JPS6161930B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a molding machine for forming an electrode core material for electrical discharge machining, an electrode matrix, etc. from a photosensitive resin.

Conventionally, electrodes for electrical discharge machining require highly precise molding of easily processable materials such as copper or graphite into a shape that matches the shape of the workpiece, and this requires processing such as grinding and filing. However, if the electrode shape is complex, it not only requires a lot of processing time but also has the disadvantage that processing becomes difficult.

To eliminate the above drawbacks, there was a special public
No. 15320 provides a method for manufacturing an electrode for electrical discharge machining, which is characterized in that a metal plate of a desired shape is produced by photoetching, and a large number of the metal plates are laminated and fixed.

However, in the above manufacturing method, the thickness of the metal plate is
For example, 15
It takes 150 metal plates to fabricate an electrode with a length of m/m, and each one is coated with a photosensitive agent, dried, baked, heat-cured, developed, and subjected to a series of photo-etching steps such as removing the resist. The work has to be done repeatedly, which requires a lot of effort and time. Furthermore, when laminating and fixing photoetched metal plates one by one, there is a possibility that the laminated electrodes are fixed while being distorted or bent. For this reason, even if an electrode with a complicated shape can be obtained, it is difficult to obtain a highly accurate electrode for electric discharge machining.

The present invention has been made in view of the above circumstances, and aims to provide a novel molding machine that forms laminated electrodes and electrode matrices in a short time and with high precision using photosensitive resin as a material. Two inventions of molding machines will be explained with drawings.

First, the outline of the photosensitive resin used in the molding machine of the present invention will be explained. The photosensitive resin is Tevista,
It is commercially available under names such as APR resin and Aronix, and is a liquid resin that solidifies when exposed to ultraviolet light. The relationship between the exposure time and the depth of solidification is as follows: When using a 500W xenon lamp light source, the depth from the resin surface to the deep part is approximately 3 mm after 1 minute, approximately 8 mm after 5 minutes, approximately 12 mm after 10 minutes, and approximately 16 mm after 20 minutes. solidify.

The first aspect of the present invention is a molding machine that uses this liquid resin to solidify a region corresponding to the cross-sectional shape of the electrical discharge machining electrode to be formed, and stacks the solidified layers. The same cross-sectional shape of the electrode and matrix to be molded is drawn transparently on a transparent film, and the number of cross-sectional views the electrode and matrix are divided into depends on the complexity and precision of the electrode shape. It is determined that However, no matter how complex the cross-sectional shape is, as long as each part of the columnar electrode has the same dimensions and the same cross-sectional shape, a single transparent film is sufficient. That is, the embodiment shown in FIG. 3 shows the manufacturing process of an electrode for electrical discharge machining using one transparent film. Figure 1 shows the first step in which electrodes for electrical discharge machining are manufactured using photosensitive resin.
An embodiment of the electrode forming machine 10 of the invention is shown, in which the top surface of a square water tank 1 is open, and a table 2 that is driven up and down is provided inside the tank. The table 2 is connected via a lower end bevel gear 4 on a rotating shaft 3 of a pulse motor PM and a bevel gear 6 on a horizontal drive shaft 5, and the table is raised and lowered by forward and reverse rotation of the pulse motor PM. C is the control box for table 2,
Knob S ₁ for setting the inching feed amount, full stroke setting knob S ₂ , timer knob S ₃ for setting the inching interval for the inching feed amount, setting knob S ₄ for table continuous slow feed, power supply and Start switch S ₅
, a selection switch _S6 for inching feed/continuous feed, and a table upward/downward feed selection switch _S7 . And L _a is a xenon lamp 500W
The light source irradiates the top surface of the table 2 perpendicularly to the top surface of the table 2 as parallel light beams through a condenser lens 7. This light source L
When _the inching feed is set, the light a is turned off when the table 2 is raised or lowered, and the upper and lower limit positions of the table 2 are detected by proximity sensors L ₁ and L ₂ . F ₀ is a film plate that covers the upper surface of the water layer 1, and the transparent portion is processed to have a four-petal shape F ₁ that is the same as the cross-sectional shape of the electrode. Now, the ray passing through the film plate F ₀ is
The upper surface of the flower can be irradiated into a petal shape _F1 . Then, in the water tank 1, there is a liquid resin photosensitive resin HP.
Pour until almost full.

