SHEET TO BE USED IN CUTTING A COMPOSITE MATERIAL REINFORCED BY FIBERS AND / OR UMMETAL, CUTTING METH

专利摘要:
ENTRY SHEET TO CUT COMPOSITE MATERIAL REINFORCED BY FIBERS OR METAL, AND, CUTTING METHOD TO CUT MATERIAL REINFORCED BY FIBERS OR METAL. This entry sheet is characterized by being used when a fiber-reinforced composite material or metal is cut. This cutting method is characterized by cutting a composite material reinforced by fibers and / or metal using the input sheet.
公开号:BR112015021661B1
申请号:R112015021661-7
申请日:2014-03-27
公开日:2021-01-12
发明作者:Umehara Noritsugu；Tokoroyama Takayuki；Matsuyama Yousuke；Takuya Horie Shigeru Hasaki
申请人:Mitsubishi Gas Chemical Company, Inc.；
IPC主号:

专利说明:

TECHNICAL FIELD
[0001] The present invention relates to an entry sheet for cutting a fiber-reinforced composite material or a metal, and a cutting method for cutting a fiber-reinforced composite material or a metal. BACKGROUND ART
[0002] Fiber-reinforced composite materials represented by fiber-reinforced plastics (FRP), and, among others, carbon fiber-reinforced plastics (CFRP) have greater tensile strength and tensile strength and a lower density, in compared to glass fiber reinforced plastics (GFRP), aramid fiber reinforced plastics (AFRP), and stainless steel materials (SUS), and therefore there is a trend that these plastics have often been used for external boards or similar aircraft and vehicles in recent years. The CFRP here denotes plastics produced by laminating one or two or more prepregs, obtained by impregnating a carbon fiber matrix resin and then performing heat molding or heat and pressure molding. The members formed from CFRP are fixed to a structure using fastening elements, such as screws or rivets. Therefore, when CFRPs are attached to a structure such as an aircraft part, cuts and, among others, drilling are necessary to drill a plurality of holes in CFRP for the fasteners to pass.
[0003] Some technologies have already been proposed for obtaining high quality holes in CFRP drilling. Methods in which the shape of a tool, for example, or the curvature of a sloping surface or the angle of a drill bit, for example, is changed in stages have been given as examples (see, for example, Patent Document 1 and Patent Document 2). In addition, since CFRPs are difficult to cut materials, the drilling life is very short, in the case where CFRP drilling is done. Thus, methods for reducing the load on a drill to avoid shortening the drill's processing life by changing the drill shape or changing the processing conditions have been given as examples (see, for example, Patent 3 and Patent Document 4). In addition, when processing fiber-reinforced plastics other than perforation, cutting with a processing apparatus using high-power laser and ultra-short pulsed laser together, and other processing were given as examples (see, for example, Patent Document 5). In addition, in the field of printed circuit boards which is different from the field of CFRPs, a method for drilling in which a composite film made of a synthetic resin material and a composite material, such as carbon fiber, is arranged on the face drill bit and is used as a reinforcement plate has also been filed (see, for example, Patent Document 6). However, in the method described in Patent Document 6, CFRP is the reinforcement plate and is not the cutting object, and the technology based on a reinforcement plate to process CFRP does not exist. Furthermore, in the method described in Patent Document 6, it is insisted that the lack of registration of the drill is avoided and the positional accuracy of the holes forming is exceptionally improved when the reinforcement plate is made using carbon fiber, which is a material difficult to cut and with which the drill blade is susceptible to wear, however, this is not confirmed by examples.
[0004] In addition, the main constituent of materials for machine body structures (frame materials) for aircraft is a metal material, and aluminum alloys are responsible for most metallic materials. In addition, titanium alloys, stainless steel, and so on, which are heat resistant alloys, are used in portions whose temperature can easily become higher than the other portions in the machine body structure, for example, around exhaust portions of the jet, and an afterburner. In addition, when aircraft speeds up in the future, the strength of conventional aluminum alloys will be reduced due to aerodynamic heating. Therefore, from the present moment to the future, titanium or stainless steel alloys having a higher hardness are expected to be used as the main constituent of the machine body structures. It is necessary to drill with a drill for these materials that make up the body structure of the aircraft machine, in order to fasten, with screws, metal materials, or a metal material and other structure material of different material quality, as a CFRP (carbon fiber reinforced plastic).
[0005] In drilling metals, some technologies have already been proposed. For example, since titanium alloy materials are difficult to cut materials, the service life of drilling is very short. In the face of such a problem, a processing method by spraying a cutting oil and a method to reduce the load on a bit in order to avoid shortening the bit's processing life by changing the bit shape was given as examples (see , for example, Patent Document 7 and Patent Document 8).
[0006] Furthermore, with respect to the drilling relationship as CFRP as fiber-reinforced composite materials, a method in which a shape of a cutting tool, for example, the curvature of a sloping surface or tip angle of a drill is changed into stable has been presented as an example (see, for example, Patent Document 2).
[0007] On the other hand, with regard to the field of printed circuit boards that is different from the field of metal processing, a method for drilling using an input sheet has been proposed (see, for example, Patent Document 9). However, materials used for printed circuit boards are made of an organic compound, glass cloth, and a thin sheet of copper, so the load for the drill is small, and the processability is extremely easy when compared to the processability of metals. LIST OF PREVIOUS ART DOCUMENTS
[0008] Patent Documents Patent Document 1: Japanese Patent subject to public inspection No. 2012-210689 Patent Document 2: Japanese Patent subject to public inspection No. 2012-223882 Patent Document 3: Japanese Patent subject to public inspection No 2009-241239 Patent Document 4: Japanese Patent subject to public inspection No. 2009-39810 Patent Document 5: Japanese Patent subject to public inspection No. 2011-56583 Patent Document 6: Japanese Patent subject to public inspection No. 2000 -61896 Patent Document 7: Japanese Patent subject to public inspection No. 2006-150557 Patent Document 8: Japanese Patent subject to public inspection No. 2002-210608 Patent Document 9: Japanese Patent subject to public inspection No. 2003-175412 SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION
[0009] Drilling for the CFRP is usually performed using a drill. The drilling service life is extremely short when drilling the CFRP with a general drill. When the number of processed holes is increased, the drill blade wears out and the quality of the processed holes is reduced. Specifically, the inside diameter of the processed holes is liable to become small, carbon fiber fluff becomes liable to be produced in the outlet portion where the drill bit penetrates, and the interlayer detachment between laminated prepregs is also susceptible to to occur. In addition, the internal diameter of processed holes is not uniform due to wear, and interlayer detachment sometimes occurs from the irregularity as a starting point. Such phenomena are recognized as major defects. As described above, there is a high possibility that quality problems occur in processed holes attributable to the wear of the drill blade. In the face of such problems, particularly high quality drilling is required in particular in the production and the like of structures using CFRP for aeronautics, and it is extremely important to solve such problems as the formation of plumes and interlayer detachment.
[0010] Now, there is a wide variety of CFRP. CFRP products for general use seek a balance between costs and performance using prepregs, obtained by impregnating a carbon fiber matrix resin to thicken the thickness of the resin between the prepregs, thus reducing the amount of the fiber carbon used. In addition, a pre-impregnated (cloth material), obtained by impregnating a matrix resin in carbon fiber woven cloth, is used for the CFRP surface layer, however, there is a laminated configuration, on the inside , using a prepreg (UD material, unidirectional material), obtained by impregnating a carbon fiber matrix resin in which the fiber direction is arranged in a single direction. Needless to say, there is also a configuration in which all layers, including a surface layer, are laminated by the UD material. In addition, when UD material is used, there is also a configuration in which the prepregs are laminated in such a way that the direction of the fiber is rotated by 45o or 90o between the prepregs. Or, there is also a granule-shaped injection molding material, in which the short fibers obtained by cutting the carbon fiber are dispersed in a matrix resin to reinforce the matrix resin. Injection molding CFRP is a material applied to, for example, automotive use. On the other hand, high strength and high accuracy over several tens of years are required for CFRP products for use in aeronautics due to their applications. In addition, defects within the CFRPs cannot be detected in appearance. Therefore, through the use of prepregs in which the amount of matrix resin impregnated in the carbon fiber is strictly controlled in particular, and by adjusting the thickness of the resin layers between the prepregs to be thin to densely overlap the fiber carbon, the variation in resistance generated between the carbon fiber layers and the layers made of resin is only reduced in order to achieve high strength and high reliability. And the pre-impregnated for aeronautical use is not limited to cloth materials using carbon fiber woven cloth, UD materials in which the fiber direction of UD materials is appropriately rotated in order to ensure isotropy are also used. In addition, in matrix resins for aeronautical use, compositions are applied placing a particularly high priority on high toughness in addition to adhesion properties.
[0011] In CFRP drilling, the quality problem of the processed holes becomes likely to occur as tool wear progresses and the cutting resistance becomes greater. Particularly in high-strength CFRPs or the like, for aeronautical use, carbon fiber exists densely, and thus the frequency of rubbing the carbon fiber with a drill is increased and the drill wear progresses more quickly. As a preventive measure, the tool change time is advanced in order to maintain the orifice quality, and the current situation is that the ratio of tool costs to processing costs becomes high. In addition, in CFRP using a UD material, when the fiber direction of the carbon fiber and the direction of rotation of the drill blade relative to a direction that is parallel to the direction of the carbon fiber are noted, the drill blade rubs the bundle of carbon fibers in a direction parallel to the bundle of carbon fiber at an angle of 0o and 180o, the angle being parallel to the direction of the carbon fibers. At an angle of 90o and 270o, the drill blade is orthogonal to the bundle of carbon fibers and is capable of cutting the bundle of carbon fibers. At the 45o and 225o angle, the drill blade enters the CFRP at such an angle that the drill blade bites and digs into the carbon fiber bundle, and at an angle of 135o and 315o, the drill blade rubs the bundle of carbon fibers while marking the bundle of carbon fibers. Therefore, the following problem occurs: a portion of fiber deformation is likely to occur in the vicinity of an angle of 45O and 225O.
[0012] As described in Patent Documents 1 to 6, improvements in the processability of fiber-reinforced composite materials (for example, CFRPs) where drilling is difficult to apply have been studied from the point of view of tools, however, the effect was insufficient.
[0013] Thus, the first problem of the present invention aims to improve the processability with another approach than the tools in cutting of the fiber reinforced materials (for example, the CFRPs) and consists in providing an entrance sheet with which the wear of the drill bit is suppressed and with which high quality processed holes, whose internal diameter is uniform, can be obtained by reducing the load to the bit compared to, for example, conventional drilling of fiber reinforced composite materials (eg CFRP ).
[0014] In addition, drilling a metal is usually performed using a drill bit, however the drilling service life is short, even when a drill dedicated to cutting metals is used, and the drilling life time is extremely short in case a general drill is used. In addition, as the number of processed holes increases, wear occurs in the drill blade, and the quality of the processed holes is reduced. Specifically, the internal diameter of the processed holes is likely to become small, and burrs are also likely to be generated in the outlet portion where the drill bit penetrates. In addition, a gap is generated between the metal material and the structure material like CFRP having another material quality, which are fixed by screws, due to the wear of the drill, and it sometimes occurs that an elevation is generated between these materials of structure and shavings enter the generated gap. Such phenomena are recognized as major defects. As described above, there is a high possibility that quality problems occur in processed holes and are attributable to the wear of the drill blade. In such a situation, a particularly high quality drilling is required for the production and similar of the structures using aircraft titanium alloy materials, and it is extremely important to solve the problems described above, such as the drill's service life and the elevation generated between the metal material and the different type of structural material.
[0015] As described in Patent Documents 2, 7, and 8, improvements in the processability of metals where drilling is difficult to apply have been studied from the point of view of cutting tools and cutting methods, however, the effect it was insufficient. In addition, the present inventors also studied improvements in processability with an input sheet for printed circuit boards, however, the effect was insufficient.
[0016] Thus, the second problem of the present invention aims, in cutting metals, to improve the processability of metals with a different approach than cutting tools, and consists in providing an entry sheet with which the drill wear is suppressed and with which the prolongation of the drilling life can be achieved by reducing the load on the drill bit, compared to, for example, conventional drilling of metals.
[0017] In addition, in the case where drilling of a metal is carried out with a drill, frictional heat is generated between the rotary drill and the metal, and the temperature around the processed holes increases locally. Therefore, in the event that the number of orifices processed is high, heat is accumulated in the metal such as the drill and the workpiece. In the case of a metal having a low thermal conductivity, since the heat dissipation is insufficient, the temperature around the processed holes increases. When, at this moment, the temperature of the metal increases, the metal softens and thus burrs are generated in the outlet portion when the drill bit penetrates a processed orifice. In addition, metal chips are welded to the bit due to the heat of processing, an excessive load is applied to the bit, and it sometimes occurs that the processing device shuts down. As described above, there is a high possibility that quality problems occur in the processed holes attributable to heat build-up during drilling. In such a situation, a particularly high quality drilling is required in the production and the like of the structures using the aircraft titanium alloy materials, and it is extremely important to solve the above described problem with burrs.
[0018] Wet processing using a cutting oil or similar has been conventionally carried out with the purpose of avoiding such heat accumulation in the cutting portion and the drill, however, in the case of wet processing, a cleaning process makes if necessary at the end of the cut. In addition, in the event that the oil is left around or inside the processed holes, there is a possibility that deterioration of screws will occur as fixing tools in fixing through the through holes or loosening in the fixing portion, carrying a risk that these defects will lead to fatal accidents.
[0019] As described in Patent Documents 2, 7, and 8, improvements in the processability of metals where drilling is difficult to apply have been studied from the point of view of cutting tools and cutting methods, however, the effect it was insufficient.
[0020] Thus, the third problem of the present invention is to provide a cutting method by which the amount of burrs produced around processed orifices can be reduced compared to conventional cutting methods by suppressing the accumulation of heat around the orifices processed in cut (for example, drilling with a drill) of a composite material reinforced by fibers and / or a metal. In addition, the third problem of the present invention is to provide high quality through holes formed by the cutting method. MEANS TO SOLVE PROBLEMS
[0021] The present inventors carried out several studies with the purpose of solving the first problem to verify that: by placing an entry sheet (for example, a resin sheet having lubricity) on an entry face of the cutting tool (for example , a drill) in a fiber-reinforced composite material (for example, CFRP) when cutting (for example, drilling) a fiber-reinforced composite material (for example, CFRP), the shear stress, such as thrust or torque, is reduced when the cutting tool (for example, a drill) enters the fiber-reinforced composite material (for example, the CFRP), thereby reducing the load on the cutting tool (for example, a drill) from in order to suppress cutting tool wear (for example, a drill); thus, in the case of drilling, high quality processed orifices whose internal diameter is uniform are obtained, and have completed the present invention.
[0022] In addition, the present inventors carried out several studies in order to solve the second problem to verify that, in section (for example, drilling) of a metal, an entry sheet (for example, an entry sheet containing a resin sheet having lubricity) which is arranged on the entry face of the cutting tool (for example, a drill) on the metal reduces the cutting tension so that the thrust load or torque when the cutting tool (for example , a drill) enters the metal, thereby reducing the load on the cutting tool (for example, a drill) in order to suppress the wear of a cutting tool (for example, a drill). Finally, the present inventors have found that the input sheet (for example, an input sheet containing a resin sheet) prolongs the cutting life (for example, perforation) of the cutting tool (for example, a drill) , and completed the present invention.
[0023] In addition, the present inventors carried out several studies in order to solve the third problem to verify that, when making the cut while cooling the cutting portion and / or the cutting tool (for example, a drill) using a gas when cutting (for example, drilling) a fiber-reinforced composite material and / or a metal, the heat generated by the heat of friction between the fiber-reinforced composite material and / or the metal and special cutting tool (for example, a drill) can thus be suppressed in the case of drilling, making it possible to reduce the amount of burrs produced around the processed orifices and provide high quality processed orifices. In addition, the present inventors have found that, using an input sheet having a metal sheet and / or a resin sheet together with the cooling in the cut (for example, perforation), the lifetime of the cut (for example, drilling) is prolonged, and completed the present invention.
[0024] That is, say, the present invention is as follows.
[0025] (1) An entry sheet used in cutting a composite material reinforced by fibers and / or a metal.
[0026] (2) The entry sheet according to (1), comprises a resin sheet.
[0027] (3) The input sheet according to (2), wherein the resin sheet comprises a water-soluble resin.
[0028] (4) The input sheet according to (2) or (3), wherein the resin sheet comprises a water-insoluble resin.
[0029] (5) The input sheet according to any one of (2) to (4), wherein the resin sheet comprises a solid lubricant.
[0030] (6) The input sheet according to any one of (2) to (5), wherein the resin sheet comprises two or more layers of resin composition.
[0031] (7) The input sheet according to any one of (2) to (6), wherein the resin sheet has a thickness of 0.1 mm or more and 20 mm or less.
[0032] (8) The entry sheet according to any one of (2) to (7), wherein at least one face of the resin sheet comprises a metal sheet.
[0033] (9) The entry sheet according to (8), wherein an adhesive layer is formed between the metal sheet and the resin sheet.
[0034] (10) The entry sheet according to (9), wherein the adhesive layer is a resin coating.
[0035] (11) The entry sheet according to any one of (1) to (10), in which an adhesive layer is formed on a face that contacts the fiber-reinforced composite material and / or the metal.
[0036] (12) The entry sheet according to any one of (1) to (11), wherein the fiber reinforced composite material to be cut comprises a carbon fiber reinforced plastic.
[0037] (13) The entry sheet according to any one of (1) to (12), wherein the metal to be cut comprises a titanium alloy.
[0038] (14) The entry sheet according to any one of (1) to (13), wherein the metal to be cut comprises an aluminum alloy.
[0039] (15) The entry sheet according to any one of (1) to (14), in which an object to be cut is a material obtained by overlapping the metal and the fiber-reinforced composite material in order to contact each other.
[0040] (16) The entry sheet according to any one of (1) to (15), comprising a metal.
[0041] (17) The entry sheet according to any one of (1) to (16) used in cutting a fiber-reinforced composite material and / or a metal while cooling a cutting portion and / or a cutting tool cut using a gas.
[0042] (18) A cutting method for cutting a fiber-reinforced composite material and / or a metal using the input sheet according to any one of (1) to (17).
[0043] (19) The cutting method according to (18), in which cutting is carried out by arranging the entry sheet on an entry face of the cutting tool in the fiber-reinforced composite material and / or in the metal to be cut .
[0044] (20) The cutting method according to (18) or (19), in which the cut is by drilling.
[0045] (21) The cutting method according to any one of (18) to (20), wherein the input sheet comprises an aluminum sheet.
[0046] (22) The cutting method according to any one of (18) to (21), in which the cutting is carried out while cooling a cutting portion and / or a cutting tool using a gas having a temperature of 30 ° C or lower.
[0047] (23) The cutting method according to any one of (18) to (22), in which the cutting tool used to cut is a drill made of cemented carbide.
[0048] (24) The cutting method for cutting a metal according to any one of (18) to (23), in which the cut is processed to form a through hole in a fiber-reinforced composite material and / or a metal.
[0049] (25) The cutting method according to any one of (18) to (24), in which the cutting is performed while cooling a cutting portion and / or a cutting tool using a gas, an amount of gas supplied to the cutting portion and / or the cutting tool is 5 to 300 L / min, an outlet from the gas area on a gas supply apparatus is 7 mm2 to 2000 mm2, and a distance between a gas outlet of the apparatus for supplying the gas and the cutting portion and / or the cutting tool is 100 mm to 500 mm.
[0050] (26) The cutting method according to any one of (18) to (25), in which the cutting is carried out while cooling a cutting portion and / or a cutting tool using a gas, and a content of moisture contained in the gas supplied to the cutting portion and / or the cutting tool is 20 g / m3 or less.
[0051] (27) The cutting method according to any one of (18) to (26), in which the cutting is carried out while cooling a cutting portion and / or a cutting tool using a gas, and a content of oil contained in the gas supplied to the cutting portion and / or the cutting tool is 10 mg / m3 or less.
[0052] (28) The cutting method according to any one of (18) to (27), wherein the metal to be cut comprises a titanium alloy.
[0053] (29) The cutting method according to any one of (18) to (28), wherein the metal to be cut comprises an aluminum alloy.
[0054] (30) The cutting method according to any one of (18) to (29), in which an object to be cut is a material obtained by superimposing a metal and a fiber-reinforced composite material in order to contacting one another, and cutting is carried out by arranging the fiber-reinforced composite material so that it is on a side closer to an entry side of the cutting tool than the metal.
[0055] (31) A through hole formed by the cutting method according to any one of (18) to (30).
[0056] (32) Method for producing a fiber reinforced composite material, comprising a step of cutting a fiber reinforced composite material by the cutting method according to any one of (18) to (30).
[0057] (33) A method for producing a metal, comprising a step of cutting a metal by the method of cutting according to any one of (18) to (30). ADVANTAGES OF THE INVENTION
[0058] When cutting a fiber-reinforced composite material (for example, CFRP), the load for a cutting tool (for example, a drill) can be reduced to suppress wear on a cutting tool (for example, a drill) and, in the case of drilling, to obtain high quality processed orifices having a uniform internal diameter of the orifices processed using an input sheet of the present invention. As a result of this, a cut (for example, perforation) that is high quality and excellent in productivity becomes possible.
[0059] In addition, when cutting a metal, using the input sheet of the present invention, the load on the cutting tool (for example, a drill) can be reduced to suppress the wear of a cutting tool (for example , a drill) and to make the cutting life (for example, drilling) long. As a result of this, it is possible to cut (for example, perforation) that is more excellent in productivity than conventional technologies.
[0060] Furthermore, when cutting a composite material reinforced by fibers and / or a metal, heat build-up around a cutting portion generated during cutting can be effectively reduced according to the cutting method for cutting a metal from the present invention and thus high quality processing can be carried out in which the amount of burrs produced around a cutting portion is extremely less as compared to conventional processing. Drilling that is more excellent in productivity and product quality than conventional technologies is made possible particularly in drilling. BRIEF DESCRIPTION OF THE DRAWINGS
[0061] [Figure 1-1] Figure 1-1 shows comparison of change in orifice diameter in Example 1-1 and Comparative Example 1-1.
[0062] [Figure 1-2] Figure 1-2 shows results of buoyancy measurement in Example 1-1 and Comparative Example 1-1.
[0063] [Figure 1-3] Figure 1-3 shows cutting torque measurement results in Example 1-1 and Comparative Example 1-1.
[0064] [Figure 1-4] Figure 1-4 shows comparison of thrust force, cutting torque, and loss due to drill wear in Example 1-1 and Comparative Example 1-1.
[0065] [Figure 1-5] Figure 1-5 shows comparison of internal wall roughness (Ra: arithmetic mean roughness) of holes in Examples 1-2 to 1-9 and Comparative Examples 1-2 to 1-6.
[0066] [Figure 1-6] Figure 1-6 shows comparison of internal wall roughness (Rz: roughness obtained by averaging ten points) of holes in Examples 1-2 through 1-9 and Comparative Examples 1-2 to 1-6.
[0067] [Figure 1-7] Figure 1-7 shows comparison of drill wear loss in Examples 1-2 to 1-9 and Comparative Examples 1-2 to 1-6.
[0068] [Figure 2-1] Figure 2-1 shows photographs of a new drill tip used in Examples 2-1 to 2-9 and Comparative Examples 2-1 to 2-3.
[0069] [Figure 2-2] Figure 2-2 shows photographs of a drill bit after processing in Examples 2-1 to 2-9.
[0070] [Figure 2-3] Figure 2-3 shows photographs of a drill bit after processing in Comparative Examples 2-1 to 2-3.
[0071] [Figure 2-4] Figure 2-4 shows the residual amount of cutting wire after processing with respect to new drills in Examples 2-1 to 2-9 and Comparative Examples 2-1 to 2-3.
[0072] [Figure 3-1] Figure 3-1 shows photographs of a hole processed on a drill outlet side of titanium alloy plates in Examples 3-1 to 3-4 and Comparative Examples 3-1 to 3- two.
[0073] [Figure 3-2] Figure 3-2 shows burr heights on a drill outlet side of titanium alloy plates in Examples 3-1 to 3-4 and Comparative Examples 3-1 to 3-2.
[0074] [Figure 3-3] Figure 3-3 shows photographs of a new drill used in Examples 3-1 to 3-4 and Comparative Examples 3-1 to 3-2 and a drill bit after processing in Examples 3- 2 and Comparative Examples 3-1 to 3-2. MODE FOR CARRYING OUT THE INVENTION
[0075] In the following, the embodiments of the present invention (hereinafter also referred to as "the present embodiments") will be explained. In addition, the following embodiments are an example to explain the present invention, and the present invention is not limited to the embodiments only.
[0076] Entrance sheets of the present embodiments are used in cutting a composite material reinforced by fibers and / or a metal.
[0077] The present first embodiment is an entry sheet used for cutting fiber-reinforced composite material (for example, carbon fiber-reinforced plastic).
[0078] In the present first embodiment, the fiber-reinforced composite material, which is the material on which the cut is made, is a material whose properties are enhanced by fully combining two different raw materials, and is not particularly limited as long as it is a material having the constitution in which a matrix resin and fiber reinforcement are combined.
[0079] The type and shape of the reinforcement fiber used for the fiber reinforced composite material are not particularly limited. For example, fiberglass, carbon fiber, aramid fiber and others are preferable as the type of the reinforcement fiber. Among these, carbon fiber reinforced plastic in which carbon fiber is used as a reinforcement fiber is particularly preferable. The shape of the reinforcing fiber is not particularly limited, however examples of it include a filament, a tow, a cloth, a blade, a cut piece, crushed fiber, a felt mat, paper, a prepreg and others.
[0080] As the matrix resin used for fiber reinforced composite material, a resin component is not particularly limited. Specifically, thermosetting resins such as epoxy resins, phenol resins, cyanate resins, vinyl ester resins, and unsaturated polyester resins and thermoplastic resins such as ABS (acrylonitrile-butadiene-styrene) resins, PA resins (polyamide ), PP (polypropylene) resins, PC (polycarbonate) resins, methyl methacrylate resins, and polyethylene, acrylic and polyester resins are preferable. In addition, an inorganic filler, an organic filler, or the like can be suitably mixed into the matrix resin of the fiber-reinforced composite material. In addition, the composite material in which the thermoplastic resin is used as the matrix resin and the carbon fiber is used as a reinforcing fiber in the fiber reinforced composite material is sometimes referred to as a carbon fiber reinforced thermoplastic (CFRTP, carbon fiber reinforced thermoplastic) in order to distinguish it from the composite material in which resin other than thermoplastic resin is used, but is included in carbon fiber reinforced plastics (CFRP) in the present embodiments.
[0081] It is preferable that the entry sheet of the present first embodiment contains a sheet of resin.
[0082] In the entry sheet of the present first embodiment, the component that forms the resin sheet can be a water-soluble resin or a water-insoluble resin, and is not particularly limited.
[0083] In the case where water-soluble resin is used as the component that forms the resin sheet, water-soluble resin is not particularly limited as long as it is a polymer compound that dissolves 1 g or more with respect to 100 g of water at 25 ° C and 1 atm. In the case where the water-soluble resin is used as the component that forms the resin sheet, the discharge performance of the cuttings during cutting is improved due to the lubricity of the water-soluble resin, in addition to which an effect of reduce the load to the cutting tool because the surface hardness of the resin sheet becomes moderately smooth, and even more it is possible to easily remove a resin component adhered to the processed holes after cutting. Specific examples of the water-soluble resin include, but are not particularly limited to, for example, polyethylene oxides, polyethylene glycols, polypropylene oxides, water-soluble urethanes, water-soluble polyether resins, water-soluble polyesters, polyacrylates sodium, polyacrylamides, polyvinylpyrrolidones, polyvinyl alcohols, polyalkylene glycols esters, polyalkylene glycols ethers, polyglycerin monostearates, polyoxyethylene / propylene copolymers, and derivatives thereof, and at least one of them can be selected. Among them, water-soluble resins are more preferably polyethylene oxides, polyethylene glycols, and polyether-based water-soluble resins.
[0084] In the case where the water-insoluble resin is used as the component that forms the resin sheet, the type of the water-insoluble resin is not particularly limited. In the case where the water-insoluble resin is used as the component that forms the resin sheet, the surface hardness of the resin sheet is greater than in the case where the water-soluble resin is used, and so, for example , the bit's bite property during drilling is improved, making it possible to drill a hole in a position as designed, and furthermore the rigidity of the resin sheet is improved and the handling property is improved. Examples of the component forming the resin sheet include, but are not particularly limited to, urethane based polymers, acrylic based polymers, vinyl acetate based polymers, vinyl chloride based polymers, polyester based polymers, copolymers thereof, epoxy resins, phenol resins, cyanate resins, melamine resins, urea resins, thermosetting polyimides and others.
[0085] On the other hand, examples of the lubricity-improving component among the components that form the resin sheet include, but are not particularly limited to, amide-based compounds such as modified polyamides, ethylene bis-stearamide, acid amide oleic, stearic acid amide, and methylene bis-stearamide; fatty acid-based compounds such as lauric acid, stearic acid, palmitic acid and oleic acid; compounds based on fatty acid ester such as butyl stearate, butyl oleate and glycol laurate; aliphatic hydrocarbon-based compounds such as liquid paraffin and polyethylene wax; higher aliphatic alcohols such as oleyl alcohol; and polystyrene-based resins such as styrene homopolymers (GPPS), styrene-butadiene copolymers (HIPS), and (meth) acrylic styrene-acid copolymers (for example, MS resins), and at least one of them can be selected.
[0086] With respect to the component that forms the resin sheet, cellulose derivatives can be used as the water-soluble resin. Examples of the cellulose derivative include, but are not particularly limited to, hydroxyethyl cellulose and carboxymethyl cellulose. Hydroxyethyl cellulose is a compound in which at least part of the hydrogen atoms in hydroxy groups contained in cellulose {H- (C6H10O5) n-OH} is replaced by [- (CH2-CH2-O) mH], and has a solubility for water of at least 0.05 g / L at 25 ° C and 1 atm (where neither is an integer of 1 or more). The cellulose derivative can be obtained by, for example, adding an ethylene oxide to cellulose.
[0087] On the other hand, carboxymethyl cellulose is a compound in which at least part of hydrogen atoms in hydroxy groups contained in cellulose {H- (C6H10O5) n-OH} is replaced by a carboxymethyl group [-CH2-COOH], and has a water solubility of at least 0.05 g / L at 25 ° C and 1 atm (where n is an integer of 1 or more). In addition, part of the carboxy groups in the carboxymethyl group may be a sodium salt. The cellulose derivative can be obtained by, for example, adding chloroacetic acid to cellulose. In addition, "cellulose" in the present embodiment means a polymer compound in which a large number of β-glucoses are linked via a glycosidic bond and in which hydroxy groups attached to the carbon atom in position 2, position 3, and position 6 on the cellulose glucose ring are unsubstituted. In addition, "hydroxy groups contained in cellulose" denote hydroxy groups that are attached to a carbon atom of position 2, position 3, and position 6.
[0088] An additive can be mixed as needed in the resin sheet used in the present first embodiment. Examples of the type of additive include, but are not particularly limited to, a surface adjusting agent, a leveling agent, an antistatic agent, an emulsifying agent, an antifoaming agent, a wax additive, a copulating agent, a control agent rheology, an antiseptic agent, an antifungal agent, an antioxidant, a light stabilizer, a nucleating agent, an organic filler, an inorganic filler, a solid lubricant, a plasticizer, a softening agent, a thermal stabilizer, a coloring agent and others.
[0089] In the present first embodiment, examples of the method for forming the resin sheet include, but are not particularly limited to, a production method in which the above-mentioned components that form the resin sheet are suitably melted, applied over a support, cooled and solidified, or applied to a support in liquid form, obtained by dissolving or dispersing the components in a solvent, dried, cooled, and solidified to form a resin sheet, and then the support is removed or released to produce the resin sheet.
[0090] The method for applying the components forming the resin sheet in liquid form on a support is not particularly limited as long as it is a method known to the public and used in industry. Specific examples include a method in which the components forming the resin sheets are appropriately heated and melted to be mixed using a roller, kneader, or other kneading method, and then a resin sheet is formed on a release film by a method using roller, a curtain coating method, or the like and a method in which a resin sheet having a desired thickness is formed in advance from the components forming the resin sheet using a T matrix extruder or roller, or the like .
[0091] In the present first embodiment, it is preferable that the resin sheet has a plurality of layers containing two or more layers of resin composition. Specifically, the object of the present invention can be achieved more effectively and safely by appropriately combining each of the plurality of layers such as a layer made of a resin composition that exhibits a high lubricating effect, a layer made of a composition of resin that improves positional accuracy, and a layer having a high stiffness is made of the resin composition containing a water-insoluble resin, or the like, and thus such a combination is more preferable. In addition, it is more preferable that the handling property of the input sheet of the present first embodiment is improved by providing a layer having a high stiffness and made of the resin composition containing a water-insoluble resin or the like.
[0092] Examples of the method for forming the resin sheet so as to have a plurality of layers in the present first embodiment include, but are not particularly limited to, a method in which, on at least one face of a layer previously prepared, the other layer is directly formed, a method in which a previously prepared layer and the other layer are bonded together with an adhesive resin or by a heat laminating method or the like, and other methods.
[0093] It is preferable that the entrance sheet of the present first embodiment contains a metal, being more preferable that the metal is a metal sheet.
[0094] In the case where the entry sheet of the present first embodiment contains a resin sheet and a metal sheet, it is preferable that the input sheet has a metal sheet on at least one face of the sheet resin.
