図、図２は本発明の加工方法を示す説明図であり、ワークの加工面とバイトとの関係を示したものである。図１に示すように、本微細凹部加工機１は水平テーブル２の水平テーブル上２ａにワーク保持部３が図でみて斜め前後方向Ｘ（以下Ｘ軸方向という）に移動可能にされている。ワーク保持部３には加工すべきワーク４の加工面４ａを水平テーブル２（上面２ａ）に対して垂直になるようにワークが保持される。ワーク加工面４ａに対向して水平テーブル４の垂直方向に主軸台５が設けられており、図でみて左右方向Ｚ（以下Ｚ軸方向という）に移動可能されている。主軸台５のワーク側面５ａに、上下移動台６が図でみて上下方向Ｙ（以下Ｙ軸方向という）に移動可能に取り付けられている。上下移動台６には、水平テーブル上面２ａと水平かつワーク４の加工面４ａと垂直になるように回転主軸７が設けられている。これにより回転主軸はワーク加工面４ａに対して、前後（Ｚ）方向、上下（Ｙ）方向及び左右（Ｘ）方向に相対移動可能とされる。 Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a schematic view of a fine recess processing machine showing an embodiment of the present invention, and FIG. 2 is an explanatory view showing a processing method of the present invention, showing a relationship between a work surface of a workpiece and a cutting tool. As shown in FIG. 1, in the fine recess processing machine 1, a work holding unit 3 is movable on a horizontal table 2 a of a horizontal table 2 in an oblique front-rear direction X (hereinafter referred to as X-axis direction). The workpiece holding unit 3 holds the workpiece so that the machining surface 4a of the workpiece 4 to be machined is perpendicular to the horizontal table 2 (upper surface 2a). A headstock 5 is provided in the vertical direction of the horizontal table 4 so as to face the workpiece processing surface 4a, and is movable in the left-right direction Z (hereinafter referred to as Z-axis direction) in the drawing. A vertical movement table 6 is attached to the workpiece side surface 5a of the headstock 5 so as to be movable in the vertical direction Y (hereinafter referred to as Y-axis direction). A rotary spindle 7 is provided on the vertical movement table 6 so as to be horizontal with the horizontal table upper surface 2 a and perpendicular to the machining surface 4 a of the workpiece 4. As a result, the rotation spindle can be moved relative to the workpiece processing surface 4a in the front-rear (Z) direction, the vertical (Y) direction, and the left-right (X) direction.
回転主軸７の先端側７ａにはバイトホルダー８が設けられており、バイト９が取り付けられている。図２に示すように、バイト９は四角形状断面の棒状であって、先端形状は例えば真剣バイト又は先丸剣バイト（ＪＩＳ Ｂ ０１０７）相当であり、その先端に左右対称の剣のようなとがったあるいは先端が丸コーナーとされた先端切れ刃９ａを有している。本実施の形態では、先端切れ刃９ａの先端９ｂはＲ（半径で１０μｍ〜１０ｍｍ、より好ましくは０．５〜１ｍｍ）形状にされている。この先端切れ刃の先端９ｂと回転主軸７の軸線１０とが一致するようにバイト９が軸線に沿うようにバイトホルダー８を介して回転主軸に固定される。なお、バイト９はハイス等のむく材、ダイヤモンド、焼結金属、サーメット、超硬合金チップ等を取り付けたもの、断面形状の異なるもの、Ｌ字状等種々のものがあり、バイトの種類に応じてバイトホルダーを設けることはいうまでもない。 A tool holder 8 is provided on the tip end side 7 a of the rotary spindle 7, and a tool 9 is attached to the tool holder 8. As shown in FIG. 2, the cutting tool 9 is a rod having a square cross section, and the tip shape is equivalent to, for example, a serious sword tool or a tip-round sword tool (JIS B 0107), and the tip is pointed like a symmetrical sword. Or it has the front-end | tip cutting edge 9a by which the front-end | tip was made into the round corner. In this Embodiment, the front-end | tip 9b of the front-end | tip cutting edge 9a is made into R (10 micrometers-10 mm by a radius, More preferably, 0.5-1 mm) shape. The cutting tool 9 is fixed to the rotating spindle through the tool holder 8 so that the tip 9b of the cutting edge and the axis 10 of the rotating spindle 7 coincide with each other along the axis. There are various types of tools 9 such as high speed steel, diamond, sintered metal, cermet, cemented carbide tip, etc., different cross-sectional shapes, L-shape, etc. Needless to say, a tool holder is provided.
