JP3294243B1 - Press forming apparatus and method for manufacturing resin press mold - Google Patents

Abstract

Abstract: [PROBLEMS] In the production of a press die used for press molding for producing ceramic or metal interior / exterior materials / roof materials having excellent design, cutting is easy, short delivery time and low price. Provided is a method for manufacturing a resin press die characterized by forming a deep uneven pattern. A hard synthetic resin 29, which is easy to cut and has press formability and abrasion resistance comparable to metal, is used only on a cut portion of a press die, and the hard synthetic resin layer is formed on a machining center. At 32, the pattern is cut by high-speed rotation and high-speed feed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a press forming apparatus and a method for manufacturing a resin press die, and more particularly to a ceramic or metal material having excellent design, used for interior / exterior / roof materials of houses and structures. The present invention relates to a press forming apparatus and a method for manufacturing a resin press die used for press forming for producing interior / exterior materials / roof materials.

[0002]

2. Description of the Related Art In recent years, there has been a tendency for design, design to be emphasized in interior / exterior materials / roof materials for housing. By deeply processing the pattern of the product and devising the painting, there is a demand for a three-dimensional pattern rich in design. For this reason, the surface pattern of the press mold is deep and complicated, and high mold precision is required for color application by two-tone and three-tone painting.

Conventionally, for this type of press molding, a press mold made of epoxy resin or a metal press mold manufactured by transferring silicon resin or the like is generally used.

It is difficult to obtain high precision with a resin press die formed by inversion of a silicon resin, and uneven distribution of color unevenness in two-tone and three-tone painting has become a problem.

[0005] A press die manufactured using an epoxy resin or the like has a short die life due to abrasion and is not suitable for mass production.
When a resin press die is manufactured integrally with an iron back plate, problems such as warping, cracking, shrinkage, and elongation of the die due to a difference in linear expansion coefficient between the iron back plate and the epoxy resin occur.

FIG. 10 is a schematic side view of a conventional press forming apparatus using a metal press die, and FIG. 11 is a view taken along the line XI-XI shown in FIG.

Referring to these figures, press forming apparatus 6
1, a convex metal press die 63 having a convex pattern 64 formed on its lower surface is attached to the die set 42a,
A concave metal press die 65 having a concave pattern 66 formed on its upper surface is attached to the die set 42b. The die set 42a is vertically movable along a guide pin 43 attached vertically between the press table 47 and the die set 42b. A hydraulic cylinder 44 is mounted on the upper surface of the die set 42a, and is configured to move the die set 42a up and down under predetermined control. The convex pattern 64 of the convex metal press die 63 and the concave pattern 66 of the concave metal press die 65 have a reversed relationship to each other, and when they are moved closer to each other, they are completely fitted to each other. Is configured.

When the press forming apparatus 61 is used, the convex metal press die 6 is operated by the action of the hydraulic cylinder 44.
In a state where 3 is separated from the concave metal press die 65, a metal plate 45 to be formed is fed therebetween. When the metal plate 45 stops at the predetermined feed position, the convex metal press die 63 is lowered by the action of the hydraulic cylinder 44 via the die set 42a. As a result, the portion of the metal plate 45 located between the convex metal press die 63 and the concave metal press die 65 has a convex pattern 64.
Then, a predetermined concavo-convex pattern 46 is formed by press forming with the concave pattern 66. When the forming is completed, the convex-shaped metal press die 63 is raised, the metal plate 45 is further fed by a predetermined amount, and the same press forming operation is repeated.

In this way, the metal plate 45 is passed through the press forming device 61, so that the entire surface thereof
6 will be formed continuously.

There are two methods for manufacturing a metal press die.
One is manufactured by edging using corrosion, so advanced skill and long days were indispensable.
The deeper the pattern, the longer it takes to corrode. In addition, the stepped corrosion is repeated to deepen the pattern, so that the step of the corroded surface becomes large, and it takes a long time to correct and finish.

Another method of manufacturing a metal press die is machining. Copying processing using a master model has been the mainstream for a long time, but in recent years, automatic cutting of metal press dies has become possible by automation of cutting processing at a machining center and high-speed rotation and high-speed feeding. It does not require more skill than production by etching, but it is still extremely time-consuming.

