JPH0647234B2 - Equipment for cutting hard and brittle materials - Google Patents

Description

TECHNICAL FIELD The present invention relates to a cutting device for hard and brittle substances such as stone, ceramics and concrete, and a method for operating the same. More specifically, the present invention relates to a device capable of cutting a hard and brittle substance along a curved surface having an arc shape or a cross-sectional shape in which arcs are continuous, or an inclined flat surface or horizontal surface.

[Prior Art] As a device for cutting hard and brittle materials, a disk-shaped diamond cutter that rotates at a high speed as shown in FIG. A cutting device using a grindstone (81) is generally known.
This is for cutting while cutting and moving the diamond cutter (81) along the guide (82). On the other hand, a method of sprinkling an abrasive such as iron sand or carborundum on an iron plate that reciprocates at a high speed or an endless wire rope that circulates at a high speed and wear and cut is generally known.

[Problems to be Solved by the Invention] All of the conventional methods described above are limited to cutting in a vertical plane of a workpiece, and cannot cut an inclined surface, a horizontal plane, or a curved surface. Therefore, for example, in order to create a curved surface such as an arc shape on the workpiece (S), as shown in Fig. 12, a comb-shaped cutting groove is formed in a direction substantially perpendicular to the curved surface to be obtained.
A large number of (83) are cut while changing the depth in order, the cut portions are removed, the uneven surface is smoothed to a curved surface, and polishing is performed. Therefore, the cutting distance (total of the total lengths cut by the diamond cutter) becomes extremely long, and the cutting distance further increases especially in the case of a complicated curved surface or a large diameter, and it also takes time to change the orientation of the work piece. Because of this, both time and cost become enormous. Further, it takes a lot of labor and time to level the uneven surface, and since all the work is done manually, a uniform product cannot be obtained, and there is a big problem in terms of processing accuracy.

[Means for Solving the Problems] A cutting device for hard and brittle substances according to the present invention has a pair of drums whose axial centers are arranged in parallel with each other, and an endless shape which is stretched and stretched between the pair of drums. Diamond bead wire,
Rotational drive means for driving the drum, and vertical drive means and front-back movement for providing relative vertical movement and forward-backward movement between the diamond bead wire and the workpiece in a plane intersecting with the diamond bead wire, respectively. A pair of driving means and outer peripheral grooves, which are arranged on both sides of the object to be cut on the cutting side of the diamond bead wire, respectively, have outer peripheral grooves along which the diamond bead wires are engaged, and the outer peripheral grooves are diamond beads. A pair of guide pulleys arranged substantially in the same plane so as to sandwich the wire, a swing drive means for swinging the pair of guide pulleys around the diamond bead wire, and the diamond bead wire being the object to be cut. The vertical drive means and the front-back drive means so as to draw a predetermined two-dimensional trajectory with respect to Comprising a control device for controlling in conjunction with.

[Operation] A diamond bead wire or a high speed circulation run is performed by a pair of drums driven by a rotation driving means. In that state, under the control of the control device, the up-down drive means and the front-back drive means move in association with each other, and the diamond bead wire is cut so as to draw a predetermined locus with respect to the object to be cut.

Generally, in that case, the diamond bead wire receives cutting resistance from the work piece. That is, when cutting a high-speed running diamond bead wire in a vertical plane to cut and cut an object to be cut, it receives cutting resistance upward, and when moving along a curved surface or a horizontal plane, Receives cutting resistance toward the opposite side. Therefore, as the cutting resistance of the diamond bead wire increases, the diamond bead wire tends to escape to the side opposite to the cutting direction.

In the device of the present invention, since the diamond bead wire moves so as to draw a two-dimensional trajectory, the direction of the cutting resistance also changes within a wide angle range, but the pair of guide pulleys surely guides the cutting side of the diamond bead. Therefore, the escape can be suppressed in any cutting direction.
Therefore, the predetermined locus can be traced accurately.

Further, the central portion of the stretched portion on the cutting side of the diamond bead wire follows the locus on the basis of the cutting resistance with a delay as compared with the both ends being guided. Therefore, in cutting a curved surface, the delay in the center portion causes a so-called drum-like distortion on the cut surface. However, by arranging the pair of guide pulleys in the present invention in the immediate vicinity of the material to be cut, such distortion can be minimized.