さらに、ワーク保持部３、主軸台５、上下移動台６、回転主軸７のそれぞれの移動装置を制御する制御装置が設けられている（図示せず）。また、制御装置により、回転主軸７を連続回転させかつバイト先端９ａのすくい面９ｃが常にバイト進行方向になるように回転主軸７の回転角度とワーク保持部３、上下移動台６を同期させながら、ワーク加工面４ａとバイト先端９ｂとを、上下（Ｙ）方向及び左右（Ｘ）方向に相対移動できるようにされている。 Furthermore, a control device is provided for controlling the respective moving devices of the work holding unit 3, the spindle stock 5, the vertical moving platform 6, and the rotary spindle 7 (not shown). Further, the controller rotates the rotating spindle 7 continuously and synchronizes the rotation angle of the rotating spindle 7 with the work holding unit 3 and the vertical moving table 6 so that the rake face 9c of the cutting tool tip 9a is always in the tool traveling direction. The workpiece machining surface 4a and the tool tip 9b can be moved relative to each other in the vertical (Y) direction and the horizontal (X) direction.
次に、かかる本発明微細凹部加工機でレンズアレイ用金型等の多数のレンズ穴（微細凹部）を加工する方法について述べる。図２において、レンズ穴の湾曲した十字線はレンズ穴の形状を説明するための線、円、螺旋は加工軌跡を説明するための線である。図１，２に示すように、複数のレンズ穴（この例では４個）１１〜１４を加工する場合、まず、回転主軸７の軸芯１０と加工すべきレンズ穴１１の中心Ｃ１とが一致する位置をレンズ穴とバイト先端の中心とし、これを加工原点として記憶させるＣ１（Ｘ，Ｙ）。最初の加工原点は、ワークの取付位置データ等を基に自動的に開始したり、手動で指示すればよい。図２に示すように、バイト切れ刃先端９ｂに対し、加工原点を中心とする加工部の最外径で円運動（軌跡２１）となるようにＸ，Ｙ軸を移動させる。同時に、回転主軸の角度を同期させ、常に円周方向にバイト切れ刃の先端すくい面９ｃが向くように制御される。 Next, a method for processing a large number of lens holes (fine concave portions) such as a lens array mold using the fine concave portion processing machine of the present invention will be described. In FIG. 2, the crosshairs with curved lens holes are lines for explaining the shape of the lens holes, and circles and spirals are lines for explaining the processing locus. As shown in FIGS. 1 and 2, when machining a plurality of lens holes (four in this example) 11 to 14, first, the axis 10 of the rotating spindle 7 and the center C <b> 1 of the lens hole 11 to be machined coincide with each other. The position to be used is the center of the lens hole and the tip of the cutting tool, and this is stored as the processing origin C1 (X, Y). The first machining origin may be automatically started based on the workpiece attachment position data or the like, or may be manually indicated. As shown in FIG. 2, the X and Y axes are moved with respect to the cutting edge tip 9b so as to have a circular motion (trajectory 21) at the outermost diameter of the processing portion centered on the processing origin. At the same time, the angle of the rotary spindle is synchronized, and control is performed so that the tip scoop surface 9c of the cutting tool always faces in the circumferential direction.
