TECHNICAL FIELD
[0001] The present invention relates to a blasting method in which an abrasive is ejected
together with a compressed gas to perform processes on a workpiece including cutting,
surface polishing, deburring and paint stripping, and also relates to a blasting apparatus
for use in the blasting method.
BACKGROUND OF THE INVENTION
[0002] Blasting, which uses a cutting force that is exerted when an abrasive ejected together
with a compressed gas strikes with a workpiece to process the workpiece, is widely
used in various applications including cutting, surface polishing, surface satin finishing,
deburring, paint stripping and removal of stains such as rust.
[0003] In such blasting, when an abrasive is ejected onto a workpiece together with a compressed
gas, static electricity is generated by friction that is created when the abrasive
strikes with the workpiece or friction that is caused by the strike of the abrasive
with interior walls of a cabinet as a working space, causing the ejected abrasive
or swarf produced during cutting of the workpiece to adhere not only to the workpiece
and the interior walls of the cabinet but also to the interior walls of the ducts,
cyclone, abrasive tank and so on constituting a circulating system for the abrasive.
This makes smooth recovery or supply of the abrasive impossible.
[0004] In particular, with the increasing demand for microfabrication by blasting, abrasives
used are becoming finer and finer. As a result, abrasives are more likely to adhere
to the workpiece or the interior walls of the cabinet by static electricity and, once
attached, they are hard to remove completely by, for example, air blowing. This is
one reason for low productivity because there is a need to provide a cleaning process
after blasting to remove the abrasive adhering to the workpiece.
[0005] One possible way to prevent adhesion of abrasive due to static electricity is to
provide a voltage-applying static eliminator ("ionizer") in the blasting apparatus.
[0006] However, provision of such an expensive device increases the price of the blasting
apparatus and thus causes it to lose price competitiveness in the market. In addition,
the electrode probes provided in an ionizer to generate ions are easily get dirty
and hence need frequent maintenance. Moreover, because static electricity removal
(neutralization) is carried out while the abrasive adheres to the processing object,
static electricity remains in the areas where the abrasive has been removed.
[0007] Further, an ionizer is not structurally suited for use in a blasting apparatus because
it performs corona discharge to generate ions and can therefore be an ignition source
for dust explosion and other combustion problems.
[0008] Thus, to solve such a problem caused by static electricity, it has been suggested
that moisture is provided in the working space or the circulation pathway for the
abrasive to eliminate static electricity.
[0009] As one example of such a method, it has been suggested that a compressed gas humidified
by humidification means is introduced into a blast nozzle for abrasive ejection to
adjust the humidity in the circulating system for the abrasive in order to prevent
generation of static electricity (See Paragraph [0011] and FIG. 2 in Patent Document
1).
[0010] It has been also suggested that an ultrasonic heater or heating is used to supply
water in the form of water vapor to a compressed gas that is introduced into a blast
nozzle for abrasive ejection (See Paragraph [0026] in Patent Document 2).
[0011] As a blast nozzle for use in wet blasting designed to prevent dust generation, a
blast nozzle that mixes a compressed gas, an abrasive (medium) and water in approximately
equal amounts in a chamber formed therein and ejects a three-phase stream consisting
of gas, liquid and solid (abrasive) has been suggested (See Paragraph [0006], FIG.
1, FIG. 2 and Table 1[3] in Patent Document 3).
RELATED ARTS PATENT DOCUMENTS
[0012]
Patent Document 1: Japanese Patent No. 3846842
Patent Document 2: Japanese Unexamined Patent Application Publication 2011-237378
Patent Document 3: Japanese Unexamined Patent Application Publication 2006-297568
SUMMARY OF THE INVENTION
PROBLEM TO BE SOLVED BY THE INVENTION
[0013] Among the related arts described above, the blasting method that uses a blast nozzle
as described in Patent Document 3, which ejects as large an amount of water as 160
to 200 cc/min (See Table 1 [2] and [3] in Patent Document 3), is one of the wet blasting
methods generally called "wet blasting" or "liquid honing."
[0014] When a workpiece is processed by such a wet blasting method, the generation of static
electricity can be reduced because the surface of the workpiece gets wet with the
water ejected.
[0015] However, when a workpiece is processed by such a wet blasting method, the surface
of the workpiece absolutely gets wet. Thus, such a wet blasting method cannot be applied
to a workpiece that should avoid contact with water, such as a workpiece made of a
material that rusts easily. In addition, a washing and drying step are required after
the processing in some cases, and these processes contribute to low productivity.
[0016] In addition, in a wet blasting method in which an abrasive is ejected together with
a large amount of water as described above, the processing amount (cutting speed or
rate) decreases compared to dry blasting because the water ejected together with the
abrasive absorbs the strike energy resulting from the strike of the abrasive with
the surface of the workpiece. When conditions including the material and particle
size of the abrasive used and the ejection pressure are the same, the processing amount
(cut amount) in wet blasting decreases to approximately 1/7 to 1/14 of that in dry
blasting.
[0017] As one example, FIG. 23 and FIG. 24 show the results of measurements of the difference
in coverage between dry blasting and wet blasting. The processing was performed on
a 150 mm square glass plate at an ejection pressure of 0.3 MPa using an alumina-based
abrasive ("FUJIRUNDUM WA #1000" manufactured by Fuji Manufacturing Co., Ltd.) as the
abrasive in both dry and wet blastings.
[0018] FIG. 23 shows the changes in processing time until the coverage reaches 100% with
changes in the distance between a distal end of the blast nozzle and the workpiece
(nozzle distance), and FIG. 24 shows the changes in processing time until the coverage
reaches 100% with changes in the particle size of the abrasive. It can be understood
that the processing time necessary to achieve a coverage of 100% is longer in wet
blasting than in dry blasting in all cases.