Since the pair of grooved guide pulleys are provided separately from the drum, they can be easily brought close to the material to be cut. Further, since the pair of guide pulleys can be swiveled around the diamond bead wire, when tilted in the direction of the tangent line of the movement path of the diamond bead wire (cutting advancing direction), either one of the guide pulleys will be properly moved. Since it can be backed up, it can be cut with a more accurate trajectory. It is preferable that the turning angles of the pair of guide pulleys are automatically made to follow in accordance with the ratio of the vertical movement speed and the forward and backward movement speed, that is, the cutting angle.

[Embodiment] Next, an apparatus of the present invention will be described with reference to the drawings.

1 and 2 are a front view and a side view, respectively, showing an embodiment of the apparatus of the present invention, and FIG. 2A is (II)-(I of FIG.
I) line sectional view, FIG. 2B is a perspective view of the apparatus shown in FIGS.
3 and 4 are a front view and a side view, respectively, showing an embodiment of a guide pulley according to the present invention, and FIG. 5 is a side view, FIG. 6 showing another embodiment of the guide pulley according to the present invention. Is an explanatory view showing the relationship between the turning angle of the guide pulley and the cutting locus shown in FIG. 5, and FIGS. 6A and 6B are perspective views showing examples of workpieces machined by the device of the present invention. FIG. 7 is a side view showing an embodiment of the diamond bead wire according to the present invention, and FIG. 8 is (VII) of FIG.
I)-(VIII) sectional view, FIG. 9 is a front view showing a guide mechanism of a diamond bead wire constituted by one guide pulley which cooperates with a drum, and FIG. 10 is another view of the device of the present invention. It is a front view showing an example.

The apparatus shown in FIGS. 1 and 2 has a pair of drums (1) and (2) each having a diameter of 1250 mm at opposite positions on the left and right (right and left in FIG. 1, the same applies below) so that the axes are parallel. I have it. One of them is the driving side and the other is the driven side. Drum (1), (2)
The outer peripheral groove (1a) as shown in FIG. 2A is formed in
An endless diamond bead wire (3) is laid and stretched so as to engage with the outer peripheral groove (1a).

As shown in FIGS. 2 and 2B, the drive side drum (1) is connected to the main motor (20) via the V pulley (18) and the V belt (19) attached to the other end of the drive shaft (17). ) Is giving the rotation. The direction of rotation is counterclockwise in FIG.

The driven drum (2) is urged to the left in the drawing by the air cylinder (21), which causes the diamond bead wire.
Appropriate tension is given to (3).

The mechanism around the drums (1) and (2) is vertically driven by the vertical drive means (vertical feed means) including the vertical slides (22) and (23) arranged on the left and right as shown in FIG. 2B. To be done.

The vertical slide (22) on the driven side will be explained.The vertical slide (22) on which the driven drum (2) is rotatably mounted slides vertically with a pair of left and right guides (24), (26). Guided freely. The upper ends of the upper and lower guides (24) and (26) are connected to each other by the upper and lower guide upper bases (30) passed forward and backward, and the lower ends thereof are fixed on the common base (38).

The vertical movement of the vertical slide (22) is performed by moving the ball screw nut (29) attached to the vertical slide (22) and the vertical guide upper base (30).
The upper end of which is rotatably supported by bearings, and the upper and lower guides (24) and (26) are screwed together with a vertical feed ball screw (32) extending downward.

The vertical slide (23) on the right side around the driving drum (1) is the same as that on the left side, and the upper end is connected by the vertical guide upper base (31) as shown in FIG. Guided up and down by a pair of up and down guides (25) and (27), the ball screw nut (28) and vertical feed ball screw (3
Driven by 3).

The upper and lower ends of the left and right vertical feed ball screws (32) and (33) can be changed in direction by the bevel gear cases (35) and (34), respectively, and are connected via the intermediate shaft (34a). It is rotationally driven in synchronization by a servo motor (4) connected to.

