JP7852452B2 - Molding apparatus and arched magnet - Google Patents
Molding apparatus and arched magnetInfo
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- JP7852452B2 JP7852452B2 JP2022157279A JP2022157279A JP7852452B2 JP 7852452 B2 JP7852452 B2 JP 7852452B2 JP 2022157279 A JP2022157279 A JP 2022157279A JP 2022157279 A JP2022157279 A JP 2022157279A JP 7852452 B2 JP7852452 B2 JP 7852452B2
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Description
本開示は、成形装置および弓形磁石に関する。 This disclosure relates to a molding apparatus and a curved magnet.
上パンチと下パンチとダイスによって形成されるキャビティ内に粉末を充填してプレスすることによって弓形形状の成形体を得る粉体プレス装置において、前記弓形形状の成形体に接触する前記上パンチまたは下パンチの少なくともいずれか一方の接触面に溝を有する粉体プレス装置が特許文献１に記載されている。 Patent Document 1 describes a powder press apparatus that obtains a bow-shaped molded body by filling a cavity formed by an upper punch, a lower punch, and a die with powder and pressing it, wherein at least one of the contact surfaces of the upper punch or the lower punch that contacts the bow-shaped molded body has a groove.
特許文献１の粉体プレス装置では、特許文献１の図３に示されるように、上パンチまたは下パンチの凸状湾曲面（弓形形状の成形体の内周面を形成するための面）に溝が形成されている。この溝によって、粉体プレス装置から弓形形状の成形体を取り出す際の離型性が改善される。 In the powder press apparatus described in Patent Document 1, as shown in Figure 3 of Patent Document 1, grooves are formed on the convex curved surface of the upper or lower punch (the surface for forming the inner circumferential surface of the arch-shaped molded body). These grooves improve the release properties when removing the arch-shaped molded body from the powder press apparatus.
しかし、特許文献１の粉体プレス装置であっても、成形体の形状やサイズによっては成形体の取り出しが困難な場合があり、離型性が十分であるとは言えなかった。また、得られた成形体の内周面には溝痕が形成され、当該溝痕が焼結後の焼結体にも残存するため、後工程となる焼結体の加工工程において、当該溝痕を除去するために時間を要したり歩留まりが悪くなるなどの問題が生じる場合があった。 However, even with the powder press apparatus described in Patent Document 1, depending on the shape and size of the molded body, it was sometimes difficult to remove the molded body, and the release properties were not considered sufficient. Furthermore, groove marks were formed on the inner surface of the obtained molded body, and these groove marks remained in the sintered body after sintering. This sometimes led to problems in subsequent processing steps of the sintered body, such as requiring extra time to remove the groove marks and resulting in poor yield.
本開示の実施形態は、成形装置から弓形形状の成形体を取り出す際の離型性をさらに改善できる成形装置の提供を可能にする。 The embodiments of this disclosure enable the provision of a molding apparatus that can further improve the release properties when removing a bow-shaped molded body from the molding apparatus.
また、本開示の実施形態は、焼結体の加工工程において、加工が容易な弓形磁石の提供を可能にする。 Furthermore, the embodiments of this disclosure enable the provision of a curved magnet that is easy to process in the sintering process.
本開示の限定的ではない例示的な成形装置は、
ダイと上パンチと下パンチとを含み、前記ダイと前記上パンチと前記下パンチとによって形成されるキャビティ内の磁性粉末を加圧して、外周面、内周面、周方向端面および軸方向端面を有する弓形成形体を製造する成形装置であって、
前記上パンチまたは前記下パンチは、前記内周面を形成するための凸状湾曲面と、
前記周方向端面の一部または全部を形成するための平面と、を有し、
前記平面の少なくとも一部の表面粗さＲａが、前記凸状湾曲面の表面粗さＲａよりも大きい。
Exemplary molding apparatuses not limited to this disclosure include:
A molding apparatus comprising a die, an upper punch, and a lower punch, wherein magnetic powder in a cavity formed by the die, the upper punch, and the lower punch is pressurized to produce an arch-shaped form having an outer surface, an inner surface, a circumferential end surface, and an axial end surface,
The upper punch or the lower punch has a convex curved surface for forming the inner circumferential surface,
It has a plane for forming part or all of the circumferential end face,
The surface roughness Ra of at least a portion of the plane is greater than the surface roughness Ra of the convex curved surface.