[0019] The term "coverage" as used herein refers to the ratio in percent of a total indentation
area to a processed area. Because the processing amount can be predicted from the
degree of coverage, it can be understood from FIG. 23 and FIG. 24 that the wet blasting
is inferior in processing amount (cutting speed) to the dry blasting.
[0020] In contrast to the wet blasting described above, in the blasting method described
in Patent Document 1, the humidity in the cabinet as a working space is increased
by adding moisuture to the compressed gas used to eject the abrasive in order to prevent
the generation of static electricity and the resulting adhesion of the abrasive to
the surface of the workpiece and the interior walls of the cabinet.
[0021] However, in the blasting apparatus described in Patent Document 1, water is added
to the compressed air flowing through a compressed air supply pipe provided between
a compressed air supply source and the blast nozzle. Because the compressed air flowing
through the compressed air supply pipe has a lower velocity than the compressed air
flowing through the small-diameter flow path in the blast nozzle, when water is introduced
into the compressed air supply pipe in a liquid state, it is not atomized by strike
with the compressed air stream and remains in a liquid state, and then is introduced
into the blast nozzle, which causes aggregation of the abrasive. This causes clogging
of the blast nozzle and results in malfunction of the blasting apparatus.
[0022] Thus, although no detailed explanation about the method for adding water is given
in Patent Document 1, when water is added to the compressed air flowing through the
compressed air supply pipe, the water must be converted into water vapor by an ultrasonic
or heating method before the addition to the compressed gas as described in Patent
Document 2 to avoid the malfunction caused by such clogging. The need to provide an
additional water addition mechanism that has a function of converting water into water
vapor as described above makes the apparatus complicated in configuration and expensive.
[0023] In the methods described in Patent Documents 1 and 2, although water is added to
the compressed gas before it is introduced into the blast nozzle, the fluid that is
ejected from the blast nozzle contains no "liquid" because the water is added in the
form of water vapor (gas). Thus, the inventions described in Patent Documents 1 and
2 still remain in the category of "dry" blasting in spite of the addition of water.
[0024] Thus, the methods described in Patent Documents 1 and 2 have the advantages of being
applicable to a workpiece that should avoid contact with water as these methods can
carry out processing without wetting the surface of the workpiece and of providing
a larger processing amount (cutting speed or rate) than wet blasting.
[0025] However, in the blasting methods described in Patent Documents 1 and 2, the generation
of static electricity cannot be sufficiently prevented when the amount of water supplied
is too small to humidify the interior of the processing chamber sufficiently. On the
other hand, when the amount of water supplied is greater than the amount of saturated
water vapor, the water condenses in the working space and wets the surface of the
workpiece and the interior walls of 6the cabinet. In this case, the generation of
static electricity can be prevented but the merits of dry blasting are lost.
[0026] Thus, in the blasting method described in Patent Document 1, the humidity in the
processing chamber is detected to calculate the amount of water needed before supplying
water. The control for it is very complicated and makes the apparatus complex in configuration
and expensive.
[0027] As described above, the inventions described in Patent Documents 1 and 2 still remain
in the category of dry blasting and can therefore maintain a larger processing amount
(higher cutting speed or rate) than wet blasting, and, at the same time, can overcome
the challenge of preventing the generation of static electricity. In order to achieve
this, however, the adoption of a special apparatus configuration and complicated control
are indispensable.
[0028] On the other hand, as described in Patent Document 3, wet blasting can significantly
reduce the generation of static electricity with a relatively simple apparatus configuration
and without the need for complicated control. However, wet blasting requires washing
and drying after the processing because it wets the workpiece, and the addition of
these steps lowers its productivity. In addition, because the processing amount (cutting
speed or rate) significantly decreases in wet blasting compared to that in dry blasting,
wet blasting is much inferior in machinability (processing performance) and productivity
to dry blasting also in this respect. Each method has both advantages and disadvantages.
[0029] In view of the above, the inventors of the present invention have conducted intensive
studies for the purpose of achieving blasting that can prevent the generation of static
electricity without sacrificing the processing amount and, consequently, have found
that the generation of static electricity can be prevented and the processing amount
can be significantly improved by supplying water in an atomized state at a position
immediately upstream of the ejection port of the blast nozzle and limiting the amount
of water added to a predetermined range that is much smaller than that used in known
wet blasting.
[0030] In addition, it has been confirmed that the processing amount that can be obtained
by this method is greater than that obtained by wet blasting and, surprisingly, even
much greater than that obtained by dry blasting, and some additional effects that
cannot be expected from Patent Document 1 can be obtained in addition to the improvement
in processing amount.
[0031] The present invention has been made based on the findings obtained by the inventors
as a result of the intensive studies, and an object of the present invention is to
provide a blasting method and a blasting apparatus that can be adopted simply by adding
minor structural changes to an existing dry blasting apparatus and that not only can
prevent the generation of static electricity during blasting but also can improve
the processing amount (cutting speed or rate) compared to conventional dry blasting
and even to conventional wet blasting.
MEANS FOR SOLVING THE PROBLEMS
[0032] Means for solving the problems will be described below using reference numer als
used in embodiments of the invention. It is to be noted that these reference num erals
are only provided for clarifying the correspondence relationship between the scop
e of the claims and the embodiments of the invention, but should not be used for lim
iting the interpretation of the technical scope of the claims of the present invention.