The left and right upper and lower guide upper bases (30) and (31) are connected to each other by front and rear upper beams (36) and (37), and the four upper and lower guides (24), (25), (26), ( The lower end of 27) is integrally connected by a common base (38).

At the center of the common base (38), there is a workpiece mounting table (40) that is driven back and forth by a servo motor (5) and a front and rear feed ball screw (39), and its wheels (41) and (42) are rails. (43),
(44) Roll up. The servo motor (5) and the like constitute a front-rear driving means (front-rear feeding means). The work (S) is installed on the work rest (40), but if necessary, the fixed shelf (4
5), (46), etc. are used so that they are fixed so that they will not shift during processing.

As will be described in more detail, as shown in FIG. 2A, hard rubber (JIS hardness HsA) is added to the portions where the drums (1), (2) and the diamond bead wire (3) are in contact with each other.
50-70, especially around 60) and other super wear resistant hard rubber layers (4
7) is fitted in a ring to prevent abrasion of the drums (1) and (2). For the drums (1) and (2), cast products such as hard aluminum alloy are used for the purpose of weight reduction.

As described above, the diamond bead wire (3), which is laid between such drums (1) and (2) and is circulated at a high speed, is always tensioned, but in the device of the present invention, further tension is applied. To prevent displacement of the cutting position due to slack or delay in the center part, guide guides (6) to the left and right,
(7) is provided.

Explaining one guide guide (6), in the apparatus shown in FIG. 1, the guide guide (6) is a pair of rotatably supported on a bracket (61) as shown in FIGS. It is composed of guide pulleys (62) and (63).

Peripheral grooves (64) as shown in FIG. 4 are formed around the guide pulleys (62) and (63), and hard urethane rubber (in this embodiment, in the contact portion with the diamond bead wire (3) is formed. J
Rubber layers (49) and (50) made of IS hardness HsA 90) are fitted.

The brackets (61) of the respective guide guides (6) and (7) are for the purpose of receiving cutting resistance at the position closest to the work (S), and the brackets (61) of the drum covers (51) and (52) shown in FIG. Each is attached to the inside through, for example, a mounting member (65) as shown in FIG. Further, the mounting member (65) is provided with a guide surface (66) for adjusting the guides (6) and (7) by moving them along the diamond beads (3).

Diamond bead wire for guide pulleys (62), (63)
The outer peripheral groove (64) engaging with (3) is a concave groove having a semicircular cross section with a radius slightly larger than the radius of the diamond beads ((16) in FIG. 7). A pair of guide pulleys (62), (6
3) are set up and down so that the diamond bead wire (3) is sandwiched by the outer peripheral groove (64), and the interval is the outer peripheral groove.
The surface of (64) is not separated from the surface of diamond beads (16) by 1 mm or more.

For the purpose of further improving the cutting accuracy, the guide guides (6) and (7) can be tilted in the cutting tangential direction as shown in FIG.
It is configured to be able to turn around. Such turning is performed, for example, by the spiral gear (worm gear) shown in FIG.
It is driven by the servo motor (8) via (53) and the like, and is performed so as to follow the change of the cutting angle which is determined according to the speed ratio of the front-rear moving means and the vertical moving means.

With such a configuration, for example, as shown in FIG. 6, when controlling the forward and backward moving means and the vertical moving means along a circular locus (M) for cutting a cylindrical surface, the guide pulley (6
2) The guide guide (6) is turned so that the center plane (plane orthogonal to the rotation axis) (L) of (63) coincides with the tangential direction of the cylindrical surface. In this way, a work (S) 'having a curved surface (M) as shown in Fig. 6A or Fig. 6B is obtained.

In addition, a pair of guide pulleys ((62),
Instead of the guide guide constituted by (63), a simple guide guide shown in FIG. 9 can be adopted, although it is outside the scope of the present invention. The guide guide shown in FIG. 9 is composed of guide pulleys (6a) and (7a) arranged one each at a position slightly inside the lower ends around the drums (1) and (2).