ある実施形態において、前記平面の表面粗さＲａは０．１μｍ以上であり、前記凸状湾曲面の表面粗さＲａは０．１未満である。 In one embodiment, the surface roughness Ra of the flat surface is 0.1 μm or greater, and the surface roughness Ra of the convex curved surface is less than 0.1 μm.
ある実施形態において、前記凸状湾曲面には１μｍ以下のコーティング層が設けられている。 In one embodiment, the convex curved surface is provided with a coating layer of 1 μm or less.
本開示の限定的ではない例示的な弓形磁石は、
外周面、内周面、周方向端面および軸方向端面を有する弓形磁石であって、
研削加工前の焼結体において、前記周方向端面の少なくとも一部の表面粗さＲａが、前記内周面の表面粗さＲａよりも大きい。
Examples of arc-shaped magnets not limited to this disclosure include:
An arc-shaped magnet having an outer circumferential surface, an inner circumferential surface, a circumferential end surface and an axial end surface,
In the sintered body before grinding, the surface roughness Ra of at least a portion of the circumferential end face is greater than the surface roughness Ra of the inner circumferential face.
ある実施形態において、弓形磁石がフェライト焼結磁石である。 In one embodiment, the curved magnet is a ferrite sintered magnet.
本開示の実施形態によれば、成形装置から弓形形状の成形体を取り出す際の離型性をさらに改善できる成形装置の提供が可能となる。 According to the embodiments of this disclosure, it is possible to provide a molding apparatus that can further improve the release properties when removing a bow-shaped molded body from the molding apparatus.
また、本開示の実施形態によれば、焼結体の加工工程において、加工が容易な弓形磁石の提供が可能となる。 Furthermore, according to the embodiments of this disclosure, it becomes possible to provide a bow-shaped magnet that is easy to process in the sintering process.
本開示の実施形態による成形装置は、ダイと上パンチと下パンチとを含み、前記ダイと前記上パンチと前記下パンチとによって形成されるキャビティ内の磁性粉末を加圧して、外周面、内周面、周方向端面および軸方向端面を有する弓形成形体を製造する成形装置であって、前記上パンチまたは前記下パンチは、前記内周面を形成するための凸状湾曲面と、前記周方向端面の一部または全部を形成するための平面と、を有し、前記平面の少なくとも一部の表面粗さＲａが、前記凸状湾曲面の表面粗さＲａよりも大きいことを特徴する。 A molding apparatus according to an embodiment of the present disclosure includes a die, an upper punch, and a lower punch, and is used to manufacture a bow-shaped form having an outer circumferential surface, an inner circumferential surface, a circumferential end face, and an axial end face by pressurizing magnetic powder in a cavity formed by the die, the upper punch, and the lower punch, wherein the upper punch or the lower punch has a convex curved surface for forming the inner circumferential surface and a flat surface for forming part or all of the circumferential end face, and the surface roughness Ra of at least a portion of the flat surface is greater than the surface roughness Ra of the convex curved surface.
すなわち、前記特許文献１のように、上パンチまたは下パンチにおける、弓形形状の成形体の内周面を形成するため凸状湾曲面に溝を形成するのではなく、図１に示すように、上パンチまたは下パンチ１における、前記弓形成形体の前記周方向端面の一部または全部を形成するための平面２（図１の斜線部分）の少なくとも一部の表面粗さＲａを、凸状湾曲面３の表面粗さＲａよりも大きくする。これによって、成形装置から弓形形状の成形体を取り出す際の離型性をさらに改善できる。 In other words, as described in Patent Document 1, instead of forming grooves on the convex curved surface of the upper or lower punch to form the inner circumferential surface of the arch-shaped molded body, the surface roughness Ra of at least a portion of the plane 2 (the shaded portion in Figure 1) that forms part or all of the circumferential end face of the arch-shaped form in the upper or lower punch 1 is made greater than the surface roughness Ra of the convex curved surface 3. This further improves the release properties when removing the arch-shaped molded body from the molding apparatus.