[0033] In order to achieve the above objective, a blasting method according to the pre sent
invention in which an abrasive is ejected together with a compressed gas onto a workpiece
W through a blast nozzle 8 comprises the step of:
introducing a liquid into the blast nozzle 8 and atomizing the liquid by causing the
liquid to contact or strike with the compressed gas flowing through the blast nozzle
8 or the compressed gas ejected from the blast nozzle 8, and ejecting the liquid together
with the compressed gas and the abrasive, an amount of the liquid introduced into
the blast nozzle 8 being 0.06 cc/min to 150 cc/min.
[0034] Examples of the liquid may include pure water or hard water which contains a scale
remover added for scale removal or contains a paint or fluorescent paint added for
marking to identify the processed region in addition to what are called "waters" such
as tap water, pure water, purified water and alkali ion water.
[0035] In a blasting apparatus 1 according to the present invention for use in the bla sting
method as described above, the blasting apparatus 1 for ejecting a stream of co mpressed
gas supplied from a compressed gas supply source (not shown) and an abras ive from
a blast nozzle 8 as a mixed fluid comprises:
a liquid introduction path 88 provided in the blast nozzle 8, having one end communicable
with a liquid supply source (not shown) and an other end opened in a compressed gas
flow path in the blast nozzle 8 or at an ejection port of the blast nozzle 8, the
liquid introduction path 88 being configured to cause a liquid introduced from the
liquid supply source to strike with a stream of compressed gas flowing through the
blast nozzle 8 or a stream of compressed gas ejected from the blast nozzle 8 to atomize
the liquid, and
a flow rate control means such as a flow control valve 7 or a pump provided between
the liquid introduction path 88 and the liquid supply source.
[0036] In the blasting apparatus 1 configured as described above, the blast nozzle 8 is
a suction-type blast nozzle having a nozzle tip 82 directed in the ejection direction
of a rear nozzle 83 communicated with a compressed gas supply source (not shown),
and an abrasive introduction chamber 85 communicated with an abrasive supply source
between the rear nozzle 83 and the nozzle, the blast nozzle 8 being configured to
create a negative pressure in the abrasive introduction chamber 85 by ejection of
a stream of compressed gas from the rear nozzle 83 to suck an abrasive in the abrasive
supply source, and eject the compressed gas and the abrasive as a mixed fluid, and
the other end (distal end 88a) of the liquid introduction path 88 is opened in a compressed
gas flow path 86 formed in the rear nozzle 83 or in front of an ejection port of the
rear nozzle 83.
[0037] In the blasting apparatus 1 configured as above, the liquid introduction path 88
may be formed by a conduit inserted concentrically in the compressed gas flow path
86 provided in the rear nozzle 83, and the other end (distal end 88a) of the liquid
introduction path 88 may be opened at the ejection port of the rear nozzle 83.
[0038] The blasting apparatus 1 may further comprise a fixed quantity liquid supply means
such as a pump for supplying the liquid in the liquid supply source to the liquid
introduction path 88 in a fixed quantity.
EFFECT OF THE INVENTION
[0039] According to the blasting method and blasting apparatus of the present invention
having the configuration of the present invention as described above, the following
remarkable effects can be obtained.
[0040] Because a liquid such as water is atomized by causing it to strike with the compressed
gas flowing through the blast nozzle 8 or the compressed gas ejected from the blast
nozzle 8, and because the amount of liquid that is introduced into the blast nozzle
is limited to 0.06 to 150 cc/min, the atomized liquid is quickly evaporated into water
vapor in the space between the blast nozzle 8 and the workpiece W or on the surface
of the workpiece W because of the pressure drop after the ejection from the blast
nozzle 8 and the heat that is produced when the abrasive strikes with the workpiece
W. This increases the humidity in the processing chamber 21 to prevent the generation
of static electricity.
[0041] In addition, the blasting method of the present invention, which does not wet the
workpiece W or even if the method wets the workplace W, however, wet degrees are small
compared to known wet blasting in spite of the prevention of the generation of static
electricity as described above, is applicable to a workpiece made of a material that
should avoid contact with water by adjusting the water supply conditions, and does
not require additional steps such as washing and drying after the processing.
[0042] Further, in addition to the effect of preventing the generation of static electricity
as described above, the blasting method of the present invention has new unexpected
effects including the improvement of the processing amount (cutting speed or rate)
that is greater than that obtainable by a known dry blasting method, prevention of
sticking or lodging of the abrasive into the surface of the workpiece, reduction of
consumption of the abrasive, improvement of cutting speed or rate and efficiency of
removal of a coated film and burrs, reduction of elongation and warpage of the workpiece,
and prevention of temperature rise of the workpiece and the resulting reduction of
burning of the product.
[0043] Although the reason for the effects, such as the increase in the cutting speed or
rate, is not known, it seems probable that the effects result from the fact that the
liquid which is sprayed in an atomized state as a result of the strike with a stream
of compressed gas and turns into microdroplets because of the rapid decrease in pressure
after the ejection from the blast nozzle, evaporates quickly in the space in front
of the workpiece or on the surface of the workpiece upon contact with the workpiece
heated by the strike with the abrasive, and absorbs a large amount of vaporization
heat from the surrounding air and the surface of the workpiece during evaporation
(spray cooling).
[0044] When consideration is given to the improvement in the processing amount (cutting
speed or rate) among the effects described above as one example, it is concluded that
one possible reason for the smaller processing amount (cutting speed or rate) in wet
blasting than in dry blasting is that the water ejected together with the abrasive
forms a water film on the surface of the workpiece and the water film absorbs the
strike energy of the abrasive just about being struck with the surface of the workpiece.
[0045] However, in the method of the present invention, because the liquid ejected in an
atomize state evaporates immediately after exiting the blast nozzle 8 as described
above, the workpiece W does not get wet or even if it gets wet, however, wet degrees
are small compared to known wet blasting. It is therefore believed that the strike
energy can be maintained at the same level as in dry blasting, and, consequently,
a large processing amount can be maintained even when a liquid is ejected.
