JP4480282B2 - Thermal spraying method for three-dimensional articles - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a thermal spraying method for a three-dimensional article for drawing a character or a pattern by thermal spraying on a surface of a muffler attached to a motorcycle, for example.
[0002]
[Prior art]
The muffler attached to the motorcycle has a decorative effect related to the appearance of the entire motorcycle in addition to the function of exhausting the exhaust from the engine, etc. From the viewpoint of improving the design, the above-mentioned device has been devised, and a material having a heavy taste with titanium as a material has been provided.
[0003]
Furthermore, in addition to the material of the muffler being titanium as described above, conventionally, the surface of the muffler made of titanium has been subjected to thermal spraying to depict characters and patterns to further improve the decoration effect, The thing which improved heat resistance and weather resistance, such as a pattern, is also proposed. Such a titanium muffler has been obtained by spraying on a titanium blank surface to depict a desired character or pattern, and then rolling or welding to a predetermined shape.
[0004]
[Problems to be solved by the invention]
However, the conventional muffler manufacturing method has the following problems. That is, the surface of the muffler is usually buffed, but the sprayed part has a higher surface roughness than the surrounding surface, and the abrasive powder generated during buffing is likely to adhere, When a buffing process is performed on a character or pattern drawn by thermal spraying, the polishing powder adheres to the character or pattern and the appearance is likely to deteriorate.
[0005]
On the other hand, if the buffing is performed on the entire surface of the blank before the thermal spraying process, the above problem is solved, but the manufacturing method is difficult for the following reasons. That is, polishing work for rare metals such as titanium requires delicate skills of the operator, so it is difficult to perform it with a general-purpose polishing machine. However, when the object to be polished is blank, it is deformed when pressed and proper buffing cannot be performed.
[0006]
The present invention has been made in view of such circumstances, and a thermal spraying method for a three-dimensional article capable of easily drawing characters or patterns by thermal spraying while maintaining decorativeness for a three-dimensional article such as a muffler. It is to provide.
[0007]
[Means for Solving the Problems]
Invention of Claim 1 is a thermal spraying method to the solid article which sprays on the surface of the article processed into a three-dimensional shape from a blank, and draws a decorative character or pattern, Comprising: A pre-polishing step for polishing a portion to be drawn, a thermal spraying step for spraying the portion polished by the pre-polishing step to depict the character or pattern, and a three-dimensional shape of the thermal sprayed blank And a post-polishing step of polishing a surface of the three-dimensional article processed in the processing step other than the portion polished in the pre-polishing step.
[0008]
According to such a configuration, a portion other than a portion where a character or a pattern is to be drawn is polished in advance, and the portion is drawn by thermal spraying to be processed into a three-dimensional shape. A portion other than the portion polished in the pre-polishing step of the three-dimensional article is further polished to obtain a three-dimensional article as a final product. In this case, processing in the processing step includes processing for forming various three-dimensional shapes such as press processing and rolling processing, and polishing in the pre-polishing step and the post-polishing step is performed in various ways for surface finishing of a blank or a three-dimensional article. Includes polishing.
[0009]
The invention according to claim 2 is characterized in that the three-dimensional article is formed, polished, and sprayed in the order of the pre-polishing step, the processing step, the thermal spraying step, and the post-polishing step.
[0010]
The invention according to claim 3 is characterized in that the thermal spraying selects a kind of a material to be thermally sprayed so as to describe a character or a pattern of a desired color.
[0011]
The invention according to claim 4 is characterized in that the thermal spraying is performed by spraying the heat-melted ceramics to a desired portion of the blank.
[0012]
The invention of claim 5 is characterized in that the blank is made of titanium.
[0013]
According to a sixth aspect of the present invention, the article is a muffler attached to a motorcycle, and the polishing performed in the pre-polishing process and the post-polishing process is buffing, and the processing by the processing step is rolling processing It is characterized by being.
[0014]
According to such a configuration, a portion other than a portion where a character or a pattern is to be drawn is buffed in advance, and the portion is drawn by thermal spraying and rolled into a muffler shape. A part other than the part buffed in the muffler pre-polishing step is further buffed to obtain a muffler as a final product. In this case, the blank material may be titanium or another metal, and a desired material to be sprayed by spraying may be selected.
[0015]
The invention according to claim 7 is characterized in that the surface of the article processed by the processing step forms a curved surface and is sprayed by a manipulator or a robot hand that can move relative to the surface in three dimensions.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
A three-dimensional article to which the present embodiment is applied is a titanium muffler 1 attached to a motorcycle as shown in FIG. 8, and characters as shown in the figure are depicted on the surface of the muffler 1. Such characters are drawn by thermal spraying, and the design of the motorcycle can be improved by adding a pattern such as a graphic in addition to the characters.