Next, electric circuit E in control box C
will be explained with reference to FIG. The pulse motor PM that drives the table 2 up and down is controlled by a control unit 13 that receives commands from an inching feed setting unit 11 or a fine movement setting unit 12.
It is driven by the drive 14 via. Then, the setting knob S ₁ of the jog feed setting unit 11 sets the jog feed amount mm, and the feed operation interval is determined by the knob S ₃ of the timer 15. Further, the fine movement feed mm/mm of the table 2 is determined by the setting knob _S4 of the fine movement feed setting section 12, and selection between the two is made with the inching and fine movement selection switch _S6 .
The downward feed is determined by the changeover switch _S7 of the inverter 16. Furthermore, the amount of elevation of the table 2, that is, the electrode height (length) is set using the setting knob _S2 of the length measuring device 17, and the feed amounts from the inching feed setting section 11 and the fine movement setting section 12 are integrated. When reaching a predetermined value, the controller 1
Send a stop command to 3. When the full stroke limiter 18 receives input signals from the proximity sensors L ₁ and L ₂ at the upper and lower limit positions, it sends a stop signal to the length measuring device 17 to stop driving the pulse motor PM. In addition, the light source L _a is a lighting circuit 1 that is powered off and turned off only when the sending signal from the inching feed setting section 11 is oscillated.
Controlled by 9. Note that when the pulse motor PM is driven by a command from the fine movement feed setting section 12, the light source L _a continues to be lit.

The manufacturing process of the electrode core material by the molding machine 10 of the first invention will be explained with reference to FIGS. 2 and 3. First, the film plate _F0 is placed and fixed on the top surface of the water tank,
Set the inching feed amount (solidified layer thickness that becomes unit thickness) and its stopping time (solidifying time) with each knob _S1 and _S3 . After that, when the inching selection switch S ₆ and the start switch S ₅ are pressed, the pulse motor PM is started via the control unit 13 and the drive 14, and the table 2 is moved to the liquid resin photosensitive resin HP as shown in Fig. 3a. The photosensitive resin HP is submerged by a unit thickness of h ₁ from the liquid level and stopped, and at the same time the light rays from the light source L _a turned on are irradiated onto the photosensitive resin HP via the condenser lens 7 and the film plate F ₀ . Now, the photosensitive resin HP is solidified to a unit thickness of h ₁ in the same shape as the pattern F ₁ of the transparent part, and the solidified resin is
It becomes P ₁ . When the resin is sufficiently solidified, the timer 15 causes the table 2 to be inched again by h ₁ and lowered to form the second layer of solidified resin P ₂ . Thereafter, as shown in FIG. 2b, the above operations are repeated until the solidified resin reaches a predetermined height h ₀ determined by the length measuring device 17, thereby forming the electrode core material P ₀ of multiple solidified layers h ₁ . The electrode core material P ₀ is taken out from the table 2 and washed with water in a shower W as shown in FIG. 3c. After this, d in Figure 3
In order to make the electrode core material P ₀ conductive, the surface of the electrode core material P ₀ is coated with metal by forming an electrode layer M by, for example, copper plating or thermal spraying. On the other hand, electrode core material
When manufacturing P ₀ , if the table 2 is to be lowered at a slow speed, press the sorting switch _S6 on the fine feed setting section 12, and use the setting knob _S4 to lower the length measuring device 17 to the predetermined slow speed and electrode length. After making adjustments with knob S ₂ , press start switch S ₅ to start driving. With the above operations, table 2 begins to descend at a slow speed,
After descending a predetermined distance, stop and remove the electrode core material.
Solidify P ₀ to form.