主軸台３を右方向に移動させ、連続回転（軌跡２１）するバイト９をワーク加工面４ａに向かって移動させる（Ｚ軸方向）。バイト切れ刃の先端９ｂがワークに接すると、Ｚ軸方向の移動を停止、あるいは微速、あるいは戻しながら、バイト切れ刃先端９ｂに対し、加工原点を中心とする加工部の最外径から螺旋円（軌跡２２）となるように中心に向かってＸ，Ｙ軸を微動させる。このときも回転主軸の角度を同期させ、常に円周方向にバイト切れ刃の先端すくい面９ｃが向くように制御される。これにより、ワーク加工面４ａにレンズ穴が加工される。Ｘ，Ｙ，Ｚ軸を適宜移動させることにより、球面はもとより、自由曲面、非球面のレンズ穴が加工できる。 The headstock 3 is moved in the right direction, and the tool 9 that continuously rotates (trajectory 21) is moved toward the workpiece machining surface 4a (Z-axis direction). When the tip 9b of the cutting tool comes into contact with the workpiece, it stops from moving in the Z-axis direction, is slow, or returns to the cutting edge 9b with respect to the cutting tool tip 9b from the outermost diameter of the machining center. The X and Y axes are slightly moved toward the center so as to be (trajectory 22). At this time as well, the angle of the rotary spindle is synchronized, and the tip rake face 9c of the cutting tool edge is always controlled in the circumferential direction. Thereby, a lens hole is processed in the workpiece processing surface 4a. By appropriately moving the X, Y, and Z axes, not only spherical surfaces but also free curved surface and aspheric lens holes can be processed.
中心側と外周側とでは、切削速度が異なるので、外周方向では回転主軸の回転速度を下げ、中心側では回転速度を上げるのが好ましい。レンズの直径が１ｍｍ〜５ｍｍの場合には主軸回転数は５〜１００ｒｐｍの範囲で制御する。より好ましくは中央側で１００ｒｐｍ程度である。バイト９はバイトホルダー８で回転主軸に確実に固定されているので、バランス調整が不要、又は、バランス調整が容易であり、さらに、連続回転中のアンバランスによる振動や制御不良等の影響がない。また、バイト９とワーク微細凹部１１とは、バイトの先端側からみれば、ワークは加工原点回りに円運動と回転運動をしていることとなり、従来の旋盤加工と同じ条件となっており、Ｘ，Ｙ，Ｘ軸方向の移動量や切り込み量等も従来のデータを適用又は参考にできる。 Since the cutting speed is different between the central side and the outer peripheral side, it is preferable to decrease the rotational speed of the rotating spindle in the outer peripheral direction and increase the rotational speed on the central side. When the lens diameter is 1 mm to 5 mm, the spindle speed is controlled in the range of 5 to 100 rpm. More preferably, it is about 100 rpm on the center side. Since the tool 9 is securely fixed to the rotating spindle by the tool holder 8, the balance adjustment is unnecessary or the balance adjustment is easy, and there is no influence of vibration or control failure due to unbalance during continuous rotation. . Further, the cutting tool 9 and the work fine recess 11 have a circular motion and a rotational motion around the processing origin when viewed from the tip side of the cutting tool, and have the same conditions as conventional lathe processing, Conventional data can also be applied or referred to for the amount of movement and the amount of cut in the X, Y, and X axis directions.
第一のレンズ穴の加工終了後、主軸台５を反ワーク側へ戻し、ワーク保持具３を図でみて斜め向こう側に移動させながら、上下移動体を移動させ、軸芯１０とレンズ穴１２の中心Ｃ２とを一致させ、レンズ穴１２とバイト９との中心を新たな加工原点として記憶させるＣ２（Ｘ，Ｙ）。さらに前述したと同様に、回転主軸７を回転させながらレンズ穴１２を加工する。同様に、レンズ穴１３，１４を加工する。これにより、多数のレンズ穴を有するレンズアレイ用金型が製作できる。 After finishing the processing of the first lens hole, the headstock 5 is returned to the side opposite to the workpiece, and the vertical moving body is moved while moving the workpiece holder 3 diagonally as seen in the figure, and the shaft core 10 and the lens hole 12 are moved. And the center of the lens hole 12 and the cutting tool 9 is stored as a new processing origin C2 (X, Y). Further, as described above, the lens hole 12 is processed while rotating the rotary spindle 7. Similarly, the lens holes 13 and 14 are processed. Thereby, a lens array mold having a large number of lens holes can be manufactured.