[0012]

Even if the cutting work of the metal press die is automated, since the material of the metal press die is iron, the finer and finer the pattern is, the finer the cutting tool attached to the machining center becomes. Tip radius 0.3
mm to 1.0 mm taper ball end mill). If the processing is hurried, the cutting tool will be damaged. Therefore, in order to reduce the burden on the cutting tool, the feed speed must be reduced, and the cutting amount per operation must be reduced. Therefore, the required processing time becomes longer in proportion to the depth of the pattern, so that the cost of the mold becomes expensive and the delivery time is delayed.

In addition, the fine adjustment of the metal press die in the trial production type before mass production has to rely on skilled manual work, and it takes more days to cut and fill the metal little by little. From the above, it is extremely difficult to manufacture a metal press die on which a deep fine pattern is formed at a short delivery time and at a low price.

Also, it is difficult to improve the performance of a die using a resin press die using an epoxy resin or the like, because of the physical properties of the material used for the die production and the die structure.

The present invention solves the above-mentioned problems, and an object of the present invention is to provide a method of manufacturing a high-design, high-accuracy, short-term, low-cost resin press die without requiring a high level of skill, and a method of manufacturing the same. And a press forming apparatus using the same.

[0016]

In order to achieve the above object, the invention according to claim 1 is a press forming apparatus for forming a sheet-like molded product by using a pair of press dies, such as a metal plate or the like. Is a synthetic resin that cures at room temperature and has a Shore D hardness (ISO 86
8) about 65 to 70, and the elongation at break is 100 to 1
About 1% when pressurized at about 50% and resin thickness 10mm
A convex resin press formed by forming a synthetic resin layer made of a synthetic resin having a compressive stress of 1.5 to 3.0 kg / mm ^{2 when} deformed by 0%, and forming a convex pattern on the synthetic resin layer by cutting. The mold and the convex pattern press die are arranged so as to face each other, and are formed with the same dimensions and the same material as the convex pattern resin press die, and the synthetic resin layer has a concave pattern inverted from the convex pattern. And a concave resin press die formed by cutting.

With this configuration, the molded product is formed between a pair of convex and concave patterns formed by cutting the synthetic resin layer.

According to a second aspect of the present invention, there is provided a press forming apparatus for forming a sheet-like molded product by using a pair of press dies, wherein a synthetic resin which is hardened at room temperature on one surface of a mounting table such as a metal plate. And the Shore D hardness after heat curing (I
SO868) is about 65 to 70, and the elongation to break is 1
A synthetic resin layer made of a synthetic resin having a compressive stress of 1.5 to 3.0 kg / mm ² with a deformation of about 10% when pressed at about 100 to 150% and a resin thickness of 10 mm is formed,
The synthetic resin layer is formed of a metal press having a convex or concave pattern formed by cutting, and a metal material having the same dimensions as the resin press die, which is disposed so as to face the resin press die. A metal press die on the surface of which a concave or convex pattern inverted from the convex or concave pattern is formed.

With this configuration, the synthetic resin layer is formed between a convex or concave pattern formed by cutting and a concave or convex pattern formed on the metal surface.

According to a third aspect of the present invention, there is provided a method for manufacturing a resin press die, wherein a synthetic resin which is cured at room temperature on one surface of a mounting table such as a metal plate, and has a Shore D hardness after heat curing. (ISO868) is about 65 to 70, elongation to break is about 100 to 150%, and resin thickness is 10 m
1.5-3.0k with about 10% deformation when pressurized at m
It comprises a step of forming a synthetic resin layer made of a synthetic resin having a compressive stress of g / mm ² , and a step of cutting the formed synthetic resin layer with a machining center to form an uneven pattern.

With this configuration, the synthetic resin layer formed on the mounting table is cut.

According to a fourth aspect of the present invention, in the configuration of the third aspect of the present invention, a material having high releasability is mixed into the synthetic resin layer.

With this configuration, a part of the material having high releasability appears on the surface by cutting the synthetic resin layer.

According to a fifth aspect of the present invention, in the constitution of the third or fourth aspect, a step of performing a ceramic blasting process on the cut synthetic resin layer is further provided.

With this configuration, fine irregularities are formed on the surface of the synthetic resin layer.

[0026]

[0027]

[0028]

[0029]

[0030]

As described above, according to the first aspect of the present invention, the molded article is formed between the pair of convex and concave patterns formed on the synthetic resin layer by cutting. There is no risk of damaging the surface during molding. In addition, since the synthetic resin layers of the respective press dies are elastically deformed during molding, wear of the synthetic resin layers due to the influence of the molded product is reduced.