[0046] On the other hand, one reason for the lower cutting speed or rate in dry blasting
is believed to be that the surface temperature of the workpiece increases as a result
of the strike with the abrasive and the temperature rise makes the surface of the
workpiece soft enough to absorb the strike energy of the abrasive.
[0047] In contrast to this, in the method of the present invention, the spray cooling as
described above prevents the increase in surface temperature of the workpiece and
enables the processing to be carried out with the surface hardness of the workpiece
maintained. This is believed to be the reason why the processing amount (cutting speed
or rate) is improved compared even to dry blasting.
[0048] The blasting method of the present invention described above can be achieved by making
relatively simple structural changes in the configuration of an existing dry blasting
apparatus, i.e., by replacing the blast nozzle with a blast nozzle 8 that can eject
a liquid as described above, and adding a liquid supply source for supplying the liquid
to the blast nozzle 8 and a flow rate control means such as a flow control valve 7
or a pump for controlling the amount of the liquid to be supplied to the blast nozzle
8.
[0049] In the configuration in which a conduit is concentrically inserted as the liquid
introduction path 88 in the compressed gas flow path 86 of the rear nozzle 83 of the
blast nozzle 8 with an other end (distal end 88a) opened at the ejection port of the
rear nozzle 83, the negative pressure resulting from the ejection of the compressed
gas from the rear nozzle 83 can be used to introduce the liquid through the liquid
introduction path 88, and there is no need to provide an additional means for supplying
the liquid such as a pump, furthermore, the introduction of the liquid is started
and stopped in synchronization with the start and stop of the introduction of the
compressed gas into the blast nozzle 8. Consequently, there is no need to provide
an additional means for starting and stopping the supply of the liquid. Further, existing
facilities can be used as long as the rear nozzle 83 of the blast nozzle 8 is replaced.
[0050] However, a fixed quantity supply means such as a pump for supplying a fixed quantity
of liquid from the liquid supply source to the liquid introduction path 88 may be
provided. In this case, the design latitude for the position at which the liquid is
introduced into the blast nozzle 8 increases and the liquid can be supplied more stably
and reliably.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051]
FIG. 1 is an explanatory diagram illustrating one configuration example of a blasting
apparatus of the present invention;
FIGS. 2A and 2B are explanatory diagrams of a blast nozzle provided in the blasting
apparatus of the present invention. FIG. 2A is a cross-sectional view of the entire
blast nozzle and FIG. 2B is an explanatory diagram illustrating modifications of a
nozzle tip;
FIGS. 3A and 3B are explanatory diagrams of the position at which a liquid is introduced
into the blast nozzle (suction-type). FIG. 3A is an explanatory diagram of the position
at which a liquid is introduced into a blast nozzle having an ordinary nozzle tip
and FIG. 3B is an explanatory diagram of the position at which a liquid is introduced
into a blast nozzle having a divided-continuous nozzle tips (822, 821);
FIGS. 4A and 4B are explanatory diagrams of the position at which a liquid is introduced
into the blast nozzle (direct-pressure type). FIG. 4A is an explanatory diagram of
the position at which a liquid is introduced into a blast nozzle having an ordinary
nozzle tip and FIG. 4B is an explanatory diagram of the position at which a liquid
is introduced into a blast nozzle having a divided-continuous nozzle tips (822', 821');
FIG. 5 is a cross-sectional view of another blast nozzle provided in the blasting
apparatus of the present invention;
FIG. 6 is a graph showing the changes in processing amount with changes in water supply
amount (boron plate);
FIG. 7 is a graph showing the changes in processing amount with changes in water supply
amount (carbide plate);
FIG. 8 is a graph showing the changes in processing amount with changes in water supply
amount (urethane rubber plate);
FIG. 9 is a graph showing the changes in processing amount with changes in water supply
amount (aluminum plate);
FIG. 10 is a graph showing the changes in processing amount with changes in water
supply amount (stainless plate);
FIG. 11 is a graph showing the changes in processing amount with changes in water
supply amount (iron plate);
FIG. 12 is a graph showing the changes in processing amount with changes in water
supply amount (acrylic plate);
FIG. 13 is a graph showing the changes in processing amount with changes in water
supply amount (epoxy glass plate);
FIG. 14 is a graph showing the changes in processing amount with changes in water
supply amount (granite);
FIG. 15 is a graph showing the changes in the amount of abrasive stuck with changes
in water supply amount (urethane rubber);
FIG. 16 is a graph showing the changes in the amount of abrasive stuck with changes
in water supply amount (stainless);
FIG. 17 is a graph showing the changes in the amount of abrasive stuck with changes
in water supply amount (iron);
FIG. 18 is a graph showing the changes in the amount of abrasive stuck with changes
in water supply amount (acrylic);
FIG. 19 is a graph showing the changes in the amount of abrasive stuck with changes
in water supply amount (epoxy glass);
FIG. 20 shows photographs showing the particle structures of an abrasive after use
in a blasting method of the present invention (example) and an abrasive used in a
dry blasting method (comparative example);
FIGS. 21A and 21B show surface roughness data of polycarbonate products after stripping
paint by blasting. FIG. 21A shows the data of a product treated by a method of the
present invention (example) and FIG. 21B shows the data of a product treated by dry
blasting (comparative example);
FIGS. 22A and 22B show surface roughness data of polyphenylene sulfide products after
deburring by blasting. FIG. 22A shows the data of a product treated by a method of
the present invention (example) and FIG.22B shows the data of a product treated by
dry blasting (comparative example);
FIG. 23 is a correlation diagram showing the changes in time until the coverage reaches
100% with changes in nozzle distance; and
FIG. 24 is a correlation diagram showing the changes in time until the coverage reaches
100% with changes in particle size of the abrasive.