本開示の実施形態において、前記平面の表面粗さＲａは、平面の全体（全部）が同じ表面粗さＲａになっていることが好ましいが、加工や処理の仕方によっては、部分的に異なる表面粗さＲａになっている場合も想定される。しかし、この場合においても、平面の少なくとも一部、好ましくは面積割合で約５０％以上の表面粗さＲａが凸状湾曲面の表面粗さＲａよりも大きくなっていれば、離型性を改善することができる。 In the embodiments of this disclosure, it is preferable that the surface roughness Ra of the plane is the same across the entire plane. However, depending on the processing or treatment method, it is conceivable that the surface roughness Ra may differ in parts. Even in this case, however, if the surface roughness Ra of at least a portion of the plane, preferably about 50% or more by area ratio, is greater than that of the surface roughness Ra of the convex curved surface, the release properties can be improved.
前記平面の表面粗さＲａは０．１μｍ以上が望ましく、前記凸状湾曲面の表面粗さＲａは０．１未満であることが望ましい。前記平面の表面粗さＲａを０．１μｍ以上、前記凸状湾曲面の表面粗さＲａは０．１未満にするには、以下の方法を採用することができるが、これらに限られない。
（ａ）前記上パンチまたは下パンチの前記凸状湾曲面と前記平面とを別々に加工して、前記凸状湾曲面をＲａ０．１未満、前記平面をＲａ０．１μｍ以上に加工する。
（ｂ）前記凸状湾曲面と前記平面を含む前記上パンチの下面または下パンチの上面を、Ｒａ０．１μｍ以上となるように加工した後、前記凸状湾曲面のみをＲａ０．１未満となるように加工する。
（ｃ）前記凸状湾曲面と前記平面を含む前記上パンチの下面または下パンチの上面を、Ｒａ０．１未満となるように加工した後、前記平面のみをＲａ０．１μｍ以上となるように加工する。
（ｄ）前記凸状湾曲面と前記平面を含む前記上パンチの下面または下パンチの上面を、Ｒａ０．１μｍ以上となるように加工した後、前記凸状湾曲面のみにＲａ１μｍ未満となるようにコーティング層を設ける。
（ｅ）前記凸状湾曲面と前記平面を含む前記上パンチの下面または下パンチの上面に、Ｒａ０．１μｍ未満となるようにコーティング層を設けた後、前記平面のみをＲａ０．１μｍ以上なるように加工する。
The surface roughness Ra of the flat surface is preferably 0.1 μm or more, and the surface roughness Ra of the convex curved surface is preferably less than 0.1. The following methods can be used, but are not limited to them, to achieve a surface roughness Ra of 0.1 μm or more for the flat surface and a surface roughness Ra of less than 0.1 for the convex curved surface.
(a) The convex curved surface and the flat surface of the upper or lower punch are processed separately, so that the convex curved surface has a Ra of less than 0.1 and the flat surface has a Ra of 0.1 μm or more.
(b) After processing the lower surface of the upper punch or the upper surface of the lower punch, which includes the convex curved surface and the flat surface, to an Ra of 0.1 μm or more, the convex curved surface alone is processed to an Ra of less than 0.1 μm.
(c) After machining the lower surface of the upper punch or the upper surface of the lower punch, which includes the convex curved surface and the flat surface, to a Ra of less than 0.1, the flat surface alone is machined to a Ra of 0.1 μm or more.
(d) After processing the lower surface of the upper punch or the upper surface of the lower punch, which includes the convex curved surface and the flat surface, to an Ra of 0.1 μm or more, a coating layer is provided only on the convex curved surface to an Ra of less than 1 μm.
(e) After applying a coating layer to the lower surface of the upper punch or the upper surface of the lower punch, which includes the convex curved surface and the flat surface, such that the Ra is less than 0.1 μm, the flat surface is processed so that the Ra is 0.1 μm or more.
前記コーティングには、例えば、ＰＶＤ・ＣＶＤコーティング、ＴｉＮ・ＴｉＣコーティング、硬質クロムコーティング、ニッケルコーティング、セラミックコーティング、ＤＬＣコーティングなどの公知のコーティングを採用すればよい。 For the aforementioned coating, known coatings such as PVD/CVD coating, TiN/TiC coating, hard chromium coating, nickel coating, ceramic coating, and DLC coating may be used.
本開示の実施形態において、前記周方向端面を形成するための平面を一部または全部としたのは、弓形成形体の周方向端面の全部が図１の斜線部分の平面で形成される場合と、弓形成形体の周方向端面の一部が図１の斜線部分の平面で形成され、他部がダイの内面で形成される場合（前記弓形成形体の周方向端面が軸方向断面視で「く」の字状の場合）があるからである。 In the embodiments of this disclosure, the reason for partially or entirely defining the plane for forming the circumferential end face is that there are cases where the entire circumferential end face of the arch-forming structure is formed by the plane in the shaded area of Figure 1, and cases where a portion of the circumferential end face of the arch-forming structure is formed by the plane in the shaded area of Figure 1, and the other portion is formed by the inner surface of the die (i.e., the circumferential end face of the arch-forming structure is "V" shaped in an axial cross-sectional view).