[0095] In the event that the entry sheet of the present first embodiment contains a plurality of layers each having a metal sheet on at least one face of the resin sheet as described above, the stiffness is improved and the property handling is improved. Also, in the case where drilling is performed, for example, the straight feed property of a drill bit is maintained by the metal sheet to improve the drill's centipede property, thus making it possible to drill a hole in a position as designed. In addition, the metal sheet exists between the workpiece and the resin sheet, thus playing a role in preventing the components forming the resin sheet, which are thermally melted, from attaching to the upper portion and within the processed holes.
[0096] The thickness of the metal sheet used in the present first embodiment is preferably 0.05 to 0.5 mm, more preferably 0.05 to 0.3 mm. When the thickness of the metal sheet is 0.05 mm or more, the handling property during production or drilling tends to be improved. On the other hand, when the thickness of the metal sheet is 0.5 mm or less, it becomes easy to unload the cuttings generated during cutting.
[0097] In addition, aluminum is preferable as the metal type of the metal sheet, and aluminum having a purity of 95% or more is preferable due to the material quality of the aluminum sheet. Specific examples of material quality include, but are not particularly limited to, 5052, 3004, 3003, 1N30, 1N99, 1050, 1070, 1085, 1100, 8021, and others, as specified in JIS-H4160. In the case where drilling is performed, for example, the breakage or local wear of the drill caused by impurities contained in the aluminum foil can be reduced by using high-purity aluminum foil as the metal foil, thus making it possible to reduce the load of cut for the drill.
[0098] In the case where the entry sheet of the present first embodiment contains a resin sheet and a metal sheet, it is preferable that an adhesive layer is formed between the metal sheet and the resin sheet. It is more preferable that the adhesive layer is a resin coating.
[0099] In the present first embodiment, examples of the method for forming a plurality of layers containing a resin sheet and a metal sheet include, but are not particularly limited to, a method in which a resin sheet is directly formed on at least one face of a metal sheet, a method in which a prepared resin sheet and a prepared metal sheet are each first glued together by a lamination method or the like, and other methods. Examples of the method also include a method in which, in forming the plurality of layers, the resin sheet and the metal sheet are laminated and integrated using, as a support, the metal sheet on which an adhesive layer is previously formed.
[00100] With respect to a metal sheet in which an adhesive layer is formed in advance for the purpose of laminating and integrating the resin sheet and the metal sheet, it is preferable to use a metal sheet in which a resin coating having a thickness from 0.001 to 0.5 mm is formed from the point of view of improving the adhesiveness between the metal sheet and the resin sheet. The resin used for the resin coating is not particularly limited and can be any of the thermoplastic resins and thermosetting resins, and the thermoplastic resin and the thermosetting resin can be used together. Examples of a thermoplastic resin include, but are not particularly limited to, urethane-based polymers, acrylic-based polymers, vinyl acetate-based polymers, vinyl chloride-based polymers, polyester-based polymers, and copolymers of the same. Examples of the thermosetting resin include, but are not particularly limited to, resins such as phenol resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, thermosetting polyimides, and cyanate. Suitable resins include epoxy resins and polyester based resins. In addition, the metal sheet obtained by coating a commercially available metal sheet in advance with a resin coating by a method known to the public can be used as the metal sheet used in the present first embodiment.
[00101] In the entry sheet of the present first embodiment, it is preferable to form a layer (sticky layer) having stickiness on the surface of the resin sheet or metal sheet that contacts the workpiece (for example, CFRP) with purpose of letting the entry sheet of the present first embodiment and the workpiece (for example, CFRP) come into contact with each other. The adhesive layer component is not particularly limited and can be any of the thermoplastic resins and thermosetting resins, and the thermoplastic resin and the thermosetting resin can be used together. Examples of thermoplastic resin include, but are not particularly limited to, urethane-based polymers, acrylic-based polymers, vinyl acetate-based polymers, vinyl chloride-based polymers, polyester-based polymers, and copolymers thereof. . Examples of the thermosetting resin include, but are not particularly limited to, resins such as phenol resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, thermosetting polyimides, and cyanate resins . Among these, acrylic-based adhesives are more preferable because the property by which tackiness is easily possible at normal temperature without glue residue on the workpiece (for example, CFRP) is required. In addition, among acrylic-based sizing agents, solvent-based acrylic sizing agents and emulsion (water-based) acrylic sizing agents are used appropriately. The acrylic based tacky agent is a composition containing a poly (meth) acrylic acid ester and a tackiness enhancer as the main components. In addition, an agent to prevent degradation, such as antioxidant, and an inorganic filler such as calcium carbonate, talc and silica, can be added as necessary to the component of the adhesive layer.
[00102] The method for forming the sticky layer on the surface of the input sheet is not particularly limited as long as it is a method known to the public and used in industry. Specific examples thereof include a method in which an adhesive layer is formed by a roll method, a curtain coating method, a spray jet method, or the like, a method in which an adhesive layer having a desired thickness is formed in advance using a T die extruder or roller, or similar, and other methods. The thickness of the adhesive layer is not particularly limited, and the optimum thickness can be appropriately selected considering the curvature of the workpiece (for example, CFRP) and the constitution of the resin sheet and the entry sheet.
[00103] When the input sheet of the present first embodiment is used, it is not always the case that the workpiece (for example, CFRP) is flat, and it sometimes occurs that the workpiece has a curved surface. Thus, the conformability of the curved surface is sometimes required for the entry sheet of the present first embodiment. In the entry sheet of the present first embodiment, it is preferable, for example, to mix a plasticizer or the softening agent in the resin composition that forms a resin sheet for the purpose of imparting conformability of the curved surface. As specific examples of the plasticizer and the softening agent, phthalic acid esters, adipic acid esters, trimellitic acid esters, polyesters, phosphoric acid esters, citric acid esters, epoxidized vegetable oils, sebacic acid esters and others are preferable . When the input sheet is laid out on the curved surface of the workpiece (eg CFRP), for example, the stress or strain on the resin sheet is reduced by mixing the plasticizer or softening agent, thus making it possible to suppress cracks on the resin sheet.
[00104] The entry sheet of the present first embodiment is used, for example, in cutting such as drilling, machining, and cutting by cutting CFRPs, and the tool and method for cutting are not particularly limited. Specific examples include drilling where through holes or non-through holes are formed with a drill, cutting router, milling machine, end mill, side cutter, or the like and cutting by separating the CFRP with a cutting router, a pipe cutter, end mill, metal saw, or the like. Furthermore, there is no problem when a coating film such as titanium, a diamond, or diamond-like carbon coating film is formed on a cutting edge of a cutting tool in order to improve hardness to suppress wear.
[00105] In the present first embodiment, the fiber-reinforced composite material (for example, the CFRP) is intended to be the cutting object, however the cutting object is not limited to the fiber-reinforced composite material (for example , the CFRP). In the present first embodiment, the entry sheet is also applicable to cutting a difficult to cut metal such as a titanium alloy. Furthermore, it is preferable that the object to be cut is a material in which the metal and the fiber-reinforced composite material are superimposed in order to contact each other. In the present first embodiment, no problem occurs, for example, when the CFRP and the titanium alloy are drilled together in a material in which the CFRP and the titanium alloy are superimposed for the following reason. The optimal drilling conditions in the CFRP and the titanium alloy are very different. High speed rotation and low speed feed rates are appropriate for drilling the CFRP. On the other hand, with respect to the titanium alloy, in the case where drilling is carried out, for example, rotation rates at low speed and high speed feed are appropriate because the rise in the drill temperature is suppressed and the wear of the blade of the drill is suppressed. Such a drilling condition is particularly necessary in a diamond-coated drill bit that is weak to heat. When facing contrary drilling conditions, drilling is carried out at an actual processing site in such a way that the drilling condition is changed at the edge of the CFRP and titanium alloy or the drilling is carried out using the average condition and maintaining the same condition as used throughout the drilling. Or, in the case where drilling is carried out, for example, an effort to collect dust by a dust collection device while blowing cold wind during drilling of the titanium alloy for aeronautical use was made in order to avoid this increase in the temperature of the drill. However, using the inlet sheet of the present first embodiment, a side effect of largely relieving the drilling conditions restrictions of the titanium alloy that easily generates heat due to frictional heat occurs. Also, CFRP and an aluminum alloy, limited to a titanium alloy, can be drilled together in a material obtained by overlapping the CFRP and the aluminum alloy. In addition, the entry sheet of the present first embodiment can be used for cutting such as drilling, machining, and cutting by cutting the titanium alloy or aluminum alloy alone.
[00106] The present inventors consider that, when using the entry sheet containing a resin sheet in cut of the fiber-reinforced composite material and / or metal, when drilling is performed for example, the lubricity between the drill surface including a the groove surface of the drill and the inside of the processed hole is improved, the discharge of carbon fiber or hard-to-cut particles into a hard-to-cut metal to be cut by the drill blade is made easy, and the frequency and degree of rubbing with the drill blade are reduced and thus the wear of the drill blade is reduced. In the case where drilling is carried out, for example, abrasive wear occurs when hard-to-cut particles and the drill blade are rubbed and, thus, the reduction of abrasive wear leads to reduction in the wear of the drill blade. In addition, this action principle is applicable to cutting tools in general. Thus, the entry sheet of the present first embodiment exhibits a notable effect particularly in cutting the high strength CFRP for aeronautical or similar use. The reason is because the carbon fiber in the CFRP exists densely, for example, in the drilling of the CFRP for aeronautical or similar use, as previously described to greatly increase the amount of the cut carbon fiber and thus the drill blade is subject to be worn out. Consequently, the entry sheet of the present first embodiment that contributes to reducing the wear of the drill blade becomes an effective solution that has never been achieved before in drilling the CFRP for aeronautical or similar use. In addition, in the case of drilling a UD material, the drill blade enters the bundle of carbon fibers at both angles of 45 ° and 225 ° in such a way that the drill blade bites in and removes the bundle of fibers from carbon and thus a portion of fiber bundle is possible to occur in the inner wall of a hole around 45 ° and 225 °. In the event that the inlet sheet of the present first embodiment contains a lubricity-enhancing agent, the inlet sheet is excellent in lubricity to suppress the formation of fiber bundles and further suppress the high temperature due to frictional heat and thus it becomes difficult for the matrix resin to reach the glass transition point (temperature) or the softening point and the state in which the carbon fiber is firmly formed into bundles can be maintained, thus suppressing the bundles of fibers . Thus, the entry sheet of the present first embodiment exhibits a marked effect also in the case of cutting the UD material.
[00107] In the case where the resin sheet is contained in an entry sheet of the present first embodiment, the thickness of the resin sheet is appropriately selected considering, for example, the separation by cutting and cutting method, area, and cut-off volume of the CFRP, a drill diameter used in drilling, the constitution and thickness of the CFRP, and others. It is preferred that the thickness of the resin sheet is in a range of 0.1 to 20 mm, more preferably in a range of 0.2 to 10 mm, still preferably in a range of 0.5 to 5 mm. When the thickness of the resin sheet is 0.1 mm or more, a sufficient reduction in shear stress is obtained, and in the case where drilling is performed for example, the load on the drill becomes small, making it possible to suppress the break of the drill. On the other hand, when the thickness of the resin sheet becomes 20 mm or less, winding of the resin sheet over the bit is reduced in the case where drilling is performed, for example, making it possible to suppress the occurrence of cracks in the resin sheet. Particularly in the case where the amount of resin is appropriate, it can be suppressed for the resin to become a binder for the cut powder and it can also be suppressed for the cut powder to remain in the processed orifice and thus this can be suppressed for the irregularity inside the hole expands. That is, say, lubricity can be improved by appropriately adjusting the composition and thickness of the resin sheet, and in the case where drilling is carried out for example, the discharge of the cut powder through the groove can be optimized. In addition, it is preferable to properly control the total thickness of the resin sheet in order to further achieve the effect of the present invention, and it is also possible to use thin resin sheets in such a way that a plurality of thin resin sheets are superimposed.
[00108] The thickness of each layer such as the resin sheet layer, the metal sheet, the adhesive layer, or the adhesive layer that constitutes the entry sheet of the present first embodiment is measured as follows. First, the entry sheet is sectioned in a direction perpendicular to the entry sheet using cross section polisher (CROSS-SECTION POLISHER SM-09010 manufactured by JEOL Ltd. DATUM) or an ultramicrotome (EM UC7 manufactured by Leica Microsystems Co., Ltd.). Next, the cut section is viewed from a direction perpendicular to the cut section using a SEM (scanning electron microscope, VE-7800 manufactured by KEYENCE CORPORATION) to measure the thickness of each layer that makes up the entry sheet. When measuring thickness, the thickness at 5 points per 1 visual field is measured, and the average value is defined as the thickness of each layer.
[00109] With respect to perforation using the entry sheet of the present first embodiment, it is preferable to perform the drilling of the CFRP from the face of the resin sheet on the entrance sheet by arranging the resin sheet on the entrance sheet on the face the uppermost of the CFRP in which the drilling must be carried out so that the resin sheet becomes an entrance face of the drill.
[00110] The present second embodiment is an entry sheet used in cutting a metal. It is preferable that the entry sheet of the present second embodiment contains a resin sheet.
[00111] Metal as the cutting object for which the entry sheet of the present second embodiment can be used is not particularly limited as long as it is a metal that is generally used with a structural material, however, examples of such metals include, but are not particularly limited to, metallic materials used as a material for the aircraft machine frame structure. Among these, high-strength metals such as aluminum alloys, magnesium alloys, titanium alloys, low-alloy steel, stainless steel, and heat-resistant alloys are preferable as the metal that is the object of cutting using the entry sheet of the present second embodiment. The reason is because the effect of extending the life of cutting tools becomes more noticeable when the metal has a greater resistance. The metal as the cutting object can be used alone or in combination of two or more. In addition, among the metals described above, the titanium alloy is particularly preferable as the metal that is the cutting object. The reason is because although the titanium alloy has a tensile strength twice as strong as that of the aluminum alloy and is an excellent material in corrosion resistance and heat resistance, the titanium alloy is a difficult material to cut with a high hardness and, therefore, it is necessary to make the cutting conditions or the shapes of the cutting tools special in conventional technologies, however, when the entry sheet of the present second embodiment is used, it becomes unnecessary to make the cutting conditions special. cutting or the shapes of the cutting tools and the service life of cutting tools can be made long. In addition, the metal as the cutting object may contain a different type of construction material, such as a fiber-reinforced composite material in the present embodiment.
[00112] Examples of the cutting method in which the entry sheet of the present second embodiment can be used include, but are not particularly limited to, drilling to form a through or non-through hole, machining, cut separation and similar. In addition, examples of the type of cutting tools that can be used in cutting include, but are not particularly limited to, a drill, cutting router, milling machine, end mill, side cutter and others. In addition, these cutting tools can be a cutting tool having a general material quality, or a special cutting tool in which a coating film, such as a titanium, diamond, or diamond-like carbon coating film, is formed on the cutting edge of the cutting tool to improve hardness and suppress wear. The reason is because, in any processing using a cutting tool having a general material quality and processing using a special cutting tool, in which a coating film, such as a titanium coating film, diamond-like carbon is formed on the edge of the blade of a cutting tool, the input sheet of the present embodiment can extend the service life of the processing of a cutting tool. Particularly in processing using a special cutting tool, in which a coating film such as a coating film of titanium, diamond, or diamond-like carbon is formed on the edge of the blade of a cutting tool, the effect of prolonging the processing lifetime is remarkable and it is therefore appropriate to use the input sheet of the present embodiment for processing using such a tool.
[00113] The drill used for drilling in which the entry sheet of the present second embodiment can be used is not particularly limited with respect to the diameter, quality of the material, and shape of the drill and whether the surface coating exists or not, provided that is a drill bit that is generally used. For example, it is preferable that a drill diameter is 1 mmΦ or more and 10 mmΦ or less. The diameter of 2 mmΦ or more and 7 mmΦ or less, which is often used when drilling base materials for aeronautical use, is more preferable. Furthermore, it is preferable that the quality of the drill material is that of the cemented carbide produced by sintering a hard metal carbide powder. Examples of such a cemented carbide include, but are not particularly limited to, a metal obtained by mixing and sintering tungsten and cobalt carbide as a binder. Titanium carbide, tantalum carbide, or the like are sometimes added to such a cemented carbide in order to further improve the properties of the material according to the intended use. On the other hand, the drill shape can be appropriately selected considering the drilling conditions, the type and shape of the workpiece and others. The shape of the drill is not particularly limited, and factors for determining the shape of the drill include the angle of the drill tip, the angle of twist of the groove, the number of cutting wires and others. The surface coating of the drill bit can be appropriately selected considering the drilling conditions, the type and shape of the workpiece and others. Preferred types of surface coating include diamond coating, diamond coating, ceramic coating and others.
[00114] Next, the entry sheet for the present second embodiment will be explained in detail. Examples of the method for producing the input sheet of the present second embodiment include, but are not particularly limited to, a method for producing an input sheet containing a resin sheet in which the resin composition is suitably melted to change to a liquid form, then the resin composition is applied on a support, cooled, and solidified to form the resin composition layer (resin sheet), and then the support is removed or released. In addition, the examples also include a method for producing an input sheet containing a resin sheet in which the resin composition is dissolved or dispersed in a solvent to change to a liquid form, then the resin composition is applied to a support , dried, cooled, and solidified to form the resin composition layer, and then the support is removed or released. In the production of the input sheet, the support is not particularly limited, and, for example, a metal sheet or film, a metal roll and the like can be used appropriately. The method for forming the resin composition layer in a liquid form on a support is not particularly limited as long as it is a method known to the public and used in the industry. Examples of the same include a method in which the resin composition is appropriately heated and melted to be mixed using a roller, kneader, or other kneading method, and then the resin composition layer (resin sheet) is formed on a support by a roller method, a curtain coating method, or the like. In addition, the examples also include a method in which the resin composition layer (resin sheet) is formed on a support by a coating method or the like by applying the resin composition dissolved or dispersed in a solvent using a bar coater , an engraving roll, a matrix, or the like. On the other hand, unlike the methods described above for forming the resin composition layer (resin sheet) on a support, a method or the like can also be used in which the resin composition is suitably heated and melted to be mixed using a roller, a kneader, or other kneading method, and the resin composition layer having a desired thickness is formed as a resin sheet using a roller, a T matrix extruder or the like without using a support.
[00115] As the component of the resin composition that forms the resin sheet, water-soluble resins and water-insoluble resins are generally used, and also in the case where the entry sheet of the present second embodiment contains a sheet of resin, water-soluble resins and water-insoluble resins can be used as the component of the resin composition that forms the resin sheet. These resins have a role in improving lubricity during processing as the lubricity enhancing component or have a role in improving processability as a component forming the resin sheet. Among these resins, water-soluble resins have an effect of improving the discharge properties of cutting chips during cutting due to the lubricity of the resins. In addition, the resin sheet containing a water-soluble resin as the component of the resin composition has a moderately soft surface hardness and thus also has an effect of reducing the processing load of cutting tools. In addition, it is possible to easily remove, after cutting, a resin component adhered to the processed orifice. On the other hand, the resin sheet using a water-insoluble resin as the component of the resin composition has greater surface hardness than a resin sheet using a water-soluble resin and thus in the case where drilling is carried out for example, it has a feature that the bite bit property is favorable and the holes can be drilled in a position as designed. In addition, the resin sheet has high rigidity and is thus excellent in handling properties.
[00116] In the entry sheet of the present second embodiment, a category of water-soluble resins preferred as the component of the resin composition in the resin sheet is a polymer compound that dissolves 1 g or more with respect to 100 g of water at 25 ° C and 1 atm. Examples of such a water-soluble resin include, but are not particularly limited to, polyethylene oxides, polyethylene glycols, polypropylene oxides, water-soluble urethanes, water-soluble polyether resins, water-soluble polyesters, sodium polyacrylates, polyacrylamides, polyvinyl pyrrolidones, polyvinyl alcohols, polyalkylene glycols, polyalkylene glycols esters, polyalkylene glycols ethers, polyglycerin monostearates, polyoxyethylene / propylene copolymers, and derivatives thereof, and at least one or more of these can be selected and used. Among these, polyethylene oxides, polyethylene glycols, and polyether-based water-soluble resins are more preferable as the component of the resin composition.
[00117] In an entry sheet of the present second embodiment, another category of water-soluble resins preferred as the component of the resin composition that forms the resin sheet is a cellulose derivative. In addition, "cellulose" in the present second embodiment means a polymer compound in which a large number of β-glucoses are linked via a glycosidic bond and in which hydroxy groups attached to a carbon atom in position 2, position 3 , and position 6 on the cellulose glucose ring are not replaced. In addition, the "hydroxy groups contained in cellulose" denote hydroxy groups that are attached to a carbon atom of position 2, position 3, and position 6 in the glucose ring of cellulose. Examples of the cellulose derivative include hydroxyethyl cellulose and carboxymethyl cellulose. Hydroxyethyl cellulose, in general, is a compound in which at least part of hydrogen atoms in hydroxy groups contained in cellulose {H- (C6H10O5) n-OH} is replaced by [- (CH2-CH2-O) mH] (in which are not even integers of 1 or more), and have a water solubility of at least 0.05 g / L at 25 ° C and 1 atm. Hydroxyethyl cellulose is synthesized, for example, by adding an ethylene oxide to cellulose.
[00118] On the other hand, carboxymethyl cellulose is a compound in which at least part of hydrogen atoms in hydroxy groups contained in cellulose {H- (C6H10O5) n-OH} is replaced by a carboxymethyl group [-CH2-COOH] ( where n is an integer of 1 or more), and has a water solubility of at least 0.05 g / L at 25 ° C and 1 atm. In addition, part of the carboxy groups in the carboxymethyl group may be a sodium salt. Carboxymethyl cellulose can be obtained by, for example, adding chloroacetic acid to cellulose.
[00119] In the case where the resin sheet is contained in an input sheet of the present second embodiment, the water-insoluble resin that can be used as the component of the resin composition that forms the resin sheet is not particularly limited. In the present second embodiment, the water-insoluble resin is used as a component forming the resin sheet, lubricity-improving component, or the like. Examples of the preferred water-insoluble resin, which is used as a component forming the resin sheet, include, but are not particularly limited to, urethane based resins, acrylic based resins, vinyl acetate based resins, resins based on vinyl chloride, polyester based resins, copolymers thereof, phenol resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, thermosetting polyimides, cyanate resins , epoxy resins, and polyester based resins. In addition, at least one of them can be selected and used as a component forming the resin sheet. On the other hand, examples of the preferred water-insoluble resin that is used as the lubricity-improving component include, but are not particularly limited to, amide-based compounds, such as modified polyamides, ethylene bis-stearamide, oleic acid amide , stearic acid amide, and methylene bis-stearamide; fatty acid-based compounds such as lauric acid, stearic acid, palmitic acid and oleic acid; fatty acid ester-based compounds, such as butyl stearate, butyl oleate and glycol laurate; aliphatic hydrocarbon-based compounds, such as liquid paraffin and polyethylene wax; higher aliphatic alcohols such as oleyl alcohol; and polystyrene-based resins, such as styrene homopolymers (GPPS), styrene-butadiene copolymers (HIPS), and (meth) acrylic styrene-acid copolymers (for example, MS resins). At least one of them can be selected and used as the lubricity enhancing component. Furthermore, in the entry sheet of the present second embodiment, a component forming the resin sheet and a lubricity enhancing component can be used together.
[00120] In the case where the resin sheet is contained in the entry sheet of the present second embodiment, the thickness of the resin sheet is appropriately selected considering the type and thickness of the metal to be a cutting object, the type cutting tools used for cutting, the cutting method, a drill diameter used in drilling, and others. The thickness of the resin sheet is preferably in a range of 0.1 to 20 mm, more preferably in a range of 0.2 to 10 mm, still preferably in a range of 0.5 to 5 mm. When the thickness of the resin sheet is 0.1 mm or more, a sufficient reduction in shear stress is obtained, and in the case where drilling is performed for example, the load on the drill becomes small, making it possible to suppress the break of the drill. On the other hand, when the thickness of the resin sheet becomes 20 mm or less, the winding of the resin composition over the bit is reduced in the case where drilling is performed, for example, making it possible to suppress the occurrence of cracks in the sheet. resin. Particularly in the case where the thickness of the resin sheet is appropriately adjusted to the desired cut, this can be suppressed so that the resin composition becomes a binder for the cut powder and can be reduced so that the cut powder remains in the portion cutting and thus the rise in temperature around a cutting portion can be suppressed and welding the metal as the cutting object can be suppressed. That is to say, by appropriately adjusting the composition of the resin sheet, the components of the resin composition and the thickness of the resin sheet, according to the cutting object and the cutting method, the lubricity and the discharge of the cut powder through a processed groove they can be optimized. As described above, it is preferable to properly control the total thickness of the resin sheet in the present embodiment, and it is also possible to use thin resin sheets in such a way that a plurality of thin resin sheets are superimposed.
[00121] In the case where the resin sheet is contained in an entry sheet of the present second embodiment, the resin sheet can have a structure configured of a single layer of resin composition or a structure configured of a plurality of layers of resin composition, however it is preferable that the resin sheet contains a layered structure in which two or more layers of resin composition are laminated due to reasons regarding properties and improvements in operability. In such an entry sheet of the present second embodiment, the combination of the resin composition layers is not particularly limited, however it is preferable in terms of high processing precision, long processing life, and a property for favorable handling properly combine: the resin composition layer made of a water-soluble resin having a role of improving lubricity during cutting and a water-insoluble resin as a component of improving lubricity; and the resin composition layer made of a water-insoluble resin as a resin sheet component having a role of improving positional accuracy and improving rigidity.
[00122] In the entry sheet of the present second embodiment, examples of the method for producing the resin sheet containing a layered structure in which a plurality of layers of resin composition are laminated include, but are not particularly limited to, a method in which at least one face of a resin sheet being prepared previously and made of a single resin composition layer or a plurality of resin composition layers, the resin composition layer is further formed directly. Examples of the method for forming the resin composition layer on one face of the resin sheet include, but are not particularly limited to, a method in which the resin composition is appropriately melted to change to a liquid form and then the composition liquid resin is applied to the resin sheet as a support, cooled, and solidified to form the resin composition layer. In addition, the examples also include a method in which the resin composition is dissolved or dispersed in a solvent to change to a liquid form, then the resin composition in liquid form is applied to the resin sheet as a support, dried, cooled, and solidified to form the resin composition layer. The method for forming the resin composition layer in liquid form on the resin sheet as a support is not particularly limited, as long as it is a method known to the public and used in industry. Examples of the same include a method in which the resin composition layer is formed by a coating method or the like by applying the resin composition dissolved or dispersed in a solvent using a bar coat, an engraving roller, a matrix, or the like , and a method in which the resin composition is appropriately heated and melted to be mixed using a roller, kneader, or other kneading method, and then the resin composition layer is formed by a roller method, a method curtain coating, or the like.
[00123] As another method for producing a resin sheet containing a layered structure in which a plurality of resin composition layers are laminated, a method is also listed in which a plurality of resin sheets, each made of a a single layer of resin composition or a plurality of layers of resin composition, are superimposed and glued together using a resin or by a thermal lamination method. The method of bonding resin sheets together using a resin or the method of thermal lamination are not particularly limited, as long as they are a method known to the public and used in industry.
[00124] In the case where the resin sheet is contained in an entry sheet of the present second embodiment, an additive can be mixed, as necessary, in the resin sheet. The type of additive is not particularly limited, however, for example, a surface-adjusting agent, a leveling agent, an antistatic agent, an emulsifying agent, an antifoaming agent, a wax additive, a copulating agent can be used, a rheology control agent, an antiseptic agent, an antifungal agent, an antioxidant, a light stabilizer, a nucleating agent, an organic charge, an inorganic charge, a solid lubricant, a plasticizer, a softening agent, a thermal stabilizer, and a coloring agent.
[00125] Among these, the solid lubricant has an effect of improving the lubricity of the inlet sheet and prolonging the service life of cutting tools and, therefore, it is preferable that the resin sheet contains a solid lubricant in the sheet entry of the present second embodiment. The type of solid lubricant is not particularly limited as long as it is a solid having lubricity. For example, graphite, molybdenum disulfide, tungsten disulfide, molybdenum compounds, polytetrafluoroethylenes, polyimides and others are preferable. Among these, graphite is preferable because graphite has a moderate hardness, and natural graphite, artificial graphite, activated carbon, acetylene black, carbon black, colloidal graphite, pyrolytic graphite, expanded graphite, and scale graphite, can be used appropriately. . Among these, scaled graphite is particularly preferable because wear reduction can be improved more effectively due to the shape and diameter of particles. These graphites can be used alone or in combination of two or more.
[00126] In the entry sheet of the present second embodiment, the effect of using the solid lubricant and the resin composition in combination can be explained as follows. In drilling, for example, the resin composition and solid lubricant exhibit lubricity by adhering to the surface and groove of the drill bit and on the side of the processed holes in a workpiece. When the solid lubricant is adhered to it, the change in volume and hardness associated with the temperature change is less in the solid lubricant, as compared to the resin composition, and thus, in the case where drilling is performed for example, the volume Constant hardness and can be maintained with the solid lubricant even when the temperature of the bit and processed portion rises. That is, say, in the case where drilling is performed, for example, the solid lubricant is constantly present between the drill and the workpiece to accentuate the lubricity and can exhibit the effect similar to the effect exhibited by a support and, thus, the Solid lubricant has an effect of suppressing drill wear.
[00127] The reason why graphite is preferable among the solid lubricants that can be used for the input sheet of the present second embodiment is mentioned. When the solid lubricant has a small hardness, the solid lubricant has a weak support effect and it sometimes happens that the lubricity is decreased. On the other hand, when the solid lubricant has a great hardness, there is a possibility that the problem of acceleration in the wear of the bit tip or breakage of the bit tip occurs in the case where drilling is performed for example. Thus, graphite having a moderate hardness is preferable as the solid lubricant.
[00128] Regarding the amount of the solid lubricant used, it is preferable to use 5 parts by weight to 200 parts by weight of the solid lubricant in total, based on 100 parts by weight of the resin composition, more preferably 10 parts by weight to 100 parts by weight, particularly preferably 20 parts by weight to 100 parts by weight. In the event that the amount of the solid lubricant used is 5 parts by weight or more, the lubricating effect due to the solid lubricant is completely exerted. On the other hand, the quantity of the used solid lubricant of 200 parts by weight or less has economic rationale and is advantageous in production.
[00129] When the entry sheet of the present second embodiment is used, the metal as a workpiece is not always flat, and it sometimes happens that the metal has a curved surface. Thus, conformability of the curved surface (flexibility) is sometimes required for the entry sheet of the present second embodiment. In the input sheet of the present second embodiment, it is preferable, for example, to mix a plasticizer or a softening agent as necessary in the resin composition that forms the resin sheet for the purpose of imparting conformability of the curved surface. As the plasticizer and the softening agent, phthalic acid esters, adipic acid esters, trimellitic acid esters, polyesters, phosphoric acid esters, citric acid esters, epoxidized vegetable oils, sebaceic acid esters and others are preferable. When the entry sheet is laid on the curved surface of the metal, the stress or strain on the resin sheet is reduced by mixing the plasticizer or softening agent, thus making it possible to suppress cracks in the resin sheet.
[00130] It is preferable that the entrance sheet of the present second embodiment contains a metal, being more preferable that the metal is a metal sheet.