MODE FOR CARRYING OUT THE INVENTION
[0052] An embodiment of the present invention is next described below with reference to
the accompanying drawings.
1. Blasting apparatus
(1) General configuration
[0053] A configuration example of a blasting apparatus 1 of the present invention is shown
in FIG. 1.
[0054] As shown in FIG. 1, the blasting apparatus 1 includes a compressed gas supply source
(not shown), an abrasive tank 3 as an abrasive supply source, and a blast nozzle 8
for merging a compressed gas introduced from the compressed gas supply source with
an abrasive from the abrasive tank 3 and ejecting the mixture. In the illustrated
embodiment, the blasting apparatus 1 is constituted as what is called a "suction-type"
blasting apparatus in which the abrasive from the abrasive tank 3 which is sucked
by a negative pressure created in the blast nozzle 8 by the introduction of the compressed
gas from the compressed gas supply source, is merged with a stream of the compressed
gas and ejected onto a workpiece W. In this embodiment, the gas is compressed air.
[0055] In the illustrated embodiment, the blasting apparatus 1 includes a processing chamber
21 formed in a cabinet 2 accommodating the blast nozzle 8, the abrasive tank 3 which
is a cyclone communicated with a hopper formed at a lower end of the processing chamber
21 via an abrasive recovery pipe 91, and a dust collector 5 for sucking the inside
of the abrasive tank 3. When the abrasive is ejected from the blast nozzle 8 accommodated
in the processing chamber 21 with an exhauster 6 in the dust collector 5 being actuated
to suck the inside of the abrasive tank 3 as a cyclone, the ejected abrasive is introduced
into the abrasive tank 3 through the abrasive recovery pipe 91 together with swarf
and other objects. As a result of air classification in the abrasive tank 3, reusable
abrasive is recovered to the bottom of the abrasive tank 3 and crushed abrasive and
dust are sucked and removed by the dust collector 5. The recovered abrasive can be
cyclically used.
[0056] The basic configuration of the blasting apparatus 1 is not limited to the circulation
type configuration in which the abrasive is cyclically used as described above. For
example, the blasting apparatus 1 may have a batch-type configuration in which the
abrasive after use is not reused but is disposed of after each use. In this case,
the configuration provided for air classification of the dust including swarf and
the abrasive may be omitted and the dust collector 5 may be used to remove or collect
the abrasive after use and dust in the processing chamber 21 together.
[0057] While the description is made based on the assumption that the blasting apparatus
is constituted as a suction-type in the illustrated example, the present invention
is also applicable to a direct-pressure type blasting apparatus in which a compressed
gas in a pressurized tank and an abrasive are introduced together into a blast nozzle
and ejected therefrom, for example. Any of various structures employed in known blasting
apparatuses can be employed as a basic configuration of the blasting apparatus.
[0058] In the blasting apparatus 1 of the present invention, a liquid, in this embodiment,
water, is introduced into the blast nozzle 8. The water is caused to strike with a
stream of compressed gas flowing through the blast nozzle 8 to atomize it into droplets
with an average particle diameter of 1 mm or less, preferably 300 [µm or less, more
preferably 100 µm or less, and the atomized liquid is incorporated into the compressed
gas immediately before it is ejected onto the workpiece W. In this way, the atomized
liquid can be sprayed onto the workpiece W together with the abrasive.
[0059] In order to make it possible to incorporate the atomized liquid into the compressed
gas ejected toward the workpiece W as described above, the blasting apparatus 1 of
the present invention is provided with a liquid supply source (not shown) for supplying
a liquid (water) to the blast nozzle 8, and has a liquid introduction path 88 in the
blast nozzle 8 through which the water supplied from the liquid supply source is introduced
into the blast nozzle 8, and a flow rate control means constituted of a flow control
valve 7 or a pump in a conduit communicating the liquid supply source and the liquid
introduction path 88 of the blast nozzle 8.
(2) Blast nozzle
[0060] An example of a configuration of the blast nozzle 8 provided in the blasting apparatus
1 of the present invention is shown in FIG. 2.
[0061] The blast nozzle 8 shown in FIG. 2 has the basic structure of an existing suction-type
blast nozzle, and is constituted of a body 81 forming a primary part of the blast
nozzle 8, and a nozzle tip 82 and a rear nozzle 83 attached to the body 81.
[0062] The body 81 is provided with an abrasive introduction port 84 through which the abrasive
supplied from the abrasive tank 3 as an abrasive supply source is introduced, and
an abrasive introduction chamber 85 formed therein in communication with the abrasive
introduction port 84 and having the shape of a generally cylindrical container.
[0063] The nozzle tip 82 attached to the body 81 has a conical inner surface 82a tapered
conically, and is configured such that the abrasive introduction chamber 85 formed
in the body 81 and a flow path in the nozzle tip having the conical inner surface
82a are communicated with each other when the nozzle tip 82 is attached to a front
end side of the body 81.
[0064] As shown in FIG. 2B, the nozzle tip 82 may be either one having a circular opening
(round type) or one having a slit-like opening (slit type), and the flow path formed
therein may have a venturi-type shape with a cross-section that first narrows from
its entrance and then widens again toward the exit.
[0065] The rear nozzle 83 is attached to a rear end side of the body 81 with its distal
end pointing toward the center of the conical inner surface 82a of the nozzle tip
82. The blast nozzle 8 is the same in configuration as a known suction-type blast
nozzle 8 in that when the compressed gas from the compressed gas supply source (not
shown) is ejected from the rear nozzle 83, the abrasive from the abrasive tank 3,
which is sucked into the abrasive introduction chamber 85 by a negative pressure created
by the ejection of the compressed gas from the rear nozzle 83, is merged into the
compressed gas ejected from the rear nozzle 83 and ejected from the distal end of
the nozzle tip 82.