本開示の実施形態による成形装置によれば、前記特許文献１に記載される粉体プレス装置のように、比較的面積が大きい前記凸状湾曲面に溝を形成しなくとも（溝加工を行わずと）、比較的面積が小さい前記平面にのみに加工などを施すことによって、離型性を改善できるため、上パンチの下面または下パンチの上面（成形面）の加工コストを低減できることができる。 According to the molding apparatus of this disclosure, unlike the powder press apparatus described in Patent Document 1, it is possible to improve mold release properties by performing processing only on the relatively small flat surface, without forming grooves on the relatively large convex curved surface (i.e., without performing groove processing). Therefore, the processing cost of the lower surface of the upper punch or the upper surface of the lower punch (molding surface) can be reduced.
また、前記特許文献１に記載される粉体プレス装置では、前記凸状湾曲面に溝を有することにより離型性が改善されるが、前記の通り、前記凸状湾曲面は比較的面積が大きく、成形体の形状やサイズによっては溝の効果が低下し、成形体の取り出しが困難になる場合がある。一方、本開示の実施形態による成形装置によれば、前記平面の表面粗さＲａを、前記凸状湾曲面の表面粗さＲａよりも大きくするだけで、成形体の形状やサイズを問わず、優れた離型性が得られる。すなわち、離型性をさらに改善することができる。 Furthermore, in the powder press apparatus described in Patent Document 1, the release properties are improved by having grooves on the convex curved surface. However, as mentioned above, the convex curved surface has a relatively large area, and depending on the shape and size of the molded body, the effect of the grooves may decrease, making it difficult to remove the molded body. On the other hand, according to the molding apparatus of the embodiment of this disclosure, excellent release properties can be obtained regardless of the shape and size of the molded body simply by making the surface roughness Ra of the flat surface greater than the surface roughness Ra of the convex curved surface. In other words, the release properties can be further improved.
本開示の実施形態による成形装置によって成形された弓形成形体を焼結（焼成）することによって、外周面、内周面、周方向端面および軸方向端面を有する弓形磁石であって、研削加工前の焼結体において、前記周方向端面の少なくとも一部の表面粗さＲａが、前記内周面の表面粗さＲａよりも大きい、本開示の実施形態による弓形磁石が得られる。 By sintering (firing) the arch-shaped form formed by the molding apparatus according to the embodiment of this disclosure, an arch-shaped magnet having an outer circumferential surface, an inner circumferential surface, a circumferential end surface, and an axial end surface is obtained, wherein, in the sintered body before grinding, the surface roughness Ra of at least a portion of the circumferential end surface is greater than the surface roughness Ra of the inner circumferential surface.
本開示の実施形態による弓形磁石は、特許文献１の粉体プレス装置によって得られる弓形形状の成形体のように内周面に溝痕が形成されないので、後工程となる焼結体の加工工程において、焼結体に残存する当該溝痕を除去するために時間を要したり歩留まりが悪くなるなどの問題が生じ難く、加工が容易である。 The curved magnet according to the embodiment of this disclosure does not have groove marks formed on its inner circumferential surface, unlike the curved molded body obtained by the powder press apparatus of Patent Document 1. Therefore, in the subsequent sintering process, problems such as requiring time to remove the groove marks remaining on the sintered body or poor yield are less likely to occur, and processing is easier.
前記弓形磁石は、フェライト焼結磁石や、Ｒ－Ｔ－Ｂ系焼結磁石などの希土類焼結磁石であってよいが、希土類焼結磁石よりも平均結晶粒径が小さいフェライト焼結磁石である場合に、前記効果が顕著となる。 The aforementioned arc-shaped magnet may be a ferrite sintered magnet or a rare-earth sintered magnet such as an R-T-B type sintered magnet. However, the effect is particularly pronounced when it is a ferrite sintered magnet with a smaller average crystal grain size than a rare-earth sintered magnet.