[00131] In the case where the entry sheet of the present second embodiment contains a resin sheet and a metal sheet, it is more preferable that the input sheet has a metal sheet on at least one face of the sheet of resin. The reason is because, when the input sheet having a metal sheet on at least one face of the resin sheet is used, the centipede property of the bit is improved due to the rigidity of the metal sheet in the case where drilling is performed for example, thus making it possible to drill a hole in a position as designed. In addition, by arranging the metal sheet between the metal as the cutting object and the resin sheet, there is also an effect of preventing the thermally molten resin composition that forms the resin sheet from attaching to the upper portion and within the holes processed. Among others, a three-layer structure of the inlet sheet having metal sheets on both sides of the resin sheet is particularly preferable because the lubricity of the resin sheet can be fully exercised. When the metal sheet is disposed on the outermost layer of the inlet face of the drill in the case where drilling is carried out, for example, this can be suppressed so that the resin sheet is scooped out by rotating the chips metal that are wrapped around the drill bit while cutting the metal. As a result of this, lubricity can be fully exercised and the effect of reducing drill wear is improved.
[00132] The thickness of the metal sheet that can be used on the entry sheet of the present second embodiment is not particularly limited, however it is preferable that the thickness of the metal sheet is from 0.05 to 0.5 mm, more preferably 0.05 to 0.3 mm. When the thickness of the metal sheet is 0.05 mm or more, the handling property during the production of the entry or drilling sheet tends to be improved. On the other hand, when the thickness of the metal sheet is 0.5 mm or less, it becomes easy to unload the cuttings generated during cutting.
[00133] The type of the metal sheet that can be used in the entry sheet of the present second embodiment is not particularly limited, however, an aluminum sheet is preferable. The reason is because, in the case where the aluminum foil is used as the metal foil, the aluminum foil has a moderate softness when compared to the metal like that of the workpiece, thus, in the case where drilling is carried out for example, there is an effect of suppressing the oscillation of the drill core when the rotating drill enters the aluminum sheet, and, as a result, a hole, the position of which is correct with respect to the coordinate set, can be drilled. In addition, by suppressing the oscillation of the rotary drill core, the movement distance of the drill and the area of contact with the workpiece becomes small and thus there is also an effect of reducing the wear of the drill.
[00134] The purity of aluminum in the case where the aluminum foil is used as a metal foil is not particularly limited, however it is preferable that the aluminum has a purity of 95% or more. The reason is because, in the case where drilling is performed for example, the breakage, local wear, or similar of the drill caused by impurities contained in the aluminum foil can be reduced by using a high-purity aluminum foil as a foil. metal, thus making it possible to reduce the cutting load for the drill. Examples of such aluminum foil include, but are not particularly limited to, 5052, 3004, 3003, 1N30, 1N99, 1050, 1070, 1085, 1100, 8021 and others specified in JIS-H4160.
[00135] In the present second embodiment, examples of the method for preparing the entry sheet having a metal sheet on at least one face of the resin sheet include, but are not particularly limited to, a method in which a single resin composition layer or a plurality of resin composition layers are directly formed on at least one face of the metal sheet and a method in which a resin sheet and a metal sheet, each previously prepared, are glued together by a thermal lamination method or similar. Examples of the method for directly forming the single layer of resin composition or the plurality of layers of resin composition on at least one face of the metal sheet include, but are not particularly limited to, a method in which the resin composition it is appropriately melted to change to a liquid form, and then the resin composition in liquid form is applied to the metal sheet as a support once or a plurality of times, cooled and solidified to form a single layer of resin composition or a plurality of resin composition layers. In addition, the examples also include a method in which the resin composition is dissolved or dispersed in a solvent to change to a liquid form, and then the resin composition in liquid form is applied to the metal sheet as a support one once or a plurality of times, dried, cooled, and solidified to form a single layer of resin composition or a plurality of layers of resin composition. The method for forming the resin composition layer in liquid form on the metal sheet as a support is not particularly limited as long as it is a method known to the public and used in the industry. Examples of the same include a method in which the resin composition layer is formed by a coating method or the like by applying the resin composition dissolved or dispersed in a solvent using a bar coat, an engraving roller, a matrix, or the like , and a method in which the resin composition is appropriately heated and melted to be mixed using a roller, kneader, or other kneading method, and then the resin composition layer is formed by a roller method, a method curtain coating, or the like. On the other hand, the method for bonding the resin sheet and the metal sheet together by a thermal lamination method is not particularly limited as long as it is a method known to the public and used in the industry.
[00136] When the entry sheet of the present second embodiment is prepared, an adhesive layer can be formed between the metal sheet and the resin sheet. In the entry sheet of the present second embodiment, it is preferable to form the adhesive layer between the metal sheet and the resin sheet because the adhesiveness between the metal sheet and the resin sheet can be made favorable. In addition, a layer of a compound used to obtain an adhesive between the metal sheet and the favorable resin sheet is defined as an adhesive layer in the present description. The resin that can be used for the adhesive layer is not particularly limited, and, for example, thermoplastic resins and thermosetting resins can be used. In addition, the thermoplastic resin and the thermosetting resin can be used together. Preferred thermoplastic resins include urethane based resins, acrylic based resins, vinyl acetate based resins, vinyl chloride based resins, polyester based resins, and copolymers thereof. In addition, preferred thermosetting resins include phenol resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, thermosetting polyimides, and cyanate resins. Among these, epoxy resins and resins based on unsaturated polyester are more preferable. It is preferable that the thickness of the adhesive layer is from 0.001 to 0.5 mm. The reason is because a sufficient adhesive effect is obtained within the range in order to make the adhesion between the metal sheet and the resin sheet favorable. In addition, the method for forming the adhesive layer is also not particularly limited as long as it is a method known to the public and used in industry. Examples of the same include a method in which an adhesive layer is formed by a coating method or the like by applying the resin dissolved or dispersed in a solvent using a bar coating, an engraving roller, a matrix, or the like, and a method in that the resin is appropriately heated and melted to be mixed using a roller, kneader, or other kneading method, and then an adhesive layer is formed by a roller method, a curtain coating method, or the like. Furthermore, no problem occurs when a commercially available product obtained by coating a sheet of metal with an adhesive layer is used as the sheet of metal that is used in the present second embodiment.
[00137] In the cutting method using the input sheet of the present second embodiment, examples of the method for intimately contacting the input sheet and the metal as a workpiece with each other include, but are not particularly limited to , a method in which the entry sheet and metal as a workpiece are physically fixed with a clamp or template and a method of using an entry sheet in which a layer (sticky layer) of the compound having tackiness is formed on the surface of the resin sheet or metal sheet that contacts the metal as the workpiece. In addition, a layer of a compound having tackiness, the layer used to fix the metal as the workpiece and the entry sheet are defined as the sticky layer in the present description. It is preferred to use, among others, an entry sheet in which an adhesive layer is formed on the surface of the resin sheet or metal sheet that contacts the metal as the workpiece because fixing by a template or similar is not necessary . Consequently, it is preferable that the entry sheet of the present second embodiment is an entry sheet in which an adhesive layer is formed on the surface of the resin sheet or metal sheet which contacts the metal as the workpiece. The component of an adhesive layer is not particularly limited and, for example, thermoplastic resins and thermosetting resins can be used. In addition, the thermoplastic resin and the thermosetting resin can be used together. Preferred thermoplastic resins include urethane based resins, acrylic based resins, vinyl acetate based resins, vinyl chloride based resins, polyester based resins, and copolymers thereof. Preferred thermosetting resins include phenol resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, thermosetting polyimides and cyanate resins. Among these, acrylic based adhesives are more preferable, because acrylic based adhesives have the property by which it is possible to easily adhere at normal temperature without glue residues on a metal as the workpiece. In addition, among acrylic-based adhesives, solvent-based acrylic adhesives and emulsion-type acrylic adhesives (water-based) are particularly preferable. Here, the acrylic based sticking agent in the present description denotes a composition containing a poly (meth) acrylic acid ester and a tackiness enhancer as major components, unless specifically noted otherwise. In addition, an agent to prevent degradation, such as an antioxidant, and an inorganic filler, such as calcium carbonate, talc and silica can be added as necessary to the component of the adhesive layer.
[00138] The method for forming the sticky layer on the surface of the input sheet is not particularly limited as long as it is a method known to the public and used in industry. Examples of the same include a method in which an adhesive layer is formed by a roll method, a curtain coating method, a spray jet method, or the like, a method in which an adhesive layer is formed using a die extruder Tee or roller, or similar and others. The thickness of the adhesive layer is not particularly limited, and the optimum thickness can be appropriately selected considering the curvature of the metal and the constitution of the resin sheet and the entry sheet.
[00139] The thickness of each layer such as the resin sheet layer, the metal sheet, the adhesive layer, or the adhesive layer that constitutes the entry sheet of the present second embodiment is measured as follows. First, the entry sheet is sectioned in a direction perpendicular to the entry sheet using cross section polisher (CROSS-SECTION POLISHER SM-09010 manufactured by JEOL Ltd. DATUM) or an ultramicrotome (EM UC7 manufactured by Leica Microsystems Co., Ltd.). Next, the cut section is viewed from a perpendicular direction to the cut section using a SEM (scanning electron microscope, VE-7800 manufactured by KEYENCE CORPORATION) to measure the thickness of each layer that makes up the entry sheet. When measuring thickness, the thickness at 5 points per 1 visual field is measured, and the average value is defined as the thickness of each layer.
[00140] The cutting object to which the entry sheet of the present second embodiment can be used is not limited to just one metal, but can be a material in which a metal and a fiber-reinforced composite material are superimposed to contact each other. The entry sheet of the present second embodiment is also applicable to, for example, drilling in which a metal and a fiber-reinforced composite material, such as CFRP, are drilled together in a material in which the metal and the composite material fiber-reinforced are superimposed to contact each other. The overlapping aspect is not particularly limited. Specific aspects include a method in which the metal and the fiber-reinforced composite material are superimposed with a template and fixed, a method in which the metal and the fiber-reinforced composite material are superimposed through an adhesive layer and fixed and others. It is generally known that the optimal drilling conditions in, for example, titanium alloy and CFRP, are very different. In the case where drilling is carried out, for example, low speed rotation and high speed feed rate are suitable for drilling the titanium alloy because the increase in the drill temperature is suppressed and the wear of the drill blade is suppressed. This drilling condition is required particularly in a diamond-coated drill bit that is difficult to heat. On the other hand, high speed rotation and low speed feed rate are suitable for drilling the CFRP. Faced with such opposing drilling conditions, drilling is carried out at an actual processing site in such a way that the drilling condition is changed at the edge of the titanium alloy and the CFRP or the drilling is carried out using the average condition and maintaining the same condition. condition as used throughout drilling. In addition, a method in which processing is performed while cutting oil is poured while drilling the titanium alloy for aeronautical use is also adopted in order to avoid this temperature increase. In such a situation, particularly in the case where a carbon fiber composite material, such as CFRP, is produced by: laminating one or two or more prepregs obtained by impregnating a carbon fiber matrix resin; and then, when conducting thermal molding or heat and pressure molding, it is processed with a drill in which wear is progressive, interlayer detachment is possible between laminated prepregs because the cut is carried out in such a state that the carbon fiber is pressed and cut, and, as a result, an inconvenience occurs where fluff from a carbon fiber can appear in the outlet portion where the drill bit penetrates. However, using an entry sheet of the present second embodiment, the wear of the drill during, for example, cutting a metal, is suppressed for example, and thus an effect of greatly easing the restrictions on cutting of a carbon fiber composite material that is possible to have an impact on the quality of the processed holes due to drill wear.
[00141] In the cutting method using the input sheet of the present second embodiment, it is preferable to perform the cut by arranging the input sheet of the present second embodiment on an input face of the cutting tool during cutting. In the case where the input sheet containing a resin sheet is used when cutting is performed, it is preferable to perform the cut from the face of the resin sheet of the input sheet by arranging the input sheet on the outermost cutting surface so that the face of the resin sheet of the input sheet becomes an input face of the cutting tool. In addition, when drilling the metal and fiber-reinforced composite material together, it is preferable to cut from the face of the resin sheet of the input sheet by arranging the input sheet on the outermost surface in a state where the metal and the fiber-reinforced composite material are superimposed so that the face of the resin sheet of the entry sheet becomes an entry face of the cutting tool. On the other hand, in the case where the input sheet having a metal sheet on at least one face of the resin sheet is used, it is preferable to perform the cut from the outermost surface of the input sheet by arranging the sheet so that the metal sheet face of the input sheet contacts the cutting surface. In addition, when drilling the metal and fiber-reinforced composite material together, it is preferable to cut from the outermost surface of the input sheet by arranging the input sheet so that the face of the metal sheet of the input sheet contacts the outermost surface in a state in which the metal and fiber-reinforced composite material are superimposed. In addition, when cutting the fiber-reinforced composite material and / or the metal is carried out, it is particularly preferable to perform the cut while cooling a cutting portion and / or a cutting tool using a gas.
[00142] The present inventors consider the effect of using the entry sheet containing a resin sheet, for example, when drilling using a drill bit as explained below. The present inventors consider that, by using the entry sheet containing a resin sheet, the lubricity between the drill surface including a groove surface of the drill and the interior of the processed hole is improved, the discharge of particles difficult to cut into the difficult metal of cutting cut by the drill blade is made easy, and the degree of rubbing with the drill blade can be reduced and, as a result, wear of the drill blade is reduced. That is, say, abrasive wear occurs when the hard-to-cut particles and the drill blade are rubbed and, thus, the reduction of abrasive wear leads to a reduction in the wear of the drill blade. In addition, this principle of action is applicable to cutting tools in general. Thus, the present second embodiment exhibits a notable effect particularly on cutting a high-strength metal for aeronautical or similar use. The reason is because there is a tendency that the metals for aeronautical or similar use contain a metal having a greater hardness in order to improve the resistance, and, in cut of such a metal, the entrance sheet of the present second form of realization that contributes to the reduction in the wear of cutting tools becomes an effective solution that has never been achieved until now.
[00143] The present third embodiment is a cutting method for cutting a fiber-reinforced composite material and / or a metal using the aforementioned entry sheet.
[00144] In the present third embodiment, it is preferable to perform the cut while cooling a cutting portion and / or a cutting tool using a gas when cutting a fiber-reinforced composite material and / or a metal.
[00145] In the present third embodiment, the metal as the cutting object is not particularly limited as long as it is a metal that is generally used as a structural material. Examples of such a metal include, but are not particularly limited to, the metallic materials used as a material for aircraft machine frame structures. Among these, high strength metals such as aluminum alloys, magnesium alloys, titanium alloys, low alloy steel, stainless steel, and heat resistant alloys are preferable as the metal that is the cutting object to which the cutting method of the present third embodiment. The reason is because the extent of the rise in temperature due to the frictional heat during cutting is greater when the metal has a greater resistance, so the amount of burrs generated tends to be large, and the cutting method of the present third embodiment it is efficient. The metal that is the cutting object can be used alone or in combination with two or more. In addition, among metals, titanium alloys are more preferable as the metal that is the cutting object to which the cutting method of the present third embodiment is applicable. In addition, among the titanium alloys, Ti-6Al-4V made of titanium, aluminum, and vanadium and having a higher strength is particularly preferable. The titanium alloy has a tensile strength 2 times as strong as that of the aluminum alloy and is a material that is excellent in corrosion resistance and heat resistance, however the titanium alloy has a high hardness and, in addition, a small thermal conductivity and thus has a characteristic that the amount of burring caused by the increase in temperature due to frictional heat can become extremely large. Thus, a considerable load is applied to the cutting tools when drilling titanium alloys in conventional technologies and, therefore, it becomes necessary to improve the processing conditions, shapes of the cutting tools and others, however, in the cutting method of this third embodiment, cutting can be carried out without elaborating the processing conditions and shapes of the cutting tools.
[00146] The cutting object to which the cutting method of the present third embodiment is applicable is not limited to just one metal, but the cutting object can be a fiber-reinforced composite material, a material in which a metal and a fiber-reinforced composite material is combined, and a material in which a metal and a fiber-reinforced composite material are superimposed in order to contact each other. The cutting method of the present third embodiment is also applicable to, for example, drilling in which a metal and a carbon fiber composite material, such as CFRP, are drilled together in a material in which the metal and the composite material fiber-reinforced are superimposed to contact each other. The overlapping aspect is not particularly limited. Specific examples include a method in which the metal and the fiber-reinforced composite material are superimposed with a template and fixed, a method in which the metal and the fiber-reinforced composite material are superimposed through an adhesive layer and fixed, and other methods . It is generally known that the optimal drilling conditions in, for example, CFRP and titanium alloy, are very different. In the case where drilling is performed for example, low speed rotation and high speed feed rate are suitable for drilling the titanium alloy because the increase in the drill temperature is suppressed and the wear of the drill blade is suppressed. This drilling condition is required particularly in a diamond-coated drill bit that is difficult to heat. On the other hand, high speed rotation and low speed feed rate are suitable for drilling the CFRP. Faced with such contrary drilling conditions, drilling is carried out at a real processing site in such a way that the drilling condition is changed at the edge of the titanium alloy and the CFRP or drilling is carried out using the medium condition and maintaining the same condition as used throughout the drilling. In addition, a method, in which processing is carried out while cutting oil is poured during drilling of the titanium alloy for aeronautical use, is also adopted in order to avoid these increases in temperature. In such a situation, particularly in the case where a carbon fiber composite material, such as CFRP, produced by: laminating one or two or more prepregs obtained by impregnating a matrix resin on the carbon fiber; and then conducting the thermal molding or molding by heat and pressure, it is processed with a drill in which the wear is progressive, the interlayer detachment is possible to occur between the laminated prepregs because the cut is carried out in such a state that the fiber of carbon is pressed and cut and, as a result, an inconvenience occurs where fluff from a carbon fiber can appear in the outlet portion where the drill bit penetrates. However, when using the cutting method of the present third embodiment, the increase in the temperature of the cutting portion and / or the cutting tool during the cutting of a metal is reduced and thus the amount of burrs derived from the metal is reduced, the wear of the drill is further suppressed, and thus there is an effect of greatly easing the restrictions on cutting a carbon fiber composite material that is possible to have an impact on the quality of the processed holes due to the drill wear.
[00147] In the cutting method of the present third embodiment, it is preferable that the object to be cut is a material in which a metal and a fiber-reinforced composite material are superimposed in order to contact each other and that the cut is made by arranging the fiber-reinforced composite material so that it is on the side closer to the entry side of the cutting tool than the metal. In such a case, the effect of the cutting method of the present third embodiment is most noticeable.
[00148] Examples of the type of cut in which the method of cutting of the present third embodiment is applicable include, but are not particularly limited to, drilling to form a through or non-through hole, machining, cut separation and others . In addition, examples of the type of cutting tools that can be used in cutting include, but are not particularly limited to, a drill, cutting router, milling machine, end mill, side cutter and others. In addition, these cutting tools can be a cutting tool having a general material quality, or a special cutting tool in which a coating film such as a titanium, diamond, or diamond-like carbon coating film is formed on the blade edge of a cutting tool to improve hardness and suppress wear. The reason is because, in any processing using a cutting tool having a general material quality and processing using a special cutting tool, in which a coating film such as a titanium, diamond, or diamond-like carbon coating film is formed on the blade edge of a cutting tool, the cutting method of the present third embodiment has an effect of reducing burrs by gas-cooled processing in the case where cutting a fiber-reinforced composite material and / or a metal is made while cooling a cutting portion and / or a cutting tool using a gas.
[00149] The drill that can be used for drilling in which the cutting method of the present third embodiment is used is not particularly limited with respect to the diameter, material quality, and shape of the drill and whether or not the surface coating exists as long as it is a generally used drill. For example, it is preferable that a drill diameter is 1 mmΦ or more and 10 mmΦ or less, and a diameter of 2 mmΦ or more and 7 mmΦ or less, which is often used in drilling base materials, is more preferable. for aeronautical use. In addition, it is preferable that the quality of the drill material is a cemented carbide produced by sintering a hard metal carbide powder. Examples of such a cemented carbide include, but are not particularly limited to, a metal obtained by mixing and sintering tungsten and cobalt carbide as a binder. Titanium carbide, tantalum carbide, or the like is sometimes added to such a cemented carbide in order to further improve the properties of the material according to the intended use. On the other hand, the drill shape can be appropriately selected considering the drilling conditions, the type and shape of the workpiece and others. The shape of the drill is not particularly limited, and factors for determining the shape of the drill include the angle of the drill tip, the angle of twist of the groove, the number of cutting threads and others. The surface coating of the bit can be appropriately selected considering the drilling conditions, the type and shape of the workpiece and others. Preferred types of surface coating include, but are not particularly limited to, diamond coating, diamond-like coating, ceramic coating and the like.
[00150] In the cutting method of the present third embodiment, the case in which the cutting of a fiber-reinforced composite material and / or a metal is carried out while cooling a cutting portion and / or a cutting tool using a gas will be explained in detail below. In the present third embodiment, the method for cooling the cutting portion and / or the cutting tool using a gas is not particularly limited as long as it is a method by which gas is supplied to the cutting portion and / or the tool cutting. For example, a method in which a compressed gas is supplied to the cutting portion and / or the cutting tool and a method in which a gas is supplied to the cutting portion and / or the cutting tool from the environment by suction of a gas around a cutting portion and / or cutting tool can be used in the cutting method of the present third embodiment. Among these, the method in which a compressed gas is supplied to the cutting portion and / or the cutting tool is simple and appropriate.
[00151] Furthermore, the apparatus for supplying gas to the cutting portion and / or the cutting tool is also not particularly limited. Examples of the apparatus for delivering compressed gas to the cutting portion and / or the cutting tool include, as preferred apparatus, a fan which is an air machine that raises the pressure to a compression ratio of less than 1.1 , a blower that is an air machine that raises the pressure to a compression ratio of 1.1 or more and less than 2.0, and a compressor that is a compression machine that raises the pressure to a compression ratio 2.0 or more. Among these, the compressor is particularly preferable because the compressor can supply a gas having a stable temperature in a stable amount. That is, say, the preferred method for cooling the cutting portion and / or the cutting tool using a gas in the present third embodiment is a method for providing a gas for the cutting portion and / or the cutting tool using the fan, the blower, or the compressor. Among these, the method of supplying a gas to the cutting portion and / or the cutting tool using a compressor is particularly preferable.
[00152] The apparatus for sucking gas around the cutting portion and / or the cutting tool is not particularly limited and can be used for the cutting method of the present third embodiment as long as it is a decompression device that is used in the industry.
[00153] In the cutting method of the present third embodiment, a method by which a gas having a predetermined temperature in a predetermined amount of gas can be supplied stably to the cutting portion and / or the cutting tool is preferable as described above, however, when supplying the gas, it is particularly preferable to supply the gas locally to the cutting portion and / or the cutting tool. Examples of such a method include, but are not particularly limited to, a method for supplying gas locally to the cutting portion and / or the cutting tool in which a nozzle is installed at a gas outlet of an apparatus to supply a gas . In this case, it is preferable that the cross sectional area of the tip of the nozzle is from 7 mm2 to 2000 mm2, more preferably 20 mm2 to 1000 mm2, particularly preferably 20 mm2 to 600 mm2. In the case where the cross-sectional area of the tip of the nozzle is 7 mm2 or more, the amount of gas that can be supplied is sufficient or an appropriate range can be cooled by the gas and, thus, the cooling effect of the present third form of realization can be fully exercised. On the other hand, in the case where the cross-sectional area of the tip of the nozzle is 2000 mm2 or less, the range that can be cooled by the gas does not become very wide, so local cooling becomes possible, and the cooling effect of the the present third embodiment can be fully exercised. In addition, the gas outlet of the apparatus for supplying a gas in the present embodiment includes not only the gas outlet of the main body of the apparatus, but also a gas outlet of the piping and hoses extended around the cutting portion.
[00154] In the present third embodiment, the distance between the gas outlet of the apparatus to supply a gas and the cutting portion and / or the cutting tool in the gas supply to the cutting portion and / or the cutting tool cutting is not particularly limited, however it is preferable that the distance be from 100 mm to 500 mm, still preferably 150 mm to 500 mm, particularly preferably 200 mm to 400 mm. When the distance between the gas outlet of the appliance to supply a gas and the cutting portion and / or the cutting tool is 100 mm or more, in the case where drilling is carried out, for example, the risk that cutting chips generated during drilling contact the gas outlet of the apparatus to supply a gas. On the other hand, when the distance between the gas outlet of the apparatus to supply a gas and the cutting portion and / or the cutting tool is 500 mm or less, local cooling is made possible and the cooling effect of the present third form of realization can be fully exercised.
[00155] In the present third embodiment, the type of gas that is supplied to the cutting portion and / or the cutting tool is not particularly limited, and, for example, air, nitrogen, inert gases and the like can be used . Among these, air is preferable because it is practical.
[00156] In the present third embodiment, the temperature of the gas that is supplied to the cutting portion and / or the cutting tool is not particularly limited, however it is preferable that the gas temperature is 30 ° C or lower , more preferably -50 to 30 ° C, still preferably -15 to 25 ° C. In the case where the gas temperature is 30 ° C or lower, the effect of reducing the rise in temperature of the cutting portion and / or the cutting tool during cutting is displayed, and the effect of the present third embodiment can be completely exercised. On the other hand, when the gas temperature is -50 ° C or higher, dew condensation on the workpiece or cutting tool surface due to extreme cooling can be suppressed, and thus can be suppressed. rust from the workpiece.
[00157] In the present third embodiment, the amount of gas that is supplied to the cutting portion and / or the cutting tool is not particularly limited, however it is preferable that the amount of gas is 5 to 300 L / min , more preferably 50 to 250 L / min, still preferably 80 to 200 L / min. In the case where the gas quantity is 5 L / min or more, the effect of reducing the rise in temperature of the cutting portion and / or the cutting tool during cutting is displayed, and the effect of the present third embodiment can be completely exercised. On the other hand, when the gas quantity is 300 L / min or less, it is difficult to tension the gas supply, so, in the case of drilling, for example, the decrease in the property of the centipede drill can be suppressed, and a correct drilling becomes easy.
[00158] In the present third embodiment, the moisture content contained in the gas supplied to the cutting portion and / or cutting tool is not particularly limited, however it is preferable that the moisture content is 20 g / m3 or less, still preferably 15 g / m 3, particularly preferably 10 g / m 3 or less. The lower limit of the amount of moisture contained in the gas is not particularly limited, however the lower limit is, for example, 0.5 g / m3. When the amount of moisture contained in the gas supplied is 20 g / m3 or less, the residual amount of moisture around the processed holes in a workpiece can be reduced after cutting, thus rusting or degrading the workpiece can be suppressed to improve the quality of the processed orifices.
[00159] In the present third embodiment, the method for measuring the amount of moisture contained in the gas supplied to the cutting portion and / or the cutting tool is not particularly limited as long as it is a general measurement method. Specific measurement methods include a method in which the temperature and relative humidity of the gas are determined using a psychrometer and the dew point (amount of moisture) in the gas is measured using a dew point meter, and other methods.
[00160] In the present third embodiment, the oil content contained in the gas supplied to the cutting portion and / or the cutting tool is not particularly limited, however it is preferable that the oil content is 10 mg / m3 or less, still preferably 8 mg / m3, particularly preferably 5 mg / m3 or less. When the oil content contained in the supplied gas is 10 mg / m3 or less, the residual amount of oil around the processed orifice of the workpiece can be reduced after cutting and thus the cleaning process becomes unnecessary. In addition, even in the case where cleaning is not conducted, erosion of the workpiece due to oil can be suppressed to improve the quality of the processed holes.
[00161] In the present third embodiment, the method for measuring the oil content contained in the gas supplied to the cutting portion and / or the cutting tool is not particularly limited as long as it is a general measurement method. Specific examples include a method in which the number of fine particles of the oil in the gas is measured using a particle counter (fine particle counter), a method in which the measurement is conducted using a detector tube (oil content) for measurement gas quality (602SP, manufactured by Komyo Rikagaku Kogyo KK), and other methods.
[00162] In the present third embodiment, the gas feed direction for the cutting portion of the cutting material and / or the cutting tool is not particularly limited. In the case where drilling is performed for example, gas can be supplied from the inlet side on the bit side to the cutting portion and / or the cutting tool, or gas can be supplied from the side of the face drill bit to the cutting portion and / or the cutting tool. In addition, when the cutting portion is at the final portion of the workpiece, gas can be supplied from the transverse direction of the workpiece. Among them, feeding the gas from the inlet side on the bit side, which makes it possible to directly cool the cutting portion and / or the cutting tool, is more preferable because the environment of the cutting portion can be cooled effectively .
[00163] As described above, in the cutting method of the present third embodiment, it is preferable to perform the cut while cooling the cutting portion and / or the cutting tool using a gas. When making the cut, it is preferable to make the cut using the input sheet together. The reason is because, not only the effect that the amount of burrs around the cutting portion can be reduced due to gas cooling, but also the effect of reducing the load on the bit in order to suppress the bit wear. is achieved by using the input sheet in the event that drilling is performed, for example. In the following, the entry sheet that can be used appropriately in the cutting method of the present third embodiment will be specifically explained.
[00164] The entry sheet that can be used in the cutting method of the present third embodiment is the aforementioned entry sheet. Examples such as the preferred input sheet include an input sheet containing a metal sheet, an input sheet containing a resin sheet, and an input sheet containing a metal sheet and a resin sheet. The reason is because the metal sheet has an action to improve the biting property of a tool tip and, in the resin sheet, the resin composition as the constituent component of the resin sheet has an action to improve lubricity. Among the input sheets described above, the input sheet having a layered structure in which a metal sheet and a resin sheet are laminated is more preferable in terms of an improvement in the bite property of a tool tip and a improvement in lubricity.
[00165] When cutting, the input sheet can be arranged on a cutting tool's input face and on the cutting tool's output face in the cutting material, however it is more preferable to arrange the input sheet on a face cutting tool input. In the case where the input sheet containing a resin sheet is used when cutting is performed, it is preferable to perform the cut from the face of the resin sheet of the input sheet by arranging the input sheet on the outermost cutting surface so that the face of the resin sheet of the input sheet becomes the input face of the cutting tool. In addition, in the case where the input sheet containing a metal sheet is used, it is preferable to perform the cut from the face of the metal sheet of the input sheet by arranging the input sheet on the outermost cutting surface of so that the face of the metal sheet of the input sheet becomes the input face of the cutting tool. Furthermore, when drilling together the metal and the fiber-reinforced composite material, it is preferable to cut from the face of the resin sheet of the entry sheet by placing the entry sheet on the outermost surface in a state where the metal and the fiber-reinforced composite material are superimposed so that the face of the resin sheet of the entry sheet becomes the entry face of the cutting tool. On the other hand, in the case where the input sheet having a metal sheet on at least one face of the resin sheet is used, it is preferable to perform the cut from the outermost surface of the input sheet by arranging the sheet so that the metal sheet face of the input sheet contacts the cutting surface. In addition, when piercing metal and fiber-reinforced composite material together, it is preferable to cut from the outermost surface of the input sheet by arranging the input sheet so that the face of the metal sheet of the input sheet contact the outermost surface in a state where the metal and fiber-reinforced composite material are superimposed.