Further, since the synthetic resin layer has a lower thermal conductivity than metal, there is no possibility that the heat of the molded product is rapidly removed during molding, so that the quality after molding is improved.

According to the second aspect of the present invention, since the molded product is molded between the synthetic resin layer formed by cutting and the metal surface, there is no possibility that at least one surface of the molded product is damaged during molding. Further, since the synthetic resin layer of the resin press mold is elastically deformed at the time of molding, wear of the synthetic resin layer is reduced.

According to the third aspect of the present invention, since the synthetic resin layer formed on the mounting table is cut by the machining center, a deep uneven pattern can be easily formed in a short time.

According to the fourth aspect of the present invention, in addition to the effect of the third aspect of the present invention, a part of the material having high releasability appears on the surface due to the cutting of the synthetic resin layer. In contact with this, the releasability after molding is improved.

According to the fifth aspect of the present invention, in addition to the effects of the third or fourth aspect of the present invention, fine irregularities can be formed on the surface of the synthetic resin layer. Is improved.

[0036]

[0037]

[0038]

FIG. 1 is a view showing a preparatory step in a method for manufacturing a resin press die according to a first embodiment of the present invention.

First, as shown in FIG. 1 (1), an iron plate 1
5, a resin forming surface 20 for integrating a hard synthetic resin described later.
Is subjected to shot blasting 21 and then degreased.
The iron plate 15 has a resin injection port 17 for injecting a resin at the center thereof and material rising ports 18a and 18b for confirming the resin material injected at both ends.

Then, an epoxy adhesive 23 is applied very thinly to the resin-formed surface 20 of the degreased iron plate 15 as shown in FIG. Thereby, the iron plate 1
Preparation for 5 is completed. A plurality of linear grooves (not shown) are formed on the resin forming surface 20 of the iron plate 15.
It is configured to increase the bonding strength with the hard synthetic resin.

Next, as shown in FIG. 2, spacers 26a and 26b for providing a clearance of the thickness of the hard synthetic resin 29 to be injected into the outer periphery of the iron platen 25 are set. The iron plate 15 on which the adhesive has been applied is put on the spacer 26.
a, 26b and fixed with clamps 27a, 27b. The hard synthetic resin 29 is heated to 35 ° C. to 40 ° C. from the material injection port 17 formed at the center of the iron plate 15, and is injected while applying pressure while reducing the viscosity. Here, as the hard synthetic resin, a synthetic resin which is easy to cut and has press moldability and wear resistance comparable to metal is used.

More specifically, as this synthetic resin, for example, a urethane resin (abbreviated as ED) having ureol (registered trademark of Bantico) 6414A as a main component and hardening at room temperature.
F). Shore D hardness after heat curing (ISO86
8) about 65 to 70, and the elongation at break is 100 to 1
About 50% is preferable, and other synthetic resins may be used as long as a compressive stress of 1.5 to 3.0 kg / mm ² can be obtained with a deformation of about 10% when pressed with a resin thickness of 10 mm.

After the pouring is completed, 50 ° C. is used to accelerate the curing reaction.
Put in an oven kept for more than 24 hours.

Next, as shown in FIG. 3, after the hard synthetic resin 29 is cured, the iron plate 15 integrated with the resin is placed on the iron platen 2.
Remove from 5 and cool naturally. At this time, the pattern is not formed on the resin surface and is plain.

Then, the plain press die (iron plate 15 + hard synthetic resin 29) removed as shown in FIG. 4 is set on the bed 31 of the machining center 32, and automatic cutting is performed by NC data. Cutting tool tip radius 0.3m
m to 1.0 mm is used. The feed rate at the time of cutting is about 10 times to 20 times or more as compared with the time of cutting metal. The machinability is excellent, and the cutting depth of the pattern depth (20 to 3 at a time)
(0 times or more) is possible. Fine adjustment and manual work of the pattern of the resin press die in the trial production type before mass production can be easily performed because the resin is made of resin.

By using a hard synthetic resin having excellent press formability and abrasion resistance excellent in workability and not inferior to metal only on the surface of the press die, the load on the cutting tool is reduced, and the feed speed of the machining center is reduced. As compared with metal cutting, the cutting depth is 10 to 20 times or more, and the cutting depth is 20 to 30 times or more.

FIG. 5 is a side view showing a schematic structure of a press forming apparatus according to the first embodiment of the present invention.
FIG. 6 is a diagram viewed from the VI-VI line shown in FIG. 5.