This is the outer peripheral groove (first groove) formed on the drum (1), (2).
Insert the diamond bead wire (3) between (1a) in Fig. 2A and the outer peripheral groove (same as groove (64) in Fig. 4) formed in the guide pulleys (6a) and (7a). , Guide pulley (6
The a) and (7a) are rotatably provided so as to face the drums (1) and (2), respectively.

The simplified guide guide having such a structure has a larger spacing between the support points of the diamond bead wire and cannot be swung, as compared with the guide guide pulley composed of a pair of guide pulleys shown in FIGS. Although it does not reach the guides shown in FIGS. 3 to 6, it can be sufficiently used depending on the hardness of the material to be cut and the processing shape.

Even when tension is applied to the diamond bead wire (3) as described above, the return side ((3 in Fig. 1
Since there is some slack in a)), its vibration affects the cutting side and promotes wear of the diamond beads (3).

In order to cope with such a problem, in the embodiment shown in FIG. 1, a contact piece (55) made of hard rubber is provided at a substantially central position on the return side (3a) of the diamond bead wire (3). The contact piece (55) is, for example, fitted on the inner surface of the cover (55a) and is in constant contact with the diamond bead wire (3), whereby the diamond bead wire is
Vibration due to slack in (3) is suppressed. That is, the contact piece (5
The vibration prevention device (10) is composed of 5) and its support.

Diamond bead wire used in the device of the present invention
(3) is, for example, as shown in FIGS. 7 to 8, cylindrical diamond beads (16) at appropriate intervals on the wire rope (13).
Is fixed, and when it is used, it is connected endlessly with a length matched to the machine. The commonly used size is 6mm diameter wire rope (13),
The diameter of the diamond beads (16) is about 11 mm.

Further, the diamond beads (16) are obtained by embedding diamond abrasive grains in metal, and can be said to be a grinding tool using metal as a binder.

The method of fixing the diamond beads (16) to the wire rope (13) is usually performed by attaching a cylindrical iron ring (15) to the wire rope (1).
3) It is pressure-bonded or adhered on top, and the diamond beads (16) are attached to the outer periphery by silver brazing.

However, in the diamond beads (13) used at all cutting angles in the up, down, front and back like the device of the present invention, the operating conditions are severe as compared with the case of simply cutting a vertical surface. There is a possibility that the wire rope (13) may be cracked and cut from the bonded portion of (15). In order to overcome such problems, in the diamond bead wire (3) shown in FIGS. 7 to 8, a synthetic resin coating layer (14) is provided on the wire rope (13) over the entire length, and the ring is formed on the coating layer (14). (15) is fixed, and the endless coupling process is performed after twisting about once or twice per 1 m. The twist is wire rope
Perform only in the twisting direction of (13).

With such a structure, an appropriate cushioning action is generated between the diamond beads (16) and the wire rope (13), so that the wire rope (13) and the like are protected.

Further, based on the twist, the diamond bead wire (3) naturally rotates during cutting, so that the diamond bead (16) is uniformly consumed. Therefore, it is possible to prevent distortion of the cutting path due to uneven wear of the diamond beads.

It is to be noted that, when a linear groove (16a) or a spiral groove (16b) extending in the axial direction as shown in the right end of FIG. 7 is processed on the surface of each diamond bead (16), the diamond bead (16 Since the cutting water is effectively contained in), there is an advantage that the durability of the diamond beads (16) is improved and the cutting efficiency is increased. Further, if the spiral groove (16b) is cut, the diamond bead wire (3) naturally rotates during the cutting due to the spiral effect, so that reduction in life is prevented.

In the conventional water supply method in which cutting water is poured upstream in the running direction of the diamond beads, an air film-shaped film is formed between the diamond beads (16) running at high speed and the cutting groove ((57) in Fig. 8). A space is created, just like a series of diamond beads (16) running in a tunnel. In that case, the cutting water does not hit the cutting part (57a) and a phenomenon occurs that it becomes a dry cutting, which leads to a rapid consumption of the diamond beads (16).