[00166] In the cutting method using the input sheet of the present third embodiment, examples of the method for intimately contacting the input sheet and the work piece (for example, a metal) with each other include, but are not particularly limited to, a method in which the entry sheet and workpiece (for example, a metal) are physically fixed with a clamp or template and a method of using an entry sheet in which a layer (sticky layer) of a compound having stickiness is formed on the surface of the resin sheet or metal sheet that contacts the workpiece (for example, a metal). In addition, a layer of a compound having tackiness, the layer used to fix the work piece (for example, a metal) and the entry sheet is defined as the sticky layer in the present description. It is preferred to use, among others, an entry sheet in which an adhesive layer is formed on the surface of the resin sheet or metal sheet that contacts the work piece (for example, a metal) because the fixation by a template or similar is not necessary. Consequently, it is preferable that the entry sheet used in the present third embodiment is an entry sheet in which an adhesive layer is formed on the surface of the resin sheet or metal sheet that contacts the workpiece (for example, a metal). The component of an adhesive layer is not particularly limited and, for example, thermoplastic resins and thermosetting resins can be used. In addition, the thermoplastic resin and the thermosetting resin can be used together. Preferred thermoplastic resins include urethane based resins, acrylic based resins, vinyl acetate based resins, vinyl chloride based resins, polyester based resins, and copolymers thereof. Preferred thermosetting resins include phenol resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, thermosetting polyimides, and cyanate resins. Among these, acrylic based adhesives are more preferable because acrylic based adhesives have the property that gluing is easily possible at normal temperature without glue residues on the workpiece (for example, a metal). In addition, among acrylic-based adhesives, solvent-based acrylic adhesives and emulsion-type acrylic adhesives (water-based) are particularly preferable. Here, the acrylic-based sizing agent of the present description in the composition containing a poly (meth) acrylic acid ester and a tackiness promoter as the main components, unless specifically noted otherwise. In addition, an agent to prevent degradation, such as an antioxidant and an inorganic filler, such as calcium carbonate, talc and silica can be added, as necessary, to the component of the adhesive layer.
[00167] The method for forming the sticky layer on the surface of the input sheet is not particularly limited as long as it is a method known to the public and used in industry. Examples of the same include a method in which an adhesive layer is formed by a roll method, a curtain coating method, a spray jet method, or the like, a method in which an adhesive layer is formed using a die extruder Tee or roller, or the like, and other methods. The thickness of the adhesive layer is not particularly limited, and the optimum thickness can be appropriately selected considering the curvature of the workpiece (for example, a metal) and the composition of the resin sheet and the entry sheet.
[00168] In the following, the input sheet which is appropriate in the cutting method of the present third embodiment and the method for producing the input sheet will be mentioned. <Entry sheet containing metal sheet>
[00169] In the present third embodiment, the thickness of the metal sheet that can be used on the input sheet containing a metal sheet is not particularly limited, however it is preferable that the thickness of the metal sheet is 0.05 to 0.5 mm, more preferably 0.05 to 0.3 mm. When the thickness of the metal sheet is 0.05 mm or more, the handling property during production of the input sheet or perforation is improved. On the other hand, when the thickness of the metal sheet is 0.5 mm or less, it becomes easy to unload cutting chips generated during cutting.
[00170] In the present third embodiment, the type of the metal sheet that can be used in the entry sheet containing a metal sheet is not particularly limited, however an aluminum sheet is preferable. The reason is because, in the case where the aluminum foil is used as the metal foil, the aluminum foil has a moderate softness when compared to the workpiece, so in the case where drilling is performed for example, if notes an effect of suppressing the oscillation of the drill core when the rotary drill enters the aluminum sheet, and, as a result of this, a hole whose position is correct with respect to the coordinate set can be drilled. In addition, by suppressing the oscillation of the core of the rotary drill, the distance of movement of the drill and the contact area with the workpiece becomes small and thus there is also an effect of reducing the wear of the drill.
[00171] The purity of aluminum in the case where the aluminum foil is used as the metal foil is not particularly limited, however it is preferable that the aluminum has a purity of 95% or more. The reason is because, in the case where drilling is performed for example, the breakage, local wear, or similar of the drill caused by impurities contained in the aluminum foil can be reduced by using a high-purity aluminum foil, such as the foil thus making it possible to reduce the cutting load for the drill. Examples of such aluminum foil include, but are not particularly limited to, 5052, 3004, 3003, 1N30, 1N99, 1050, 1070, 1085, 1100, 8021 and others specified in JIS-H4160.
[00172] In the present third embodiment, the method for producing the input sheet containing a metal sheet is not particularly limited, and a general method for producing a metal sheet can be used. <Entry sheet containing resin sheet>
[00173] Examples of the method for producing the input sheet which can be used appropriately in the present third embodiment and contains a resin sheet include, but are not limited to, a method for producing an input sheet containing a sheet resin where the resin composition is appropriately melted to change to a liquid form, then the resin composition is applied to a support, cooled, and solidified to form the resin composition layer, and then the support is removed or loose. In addition, the examples also include a method for producing an input sheet containing a resin sheet in which the resin composition is dissolved or dispersed in a solvent to change to a liquid form, then the resin composition is applied over a support, dried, cooled, and solidified to form the resin composition layer, and then the support is removed or released. In the production of the input sheet, the support is not particularly limited, and a sheet of metal or film, a roll of metal and others can be used appropriately. The method for forming the resin composition layer in a liquid form on a support is not particularly limited as long as it is a method known to the public and used in the industry. Examples of the same include a method in which the resin composition layer is formed on a support by a coating method or the like by applying the resin composition dissolved or dispersed in a solvent using a bar coat, an engraving roller, a matrix , or similar, and a method in which the resin composition is appropriately heated and melted to be mixed using a roller, kneader, or other kneading method, and then the resin composition layer is formed on a support by a roller method, a curtain coating method, or the like. In addition, unlike the methods described above for forming the resin composition layer on a support, a method or the like can also be used in which the resin composition is suitably heated and melted to be mixed using a roller, a kneader, or another kneading method, and the resin composition layer having a desired thickness is formed as a resin sheet using a roller, a T matrix extruder or the like without using a support.
[00174] As mentioned above, water-soluble resins and water-insoluble resins are used as the component of the resin composition used for the resin sheet contained in the input sheet, and also in the input sheet that can be used in the method of In cutting the present third embodiment, water-soluble resins and water-insoluble resins can be used as the component of the resin composition. These resins have a role in improving lubricity during cutting as the lubricity enhancing component or have a role in improving processability as a component forming the resin sheet. Among these resins, water-soluble resins have an effect of improving the discharge properties of cutting chips during cutting due to the lubricity of the resins. In addition, the resin sheet containing a water-soluble resin as the component of the resin composition has a moderately soft surface hardness and thus also has an effect of reducing the processing load of the cutting tools. In addition, it is possible to easily remove, after cutting, a resin component adhered to the processed orifice. On the other hand, the resin sheet using a water-insoluble resin as the component of the resin composition has a greater surface hardness than the resin sheet using a water-soluble resin and thus in the case where the perforation is realized, for example, the characteristic that the bit's biting property is favorable and the holes can be drilled in a position as projected. In addition, the resin sheet has high rigidity and is thus excellent in handling properties.
[00175] In the input sheet containing a resin sheet used in the present third embodiment, a category of preferred water-soluble resins as the component of the resin composition in the resin sheet is a polymer compound that dissolves 1 g or more with relative to 100g of water at 25 ° C and 1 atm. Examples of such a water-soluble resin include, but are not particularly limited to, polyethylene oxides, polyethylene glycols, polypropylene oxides, water-soluble urethanes, water-soluble polyether resins, water-soluble polyesters, sodium polyacrylates, polyacrylamides, polyvinyl pyrrolidones, polyvinyl alcohols, polyalkylene glycols, polyalkylene glycols esters, polyalkylene glycols ethers, polyglycerine monostearates, polyoxyethylene / propylene copolymers, and derivatives thereof, and at least one of them can be selected and used. Among these, polyethylene oxides, polyethylene glycols, and polyether-based water-soluble resins are more preferable as the component of the resin composition.
[00176] In the entry sheet containing a resin sheet used in the present third embodiment, another preferred category of water-soluble resins as the component of the resin composition of the resin sheet is that of cellulose derivatives. In addition, "cellulose" in the present third embodiment means a polymer compound in which a large number of β-glucoses are linked via a glycosidic bond and in which hydroxy groups attached to a carbon atom in position 2, position 3 , and position 6 on the cellulose glucose ring are unsubstituted. In addition, the "hydroxy groups contained in cellulose" denote hydroxy groups that are attached to a carbon atom of position 2, position 3, and position 6 in the glucose ring of cellulose. Examples of the cellulose derivative include, but are not limited to, hydroxyethyl cellulose and carboxymethyl cellulose. Hydroxyethyl cellulose, in general, is a compound in which at least part of hydrogen atoms in hydroxy groups contained in cellulose {H- (C6H10O5) n-OH} is replaced by [- (CH2-CH2- O) mH] (in which are not even integers of 1 or more), and have a water solubility of at least 0.05 g / L at 25 ° C and 1 atm. Hydroxyethyl cellulose is synthesized by, for example, adding an ethylene oxide to cellulose.
[00177] On the other hand, carboxymethyl cellulose is a compound in which at least part of hydrogen atoms in hydroxy groups contained in cellulose {H- (C6H10O5) n-OH} is replaced by a carboxymethyl group [-CH2-COOH] ( where n is an integer of 1 or more), and has a water solubility of at least 0.05 g / L at 25 ° C and 1 atm. In addition, part of the carboxy groups in the carboxymethyl group may be a sodium salt. Carboxymethyl cellulose can be obtained by, for example, adding chloroacetic acid to cellulose.
[00178] In the input sheet containing a resin sheet used in the present third embodiment, the water-insoluble resin that can be used as the resin composition component of the resin sheet is not particularly limited. In the present third embodiment, the water-insoluble resin is used as a component forming the resin sheet, the lubricity-improving component, or the like. Examples of the preferred water-insoluble resin that is used as the resin sheet-forming component include, but are not particularly limited to, urethane-based resins, acrylic-based resins, vinyl acetate-based resins, resin-based resins vinyl chloride, polyester based resins, copolymers thereof, phenol resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, thermosetting polyimides, cyanate resins epoxy, polyester based resins. In addition, at least one of them can be selected and used as a resin component. On the other hand, examples of the preferred water-insoluble resin that is used as the lubricity-improving component include amide-based compounds such as modified polyamides, ethylene bis-stearamide, oleic acid amide, stearic acid amide, and methylene bis -stearamide; fatty acid-based compounds, such as lauric acid, stearic acid, palmitic acid and oleic acid; fatty acid ester-based compounds, such as butyl stearate, butyl oleate and glycol laurate; aliphatic hydrocarbon-based compounds, such as liquid paraffin and polyethylene wax; higher aliphatic alcohols, such as oleyl alcohol; and polystyrene-based resins, such as styrene homopolymers (GPPS), styrene-butadiene copolymers (HIPS), and (meth) acrylic styrene-acid copolymers (e.g., MS resins). At least one of them can be selected and used as the lubricity enhancing component. Furthermore, in the input sheet, which is used in the present third embodiment, the sheet-forming component and the lubricity-improving component can be used together.
[00179] The thickness of the resin sheet on the entry sheet containing the resin sheet used in the present third embodiment is appropriately selected considering the type and thickness of the metal to be the cutting object, the type of cutting tools used for cutting, the method of cutting, and a drill diameter used in drilling, or similar. The thickness of the resin sheet is preferably in a range of 0.1 to 20 mm, more preferably in a range of 0.2 to 10 mm, still preferably in a range of 0.5 to 5 mm. When the thickness of the resin sheet is 0.1 mm or more, a sufficient reduction in shear stress is obtained and, in the case where drilling is performed, for example, the load on the drill becomes small and the break of the drill is difficult to occur. On the other hand, when the thickness of the resin sheet is 20 mm or less, winding of the resin composition over the bit is reduced and cracks or the like are unlikely to occur in the resin sheet in the case where perforation is performed for example. Particularly in the case where the thickness of the resin sheet is within the range described above in the desired cut, it can be suppressed that the resin composition plays a role of a binder for the cut powder and it can be prevented that the cut powder remains in the portion cutting and thus the increase in temperature around the cutting portion can be suppressed and the joining of the cutting object (for example, a metal) can be suppressed. That is to say, by properly adjusting the composition of the resin sheet, the components of the resin composition, and the thickness of the resin sheet, according to the cutting object and the cutting method, the lubricity and the discharge of the powder cut through the processed groove can be optimized. As described above, it is preferable to properly control the total thickness of the resin sheet in the present third embodiment, and it is also possible to use thin resin sheets so that a plurality of thin resin sheets are superimposed.
[00180] The resin sheet in the entry sheet containing the resin sheet used in the present third embodiment can have a structure configured of a single layer of resin composition or a structure configured of a plurality of layers of resin composition, however, it is preferable that the resin sheet contains a layered structure in which two or more layers of resin composition are laminated due to reasons regarding properties and improvements in operability. The combination of the resin composition layers in the input sheet used in the present third embodiment is not particularly limited, however it is preferable in terms of high processing accuracy, long processing life, and a property of favorable manipulation to appropriately combine: the resin composition layer made of a water-soluble resin having a role of improving lubricity during processing or a water-insoluble resin as a component of improving lubricity; and a resin composition layer made of a water-insoluble resin as a resin sheet component having a role of improving positional accuracy and improving rigidity.
[00181] On the input sheet containing a resin sheet used in the present third embodiment, examples of the method for producing the resin sheet containing a layered structure, wherein a plurality of layers of resin composition are laminated, include , but are not particularly limited to, a method in which, on at least one face of a resin sheet being prepared previously and made of a single layer of resin composition or a plurality of layers of resin composition, the layer resin composition is still directly formed. Examples of the method for forming the resin composition layer on one face of the resin sheet include, but are not particularly limited to, a method in which the resin composition is appropriately melted to change to a liquid form and then the composition liquid resin is applied over the resin sheet as a support, cooled and solidified to form the resin composition layer. In addition, the examples also include a method in which the resin composition is dissolved or dispersed in a solvent to change to a liquid form, then the resin composition in liquid form is applied to the resin sheet as a support, dried, cooled and solidified to form the resin composition layer. The method for forming the resin composition layer in liquid form on the resin sheet as a support is not particularly limited as long as it is a method known to the public and used in the industry. Examples of the same include a method in which the resin composition layer is formed by a coating method or the like by applying the resin composition dissolved or dispersed in a solvent using a bar coat, an engraving roller, a matrix, or the like , and a method in which the resin composition is appropriately heated and melted to be mixed using a roller, kneader, or other kneading method, and then the resin composition layer is formed by a roller method, a method curtain coating, or the like.
[00182] As another method for producing a resin sheet containing a layered structure, in which a plurality of resin composition layers are laminated, a method in which several resin sheets, each made of a single layer of resin composition resin or a plurality of resin composition layers, are superimposed and glued together using a resin or by a thermal lamination method is also listed. The method of sticking the resin sheets together, using a resin or the thermal lamination method, is not particularly limited as long as it is a method known to the public and used in industry.
[00183] In the input sheet containing a resin sheet used in the present third embodiment, an additive can be mixed as necessary in the resin composition of the resin sheet. The type of additive is not particularly limited, however, for example, a surface-adjusting agent, a leveling agent, an antistatic agent, an emulsifying agent, an antifoaming agent, a wax additive, a copulating agent, a rheology control, an antiseptic agent, an antifungal agent, an antioxidant, a light stabilizer, a nucleating agent, an organic charge, an inorganic charge, a solid lubricant, a plasticizer, a softening agent, a thermal stabilizer, and an agent colorant can be used.
[00184] Among these, the solid lubricant has an effect of improving the lubricity of the input sheet and prolonging the service life of processing of cutting tools and, therefore, it is preferable that the resin composition that forms the resin sheet is a resin composition containing a solid lubricant in the input sheet used in the present third embodiment. The type of solid lubricant is not particularly limited as long as it is a solid having lubricity. For example, graphite, molybdenum disulfide, tungsten disulfide, molybdenum compounds, polytetrafluoroethylenes, polyimides and others are preferable. Among these, graphite is preferable because graphite has a moderate hardness, and natural graphite, artificial graphite, activated carbon, acetylene black, carbon black, colloidal graphite, pyrolytic graphite, expanded graphite, and scale graphite can be used appropriately. . Among these, scaled graphite is particularly preferable because wear reduction can be improved more effectively due to the shape and diameter of particles. These graphites can be used alone or in combination of two or more.
[00185] In the input sheet containing a resin sheet used in the present third embodiment, the effect of using the solid lubricant and the resin composition in combination can be explained as follows. In drilling, for example, the resin composition and the solid lubricant exhibit lubricity by adhering to the surface and groove of the bit and on the side of the processed holes in the workpiece. When the solid lubricant is adhered to it, the change in volume and hardness associated with the temperature change is less in the solid lubricant as compared to the resin composition and thus in the case where drilling is carried out, for example, the volume constant and hardness can be maintained with the solid lubricant even when the temperature of the bit and the processed portion increases. That is, say, in the case where drilling is performed, for example, the solid lubricant is constantly present between the drill and the workpiece to accentuate the lubricity and can exhibit the effect similar to the effect exhibited by a support and thus , the solid lubricant has the effect of suppressing drill wear.
[00186] The reason why graphite is preferable among the solid lubricants that can be used for the input sheet is mentioned. When the solid lubricant has a small hardness, the solid lubricant has a weak support effect and it sometimes happens that the lubricity is decreased. On the other hand, when the solid lubricant has a great hardness, the possibility that the problem of acceleration in the wear of the bit tip or rupture of the bit tip occurs in the case where drilling is carried out, for example. Thus, graphite having a moderate hardness is preferable as the solid lubricant.
[00187] Regarding the amount of solid lubricant used, it is preferable to use 5 parts by weight to 200 parts by weight of the solid lubricant in total, based on 100 parts by weight of the resin composition, more preferably 10 parts by weight to 100 parts by weight, particularly preferably 20 parts by weight to 100 parts by weight. In the event that the amount of the solid lubricant used is 5 parts by weight or more, the lubricating effect due to the solid lubricant is completely exerted because the amount of the solid lubricant with respect to the amount of the resin composition is sufficient. On the other hand, the amount of the used solid lubricant of 200 parts by weight or less presents economic rationale and is advantageous in production.
[00188] When the input sheet containing a resin sheet used in the present third embodiment is used, the work piece (for example, a metal) is not always flat and, sometimes, it occurs that the work piece has a curved surface. Thus, the conformability of the curved surface (flexibility) is sometimes. required for the input sheet containing a resin sheet used in the present third embodiment. In the input sheet containing a resin sheet used in the present third embodiment, it is preferable to mix a plasticizer or a softening agent, as necessary, in the resin composition of the resin sheet in order to confer the conformability of the curved surface. As the plasticizer and the softening agent, phthalic acid esters, adipic acid esters, trimellitic acid esters, polyesters, phosphoric acid esters, citric acid esters, epoxidized vegetable oils, sebaceic acid esters and others are preferable. When the input sheet is laid out on the curved surface of the workpiece (for example, a metal), the stress or stress on the resin sheet is reduced by mixing the plasticizer or softening agent, thus making it possible to suppress cracks in the sheet of resin. <Entry sheet containing metal sheet and resin sheet>
[00189] In the cutting method of the present third embodiment, the entry sheet containing the metal sheet or resin sheet described above can be used appropriately, however, the entry sheet described below and having a metal sheet at least one face of the resin sheet is more preferable. The reason is because, when the inlet sheet having a metal sheet on at least one face of the resin sheet is used, the centipede property of the drill is improved due to the rigidity of the metal sheet in the event that the perforation is for example, thus making it possible to drill a hole in a position as designed. In addition, by arranging the metal sheet between the cutting object (for example, a metal) and the resin sheet, there is also an effect of preventing the thermally molten resin composition of the resin sheet from attaching to the upper portion and inside the processed holes. Among others, the entry sheet containing the three-layer structure has metal sheets on both sides of the resin sheet is particularly preferable because the lubricity of the resin sheet can be fully exercised. When the sheet of metal is disposed on the outermost layer of the inlet face of the drill in the case where drilling is carried out for example, this can be suppressed so that the resin sheet is excavated by rotating the cutting chips of the cutting object (for example, a metal) that are wrapped around the cutting bit of the cutting object (for example, a metal). As a result of this, lubricity can be fully exercised and the effect of reducing drill wear is improved.
[00190] As the metal sheet and resin sheet described above that constitute the entry sheet, the metal sheet having at least one face of the resin sheet, the metal sheet and the resin sheet explained in the paragraphs of Sheet sheet containing metal sheet and the paragraphs of sheet containing resin sheet can be used. In addition, as the component that can be added to the resin sheet, the same component explained in the same paragraphs can be used.
[00191] In the present third embodiment, examples of the method for preparing the entry sheet having a metal sheet on at least one face of the resin sheet include, but are not particularly limited to, a method in which a single resin composition layer or a plurality of resin composition layers are directly formed on at least one face of the metal sheet and a method in which a resin sheet and a metal sheet, each previously prepared, are glued together by a thermal lamination method or similar. Examples of the method for directly forming the single layer of resin composition or the plurality of layers of resin composition on at least one face of the metal sheet include, but are not particularly limited to, a method in which the resin composition it is appropriately melted to change to a liquid form, and then the resin composition in liquid form is applied to the metal sheet as a support once or a plurality of times, cooled and solidified to form a single layer of resin composition or a plurality of resin composition layers. In addition, the examples also include a method in which the resin composition is dissolved or dispersed in a solvent to change to a liquid form, and then the resin composition in liquid form is applied to the metal sheet as a support one once or a plurality of times, dried, cooled, and solidified to form a single layer of resin composition or a plurality of layers of resin composition. The method for forming the resin composition layer in liquid form on the metal sheet as a support is not particularly limited as long as it is a method known to the public and used in the industry. Examples of the same include a method in which the resin composition layer is formed by a coating method or the like by applying the resin composition dissolved or dispersed in a solvent using a bar coat, an engraving roller, a matrix, or the like , and a method in which the resin composition is appropriately heated and melted to be mixed using a roller, kneader, or other kneading method, and then the resin composition layer is formed by a roller method, a method curtain coating, or the like. On the other hand, the method for bonding the resin sheet and the metal sheet together by a thermal lamination method is not particularly limited as long as it is a method known to the public and used in the industry.
[00192] When the entry sheet having a metal sheet on at least one face of the resin sheet is prepared in the present third embodiment, an adhesive layer can be formed between the metal sheet and the resin sheet. In the entry sheet used in the present third embodiment, it is preferable to form the adhesive layer between the metal sheet and the resin sheet because the adhesiveness between the metal sheet and the resin sheet can be made favorable. In addition, a layer of a compound used to favor adhesiveness between the metal sheet and the resin sheet is defined as an adhesive layer in the present description. The resin that can be used for the adhesive layer is not particularly limited, and, for example, thermoplastic resins and thermosetting resins can be used. In addition, the thermoplastic resin and the thermosetting resin can be used together. Preferred thermoplastic resins include urethane based resins, acrylic based resins, vinyl acetate based resins, vinyl chloride based resins, polyester based resins, and copolymers thereof. In addition, preferred thermosetting resins include phenol resins, epoxy resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethanes, thermosetting polyimides, and cyanate resins. Among these, epoxy resins and resins based on unsaturated polyester are more preferable. It is preferable that the thickness of the adhesive layer is from 0.001 to 0.5 mm. The reason is because a sufficient adhesive effect is obtained within the range in order to make the adhesion between the metal sheet and the resin sheet favorable. In addition, the method for forming the adhesive layer is also not particularly limited as long as it is a method known to the public and used in industry. Examples of the same include a method in which an adhesive layer is formed by a coating method or the like by applying the resin dissolved or dispersed in a solvent using a bar coating, an engraving roller, a matrix, or the like, and a method in that the resin is appropriately heated and melted to be mixed using a roller, kneader, or other kneading method, and then an adhesive layer is formed by a roller method, a curtain coating method, or the like. Furthermore, no problem occurs when a commercially available product obtained by coating a sheet of metal with an adhesive layer is used as the sheet of metal that is used in the present third embodiment.
[00193] The through hole of the present embodiment is a through hole formed by the cutting method mentioned above. The maximum value of the burr height at the exit portion of the through hole formed by the cutting methods mentioned above, for example by drilling, can be brought to 0.3 mm or less, or 0.2 mm or less, the average value can be brought to 0.1 mm or less, or 0.08 mm or less, the standard deviation can be brought to 0.1 mm or less, or 0.05 mm or less. In addition, the burr height has a feature that an extreme increase in the burr height is not observed even when the cumulative number of holes processed by a drill is increased, provided that the drill's cutting edge is completely exhausted.
[00194] The thickness of each layer, such as the resin sheet layer, the metal sheet, the adhesive layer, or the adhesive layer that constitutes the entry sheet, can be measured as follows. First, the entry sheet is sectioned in a direction perpendicular to the entry sheet using cross section polisher (CROSS-SECTION POLISHER SM-09010 manufactured by JEOL Ltd. DATUM) or an ultramicrotome (EM UC7 manufactured by Leica Microsystems Co., Ltd.). Next, the cut section is viewed from a perpendicular direction to a cut section using a SEM (scanning electron microscope, VE-7800 manufactured by KEYENCE CORPORATION) to measure the thickness of each layer that makes up the entry sheet. When measuring thickness, the thickness at 5 points per 1 visual field is measured, and the average value is defined as the thickness of each layer.
[00195] The method for producing a fiber reinforced composite material of the present embodiment includes a step of cutting fiber reinforced composite material by the aforementioned cutting method. Furthermore, the method for producing a metal of the present embodiment includes a step of cutting a metal by the aforementioned cutting method. EXAMPLES
[00196] In the following, the present invention will be explained specifically by showing the Examples and Comparative Examples. In addition, the following Examples only show an example of the embodiments in the present invention, and the present invention is not limited to these Examples.
[00197] Specifications of resin components, etc. used for the production of the input sheets of Examples 1-1 to 1-9 and specifications for perforated materials and apparatus used for evaluation in Examples 1-1 to 1-9 and Comparative Examples 1-1 to 1-5 are shown in - 1. [Table 1]
<Example of Preparation of input sheet> (Preparation of Sheet 1-A)
[00198] Using a bidirectional kneader, 30 parts by weight of polyethylene glycol / dimethyl terephthalate polycondensate (Paogen PP-15, manufactured by DKS Co., Ltd) and 70 parts by weight of polyoxyethylene monostearate (NONION S-40, manufactured by NOF CORPORATION) were kneaded in a nitrogen atmosphere at a temperature of 150 ° C to obtain a kneaded material. The kneaded material obtained was molded with an extruder to prepare Sheet 1-A as a resin sheet having a thickness of 0.2 mm. (Preparation of Sheet 1-B)
[00199] Using a bidirectional kneader, 20 parts by weight of polyethylene glycol / dimethyl terephthalate polycondensate (Paogen PP-15, manufactured by DKS Co., Ltd), 20 parts by weight of polyethylene oxide (Altop MG150, manufactured by Meisei Chemical Works, Ltd.), 60 parts by weight of polyoxyethylene monostearate (NONION S-40, manufactured by NOF CORPORATION), and 50 parts by weight of graphite (X-100, manufactured by Ito Graphite Co., Ltd.) were kneaded in a nitrogen atmosphere at a temperature of 150 ° C to obtain a kneaded material. A resin sheet having a thickness of 0.2 mm was prepared by molding the kneaded material obtained with an extruder. An aluminum sheet having a thickness of 0.15 mm (1N30-H18, manufactured by Mitsubishi Aluminum Co., Ltd.) of which one side of a layer of polyester-based resin (Vylonal MD-1200, manufactured by Toyobo Co ., Ltd) having a thickness of 0.01 mm was formed as an adhesive layer was separately prepared. On the aluminum foil on which an adhesive layer was formed, 5 sheets of resin prepared above were superimposed, and the aluminum foil and resin sheets were laminated and integrated by thermal lamination at a temperature of 150 ° C using an apparatus lamination (OHL-2400, manufactured by ONC Inc.) to prepare Sheet 1-B. (Preparation of Sheet 1-C)
[00200] Using a bidirectional kneader, 20 parts by weight of polyethylene glycol / dimethyl terephthalate polycondensate (Paogen PP-15, manufactured by DKS Co., Ltd), 20 parts by weight of polyethylene oxide (Altop MG150, manufactured by Meisei Chemical Works, Ltd.), and 60 parts by weight of polyoxyethylene monostearate (NONION S-40, manufactured by NOF CORPORATION) were kneaded in a nitrogen atmosphere at a temperature of 150 ° C to obtain a kneaded material. A resin sheet having a thickness of 0.2 mm was prepared by molding the kneaded material obtained with an extruder. An aluminum sheet having a thickness of 0.15 mm (1N30-H18, manufactured by Mitsubishi Aluminum Co., Ltd.) of which one side of a layer of polyester-based resin (Vylonal MD-1200, manufactured by Toyobo Co ., Ltd) having a thickness of 0.01 mm was formed as an adhesive layer was separately prepared. On the aluminum foil on which an adhesive layer was formed, 5 resin sheets prepared above were superimposed, and on the uppermost portion thereof, the same aluminum foil, as prepared above, was further laminated. In laminating the aluminum foil, the resin foil and the aluminum foil were arranged so that the resin foil and the adhesive layer on the surface of the aluminum foil came into contact with each other, and the resin foil and the aluminum foil was laminated and integrated by thermal lamination at a temperature of 150 ° C using a laminating apparatus (OHL-2400, manufactured by ONC Inc.) to prepare Sheet 1-C. (Preparation of 1-D Sheet)
[00201] Using a bidirectional kneader, 20 parts by weight of polyethylene glycol / dimethyl terephthalate polycondensate (Paogen PP-15, manufactured by DKS Co., Ltd), 20 parts by weight of polyethylene oxide (Altop MG150, manufactured by Meisei Chemical Works, Ltd.), 60 parts by weight of polyoxyethylene monostearate (NONION S-40, manufactured by NOF CORPORATION), and 50 parts by weight of graphite (X-100, manufactured by Ito Graphite Co., Ltd.) were kneaded in a nitrogen atmosphere at a temperature of 150 ° C to obtain a kneaded material. A resin sheet having a thickness of 0.2 mm was prepared by molding the kneaded material obtained with an extruder. An aluminum sheet having a thickness of 0.15 mm (1N30-H18, manufactured by Mitsubishi Aluminum Co., Ltd.) of which one side of a layer of polyester-based resin (Vylonal MD-1200, manufactured by Toyobo Co ., Ltd) having a thickness of 0.01 mm was formed as an adhesive layer was separately prepared. On the aluminum foil on which an adhesive layer was formed, 5 sheets of resin prepared above were superimposed and, on the uppermost portion thereof, the same aluminum foil, as prepared above, was further laminated. In laminating the aluminum foil, the resin foil and the aluminum foil were arranged so that the resin foil and the adhesive layer on the surface of the aluminum foil came into contact with each other, and the resin foil and the aluminum foil was laminated and integrated by thermal lamination at a temperature of 150 ° C using a laminating apparatus (OHL-2400, manufactured by ONC Inc.) to prepare Sheet 1-D. (Regarding sheet 1-E)
[00202] An aluminum sheet (1N30-H18, manufactured by Mitsubishi Aluminum Co., Ltd.) having a thickness of 0.15 mm was used as Sheet 1-E. <Examples 1-1 to 1-9>
[00203] Each sheet prepared in the manner as described above was fixed on an entry face of the cutting tool (cemented carbide bit) of the workpiece with a template. With respect to Examples 1-2 through 1-9, the input sheet was arranged so that the aluminum sheet of the input sheet contacted the cutting face of the workpiece. Drilling was carried out under a cutting condition with the cemented carbide drill in which the number of revolutions was 5,000 rpm and a feed rate of 500 mm / min and also under the condition, as other conditions, as shown in Table 1-2 . With respect to Example 1-1, the thrust force, cutting torque, drill wear loss, the bore bore and the change in bore bore were evaluated. The results of the assessment are shown in Table 1-3. With respect to Examples 1-2 to 1-9, the roughness of the inner wall of the holes and the loss from wear of the drill were evaluated. The results of the assessment are shown in Table 1-4. <Comparative Examples 1-1 to 1-6>
[00204] Drilling was carried out in the same way as in Examples 1-1 to 1-6 except that a sheet was not disposed on the cut face of the workpiece. Drilling conditions are described in Table 1-2. With respect to Comparative Example 1-1, the buoyant force, cutting torque, drill wear loss, bore bore, and change in bore bore were evaluated in the same way as in Example 1- 1. The evaluation results are shown in Table 1-3. With respect to Comparative Examples 1-2 to 1-6, the roughness of the inner wall of holes and the loss through wear of the drill were evaluated. The evaluation results are shown in Table 1-4. [Table 1-2]