なお、本実施例によれば、バイトの有効刃先角の範囲で加工が行えるため、±７０度の深い非球面形状のレンズアレイ用の微細凹部を加工することができる。また、工具交換が容易となるが、さらに、非球面形状のレンズアレイの加工を行った場合に、工具の取り付けの偏心誤差、バイト先端のＲ形状の円弧部の幾何誤差が加工面に与える形状誤差は軸対称で、かつ単純な形状であるので、金型の一断面の形状を計測し、ＮＣプログラムに加える補正をワークの軸に対称に加えることで補正が可能である。よって、簡単なデータで容易に補正加工ができ、精度の高い金型を提供できる。 In addition, according to the present Example, since it can process in the range of the effective cutting edge angle | corner of a cutting tool, the fine recessed part for lens arrays of the deep aspherical shape of +/- 70 degree | times can be processed. In addition, the tool can be easily replaced. However, when an aspherical lens array is processed, the eccentricity error of tool attachment and the geometric error of the R-shaped arc at the tool tip are given to the processing surface. Since the error is axially symmetric and has a simple shape, it can be corrected by measuring the shape of one cross section of the mold and applying corrections to the NC program symmetrically to the workpiece axis. Therefore, correction processing can be easily performed with simple data, and a highly accurate mold can be provided.
以上のように本実施例によれば、簡単な構成により、バイト、ワーク共に剛性の高い配置とし、バイトを回転させることにより、Ｘ，Ｙ，Ｚの直交３軸で位置決めを行うので、アンバランスのない旋盤加工とすることができ、多数のレンズ穴を有するようなレンズアレイ用金型のようなワークの微細凹部の精度及びピッチを正確に加工することができるものとなった。 As described above, according to the present embodiment, with a simple configuration, both the tool and the workpiece are arranged with high rigidity, and by rotating the tool, positioning is performed with three orthogonal axes of X, Y, and Z. Lathe processing without a gap, and the precision and pitch of fine concave portions of a workpiece such as a lens array mold having a large number of lens holes can be accurately processed.
１ 微細凹部加工機
２ 水平テーブル
３ ワーク保持部（移動装置）
４ ワーク
４ａ ワークの加工面
５ 主軸台（移動装置）
６ 上下移動台（移動装置）
７ 回転主軸
９ バイト
９ａ 先端切れ刃
９ｂ 切れ刃の先端
９ｃ すくい面
１０ 軸線
１１、１２、１３、１４ 微細凹部（レンズ穴）
Ｘ 加工面左右方向
Ｙ 加工面上下方向
Ｚ 加工面前後方向
DESCRIPTION OF SYMBOLS 1 Fine recessed part processing machine 2 Horizontal table 3 Work holding part (moving device)
4 Work piece 4a Work surface of work 5 Spindle table (moving device)
6 Vertical moving table (moving device)
7 Spindle 9 Byte 9a Cutting edge 9b Cutting edge 9b Cutting edge 9c Rake face 10 Axis 11, 12, 13, 14 Fine recess (lens hole)
X Machining surface horizontal direction Y Machining surface vertical direction Z Machining surface longitudinal direction
Claims (6)
剣のようなとがった先端切れ刃又は先端が丸コーナーとされた先端切れ刃を有し、前記切れ刃の先端と前記回転主軸の軸線とが一致するように前記軸線に沿って前記回転主軸に取り付けられたバイトと、
前記回転主軸を回転させ前記ワーク加工面と前記バイト先端とが前後方向及び前記加工面上下方向及び前記加工面左右方向に相対移動可能とする移動装置と、
前記移動装置を制御する制御装置と、を有し、
前記ワーク加工面に微細凹部を加工する微細凹部加工方法であって、
前記制御装置により、加工すべき微細凹部に対して、前記ワーク加工面を回転することなく、前記回転主軸を連続回転させかつ前記バイト先端のすくい面が常にバイト進行方向になるように前記ワーク加工面と前記バイト先端とを相対移動させながら制御し前記微細凹部を加工することを特徴とする微細凹部加工方法。 A rotation spindle provided so that its axis is perpendicular to the machining surface of the workpiece to be machined;
It has a sharp cutting edge like a sword or a cutting edge whose tip is a rounded corner, and the rotation spindle is aligned with the rotation spindle so that the tip of the cutting edge and the axis of the rotation spindle coincide with each other. Attached bite, and