[0017]
The embodiment according to the present invention is a thermal spraying method to a muffler that draws decorative characters or patterns by spraying on the surface of a muffler 1 processed into a three-dimensional shape from a blank, as shown in FIG. Polishing step S1, masking step S2, shot blasting step S3, thermal spraying step S4, processing step S5, and post-polishing step S6 are sequentially performed, and the muffler 1 excellent in design is manufactured.
[0018]
As shown in FIG. 2, the pre-polishing step S <b> 1 is a step of buffing only the range a (in the range surrounded by the dotted line in FIG. 2) that is a portion where characters are drawn in the blank 2. The blank 2 is a single plate made of titanium. However, the blank 2 may be one to which a predetermined impurity or the like is added in order to obtain a desired rigidity and strength, and may be another metal (such as stainless steel or aluminum alloy). May be.
[0019]
Here, the buffing is a method in which an abrasive is fixed to the outer peripheral surface of a cylindrical buff made of cloth, leather, etc., and the surface is polished by pressing against the blank 2 while rotating in this state. It is performed for the purpose of improving smoothness and glossiness and improving the design of the material. Although it is one of the finish polishing, the range a may be polished by other methods. For buffing, for example, 150 endless, 240 endless, 240 uniflap, 320 sisal or the like can be used.
[0020]
As shown in FIG. 3, the masking step S2 includes a range a in a blank 2 in which a mask M on which a cutout Ma equivalent to a character or a pattern to be drawn on a muffler to be a final product has been applied is polished in the prepolishing step S1. It is a process of fixing inside. The mask M is preferably made of a material that can withstand the heat of spraying in the spraying step S4, and the back surface has a viscosity and can be adhesively fixed to the blank 2. A general-purpose adhesive tape may be bonded so that a gap similar to that of the cutout Ma is generated.
[0021]
The shot blasting step S3 is a step of performing shot blasting on the blank 2 from above the mask M fixed in the masking step S2, and increasing the surface roughness of the portion exposed by the cutout Ma in the blank 2. That is, the steel grains projected at high speed by shot blasting perform the ground treatment on the surface of the blank 2 in the cutout Ma. Since the surface roughness can be increased along the characters to be drawn by this process, the adhesion of the ceramic to the blank 2 can be improved when the ceramic is sprayed in the spraying process S4.
[0022]
The thermal spraying step S4 is a step of drawing a character by plasma spraying within a range a which is a part buffed in the pre-polishing step S1, and as shown in FIG. 3 and a spraying apparatus comprising a supply pipe 3a opened near the injection port of the nozzle 3. Here, thermal spraying refers to a process in which a predetermined substance is heated and melted and sprayed onto the surface of the target article, and the attached substance cools to form a film. In this embodiment, characters with high decorativeness ( This may be a desired pattern).
[0023]
In the plasma spraying performed in this embodiment, plasma gas (a combination of N ₂ + H ₂ · Ar + He · Ar + H ₂ ) is ionized using an electric arc to obtain a high-temperature inert atmosphere, and then alumina formed in a powder form This is performed by injecting the plasma gas while supplying ceramics (ceramic powder) such as from the supply pipe 3a. This gas flow (plasma jet) causes the ceramic particles to be irradiated at a high speed in a molten state, and after adhering in the cutout Ma, it is cooled and solidified to obtain a predetermined character or pattern (in the case of this embodiment, “ The character 4) “SHINBA” is drawn.
[0024]
The spraying conditions can be appropriately changed in consideration of the material of the muffler to be sprayed, the ambient temperature, and the like, and the character 4 is always drawn under the optimal spraying conditions. As a specific example, the voltage applied by the electric arc is 75 V, the current is 650 A, the particle diameter of the ceramic powder is about 10 to 44 μm, and the thermal spraying condition is that the film thickness formed by thermal spraying is about 0.1 mm. Is mentioned.
[0025]
In addition, according to the plasma spraying as in the present embodiment, it is preferable to obtain a high temperature atmosphere of 5000 to 6000 ° C. higher than the maximum 2500 to 3000 ° C. obtained by oxygen acetylene soot, but instead of such plasma spraying, The muffler may be drawn by other known thermal spraying methods. In addition, it is preferable to apply a binder through the mask M before spraying the ceramic particles and attach the ceramic particles from the mask M, so that adhesion of letters and the like by spraying can be further improved.