[0066] The blast nozzle 8 for use in the blasting apparatus 1 of the present invention is
provided with a liquid introduction path 88 through which the liquid from the liquid
supply source (not shown) is introduced into the blast nozzle 8 so that the liquid
can be atomized and sprayed as described above. The liquid introduction path 88 has
a distal end 88a opening in a compressed gas flow path formed in the blast nozzle
8, for example, in a compressed gas flow path 86 formed in the rear nozzle 83, in
front of the delivery port of the rear nozzle 83, in the flow path in the nozzle tip
82, or at the ejection port of the blast nozzle 8, so that the liquid can be atomized
by causing it to strike with a high-speed stream of compressed gas flowing through
the blast nozzle 8 or a high-speed stream of compressed gas ejected from the blast
nozzle 8 and sprayed.
[0067] In the present invention, a mesh material may be provided in the opening at the distal
end 88a of the liquid introduction path 88 so that the liquid can be atomized in a
more preferred manner when the liquid ejected from the distal end 88a of the liquid
introduction path 88 is atomized by causing it to strike with a high-speed stream
of compressed gas. In this case, the liquid is atomized in a more preferred manner
because the liquid supplied through the liquid introduction path 88 is preliminarily
atomized through the mesh material before it is caused to strike with the high-speed
stream of compressed gas.
[0068] The mesh material for use in the present invention is not particularly limited. For
example, various types of mesh materials, such as one obtained by weaving wires made
of a metal or a resin into a flat mesh or one formed by creating fine pores through
a plate, can be used.
[0069] In the embodiment shown in FIG. 2, the conduit as the liquid introduction path 88
is arranged concentrically in the compressed gas flow path 86 formed through the rear
nozzle 83 so that the compressed gas can flow between the interior wall of the compressed
gas flow path 86 and the exterior wall of the liquid introduction path 88, and the
distal end 88a of the liquid introduction path 88 is opened at the same position as
the opening of the rear nozzle 83 in order to cause the liquid ejected from the distal
end 88a of the liquid introduction path 88 to strike with the high-speed high-pressure
stream of compressed gas flowing along the outer periphery of the liquid to atomize
it.
[0070] In the blasting apparatus 1 of this embodiment constituted as described above, because
the liquid is sucked out of the distal end 88a of the liquid introduction path 88
by the effect of a negative pressure created in the abrasive introduction chamber
85 and merged with the stream of compressed gas, the liquid can be atomized in the
blast nozzle 8 without a fixed quantity liquid supply device such as a pump for supplying
the liquid from a liquid supply source (not shown) such as a liquid tank into the
blast nozzle 8. In addition, because the introduction of the liquid from the liquid
supply source automatically starts and stops in synchronization with the start and
stop of the introduction of the compressed gas into the blast nozzle 8, dripping and
other troubles caused by failure to start or stop the supply of the liquid does not
occur.
[0071] The configuration for causing the liquid to strike with the stream of compressed
gas is not limited to the configuration shown in FIG. 2, and the configuration of
any of various known gas-blast type two-fluid nozzles (atomizers) may be applied to
that of the rear nozzle 83. As described above, the introduction of the liquid into
the blast nozzle may be achieved by fixed quantity liquid introduction means, such
as a pump, provided in the tank as a liquid supply source or in the pipe between the
liquid supply source and the blast nozzle instead of the configuration that uses a
negative pressure in the abrasive introduction chamber.
[0072] The position at which the liquid is supplied into the blast nozzle 8 may be different
from the position shown in FIG. 2. For example, the liquid may be introduced into
the suction-type blast nozzle through a space formed around the outer periphery of
a distal portion of the rear nozzle 83 of the blast nozzle 8 as the liquid introduction
path 88 and opening toward the distal end of the rear nozzle 83 as shown in FIG. 5.
When the liquid is introduced into the liquid introduction path 88, it is ejected
to surround the outer periphery of the compressed gas ejected from the rear nozzle
83 and atomized upon strike with the high-speed, high-pressure stream of compressed
gas.
[0073] Further, as shown in FIG. 3A, the distal end 88a of the liquid introduction path
88 may be opened in the abrasive introduction chamber 85 or at the position where
the ejection port of the blast nozzle 8 is formed so that the liquid in the liquid
introduction path 88 can be sucked out by a negative pressure created by the stream
of compressed gas and caused to strike with the stream of compressed gas flowing through
the blast nozzle 8 or the stream of compressed gas ejected from the blast nozzle 8.
Alternatively, the liquid in the liquid supply source may be supplied in a fixed quantity
by a pump into a compressed gas flow path formed through the rear nozzle 83 or into
a compressed gas flow path formed through the nozzle tip 82. In place of or in addition
to introducing the liquid at the position described with reference to FIG. 2A or FIG.
5, the liquid may be introduced at one or more of the positions shown in FIG. 3A.
[0074] The nozzle tip 82 may be constituted to have two divided nozzle tips 821 and 822
coaxially and sequentially arranged in a longitudinal direction as shown in FIG. 3B
so that, when a fluid is introduced from the nozzle tip 821 having a small-diameter
flow path formed therethrough into the nozzle tip 822 having a large-diameter flow
path formed therethrough, air is sucked in through a vent 823 formed at the interface
between the nozzle tips 821 and 822 and ejected after merged water with the stream
of abrasive. When a liquid is introduced into the nozzle tip 82 having such a structure,
the liquid may be introduced through the vent 823 of the nozzle tip 82.