A moving device that rotates the rotation main shaft to relatively move the workpiece machining surface and the cutting tool tip in the front-rear direction, the machining surface vertical direction, and the machining surface left-right direction;
A control device for controlling the moving device,
A fine recess processing method for processing a fine recess on the workpiece processing surface,
By the control device, the workpiece machining is performed so that the rotation spindle is continuously rotated without rotating the workpiece machining surface with respect to the fine recess to be machined, and the rake face at the tip of the cutting tool is always in the tool advance direction. A fine recess processing method, wherein the fine recess is processed by controlling the surface and the tip of the cutting tool while moving relative to each other.
前記保持部のワーク加工面に対向して前記水平テーブル垂直方向に設けられた主軸台と、
前記主軸台に前記水平テーブルと水平かつ前記ワークの加工面と垂直になるように支持された回転主軸と、
剣のようなとがった先端切れ刃又は先端が丸コーナーとされた先端切れ刃を有し、前記切れ刃の先端と前記回転主軸の軸線とが一致するように前記軸線に沿って前記回転主軸に取り付けられたバイトと、
前記回転主軸を回転させ前記ワーク加工面と前記バイト先端とが前後方向及び前記加工面上下方向及び前記加工面左右方向に相対移動可能とする移動装置と、
前記移動装置を制御する制御装置と、を有し、
前記ワーク加工面に微細凹部を多数加工する微細凹部加工機であって、
前記制御装置により、多数の内の一つの加工すべき微細凹部に対して、前記回転主軸を連続回転させかつ前記バイト先端のすくい面が常にバイト進行方向になるように前記ワーク加工面と前記バイト先端とを相対移動させながら制御し前記微細凹部を加工可能にされていることを特徴とする微細凹部加工機。 A workpiece holding unit that is provided on a horizontal table and holds a machining surface of a workpiece to be machined so as to be perpendicular to the horizontal table;
A headstock provided in the vertical direction of the horizontal table so as to face the workpiece processing surface of the holding portion;
A rotating spindle supported on the spindle table so as to be horizontal with the horizontal table and perpendicular to the machining surface of the workpiece;
It has a sharp cutting edge like a sword or a cutting edge whose tip is a rounded corner, and the rotation spindle is aligned with the rotation spindle so that the tip of the cutting edge coincides with the axis of the rotation spindle Attached bite, and
A moving device that rotates the rotation main shaft to relatively move the workpiece machining surface and the cutting tool tip in the front-rear direction, the machining surface vertical direction, and the machining surface left-right direction;
A control device for controlling the moving device,
A fine recess processing machine for processing a large number of fine recesses on the workpiece processing surface,
With the control device, the workpiece machining surface and the cutting tool are arranged so that the rotating spindle is continuously rotated with respect to one of the fine recesses to be processed and the rake face at the tip of the cutting tool is always in the cutting tool traveling direction. A fine recess processing machine characterized in that the micro recess can be processed by controlling the tip while relatively moving.
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