[Table 1-3]
[Table 1-4]

[00205] The results of Example 1-1 and Comparative Example 1-1 in Table 1-3 are shown in Figure 1-1 through Figure 1-4 for each assessment item. It was confirmed that the shear stress (buoyant force) applied in the perpendicular direction of the drill was reduced by about 10% in the maximum value by placing the resin sheet given in Example 1-1 on the workpiece bur entry face when the cut was made. In addition, it has been confirmed that the shear stress (shear torque) applied in the direction of rotation of the drill has been reduced by about 50% by placing the resin sheet given in Example 1-1 on an inlet face of the drill bit. work when the cut was conducted. In addition, it was confirmed that the shear stress applied in the perpendicular direction described above and the direction of rotation was reduced, the load for the drill was reduced, and the wear of the drill was reduced by 30% or more by having the resin sheet given in Example 1-1 on the workpiece bit entry face when cutting was performed. It was deduced that this contributes to the reduction of burrs (fluff) on the outlet side of the processed orifice and the reduction of CFRP interlayer detachment.
[00206] Furthermore, it was confirmed that the uniformity of the bore diameter in the direction of the drill run and the uniformity of the bore diameter when the number of cut holes was increased were excellent with the resin sheet given in Example 1- 1 on the workpiece entry face of the workpiece when the cut was made. From these results, it was understood that the wear of the drill bit was reduced by placing the resin sheet over the entrance face of the drill bit of the workpiece, thus making it possible to drill uniform and high quality holes. It has been deduced that this contributes to reducing the interlayer detachment of the CFRP because it is not necessary to push the fasteners by excessive force when the CFRP is fastened to a structure using fasteners such as screws and rivets.
[00207] The results of Examples 1-2 to 1-9 and Comparative Examples 1-2 to 1-6 in Table 1-4 are shown in Figure 1-5 to Figure 1-7 for each assessment item. It has been confirmed that the roughness of the inner wall of holes becomes small and the loss due to wear of the drill also becomes small by arranging the entry sheet given in Examples 1-2 to 1-8 on the entrance face of the workpiece bit. when cutting was performed. In addition, it was confirmed that even when the aluminum foil alone, given in Example 1-9, was used, the inner wall roughness becomes similarly small and the drill wear loss also becomes small. The quality of the holes cut in the CFRP has been improved by making the internal hole wall roughness small and, in addition, the number of holes that can be cut by a drill has been able to become large by making the drill wear loss small. <Evaluation methods> (1) Measurement of thrust force and cutting torque
[00208] The thrust force and cutting torque were measured with a six-component dynamometer from Kyowa Electronic Instruments Co., Ltd. installed under the workpiece test piece (CFRP) support. The forces in the directions of the three axes and the moments in the directions of the three axes applied to the six-component dynamometer during the drill penetration into the CFRP test body were measured, and the data were stored on a personal computer via an AD converter to measure the resistance and torque in the axis direction to the direction of the drill axis, such as the thrust force and the cutting torque, respectively. (2) Measuring drill wear loss
[00209] The image of the side face of the drill was obtained with a laser microscope (manufactured by KEYENCE COPORATION), and the wear volume was calculated by measuring, on the image, the wear cross-sectional area on the wire flank cutting edge of the drill blade, and the wear length on the bit edge is multiplied by the wear cross-sectional area, thereby calculating the wear volume. (3) Measurement of the internal diameter of the hole
[00210] The internal diameter of a hole in the CFRP was measured by a deviation from the standard test body using an electric micrometer to measure the internal diameters with a resolution of 1-m. Orifice diameters are different in the inlet, in the central portion, and in the outlet portion in the perforation, and therefore, the internal diameters were measured at the positions of 3 mm from the inlet, 6.3 mm from the inlet , and 9.5 mm from the entry in the 12.5 mm plate thickness, and these are defined and measured as the internal diameter in the entry portion, in the central portion, and in the exit portion, respectively.
[00211] The specifications of the resin components, solid lubricant, metal sheets, workpieces, cutting tools and others that were used in Examples 2-1 to 2-9 and Comparative Examples 2-1 to 2-3 are shown in Table 2-1. [Table 2-1]