Next, a second aspect of the present invention will be explained with reference to an embodiment shown in FIGS. 4 and 5. This embodiment is for the case where the electrode core material has a conical shape, for example, and the film plate _F0 in the first invention is replaced by a cassette (magazine) K in which a long film strip is wound. It is something that has become familiar. This cassette K
has film winding cylinders 20 and 21 on the left and right sides, and can wind the film into its own cylinder by the respective pulse motors PM ₁ and PM ₂ , and each frame of the film has a shape of a transparent part F _{1 .} It is created and gradually becomes smaller. That is, the number of frames is determined according to the cross-sectional accuracy of the electrode core material. The cassette K has a hood 22 that covers the top surface of the aquarium 1.
The frame of the film is placed in the mounting window 23 of the camera, and the frame of the film is positioned by two position sensors D ₁ and D ₂ so that the shadow of the transparent part F ₁ irradiated with the light from the _light source L a is in the correct position. .

Next, the electric control circuit E' will be explained with reference to FIG.
For feeding to the table 2, only the inching feed setting section 11 is provided, and the related control section 13, drive 14, timer 15, vertical rapid feed section 16, length measuring device 1
7 and a full stroke limiter 18 in the same manner as in the first invention. The electric circuit for driving and controlling the pulse motors PM ₁ and PM ₂ of the cassette K is as follows:
The inching signal from the control section 13 is counted by the counter 25, and the output is sent to the computer control section 26.
A command is sent to the drive 27 as to whether or not to drive the pulse motor PM ₁ to advance frame by frame in comparison with the program. Reference numeral 28 denotes a fixed position stop circuit which has the function of accurately positioning each frame by stopping the pulse motors PM ₁ and PM ₂ based on the frame position signals picked up from the position sensors D ₁ and D ₂ .
In addition, the pulse motor PM ₁ forwards the film in the forward direction.
The pulse motor PM ₂ feeds the film in reverse to rewind it.

The second aspect of the present invention is configured as described above, and for example, a conical electrode core material is manufactured automatically. That is, prior to operation, a film cassette K in which the inching feed amount and electrode length are set and the electrode shape to be manufactured is broken down into the required number of cross sections is loaded into the mounting window 23 of the hood 22, and then the computer is opened. The contents programmed by the control unit 26 to create an electrode of a desired shape are stored in memory. Thereafter, when the start switch _S5 is pressed, the pulse motor PM is started via the control unit 13 and the drive 14, and the table is submerged by a unit thickness of _h1 from the liquid level as shown in the figure, and then stopped. At the same time, a light beam from a light source L _a turned on is applied to the photosensitive resin HP through the film of the cassette K in the shape of a transparent portion F ₁ . This solidifies the photosensitive resin in the transparent shape _F1 with a unit thickness. When it is sufficiently solidified, the timer 15 moves the table 2 again by an inch of h ₁ and lowers it.
A layer of solidified resin is created. At this time, if the cross-sectional shape is even slightly different from that of the first layer, the pulse motor PM ₁ is activated by the drive 27 based on the input from the counter 25 based on the program content in the computer control section 26, and one frame is fed. This frame-by-frame feeding is accurately positioned by two position sensors D ₁ and D ₂ , and the drive 27 is controlled by a fixed position stop circuit 28 . Thereafter, similar actions are repeated, and when the electrode core reaches a predetermined height determined by the length measuring device 17, the length measuring device 17 sends an operation end signal to the control unit 13 to stop the operation.

According to the first aspect of the present invention, a table that moves up and down by the drive of a pulse motor is installed in a water tank filled with photosensitive resin, and a control unit that controls the pulse motor via a drive is provided with a table that moves up and down with the drive of a pulse motor. Select and input a signal for inching feed every unit time determined by the inching feed setting section and the timer, and a fine movement signal per unit time for the fine movement setting section, and when the predetermined electrode length is reached, the pulse motor Equipped with a length measuring device to stop the flow, and a light source that irradiates the film plate placed on the top surface of the aquarium, any complicated columnar electrode can be automatically measured by using a film plate with a single electrode cross section. In addition to being able to produce
This has the effect of shortening the manufacturing time and making it possible to manufacture highly accurate electrode core materials without distortion. Furthermore, the molding machine of the present invention can also be used as a manufacturing machine for electrode matrix molds.