[0026]
In addition, it is possible to arbitrarily select the type of material to be heated and sprayed in order to describe characters of a desired color, which can further improve the decoration effect of the muffler 1 and match the preference of the designer and the user. A muffler can be provided. As a material to be sprayed, a metal such as stainless steel or tungsten can be used in addition to the ceramic as in the present embodiment. Here, since the muffler 1 is always exposed to the outside air and becomes high temperature, the characters 4 may be peeled off by wind and rain or high temperature. However, if the material to be injected is ceramic such as alumina, the heat resistance and weather resistance are improved. Excellent character 4 can be obtained.
[0027]
The processing step S5 is a step of rolling the blank 2 (see FIG. 5) on which the characters 4 are sprayed in the range a in the spraying step S4 into the shape of the muffler 1 (that is, a three-dimensional shape), as shown in FIG. Further, the end portions 2a and 2b of the blank 2 after the roll are welded by welding or the like to form a substantially cylindrical shape. In addition to such rolling processing, press processing or coining processing may be performed to add a predetermined shape, or shot peening or embossing processing may be performed to improve the strength of the material.
[0028]
The post-polishing step S6 is a step of buffing the surface other than the portion polished in the pre-polishing step S1 in the muffler 1 subjected to the rolling process in the processing step S5. That is, in the pre-polishing step S1, only the range a of the dotted line shown in FIG. 1 is buffed, so the other range b is buffed in this step, and the entire muffler 1 is polished. When finished, a muffler 1 (see FIG. 7) as a final product is obtained.
[0029]
The buffing process is also performed by rotating the buff with the abrasive fixed as described above. The difference from the method of the pre-polishing step S1 is that the muffler formed into a three-dimensional shape by rolling process. Is a point that the operator holds by hand and presses the surface of the muffler to be polished b on the rotating buff. That is, in the state of the blank 2, since the strength in the thickness direction is insufficient, the buff that rotates after the blank 2 is placed on the floor surface or the like is pressed. However, in the muffler formed in three dimensions, the thickness is Since the strength in the direction is improved, the above method is performed as a method that facilitates buffing.
[0030]
Thus, a series of manufacturing steps in the method for thermal spraying on the muffler according to the present embodiment is completed. According to this thermal spraying method, since characters and the like can be drawn on the plane formed by the blank 2, accurate letters or patterns as designed can be easily attached as compared with the case where characters are drawn on a three-dimensional curved surface. can do.
[0031]
Further, the muffler 1 is formed, buffed, and sprayed in the order of the pre-polishing step S1, the processing step S5, the masking step S2, the shot blasting step S3, the spraying step S4, and the post-polishing step S6 instead of the above processing order. May be. In this case, since thermal spraying is performed on the surface of the muffler that forms a curved surface, it is preferable to perform thermal spraying with a manipulator or a robot hand that can move relative to the surface in three dimensions.
[0032]
That is, when spraying on the surface of the blank 2 forming a flat surface, the nozzle 3 may be moved two-dimensionally (moving in a plane separated by a predetermined dimension from the surface of the blank 2). When describing a pattern, the operation of the nozzle 3 in consideration of the curvature is required. In order to realize this operation simply and reliably, the manipulator and the robot hand are moved three-dimensionally according to a predetermined program.
[0033]
According to the above embodiment, only the range a to which the character 4 is attached is previously buffed, and after the character 4 is drawn in the range a by thermal spraying, it is formed into a three-dimensional shape by rolling. Therefore, the buffing process on the character 4 is not necessary, and the character 4 can be prevented from being peeled off or soiled by the polishing powder. Therefore, thermal spraying to the muffler can be easily performed while maintaining the decoration effect by the characters 4.
[0034]
Although the present embodiment has been described above, the present invention is not limited to this, and can be applied to a three-dimensional article other than a muffler. For example, when the present invention is applied to a metal cup, only a predetermined range of a blank made of aluminum or the like is polished in advance, and a desired character or pattern is drawn by thermal spraying within the range. Thereafter, it is processed into a cup shape, and the range other than the drawn portion is polished to obtain a cup having an excellent decorative effect.
[0035]
In addition, it is applied when characters and patterns are drawn by spraying on various articles that are processed from a blank into a three-dimensional shape, as represented by household items such as pots and kettles, and bodies of vehicles such as cars and trains. can do. That is, the processing in the processing step of the present invention is not limited to the rolling processing of the embodiment, and includes various processing modes for making a three-dimensional shape, such as press processing such as stretch molding or bending molding.
[0036]
【The invention's effect】
According to invention of Claim 1 or Claim 2, since only the part which draws a character or a pattern is grind | polished beforehand before thermal spraying, grinding | polishing on a character or a pattern can be made unnecessary. Accordingly, it is possible to avoid contamination of the character or pattern by polishing powder during polishing, and it is possible to easily describe the character or pattern by spraying while maintaining the decorativeness of the three-dimensional article.