<Drill wear loss assessment method>
[00212] The drill wear loss in Examples 2-1 to 2-9 and Comparative Examples 2-1 to 2-3 was assessed as follows. (4) Residual area of cornbread cutting wire
[00213] After the dirt such as the cuttings adhered to the portion of the drill tip was removed, the drill tip after drilling was photographed using a V-LASER microscope (VK-9600, manufactured by KEYENCE CORPORATION). Then, the portion area, in which the wear did not occur on the second face and the third face of the cutting edge of the drill, when the observation was made from the direction of the drill tip, was calculated using analysis software (VK Analyzer version 1.2.0.2, produced by KEYENCE CORPORATION) to be determined as the residual area of the cutting edge of the drill tip. (5) Residual amount of cutting edge with respect to new drill
[00214] The residual amount of the cutting edge with respect to a new drill tip was defined as the residual ratio of the portion area in which wear did not actually occur to the cutting edge of the drill bit after cutting when the cutting area cutting edge of a new drill was assumed to be 100. <Example of Preparation of input sheet> (Preparation of Sheet 2-A)
[00215] Using a bidirectional kneader, 40 parts by weight of polyethylene oxide (Altop MG150, manufactured by Meisei Chemical Works, Ltd.), 50 parts by weight of polyethylene glycol (PEG4000S, manufactured by Sanyo Chemical Industries, Ltd.), and 10 parts by weight of polyethylene glycol / polypropylene glycol copolymer (Blaunon P174, manufactured by Aoki Oil Industrial Co., Ltd.) were kneaded in a nitrogen atmosphere at a temperature of 150 ° C to obtain a kneaded material. A resin sheet having a thickness of 0.2 mm was prepared by molding the kneaded material obtained with an extruder. Five sheets of resin obtained above were superimposed, and laminated and integrated by thermal lamination at a temperature of 150 ° C using a laminating apparatus (OHL-2400, manufactured by ONC Inc.) to prepare Sheet 2-A as an input sheet . (Preparation of Sheet 2-B)
[00216] Using a bidirectional kneader, 40 parts by weight of polyethylene oxide (Altop MG150, manufactured by Meisei Chemical Works, Ltd.), 50 parts by weight of polyethylene glycol (PEG4000S, manufactured by Sanyo Chemical Industries, Ltd.), and 10 parts by weight of polyethylene glycol / polypropylene glycol copolymer (Blaunon P174, manufactured by Aoki Oil Industrial Co., Ltd.) were kneaded in a nitrogen atmosphere at a temperature of 150 ° C to obtain a kneaded material. A resin sheet having a thickness of 0.2 mm was prepared by molding the kneaded material obtained with an extruder. An aluminum sheet having a thickness of 0.15 mm (1N30-H18, manufactured by Mitsubishi Aluminum Co., Ltd.) of which one side of a layer of polyester-based resin (Vylonal MD-1200, manufactured by Toyobo Co ., Ltd) having a thickness of 0.01 mm was formed as an adhesive layer was separately prepared. On the aluminum sheet, on which an adhesive layer was formed, 5 sheets of resin prepared above were superimposed and, on the uppermost portion thereof, the same aluminum sheet, as prepared above, was further laminated. In laminating the aluminum foil, the resin foil and the aluminum foil were arranged so that the resin foil and the adhesive layer on the surface of the aluminum foil came into contact with each other, and the resin foil and the aluminum foil was laminated and integrated by thermal lamination at a temperature of 150 ° C using a laminating apparatus (OHL-2400, manufactured by ONC Inc.) to prepare Sheet 2-B as an input sheet. (Preparation of Sheet 2-C)
[00217] Using a bidirectional kneader, 10 parts by weight of polyethylene oxide (Altop MG150, manufactured by Meisei Chemical Works, Ltd.), 40 parts by weight of polyethylene glycol (PEG4000S, manufactured by Sanyo Chemical Industries, Ltd.), and 50 parts by weight of graphite (X-100, manufactured by Ito Graphite Co., Ltd.) were kneaded in a nitrogen atmosphere at a temperature of 150 ° C to obtain a kneaded material. A resin sheet having a thickness of 0.2 mm was prepared by molding the kneaded material obtained with an extruder. An aluminum sheet having a thickness of 0.15 mm (1N30-H18, manufactured by Mitsubishi Aluminum Co., Ltd.) of which one side of a layer of polyester-based resin (Vylonal MD-1200, manufactured by Toyobo Co ., Ltd) having a thickness of 0.01 mm was formed as an adhesive layer was separately prepared. On the aluminum sheet, on which an adhesive layer was formed, 5 sheets of resin prepared above were superimposed and, on the uppermost portion thereof, the same aluminum sheet, as prepared above, was further laminated. In laminating the aluminum foil, the resin foil and the aluminum foil were arranged so that the resin foil and the adhesive layer on the surface of the aluminum foil came into contact with each other, and the resin foil and the aluminum foil was laminated and integrated by thermal lamination at a temperature of 150 ° C using a laminating apparatus (OHL-2400, manufactured by ONC Inc.) to prepare Sheet 2-C as an input sheet. (Preparation of 2-D Sheet)
[00218] Using a bidirectional kneader, 10 parts by weight of polyethylene oxide (Altop MG150, manufactured by Meisei Chemical Works, Ltd.), 40 parts by weight of polyethylene glycol (PEG4000S, manufactured by Sanyo Chemical Industries, Ltd.), and 50 parts by weight of graphite (X-100, manufactured by Ito Graphite Co., Ltd.) were kneaded in a nitrogen atmosphere at a temperature of 150 ° C to obtain a kneaded material. A resin sheet having a thickness of 0.2 mm was prepared by molding the kneaded material obtained with an extruder. An aluminum sheet having a thickness of 0.15 mm (1N30-H18, manufactured by Mitsubishi Aluminum Co., Ltd.) of which one side of a layer of polyester-based resin (Vylonal MD-1200, manufactured by Toyobo Co ., Ltd) having a thickness of 0.01 mm was formed as an adhesive layer was separately prepared. On the aluminum sheet on which an adhesive layer was formed, 15 sheets of resin prepared above were superimposed and, on the uppermost portion thereof, the same aluminum sheet, as prepared above, was further laminated. In laminating the aluminum foil, the resin foil and the aluminum foil were arranged so that the resin foil and the adhesive layer on the surface of the aluminum foil came into contact with each other, and the resin foil and the aluminum foil was laminated and integrated by thermal lamination at a temperature of 150 ° C using a laminating apparatus (OHL-2400, manufactured by ONC Inc.) to prepare Sheet 2-D as an input sheet. <Example 2-1 to 2-9>
[00219] Each entry sheet prepared in the manner described above was fixed on an entry face of the cutting tool (for example, a cemented carbide bit) of a workpiece with a template, and drilling was carried out under the conditions shown in Table 2-2. In addition, with respect to Examples 2-2 to 2-9, the input sheet was arranged so that the aluminum sheet of the input sheet contacted the cutting face of the workpiece. Drill wear loss after drilling was evaluated. The evaluation results are shown in Table 2-3. In addition, with respect to Examples 2-5 to 2-7, cutting (air-cooled cutting) was performed while supplying compressed air with a compressor and having a temperature of 25 ° C from a position 300 mm away from the portion cutting edge for the cutting portion at 155 L / min using a nozzle having a nozzle cross-sectional area of 31.7 mm2. In addition, a titanium alloy plate and carbon fiber reinforced plastic (CFRP) as the cutting objects were superimposed in order to contact each other, and cutting was performed by arranging the CFRP in order to be on the closest side next to the entry of the cutting tool than the titanium alloy plate in Example 2-9. <Comparative Example 2-1 to 2-2>
[00220] Drilling was carried out in the same manner as in Examples 2-3 to 2-4 except that an entry sheet was not disposed on the cut face of the workpiece. Drilling conditions are described in Table 2-2. Drill wear loss was assessed in the same way as in Examples 2-3 to 2-4. The evaluation results are shown in Table 2-3. <Comparative Example 2-3>
[00221] Drilling was carried out in the same way as in Example 2-4 except that an entry sheet was not laid out on the workpiece cutting face and except that processing (cutting with cutting oil) was carried out using a cutting oil. Drilling conditions are described in Table 2-2. The drill wear loss was assessed in the same way as in Example 2-4. The evaluation results are shown in Table 2-3. In addition, cutting with a cutting oil is defined as a cutting that is performed while continuously supplying the cutting oil to a drill and the drilling portion at a flow rate of 18 L / min when cutting is performed. [Table 2-2]
[Table 2-3]