Referring to these figures, press forming apparatus 3
7, the convex-shaped metal press die 38 is attached to the die set 4.
2a, a concave metal press die 40 is mounted on a die set 42b. The die set 42a
It is vertically movable along a guide pin 43 attached vertically between the press table 47 and the die set 42b. A hydraulic cylinder 44 is mounted on the upper surface of the die set 42a, and is configured to move the die set 42a up and down under predetermined control. The convex resin press mold 38 includes an iron plate 15 a and an iron plate 15.
and a hard synthetic resin 29a formed on the lower surface of a and having a convex pattern 39 cut on its outer surface.

On the other hand, the concave pattern resin press mold 40 is composed of an iron plate 15b and a hard synthetic resin 29a formed on the upper surface of the iron plate 15b and having a concave pattern 41 cut on the surface. Convex pattern 39 and concave pattern 4
Numerals 1 are inverted patterns, and when the convex resin press mold 38 and the concave resin press mold 40 are moved so as to be in contact with each other, they are completely fitted.

When using the press forming apparatus 37, the hydraulic cylinder 44 is operated to move the convex resin press mold 38 upward through the die set 42a. Then, a metal plate 45 to be formed is fed into a space between the convex resin press die 38 and the concave resin press die 40. Next, the hydraulic cylinder 44 is controlled to control the convex resin press die 3.
8 is lowered toward the concave resin press die 40. 6 is press-formed by the convex pattern 39 of the convex resin press mold 38 and the concave pattern 41 of the concave resin press mold 40, so that the metal plate 45 has an uneven pattern 46. It is formed.

When the press forming is completed, the hydraulic cylinder 4
4, the convex resin press die 38 moves upward,
The metal plate 45 is further fed by a predetermined amount. By repeating the same press forming, the press forming device 37
Is formed on almost the entire surface of the metal plate 45 that has passed through.

In the above embodiment, a resin press die is used for each of a pair of opposing press dies. However, instead of this, a resin press die may be used for only one press die, and a metal press die may be used for the other press die. In this case, if the outer surface of the steel sheet to be formed is brought into contact with the resin press die, it is possible to form the coating without damaging the coating film or the like. In this case, since a metal press die is in contact with the back surface side, it is possible to form a clearer pattern on a harder molded product.

By the way, when the press molding pressure is low, or in the case of a dewatering press structure press resin mold in which a water channel is provided on the back of the mold, the hard synthetic resin is made into a single block and automatically cut by the machining center 32 to process the pattern. It is also possible to fix to an iron plate.

If the press die size cannot be placed on the machining center bed beyond the range that can be cut by the machining center, the synthetic wood block of the entire die size is integrated in the same manner as described above in a shape opposite to the press die shape (concave). It is divided into a certain product shape (convex) and cut out.

Then, as shown in FIG. 7, the product shape (convex) block, which is a reversal master model that has been cut out, is laid out on an iron platen 25, and an integrated reversal master model 4 is formed.
8a to 48c. The surface of the iron plate 15 is blasted, degreased, and coated with an adhesive.
The spacers 26a and 26b are used to open a gap corresponding to the thickness of the integrated master models 48a to 48c, and the integrated inverted master models 48a to 48c are fixed on the iron platen 25 laid out. From the resin injection port 17 at the center of the iron plate 15, the main agent and the curing agent are mixed as compounded, and the agitated and defoamed hard synthetic resin 29 is injected. When the pouring is completed, cure at 50 ° C. for 24 hours or more in an oven. After removing the mold, the joints of the patterns, which are the joints of the integrated inverted master models 48a to 48c, are manually corrected. With this method, it is possible to produce a large-sized mold that does not fit on a machining center with the same performance and delivery time.

In the above example, the pattern of the resin press mold to be manufactured is divided into a plurality of sections, and cutting is performed for each section to form an inverted master model. However, a simpler method is to prepare a master model in which the pattern is cut out only for one section, and form multiple inverted master models using silicon resin inversion to produce a large resin press die It is also possible. FIGS. 8 and 9 are views for explaining a method of manufacturing a resin press die by such a method.

As shown in FIG. 8, a master model is formed for one divided section by cutting a block of synthetic wood by a machining center. The pattern of this master model corresponds to the pattern of the product shape. Then, based on the master model, inverted master models M1 to M6 having the same size and the same pattern as the master model are formed by silicon resin inversion. That is,
Since these inverted master models are not formed by cutting, and all have the same shape by resin inversion, the formation can be performed quickly.