[0075] In a direct-pressure type blast nozzle, the distal end 88a of the liquid introduction
path 88 may be opened at the position where the ejection port of the blast nozzle
8 is formed as shown in FIG. 4A so that the liquid in the liquid introduction path
88 is sucked out by the effect of a negative pressure created by the ejection of the
compressed gas and caused to strike with the compressed gas ejected from the blast
nozzle 8. Alternatively, the distal end 88a of the liquid introduction path 88 may
be opened in a compressed gas flow path in a rear nozzle 83' provided in a blast nozzle
body 81' or in a compressed gas flow path formed through a nozzle tip 82' attached
to the distal end of the blast nozzle 8, and the liquid from the liquid supply source
may be introduced into the blast nozzle 8 by a pump. The liquid can be introduced
at any one or more of these positions.
[0076] A divided-continuous nozzle tip having two longitudinally-divided nozzle tips 821'
and 822' arranged coaxially and sequentially in a longitudinal direction as shown
in FIG. 4B can be also used as a nozzle tip 82' in the configuration of the above
direct-pressure type blast nozzle. In this case again, the liquid may be introduced
through a vent 823' provided at the interface between the two nozzle tips 821' and
822'.
[0077] A flow rate control means for controlling the flow rate of liquid that is introduced
into the liquid introduction path 88 is provided in the conduit extending from the
liquid supply source to the liquid introduction path 88 so that the amount of liquid
that is introduced into the blast nozzle 8 can be adjusted.
[0078] In this embodiment, a flow control valve 7 is provided as the flow rate control means
in the conduit between the liquid introduction path 88 having the distal end 88a opened
at a position where a negative pressure is created and the liquid supply source. While
a valve whose opening is adjustable at eight levels is used as the flow control valve
7 in this embodiment, a valve whose opening is continuously adjustable may be used.
Any type of valve may be used as long as the flow rate of liquid can be adjusted.
[0079] A pump is provided as the flow rate control means between the liquid introduction
path 88 having the distal end 88a opened at a position other than the position where
a negative pressure is created and the liquid supply source so that the amount of
liquid that is supplied into the blast nozzle 8 can be controlled by controlling the
operating speed of the pump, such as the rotational speed of the motor for driving
the pump.
[0080] A pump may be provided between the liquid introduction path 88 and the liquid supply
source as shown as modifications in FIG. 3A and FIG. 4A even when the distal end 88a
of the liquid introduction path 88 is opened at the position where a negative pressure
is created, and a flow control valve may be provided on the secondary side of the
pump so that the flow rate of liquid that is introduced into the blast nozzle 8 can
be adjusted even when a pump is provided.
[0081] Further, the liquid introduction path 88 may be connected to a water intake (faucet)
of the water supply system so as to use the water supply system as a liquid supply
source, without providing a container such as a liquid tank as a liquid supply source.
In this case, the feed-water pressure from the water supply system may be used to
introduce the liquid into the liquid introduction path 88 and omit the installation
of the pump.
2. Effects
[0082] Taking the case as an example where the blasting apparatus 1 in FIG. 1 constituted
as described above is equipped with the blast nozzle 8 shown in FIGS. 2A and 2B, the
explanation of its operation is given below.
[0083] An abrasive is placed in the abrasive tank 3 as an abrasive supply source, and the
liquid tank (not shown) as a liquid supply source is filled with a liquid such as
water. In this state, the introduction of a compressed gas into the blast nozzle 8
from the compressed gas supply source (not shown) is started.
[0084] When the introduction of the compressed gas is started in this way, a high-speed
compressed gas is ejected from the distal end of the rear nozzle 83 of the blast nozzle
8. Then, in the nozzle tip 82, a high-speed gas stream toward its ejection port is
generated.
[0085] Thus, the gas in the abrasive introduction chamber 85 is drawn into the nozzle tip
82 by the stream of compressed gas. As a result, a negative pressure is created in
the abrasive introduction chamber 85, and the abrasive from the abrasive tank 3 is
introduced into the abrasive introduction chamber 85 through the abrasive introduction
port 84. At the same time, the liquid in the liquid introduction path 88 is sucked
out of the distal end 88a of the liquid introduction path 88 by the negative pressure.
The sucked-out liquid is atomized by the high-speed compressed gas ejected from the
rear nozzle 83 and incorporated into the compressed gas together with the abrasive
before it is sprayed from the blast nozzle 8.
[0086] In the blasting method of the present invention, a preferred ejection amount of the
abrasive is 2 g/min to 20 kg/min, whereas the amount of liquid that is introduced
into the blast nozzle 8 is as relatively small as 0.06 cc/min to 150 cc/min. In addition,
the liquid ejected together with the abrasive is atomized upon strike with the high-speed
compressed gas flowing through the blast nozzle 8 before being sprayed from the blast
nozzle 8. Further, because the compressed gas ejected from the blast nozzle 8 undergoes
a rapid decrease in pressure and because the surface of the workpiece is heated by
the strike with the abrasive, the sprayed liquid evaporates in the space between the
blast nozzle 8 and the workpiece W or on the surface of the workpiece W and absorbs
a large amount of vaporization heat from the space and the surface of the workpiece
W.
[0087] As a result, it is believed that, when blasting is carried out by the method of the
present invention, not only the generation of static electricity is prevented by the
increase in humidity resulting from the evaporation of the liquid but also several
other benefits, including the improvement of the cutting speed or rate, improvement
of the efficiency of removal of a coated film or burrs, prevention of sticking or
lodging of the abrasive into the surface of the workpiece W, and prevention of warpage
or elongation of the workpiece, can be obtained in contrast to ordinary blasting that
does not involve spraying of a liquid.