[00222] Photographs of a drill tip after drilling in Examples 2-1 to 2-9 and Comparative Examples 2-1 to 2-3 in Table 2-2 are shown in Figures 2-1 to 2-3. In addition, the residual amount of the drill cutting edge when the cutting edge area of a new drill is assumed to be 100, is shown in Figure 2-4. It was understood that when drilling was carried out, the residual amount of the cutting edge was 64 to 98% when using input sheets made from the resin sheets given in Examples 2-1 to 2-9, which was greater than the residual amount of the 5 to 51% cutting edge in case the resin sheet was not used. From these numerical values, it was understood that the input sheets made from the resin sheets given in Examples 2-1 to 2-9 had a great effect on suppressing drill wear.
[00223] Specifications of resin components, solid lubricant, sheet metal, workpiece, cutting tool and others that were used in Examples 3-1 to 3-4 and Comparative Examples 3-1 to 3 -2 are shown in Table 3-1. [Table 3-1]


[00224] In addition, in Examples 3-1 to 3-4, the burr height around the cut holes on a drill outlet side and the loss from drill wear (the residual area of the cutting edge of the drill tip and the residual amount of the cutting edge in relation to the new drill) were evaluated as follows. (6) Burr height around the cut holes in the outlet side of the drill
[00225] The exit face of the through-hole drill after cutting was photographed using a V-LASER microscope (VK-9700, manufactured by KEYENCE CORPORATION). From the data photographed, the burr height around the cut holes on one side of the drill outlet was measured using analysis software (VK_Analyzer version 1.2.0.2, produced by KEYENCE CORPORATION). When measuring a burr height, the burr height was measured at 10 points selected at random to determine the maximum value, the mean value and the standard deviation. (7) Residual cutting edge area of the drill tip
[00226] After the dirt such as cut chips adhered to the portion of the drill tip was removed, the drill tip after drilling was photographed using a V-LASER microscope (VK-9600, manufactured by KEYENCE CORPORATION). Then, the portion area, in which the wear did not occur on the second face and the third face of the cutting edge of the drill, when the observation was made from the direction of the drill tip, was calculated using analysis software (VK Analyzer version 1.2.0.2, produced by KEYENCE CORPORATION) to be determined as the residual area of the cutting edge of the drill tip. (8) Residual amount of cutting edge with respect to new drill
[00227] The residual amount of the cutting wire with respect to a new drill tip was defined as the residual ratio of the portion area in which wear did not actually occur to the cutting edge of the drill after cutting when the wire area cutting edge of a new drill was assumed to be 100. <Reference Example 3-1>
[00228] Drilling of a titanium alloy plate (material equivalent to that for aeronautical use (TI6AL4VELI)) having a thickness of 3.0 mm was continuously carried out under the condition of f 100 holes per 1 drill using a drill having a diameter of 6 mm (tip angle: 120 °, torsion angle: 40 °, without surface coating). In drilling the titanium alloy plate, drilling (air-cooled drilling) was carried out while supplying compressed air with a compressor and having a temperature of 25 ° C from a position 300 mm away from the drilling portion for the drilling portion a 155 L / min using a nozzle having a 31.7 mm2 nozzle cross-sectional area. Drilling was carried out under the processing conditions shown in Table 3-2, and the maximum burr height value around the hole drilled on a drill outlet side of the titanium alloy plate after drilling was measured for each number of holes punctured. The measurement results are shown in Table 3-3. In addition, the maximum value, average value, and standard deviation of the burr height at 10th, 50th, and 100th. holes are shown in Table 3-4. <Example 3-2>
[00229] Using a bidirectional kneader, 10 parts by weight of polyethylene oxide (Altop MG150, manufactured by Meisei Chemical Works, Ltd.), 40 parts by weight of polyethylene glycol (PEG4000S, manufactured by Sanyo Chemical Industries, Ltd.), and 50 parts by weight of graphite (X-100, manufactured by Ito Graphite Co., Ltd.) were kneaded in a nitrogen atmosphere at a temperature of 150 ° C to obtain a kneaded material. A resin sheet having a thickness of 0.2 mm was prepared by molding the kneaded material obtained with an extruder. An aluminum sheet having a thickness of 0.15 mm (1N30-H18, manufactured by Mitsubishi Aluminum Co., Ltd.) of which one side of a layer of polyester-based resin (Vylonal MD-1200, manufactured by Toyobo Co ., Ltd) having a thickness of 0.01 mm was formed as an adhesive layer was separately prepared. On the aluminum foil on which an adhesive layer was formed, 5 sheets of resin prepared above were superimposed and, on the uppermost portion thereof, the same aluminum foil, as prepared above, was further laminated. In laminating the aluminum foil, the resin foil and the aluminum foil were arranged so that the resin foil and the adhesive layer on the surface of the aluminum foil came into contact with each other, and the resin foil and the aluminum foil was laminated and integrated by thermal lamination at a temperature of 150 ° C using a laminating apparatus (OHL-2400, manufactured by ONC Inc.) to prepare Sheet 3-A as an input sheet.
[00230] Sheet 3-A obtained was disposed on a bit entrance face of the titanium alloy plate, drilling was carried out under the same conditions as in Reference Example 3-1, and the maximum burr height around of the holes drilled on a drill outlet side of the titanium alloy plate after drilling was measured for each number of holes drilled. The measurement results are shown in Table 3-3. In addition, the maximum value, average value, and standard deviation of the burr height at 10th, 50th, and 100th. orifice are shown in Table 3-4. In addition, the results of the evaluation of the drill wear loss after drilling 100 holes are shown in Table 3-5. <Example 3-3>
[00231] Sheet 3-A was prepared in the same manner as in Example 3-2. The obtained sheet 3-A was placed on a drill entrance face of a titanium alloy plate (material equivalent to that for aeronautical use (TI6AL4VELI)) having a thickness of 3.0 mm. Drilling of the titanium alloy plate on which Sheet 3-A was laid was continuously performed under the condition of 100 holes per 1 drill using a drill having a diameter of 6 mm (tip angle: 120 °, torsion angle: 40 °, without surface coating). In drilling the titanium alloy plate, drilling (air-cooled drilling) was carried out while supplying the compressed air with a compressor and having a temperature of -3.5 ° C from a position 300 mm away from the drilling portion for the drilling portion at 155 L / min using a nozzle having a 31.7 mm2 nozzle cross-sectional area. Drilling was carried out under the processing conditions shown in Table 3-2, and the maximum burr height around the hole drilled on one bit exit side of the titanium alloy plate after drilling was measured for each number of holes. punctured. The measurement results are shown in Table 33. In addition, the maximum value, average value, and standard deviation of the burr height at 10th, 50th, and 100th. holes are shown in Table 3-4. <Example 3-4>
[00232] Sheet 3-A was prepared in the same manner as in Example 3-2. The obtained sheet 3-A was placed on a drill entrance face of a titanium alloy plate (material equivalent to that for aeronautical use (TI6AL4VELI)) having a thickness of 3.0 mm. Drilling of the titanium alloy plate on which Sheet 3-A was laid was continuously performed under the condition of 100 holes per 1 drill using a drill having a diameter of 6 mm (tip angle: 120 °, torsion angle: 40 °, without surface coating). In drilling the titanium alloy plate, drilling (air-cooled drilling) was carried out while supplying the compressed air with a compressor and having a temperature of -25.5 ° C from a position 300 mm away from the drilling portion to the portion drilling at 155 L / min using a nozzle having a cross-sectional area at a nozzle tip of 31.7 mm2. Drilling was performed under the processing conditions shown in Table 32, and the maximum burr height value around the drilled hole on one bit exit side of the titanium alloy plate after drilling was measured for each number of drilled holes. The measurement results are shown in Table 3-3. In addition, the maximum value, average value, and standard deviation of the burr height in the 10th, 50th, and 100th. holes are shown in Table 3-4. <Comparative Example 3-1>
[00233] Drilling was carried out in the same way as in Reference Examples 3-1 except that air was not supplied to the drilling portion when drilling a titanium alloy plate (material equivalent to that for aeronautical use (TI6AL4VELI)) having a thickness of 3.0 mm was performed. The maximum burr height value around the holes drilled on a drill outlet side of the titanium alloy plate after drilling was measured for each number of holes drilled. The measurement results are shown in Table 3-3. In addition, the maximum value, average value, and standard deviation of the burr height in the 10th, 50th, and 100th. holes are shown in Table 3-4. In addition, the results of the evaluation of the drill wear loss after drilling 100 holes are shown in Table 3-5. <Comparative Example 3-2>
[00234] Drilling was carried out in the same way as in Reference Examples 3-1 while supplying a cutting oil (SOLEX SM-70, manufactured by SOTANI OIL. CO., LTD.) Instead of supplying air to the drilling portion when a titanium alloy plate (material equivalent to that for aeronautical use (TI6AL4VELI)) having a thickness of 3.0 mm was processed. The maximum burr height value around the hole drilled on one bit outlet side of the titanium alloy plate after drilling was measured for each number of holes drilled. The measurement results are shown in Table 3-3. In addition, the maximum value, average value, and standard deviation of the burr height in the 10th, 50th, and 100th. holes are shown in Table 3-4. In addition, the results of the evaluation of the drill wear loss after drilling 100 holes are shown in Table 3-5. [Table 3-2]
[Table 3-3]
[Table 3-4]
[Table 3-5]