The inverted master models M1 to M6 thus formed are laid out, for example, as shown in FIG. 9A, and these are integrated to form an integrated inverted master model. By setting the integrated inverted master model thus formed on the iron platen 25 as shown in FIG. 7, it is possible to easily and quickly manufacture a large-sized resin press die. Become.

Since the inverted master models all have the same pattern as described above, in order to reduce the regularity of the patterns, a layout as shown in FIG. 9 (2) is adopted. May be. That is, when the inverted master model M6 is divided into two parts and arranged as shown in the figure, the regularity due to the same pattern is relaxed as compared with the layout shown in FIG. Can be manufactured.

In the above description, an example of the layout of the inverted master model is shown in FIG. 9. However, it is needless to say that other layouts may be adopted or the number of the inverted master models may be increased or decreased.

Further, in order to further relax the regularity due to the same pattern, the number of master models obtained by cutting the block is set to two or more, and an inverted master model based on these master models is formed by silicon inversion. good. If these are arranged at random to form an integrated inverted master model, a large-sized resin press die with less regularity can be manufactured quickly.

By mixing a material having a high releasability into a hard synthetic resin integrally cast into an iron plate, it is possible to manufacture a resin press die having a very high releasability with respect to the molding material of the ceramic outer wall material. The material to be mixed is Teflon resin powder, silicon resin powder, molybdenum disulfide, silicon oil, or the like, and the mixing ratio is preferably 0.01 to 20 w%. By cutting these mixed and hardened hard synthetic resin blocks with a machining center, the releasable material buried in the resin appears on the surface and directly contacts the molding material, confirming that the releasability is improved. did it.

Chips adhering after cutting the pattern of the hard synthetic resin surface with a machining center can be removed by ceramic blasting. The particle size of the ceramic blasting treatment is preferably in the range of No. 24 to No. 220, and by applying the ceramic blasting treatment to the cutting surface, chips are removed and fine irregularities can be formed on the surface. Finally, the oil-silicone release agent becomes more familiar with the mold and the release properties are improved. In addition, it was confirmed that a small amount of air could accumulate in the micro unevenness, which had a favorable effect on the release effect of the press-formed ceramic material. The effect of the blasting process is the same as that of the resin press die formed by the inversion of the silicon resin, as well as the resin press die formed by the cutting process.

By providing a high-performance hard synthetic resin layer only on the surface of the press die as described above, the press die used for molding metal and ceramic-based exterior materials and roof materials meeting recent demands for high designability. However, it can be manufactured without the need for skilled techniques and long days. Despite having a deep and fine design, the high-speed machining of the machining center reduces the required cutting time to less than one-tenth that of metal press dies, providing a short delivery time and low cost resin press dies. You can do it.

Further, since the resin press mold has press formability and abrasion resistance comparable to metal and has the same transfer performance as a metal press mold, the manufacturer of the exterior material requires the press mold of the press forming apparatus. The molding can be performed with the existing equipment simply by replacing the existing equipment. No new capital investment is required and the production cycle can be performed at the same speed as the conventional metal press mold.

When this resin press die is used as at least one of a pair of press dies of a press forming apparatus for the production of a metal exterior material, when the surface of the coating film of the raw material of the metal exterior material in contact with the resin press die is formed. It can be molded without damaging it. Rust caused by scratches during molding is prevented, and the quality of the product is improved.

In addition, in order to give a sense of quality to coated steel sheets in recent years,
In order to frost the surface of the coated steel plate, a paint containing short glass fiber is used, which has caused the surface of the metal press die to be worn. In the resin-made press die, the surface resin was slightly elastically deformed, so that the surface wear of the press die due to short glass fibers could be prevented.

When this resin press mold is used for the production of ceramic exterior materials, the surface resin layer of the resin press mold undergoes some elastic deformation at the molding pressure during molding, so that the ceramic material is compared with the metal press mold. There is a mold that has been used for 380,000 shots and has not yet been worn due to dies. In the case of a metal press die, the die surface is shaved with a hard material such as silica sand contained in ceramic materials at the time of molding, which shortens the life of the die.