In order to solve such a problem, in the device of the present invention, the diamond bead wire (3) is cut in the traveling direction.
A water injection nozzle that jets cutting water of a jet jet toward the traveling direction in the front side of (S), for example, the guide (6) on the drive side.
It is preferable to provide (12) (see FIG. 1). With such a configuration, cutting water is sufficiently supplied to the surface of the diamond beads (16) to prevent dry cutting. Even if the cutting groove does not open upward due to the curved surface processing, the jet jet is supplied from the side so that cutting water is sufficiently supplied from the side of the cutting groove (57) along the diamond bead wire (3). There are advantages that can be provided.

Further, a water injection pipe (11) as shown in FIG. 1 is provided above the diamond bead wire (3) which is traveling at high speed in an auxiliary manner, and a plurality of holes (11a) are formed in the water injection pipe (11). By pouring cutting water, the wear of the diamond beads (16) can be further reduced. In that case, the cutting water from the traveling start side (left side in FIG. 1) almost flows in the traveling direction. Therefore, if the space between the holes (11a) of the water injection pipe (11) is widened toward the downstream side, uniform water supply can be achieved, waste of water can be avoided, and efficient water supply can be performed.

The servo motor (4) for the vertical moving means and the servo motor (5) for the forward and backward moving means in the apparatus shown in FIGS.
Both operate according to commands from the NC controller (56). Therefore, it is possible to perform cutting at an appropriate speed along a trajectory programmed in advance. Moreover, the processing of the same shape can be repeated many times. Furthermore, it is preferable that the guide guide (6) provided with the turning mechanism having the servo motor (8) shown in FIG. 5 also controls the follow angle by controlling the turning angle by inputting to the servo motor (8) by the NC controller.

If necessary, the same controller may control the running speed and tension of the diamond bead wire, the water supply amount, and the like.

The apparatus shown in FIGS. 1 and 2 employs a configuration in which the object to be cut (S) is moved back and forth, but the present invention is not limited to such a case. Secure the work (S) as shown and
It is also possible to adopt a method in which the entire upper side from 4) and (25) is moved back and forth along the base (38a), or the work (S) is moved back and forth and up and down. That is, in the present invention, relative two-dimensional movement may be applied between the diamond bead wire and the object to be cut, and the means therefor is not particularly limited.

When processing a curved surface or the like with the device of the present invention, after cutting movement for several tens of seconds (for example, a cutting movement amount of about 5 to 10 mm),
The cutting effect is enhanced when the operation is repeated by alternately repeating the operation of returning the trajectory up to that point for a few seconds or stopping the operation at that position to change the cutting resistance applied to the diamond bead wire.

That is, during the return stroke (and before the advance stroke again) or at the stop, the processing of the central portion of the diamond bead wire, which has been delayed in cutting, progresses, and at the same time, the diamond beads are provided with a dresser effect to prevent clogging. Therefore, it is possible to perform machining with an accurate trajectory, and the cutting efficiency is improved.

The tension force of the diamond bead wire (3) stretched between the drums (1) and (2) in the device of the present invention is a very important factor in regard to the processing accuracy of the curved surface.
For diamond bead wire (3) of the size shown in Fig.8, the processing accuracy is best when the driven drum is stretched by a force of about 200-350kg, especially about 300kg.
If the tension is less than 200kg, diamond bead wire
If there is a large delay in the central part of (3) and a so-called drum-shaped cut surface is obtained, and conversely if the tension force is stronger than 350 kg, excessive force is applied to the diamond bead wire (1) during cutting, Wire rope before the beads (16) themselves wear out
The phenomenon that (13) is disconnected occurs.

[Advantages of the Invention] First, by using the apparatus of the present invention, curved surface cutting, which requires much labor, cost, and time in the conventional apparatus, and curved surface processing requiring reproducibility, which has been impossible, are performed. Inclined cutting can be performed easily, in a short time and at low cost. Furthermore, since it is possible to cut in the horizontal direction, it becomes possible to cut in the longitudinal direction of a long product that could not be processed conventionally.

Also, in terms of accuracy, a smooth surface is obtained that cannot be imagined from conventional curved surface processing of hard and brittle materials. In addition, effective injection of cutting water has resulted in cutting costs that are about half those of conventional cutting water, and the experimental value up to now is 5000 yen / m ² .
In addition, the breakage of the diamond bead wire during cutting was also reduced, and the diamond beads were cut while rotating, resulting in uniform wear, no bending, and a considerable increase in cost. .