[0037]
According to the third aspect of the present invention, since the character or pattern of a desired color can be drawn by selecting the type of substance to be sprayed during spraying, it is possible to obtain a decoration effect that takes into account the color of the entire target article.
[0038]
According to the invention of claim 4, since the material to be heated and melted during the thermal spraying is made of ceramics such as alumina, it is possible to describe a character or a pattern excellent in heat resistance and weather resistance.
[0039]
According to the invention of claim 5, since the object to be sprayed is titanium, it is possible to further improve the decoration effect by drawing characters or patterns on a heavy article.
[0040]
According to the invention of claim 6, it is possible to obtain a decoration effect for the muffler that has an important influence on the design of the motorcycle, while it is possible to draw characters or patterns by spraying while maintaining the decoration. . Moreover, if the blank material is titanium or a desired material is selected as a material to be sprayed by thermal spraying, a muffler that matches the tastes of the designer and the user can be provided.
[0041]
According to the invention of claim 7, since the thermal spraying is performed by the manipulator or the robot hand, the designed character or pattern can be drawn even on the surface which is processed to form the curved surface, and the manipulator or the robot hand Thermal spraying can be performed on three-dimensional articles of various shapes simply by changing the program for controlling the operation.
[Brief description of the drawings]
FIG. 1 is a flowchart showing a thermal spraying method for a three-dimensional article according to an embodiment of the present invention. FIG. 2 shows a blank and a target range of a pre-polishing process applied to the thermal spraying method for a three-dimensional article according to an embodiment of the present invention. Schematic diagram showing FIG. 3 is a schematic diagram showing a state in which a blank applied to a method for thermal spraying a three-dimensional article according to an embodiment of the present invention is masked. FIG. 4 is a diagram showing a three-dimensional article according to an embodiment of the present invention. FIG. 5 is a schematic diagram showing a state where the blank applied to the thermal spraying method is sprayed. FIG. 5 shows a state after the thermal spraying is applied to the blank applied to the thermal spraying method to the three-dimensional article according to the embodiment of the present invention. Schematic diagram showing FIG. 6 is a schematic diagram showing a state where a blanking process is applied to a blank after thermal spraying applied to the method of thermal spraying on a three-dimensional article according to an embodiment of the present invention. FIG. Thermal spraying method for such three-dimensional articles Schematic view showing a state where the applied spray method to the three-dimensional article according to an embodiment of the schematic view showing a muffler 8 the invention fitted with applied muffler motorcycle EXPLANATION OF REFERENCE NUMERALS
DESCRIPTION OF SYMBOLS 1 ... Muffler 2 ... Blank 2a, 2b ... End part 3 ... Nozzle 4 ... Letter M ... Mask Ma ... Cutout

Claims (7)

A thermal spraying method for a three-dimensional article that is sprayed on a surface of an article to be processed into a three-dimensional shape from a blank to depict decorative characters or patterns,
A pre-polishing step of polishing a portion depicting the character or pattern in the blank;
A thermal spraying process in which the character or pattern is depicted by thermal spraying on the part polished in the pre-polishing process;
A processing step of processing the thermal sprayed blank into a three-dimensional shape;
A post-polishing step of polishing a surface other than the portion polished in the pre-polishing step in the three-dimensional article processed in the processing step;
A thermal spraying method for a three-dimensional article characterized by comprising: A spraying method for a three-dimensional article, wherein the three-dimensional article is formed, polished, and sprayed in the order of the pre-polishing step, the processing step, the thermal spraying step, and the post-polishing step instead of the processing order according to claim 1. . 3. The thermal spraying method for a three-dimensional article according to claim 1 or 2, wherein the thermal spraying selects a kind of a material to be heated and sprayed so as to describe a character or a pattern of a desired color. The said thermal spraying is performed by injecting the ceramics heat-melted to the desired site | part of the said blank, The thermal spraying method to the three-dimensional article as described in any one of Claims 1-3 characterized by the above-mentioned. The thermal spraying method for a three-dimensional article according to any one of claims 1 to 4, wherein the blank is made of titanium. The article is a muffler attached to a motorcycle,
Polishing performed in the pre-polishing process and the post-polishing process is a buffing process,
The thermal spraying method for a three-dimensional article according to any one of claims 1 to 5, wherein the processing by the processing step is rolling processing. 3. The three-dimensional article according to claim 2, wherein the surface of the article processed by the processing step forms a curved surface and is sprayed by a manipulator or a robot hand that can move relative to the surface in three dimensions. Thermal spraying method.

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