[00235] Burr photographs around the hole drilled on a drill outlet side of the titanium alloy plate after processing in Reference Example 3-1, Examples 3-2 to 3-4, and Comparative Examples 3-1 to 3-2 are shown in Figure 3-1, and the measured burr heights are shown in Table 3-3 and Figure 3-2. In addition, photographs of the drill tip after drilling in Example 3-2, Comparative Example 3-1, and Comparative Example 3-2 are shown in Figure 3-3. From Reference Example 3-1, it was understood that the burr height around the holes drilled on a drill outlet side of the titanium alloy plate was reduced by performing drilling under gas cooling when drilling was performed . In addition, from Example 3-2, it was understood that the burr height was further reduced when processing was carried out while still placing the entry sheet over the entrance face of the drill when the drilling was carried out under cooling with a gas. On the other hand, in Comparative Example 31 in which drilling was carried out without conducting a gas cooling, the burr height exceeded 1000 μm. This value was a numerical value of up to 20 times higher as compared to the case where drilling was carried out under cooling with a gas. From these facts, it was understood that the heat accumulation of a titanium alloy plate during drilling was reduced by performing the drilling under cooling with a gas and, as a result, through holes were formed without the expansion of the metal around the holes processed on a drill outlet side.
[00236] On the other hand, in the case where the cutting oil was used as in Comparative Example 3-2, the burr at the exit of the drill bit from the titanium alloy plate was suppressed in a similar way to the drilling in which cooling with a gas It was conducted. However, it has been understood that the standard deviation of the burr height becomes high as compared to drilling in which cooling with a gas was conducted. In addition, the titanium alloy plate was contaminated by the cutting oil after drilling and, therefore, cleaning with a solvent was essential.
[00237] Furthermore, from Example 3-2, it was understood that the burr at the exit of the drill from the titanium alloy plate was suppressed and an effect of suppressing the wear of the drill in the case in which the entry sheet is also noted it was used in addition to gas cooling. This is considered to be due to the lubricity of the resin composition of the input sheet. Specifically, it is considered that the lubricity between the surface of the drill including a groove surface of the drill and the interior of the processed orifice is improved, the discharge of hard-to-cut particles in a difficult-to-cut metal to be cut by the drill blade is made easy, and the frequency and degree of rubbing with the drill blade can be reduced by the existence of the resin composition and thus, as a result, the wear of the drill blade is reduced. From Comparative Example 3-2, it was understood that the lubricating effect was weak and thus the wear of the bit tip progressed in the case where the cutting oil was simply used. INDUSTRIAL APPLICABILITY
[00238] By the method of cutting (e.g., drilling) a fiber-reinforced composite material (e.g., CFRP) using the input sheet of the present invention, a favorable orifice quality can be obtained as compared to conventional machining where favorable quality had not been achieved for materials difficult to cut, thus making it possible to extend the service life of drill bits for processing. Thus, the method of the present invention can be effectively applied to CFRP, which has recently been attracting attention as a structure material for aeronautics and, thus, an increase in the use of CFRP is expected, and industrial applicability is extremely high.
[00239] In addition, the method of cutting (e.g., drilling) a metal using the input sheet of the present invention can extend the life of drill bits as compared to conventional machining in which the number of holes, which can being processed by a drill, it has been low for material difficult to cut. Also, in conventional wet processing, productivity is decreased due to contamination of a workpiece or the load against a cleaning process, however, in the present invention, dry processing is possible and processing costs can be reduced. reduced when carrying out the processing using the input sheet and thus the industrial applicability is extremely high.
[00240] Furthermore, the method of cutting (e.g., drilling) a fiber-reinforced composite material and / or a metal using the cutting method of the present invention leads to an improvement in productivity as compared to conventional wet cutting. In conventional wet processing, productivity is decreased due to contamination of the workpiece or the load against a cleaning process, however, in the cutting method of the present invention, dry processing is made possible and processing costs can be reduced. reduced by using air-cooled processing, or by using air-cooled processing and the input sheet together, and thus industrial applicability is extremely high.

权利要求:
Claims (25)
[0001]
1. Sheet to be used when cutting a fiber-reinforced composite material and / or a metal for use in a material for a structure, characterized by the fact that the sheet comprises a solid lubricant capable of maintaining hardness in the cut, a water-soluble resin and water-insoluble resin, the solid lubricant comprises graphite, the water-soluble resin comprises polyethylene oxide and polyoxyethylene monostearate, the water-insoluble resin comprises poly-condensed polyethylene glycol / dimethyl terephthalate, the fiber-reinforced composite material a carbon fiber-reinforced plastic, and the metal comprises a titanium alloy or an aluminum alloy.
[0002]
2. Sheet according to claim 1, characterized in that the sheet comprises two or more layers of resin composition.
[0003]
Sheet according to either of claims 1 or 2, characterized in that the sheet has a thickness of 0.1 mm or more and 20 mm or less.
[0004]
Sheet according to any one of claims 1 to 3, characterized in that at least one face of the sheet comprises a metal sheet.
[0005]
5. Sheet according to claim 4, characterized in that an adhesive layer is formed between the metal sheet and the sheet.
[0006]
6. Sheet according to claim 5, characterized by the fact that the adhesive layer is a resin coating.
[0007]
Sheet according to any one of claims 1 to 6, characterized in that an adhesive layer is formed on a face that contacts the fiber-reinforced composite material and / or the metal.
[0008]
Sheet according to any one of claims 1 to 7, characterized in that an object to be cut is a material obtained by superimposing the metal and the fiber-reinforced composite material in order to contact each other.
[0009]
Sheet according to any one of claims 1 to 8, characterized in that it comprises metal.
[0010]
Sheet according to any one of claims 1 to 9, characterized in that it is used for cutting fiber-reinforced composite material and / or metal while cooling a cutting portion and / or a cutting tool using a gas.
[0011]
11. Cutting method for cutting the fiber-reinforced composite material and / or the metal characterized by the fact that it uses the sheet according to any one of claims 1 to 10.
[0012]
Cutting method according to claim 11, characterized by the fact that the cutting is carried out by arranging the sheet on an entry face of the cutting tool in the fiber-reinforced composite material and / or in the metal to be cut.
[0013]
13. Cutting method according to claim 11 or 12, characterized in that the cut is drilling.
[0014]
Cutting method according to any one of claims 11 to 13, characterized in that the sheet comprises an aluminum sheet.
[0015]
15. Cutting method according to any one of claims 11 to 14, characterized in that the cutting is carried out while cooling a cutting portion and / or a cutting tool using a gas having a temperature of 30 ° C or less .
[0016]
16. Cutting method according to any one of claims 11 to 15, characterized in that the cutting tool used for cutting is a bit made of cemented carbide.
[0017]
17. Cutting method according to any one of claims 11 to 16, characterized in that the cut is processed to form a through hole in the fiber-reinforced composite material and / or in the metal.
[0018]
18. Cutting method according to any one of claims 11 to 17, characterized in that the cutting is carried out while cooling a cutting portion and / or a cutting tool using a gas, an amount of the gas fed to the portion cutting edge and / or the cutting tool is 5 to 300 L / min, a gas outlet area on a gas supply device is 7 mm2 to 2000 mm2, and a distance between a gas outlet on the device to feeding the gas and the cutting portion and / or the cutting tool is from 100 mm to 500 mm.
[0019]
19. Cutting method according to any of claims 11 to 18, characterized in that the cutting is carried out while cooling a cutting portion and / or a cutting tool using a gas, and a moisture content contained in the gas fed to the cutting portion and / or the cutting tool is 20 g / m3 or less.
[0020]
20. Cutting method according to any one of claims 11 to 19, characterized in that the cutting is carried out while cooling a cutting portion and / or a cutting tool using a gas, and an oil content contained in the gas fed to the cutting portion and / or the cutting tool is 10 mg / m3 or less.
[0021]
21. Cutting method according to any one of claims 11 to 20, characterized in that the metal to be cut comprises the titanium alloy.
[0022]
22. Cutting method according to any one of claims 11 to 21, characterized in that the metal to be cut comprises the aluminum alloy.
[0023]
23. Cutting method according to any one of claims 11 to 22, characterized in that an object to be cut is a material obtained by overlapping the metal and the fiber-reinforced composite material in order to contact each other, and cutting is carried out by arranging the fiber-reinforced composite material so that it is on a side closer to an entry side of the cutting tool than the metal.
[0024]
24. Method for producing the fiber-reinforced composite material, characterized in that it comprises a step of cutting the fiber-reinforced composite material by the cutting method according to any one of claims 11 to 23.
[0025]
25. Method for producing the metal, characterized in that it comprises a step of cutting the metal by the cutting method, according to any one of claims 11 to 23.

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同族专利:

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公开号 | 公开日

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JP2017127970A|2017-07-27|

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SG11201506893UA|2015-09-29|

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MY180144A|2020-11-23|

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EP2979832A4|2016-11-23|

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RU2015145744A|2017-05-16|

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KR102182769B1|2020-11-25|

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PH12018500223B1|2018-05-28|

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PH12015502204B1|2016-02-01|

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BR112015021661A2|2017-07-18|

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EP2979832A1|2016-02-03|

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WO2014157570A1|2014-10-02|

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EP3593990A4|2017-03-10|2020-07-29|Nissan Motor Co., Ltd.|Composite material member, method for producing composite material member, and molding die for same|

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US11225625B2|2017-05-25|2022-01-18|Mitsubishi Gas Chemical Company, Inc.|Lubricant material for assisting machining process, lubricant sheet for assisting machining process, and machining method|

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JP2019042870A|2017-09-01|2019-03-22|三菱瓦斯化学株式会社|Entry sheet for cutting work and cutting work method|

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JP2019191464A|2018-04-27|2019-10-31|日東電工株式会社|Resin sheet and method for producing the same|

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CN109094151B|2018-07-05|2020-09-15|苏州广型模具有限公司|Cover plate for cutting hard alloy|

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CN109228562B|2018-07-05|2020-09-15|苏州广型模具有限公司|Cover plate for metal cutting|

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WO2021225051A1|2020-05-08|2021-11-11|三菱瓦斯化学株式会社|Support tape for processing fiber-reinforced composite materials, and machining method|

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WO2021225052A1|2020-05-08|2021-11-11|三菱瓦斯化学株式会社|Support material for processing fiber-reinforced composite materials, and machining method|

法律状态:
2018-11-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2020-03-17| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-12-01| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-01-12| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 27/03/2014, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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JP2013-065739|2013-03-27|

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JP2013065739|2013-03-27|

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JP2013239019|2013-11-19|

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JP2013-239019|2013-11-19|

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JP2013-239018|2013-11-19|

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JP2013239018|2013-11-19|

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PCT/JP2014/059000|WO2014157570A1|2013-03-27|2014-03-27|Entry sheet for cutting fiber reinforced composite material or metal and cutting method|

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