In order to carry out these effects more efficiently, as a cutting method, during cutting, its trajectory is returned for several seconds at intervals of several tens of seconds so that the load on the diamond beads constantly changes, thereby increasing the machinability. , Also improved in accuracy.

As described above, the effect of the present invention on the curved surface and the straight line cutting of the hard and brittle material is very large.

[Brief description of drawings]

1 and 2 are a front view and a side view, respectively, showing an embodiment of the apparatus of the present invention, and FIG. 2A is (II)-(I of FIG.
I) line sectional view, FIG. 2B is a perspective view of the apparatus shown in FIGS.
3 and 4 are a front view and a side view, respectively, showing an embodiment of a guide pulley according to the present invention, and FIG. 5 is a side view, FIG. 6 showing another embodiment of the guide pulley according to the present invention. Is an explanatory view showing the relationship between the turning angle of the guide pulley and the cutting locus shown in FIG. 5, and FIGS. 6A and 6B are perspective views showing examples of workpieces machined by the device of the present invention. FIG. 7 is a side view showing an embodiment of the diamond bead wire according to the present invention, and FIG. 8 is (VII) of FIG.
I)-(VIII) sectional view, FIG. 9 is a front view showing a guide mechanism of a diamond bead wire constituted by one guide pulley which cooperates with a drum, and FIG. 10 is another view of the device of the present invention. FIG. 11 is a front view showing an example, FIG. 11 is a front view showing an example of a conventional hard and brittle material cutting machine, and FIG. 12 is an explanatory view showing an example of a conventional curved surface processing method. (Main symbols in the drawing) (1), (2): Drum (3): Diamond bead wire (4), (5), (8), (9): Servo motor (6), (7): Guide guide (10): Vibration suppressor (11): Water injection pipe (13): Wire rope (14): Coating layer (15): Ring (16): Diamond beads

Claims (8)

[Claims] 1. A pair of drums whose axial centers are arranged parallel to each other so as to face each other, an endless diamond bead wire suspended between the pair of drums, and the drum which is driven. A rotation driving means, and between the diamond bead wire and the object to be cut, a vertical driving means and a longitudinal driving means for respectively providing relative vertical movement and longitudinal movement in a plane intersecting the diamond bead wire, A pair is arranged on each side of the object to be cut on the cutting side of the diamond bead wire, and has an outer peripheral groove along which the diamond bead wire engages,
A pair of guide pulleys arranged substantially in the same plane so as to sandwich the diamond bead wire between the outer peripheral grooves, and a swing drive means for swinging the pair of guide pulleys around the diamond bead wire. A cutting device for hard and brittle substances, which comprises a controller for controlling the vertical drive means and the front-back drive means in association with each other so that the diamond bead wire draws a predetermined two-dimensional trajectory with respect to the workpiece. . 2. The pair of guide pulleys are arranged so as to be capable of reciprocating along the direction in which the diamond bead wire is stretched according to the width of the object to be cut. The device according to the item. 3. The apparatus according to claim 1, further comprising a vibration preventing device provided on the return side of the diamond bead wire and comprising an elastic member for urging the diamond bead wire toward the pair of drums. 4. A plurality of water-injecting pipes for supplying cutting water from above a cutting groove formed in an object to be cut, wherein the water-injecting pipe has a plurality of intervals in which running directions of diamond bead wires face in order. The device according to claim 1, wherein the hole is formed. 5. The apparatus according to claim 1 or 4, wherein a water injection nozzle for supplying cutting water of a jet jet is installed in the running direction of the diamond bead wire. 6. The apparatus according to claim 1, wherein a coating layer made of synthetic resin is provided between the wire rope and the ring forming the diamond bead wire over the entire length of the wire rope. 7. The device according to claim 1, wherein a linear or spiral groove extending in the axial direction is formed on the surface of the diamond bead of the diamond bead wire. 8. The device according to claim 1, wherein the diamond bead wire is one in which both ends thereof are joined in an endless form after an appropriate twist is applied in the twisting direction of the wire rope.