本開示の実施形態による弓形磁石がフェライト焼結磁石の場合、例えば、以下の工程を有する製造方法によって得ることができる。
Ｆｅ２Ｏ３などの原料粉末を混合し、混合原料粉末を得る原料粉末混合工程、
前記混合原料粉末を仮焼し、仮焼体を得る仮焼工程、
前記仮焼体を粉砕し、仮焼体の粉末を得る粉砕工程、
前記仮焼体の粉末を、上述した成形装置によって成形し、成形体を得る成形工程、
前記成形体を焼成し、焼結体を得る焼成工程。
各工程における条件などは公知の製造方法の条件などを採用することができる。
If the arched magnet according to the embodiment of this disclosure is a ferrite sintered magnet, it can be obtained, for example, by a manufacturing method having the following steps.
A raw material powder mixing step in which raw material powders such as Fe₂O₃ are mixed to obtain a mixed raw material powder,
A calcination step in which the mixed raw material powder is calcined to obtain a calcined body,
A grinding step to pulverize the calcined body and obtain powder from the calcined body,
A molding process in which the powder of the calcined body is molded using the molding apparatus described above to obtain a molded body,
A firing step in which the molded body is fired to obtain a sintered body.
The conditions in each process can be those of known manufacturing methods.
本開示の実施形態による成形装置および弓形磁石は、成形装置から弓形形状の成形体を取り出す際の離型性をさらに改善できる成形装置の提供が可能である点、焼結体の加工工程において、加工が容易な弓形磁石の提供が可能である点において、産業上の利用可能性を有する。 The molding apparatus and arched magnet according to the embodiments of this disclosure have industrial applicability in that they can provide a molding apparatus that can further improve the release properties when removing arched molded bodies from the molding apparatus, and they can provide arched magnets that are easy to process in the processing of sintered bodies.
１ 上パンチまたは下パンチ
２ 平面
３ 凸状湾曲面
1. Upper punch or lower punch 2. Flat surface 3. Convex curved surface
Claims (5)
前記上パンチまたは前記下パンチは、前記内周面を形成するための凸状湾曲面と、
前記周方向端面の一部または全部を形成するための平面と、を有し、
前記平面の少なくとも一部の表面粗さＲａが、前記凸状湾曲面の表面粗さＲａよりも大きいことを特徴する成形装置。 A molding apparatus comprising a die, an upper punch, and a lower punch, wherein magnetic powder in a cavity formed by the die, the upper punch, and the lower punch is pressurized to produce an arch-shaped form having an outer surface, an inner surface, a circumferential end surface, and an axial end surface,
The upper punch or the lower punch has a convex curved surface for forming the inner circumferential surface,
It has a plane for forming part or all of the circumferential end face,
A molding apparatus characterized in that the surface roughness Ra of at least a portion of the plane is greater than the surface roughness Ra of the convex curved surface.
研削加工前の焼結体において、前記周方向端面の少なくとも一部の表面粗さＲａが、前記内周面の表面粗さＲａよりも大きいことを特徴とする弓形磁石。 An arc-shaped magnet having an outer circumferential surface, an inner circumferential surface, a circumferential end surface and an axial end surface,
An arch-shaped magnet characterized in that, in the sintered body before grinding, the surface roughness Ra of at least a portion of the circumferential end face is greater than the surface roughness Ra of the inner circumferential face.
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| JP5968735B2 (en) | 2012-09-13 | 2016-08-10 | ゼノー・テック株式会社 | Lower punch used for forming a ferrite magnet in a magnetic field, and method for manufacturing the lower punch |
| WO2019004368A1 (en) | 2017-06-29 | 2019-01-03 | 信越化学工業株式会社 | Method for forming coating film on rare earth magnet surface, and rare earth magnet |
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| US4957668A (en) * | 1988-12-07 | 1990-09-18 | General Motors Corporation | Ultrasonic compacting and bonding particles |
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| CN101356045A (en) | 2005-11-04 | 2009-01-28 | 道尔斯特技术有限两合公司 | Press arrangement and method for pressing parts |
| JP5968735B2 (en) | 2012-09-13 | 2016-08-10 | ゼノー・テック株式会社 | Lower punch used for forming a ferrite magnet in a magnetic field, and method for manufacturing the lower punch |
| WO2019004368A1 (en) | 2017-06-29 | 2019-01-03 | 信越化学工業株式会社 | Method for forming coating film on rare earth magnet surface, and rare earth magnet |
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