Since a hard synthetic resin is used for the surface, fine adjustment of the pattern (building up, shaving, etc.) in the trial production test before mass production, which had been a problem in the case of a metal press mold, and partial change of the design. Can be easily handled. Therefore, the quality of the product can be built in a short period of time. The cutting of high hardness synthetic resin with good machinability does not cause wear and breakage of the blade, and eliminates the need for blade replacement and management of blade wear from the start to the end of processing, enabling high-speed and stable production.

Even in the case of a large die whose press die size exceeds the range that can be cut by the machining center, a block of synthetic wood of the entire die size is cut into product shapes (convex) and cut out.
After the layout, it is possible to produce an equivalent press die by a method of resin inversion or the like. By mixing a material having a high release property into a hard synthetic resin, it has become possible to produce a mold having an extremely high release property with respect to a molding material for a ceramic outer wall material.

By subjecting the cut surface to ceramic blasting, the chip removing process is facilitated, and fine irregularities are formed on the surface. In particular, when the ceramic-based outer wall material is press-formed, the oil-silicon separation is performed. The familiarity of the mold material with the mold was improved, and the releasability was improved. In addition, a small amount of air was formed in the fine irregularities, which greatly improved the releasability of press-formed ceramic materials.

The industrial value of a press molding apparatus using a resin press die having such various effects and a method of manufacturing a resin press die is extremely large.

In each of the above embodiments, the hard synthetic resin is formed by machining using a machining center. However, it goes without saying that the cutting may be performed using a method or an apparatus other than the machining center.

In each of the above embodiments, a metal plate is used as a base on which a hard synthetic resin is mounted. Instead of the metal plate, FRP, CFRP, calcium silicate plate, sand backing (silica sand is replaced with epoxy resin, etc.) Block or a ceramic may be used as the mounting base.

[0075]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in FIG. 1 (1), after a resin injection port 17 and material rising ports 18a and 18b are formed on an iron plate 15 having a length of 1500 mm × width 500 mm × thickness 30 mm
A shot blast process 21 is performed. This step is performed for the purpose of increasing the adhesive strength between the iron plate 15 and the hard synthetic resin. Thereafter, the iron plate 15 is degreased with a solvent such as acetone.

As shown in FIG. 1B, an extremely thin epoxy adhesive 23 is applied to the resin forming surface 20 of the blasted iron plate 15.

Next, as shown in FIG. 2, spacers 26a and 26b for setting a clearance of the thickness of the hard synthetic resin 29 on the outer periphery of the iron platen 25 are set. The iron plate 15 on which the bonding process has been completed is set on the spacers 26a and 26b, and is fixed by the clamps 27a and 27b. The injection port 17 of the hard synthetic resin 29 is arranged at the center of the iron plate 15, and is heated to 35 ° C. to 40 ° C. from there to apply pressure to the resin whose viscosity has been reduced.

The resin cast as shown in FIG. 2 is placed in an oven set at 50 ° C. and heated for 24 hours or more in order to accelerate the curing reaction, and then removed from the iron platen 25 as shown in FIG. The iron plate 15 and the hard synthetic resin 29 are completely integrated, and the hard synthetic resin layer 29 does not peel off from the iron plate 15 at all.

The resin press die removed as shown in FIG. 4 is mounted on the bed 31 of the machining center 32 and performs automatic cutting. Hard synthetic resin 29 on the surface of a resin press mold
Has good machinability, about 10 to 20 times that of metal.
A double feed rate and a 20 to 30 times cutting depth are possible. The feed rate is not influenced at all by the depth of the pattern to be cut, and the product can be provided at a low and stable price, whose price is not proportional to the depth of the pattern.

[0080]

[Comparative Example] The processing conditions when cutting a metal and a hard synthetic resin with the same cutting tool and the same number of revolutions in a machining center are shown below. 0.5mm taper ball end mill with a tip radius of 0.5mm (one angle of 10 °, blade material is cemented carbide), Machining center spindle speed 10,000R. P. M. In S
When processing metal of 50C, feed rate = 100 mm /
The maximum value is min, notch = 0.25 mm, and if the feed rate and the notch are further increased, the blade will be damaged. In the case of hard synthetic resin (ureol), feed rate = 2000 mm /
min, notch = 7.5 mm 2 High-speed processing became possible. As mentioned above, the burden on cutting tools is reduced,
The feed speed of the machining center is 20 times that of metal cutting, and the cutting depth is 30 times that of metal cutting. Cutting tools made of hard synthetic resin (tapered ball end mill)
Almost no wear or damage is observed.