Further, according to the second aspect of the present invention, a table that moves up and down by the drive of a pulse motor is installed in a water tank filled with photosensitive resin, and a control section that controls the pulse motor via a drive has a table mounted on the table. A hood placed on the top of the aquarium is equipped with a length measuring device that inputs a signal for inching feed every unit time determined by the inching feed setting section and a timer, and stops the pulse motor when the predetermined electrode length is reached. The mounting window is equipped with a film cassette containing a large number of frames of electrode cross sections, and the frame feed pulse motor of this cassette is driven by a computer control unit via a counter that counts inching signals from the control unit. It is equipped with a fixed position stop circuit that is connected to the drive and controls the frame advance drive by the frame position sensor of the cassette, and above the cassette is equipped with a light source that irradiates the film in the cassette with a light beam.
No matter how complex the shape of the conical electrode is, it can be automatically manufactured by using the number of electrode cross-sections stored in one cassette, and the manufacturing time can be shortened and the electrode can be made with high precision without distortion. This has the effect of making it possible to manufacture core materials. Furthermore, the molding machine of the present invention can also be used as a manufacturing machine for electrode matrix molds.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of an electrode forming machine according to the first aspect of the present invention, FIG. 2 is a block diagram showing its electric circuit, FIG. 3 is a diagram of the manufacturing process of the electrode, and FIG. FIG. 5 is a perspective view of an electrode forming machine showing the second invention, and FIG. 5 is a block diagram showing its electric circuit. 1...water tank, 2...table, 10...electrode forming machine,
PM, PM ₁ , PM ₂ ... pulse motor, L _a ... light source,
HP...photosensitive resin, _F0 ...film plate, C...control box, K...cassette, 22...hood,
23... Mounting window, 15... Timer, 11... Jog feed setting section, 12... Fine movement feed setting section, 13... Control section, 1
4, 27...Drive, 17...Length measuring device, 18...Full stroke limiter, 19...Lighting circuit, 25...Counter, 26...Computer control unit, 28...Full stroke limiter, 19...Lighting circuit, 25...Counter,
26... Computer control unit, 28... Fixed position stop circuit, _D1 , _D2 ... Position sensor, E, E'... Electric circuit,
S ₁ to S ₇ ...knobs.

Claims (1)

[Claims] 1. A water tank filled with photosensitive resin is equipped with a table that moves up and down by the drive of a pulse motor, and a control unit that controls the pulse motor via the drive includes:
A selection switch selects and inputs a signal for inching feed to the table every unit time set by a timer from the inching feed setting section, and a fine movement signal from the fine movement feed setting section, and when the predetermined electrode length is reached. A forming machine for electrodes for electric discharge machining, which is equipped with a length measuring device that stops a pulse motor, and a light source that illuminates a film plate placed above a water tank. 2. A water tank filled with photosensitive resin is equipped with a table that moves up and down by the drive of a pulse motor, and a control unit that controls the pulse motor via the drive includes:
The table is equipped with a length measuring device that inputs a signal for inching feed at every unit time determined by the inching feed setting section and a timer, and stops the pulse motor when the predetermined electrode length is reached. The mounting window of the hood is equipped with a film cassette containing a large number of frames with electrode cross sections, and the frame feed pulse motor of this cassette is controlled by the computer control unit via a counter that counts the inching signals from the control unit. Electrical discharge machining is equipped with a fixed position stop circuit that is connected to the driving drive and controls the comb feed drive using the frame position sensor of the cassette, and a light source that irradiates the film in the cassette with a light beam above the cassette. Molding machine for electrodes.