[Brief description of the drawings]

FIG. 1 is a view showing a step of preparing an iron plate in a method of manufacturing a resin press die according to a first embodiment of the present invention.

FIG. 2 is a diagram illustrating a process of forming a hard synthetic resin thereon using the iron plate shown in FIG. 1;

FIG. 3 is a view showing a schematic structure of a resin press mold before cutting formed by the process of FIG. 2;

FIG. 4 is a view showing a state in which cutting is performed on the resin press die shown in FIG. 3;

FIG. 5 is a side view showing a schematic structure of the press forming apparatus according to the first embodiment of the present invention.

FIG. 6 is a view as seen from a VI-VI line shown in FIG. 5;

FIG. 7 is a view showing specific contents of a method for manufacturing a resin press die according to a second embodiment of the present invention.

FIG. 8 is a diagram showing an example of a relationship between a master model and an inverted master model in the method for manufacturing the resin press die shown in FIG.

FIG. 9 is a diagram showing an example of a layout of an integrated inversion master model performed using the inversion master model shown in FIG. 8;

FIG. 10 is a side view showing a schematic structure of a conventional press molding apparatus.

FIG. 11 is a diagram viewed from the XI-XI line shown in FIG.

[Explanation of symbols]

 15 ... Iron plate 29 ... Hard synthetic resin 32 ... Machining center 37 ... Press molding device 38 ... Convex resin press mold 39 ... Convex pattern 40 ... Concave resin press mold 41 ... Concave pattern 45 ... Metal plate 48 ... Reverse master model In the drawings, the same reference numerals indicate the same or corresponding parts.

────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP-A-62-257720 (JP, A) JP-A-4-94825 (JP, A) JP-A-11-188737 (JP, A) JP-A-2000-210946 (JP, A) JP-A-11-197768 (JP, A) JP-A-11-90989 (JP, A) JP-A-8-337685 (JP, A) (58) Fields investigated (Int. Cl. ⁷⁾ , DB name) B21D 37/20 B28B 3/02

Claims (5)

(57) [Claims] 1. A press forming apparatus for forming a sheet-like molded product using a pair of press dies, comprising: a synthetic resin which is cured at normal temperature on one surface of a mounting table such as a metal plate; Shore D hardness (ISO8
68) is about 65 to 70, and the elongation to break is 100 to
Forming a synthetic resin layer made of a synthetic resin having a compressive stress of 1.5 to 3.0 kg / mm ² with a deformation of about 10% when pressed at about 150% and a resin thickness of 10 mm; A convex pattern resin press mold in which a convex pattern is formed by cutting, and disposed so as to face the convex pattern resin press mold,
And the same size and the same material as the convex resin press mold, the synthetic resin layer is provided with a concave resin press mold in which a concave pattern inverted from the convex pattern is formed by cutting. Also, press molding equipment. 2. A press molding apparatus for molding a sheet-like molded product using a pair of press dies, comprising a synthetic resin which cures at one temperature on a surface of a mounting plate such as a metal plate at room temperature, and which is heat-cured. Shore D hardness (ISO8
68) is about 65 to 70, and the elongation to break is 100 to
Forming a synthetic resin layer made of a synthetic resin having a compressive stress of 1.5 to 3.0 kg / mm ² with a deformation of about 10% when pressed at about 150% and a resin thickness of 10 mm; A resin press die having a convex or concave pattern formed by cutting, and is disposed so as to face the resin press die, and is formed of a metal material having the same dimensions as the resin press die, and has a surface thereof. And a metal press die in which a concave or convex pattern inverted from the convex or concave pattern is formed. 3. A method of manufacturing a resin press die, comprising a synthetic resin which is cured at room temperature on one surface of a mounting table such as a metal plate, and has a Shore D hardness after heat curing (ISO8).
68) is about 65 to 70, and the elongation to break is 100 to
Forming a synthetic resin layer made of a synthetic resin having a compression stress of 1.5 to 3.0 kg / mm ² with a deformation of about 10% when pressed at about 150% and a resin thickness of 10 mm; Forming a concavo-convex pattern by cutting the formed synthetic resin layer with a machining center. 4. The method according to claim 3, wherein a material having a high mold release property is mixed into the synthetic resin layer. 5. The method according to claim 3, further comprising the step of performing a ceramic blast treatment on the cut synthetic resin layer.
A method for producing a resin press die according to claim 4.