[0088] In other words, in the method of the present invention, water is ejected but the
ejected water evaporates quickly as described above. Thus, the surface of the workpiece
does not get wet or even if it gets wet, however, wet degrees are small compared to
known wet blasting, and the formation of a water film that absorbs the strike energy
of the abrasive on the surface of the workpiece is prevented.
[0089] On the other hand, although the above-mentioned formation of a water film is prevented,
because the sprayed water absorbs a large amount of vaporization heat when it evaporates,
the surface temperature of the workpiece is prevented from increasing. As a result,
the absorption of the strike energy from the abrasive due to softening of the surface
of the workpiece, a coated film formed on the surface of the workpiece or burrs as
the object of removal can be prevented. This is believed to be the reason why the
processing amount is improved and the efficiency of removal of a coated film or burrs
is improved compared to dry blasting in which such softening can occur.
[0090] It is believed that the sticking or lodging of abrasive as described above also occurs
because the ejected abrasive sticks into the surface of the workpiece more easily
as the surface of the workpiece becomes softer with increase in temperature.
[0091] In addition, it is believed that elongation and warpage that reduce the dimensional
stability of the product occurs because of elongation of the workpiece due to temperature
rise and a difference in elongation between the front and back sides of the workpiece,
respectively.
[0092] It is, therefore, believed that the above effects can be obtained when blasting is
carried out by the method of the present invention because the workpiece is protected
from wetting and temperature rise.
[0093] It has been also observed that the abrasive recovered in the blasting method of the
present invention has undergone less cracking and chipping than that of conventional
blasting carried out without spraying a liquid although its principle is unknown.
This means that the blasting method of the present invention can reduce the rate of
consumption of the abrasive.
[0094] As described above, the blasting method of the present invention can effectively
prevent the generation of sparks caused by accumulation of static electricity during
processing and can therefore eliminate not only breakage or failure of the products
themselves, in particular, items such as electronic components but also breakage of
electrodes and other parts provided on the product.
[0095] In addition, not only the products are prevented from accumulation of static electricity
but also the abrasive and the abrasive circulating system including the interior walls
of the cabinet and the interior walls of the ducts are prevented from accumulation
of static electricity. Several other benefits can be achieved including the prevention
of the abrasive from adhering to the interior of the cabinet 2 and the abrasive tank
3, and improvement of abrasive recovery efficiency resulting from a decrease in the
amount of abrasive that is not recovered but flows to a dust collector, because the
abrasive in a swirling flow strikes with the abrasive adhering to the interior of
the cyclone-type abrasive tank 3.
[0096] In addition, the blasting method of the present invention has beneficial effects
that cannot be predicted from conventional arts including the improvement of processing
amount as compared to ordinary dry blasting, improvement of the efficiency of removal
of a coated film or burrs, reduction of surface roughness, prevention of change in
color due to burning, prevention of sticking or lodging of abrasive that may cause
contamination during subsequent painting or plating, and prevention of warpage and
elongation of the workpiece that reduces the dimensional stability of the product
in addition to the effect of preventing the generation of static electricity.
Examples
[0097] The results of tests conducted to confirm that the blasting method of the present
invention can provide the above-mentioned benefits are shown below.
[0098] The dry blasting (comparative example) and the blasting of the present invention
(examples) were both carried out using a suction-type blasting apparatus (see FIG.
1 for the outline of the structure) as the blasting apparatus. In the blasting of
the present invention (example), which involves the supply of a liquid (water), either
the blast nozzle having the liquid introduction path 88 in the compressed gas flow
path 86 of the rear nozzle 83 as described with reference to FIG. 2A or the blast
nozzle 8 having a chamber as the liquid introduction path 88 around a distal portion
of the rear nozzle 83 as described with reference to FIG. 5 was used. On the other
hand, the dry blasting (comparative example) was carried out by ejecting an abrasive
from the blast nozzle 8 shown in FIG. 2A or FIG. 5 without supplying water to conduct
measurement, or using a blast nozzle 8 equipped with an ordinary rear nozzle (having
a structure obtained by removing the liquid introduction path 88 from the rear nozzle
83 of the blast nozzle 8 having a structure shown in FIG. 2(A)) to conduct measurement.
(1) Confirmation of antistatic effect
[0099] Blasting was performed on an acrylic plate (100 mm × 100 mm × 5 mm) and the accumulated
amount of static electricity was measured.
[0100] Nylon beads (NB) #0303 (average particle diameter: 300 µm) manufactured by Fuji Manufacturing
Co., Ltd. were used as the abrasives, and the abrasives were ejected at a nozzle distance
of 160 mm and an ejection pressure of 0.3 MPa for 40 minutes.
[0101] The processing was carried out using a circulating-type blasting apparatus having
a structure shown in FIG. 1 and equipped with the blast nozzle 8 described with reference
to FIG. 2A. The flow control valve 7 for adjusting the amount of water introduced
into the blast nozzle 8 was gradually opened from its full-closed position to increase
the water supply amount. The changes in the accumulated amount of static electricity
in the acrylic plate (measuring instrument: 709 STATIC SENSOR manufactured by 3M was
used) and the changes in temperature and humidity in the processing chamber were measured
and the condition in the processing chamber was observed. The results of measurements
are shown in Table 1.
[Table 1]
Result of test for static electricity accumulation |
Ejected amount of abrasive |
Water supply amount (cc/min) |
Accumulated amount of static electricity (kV) |
Temperature in the processing chamber (humidity) |
|
0 |
-23.4 |
21.4°C (24%) |
|
0.06 |
-14.0 |
21.3°C (24%) |
|
0.15 |
-6.4 |
21.2°C (25%) |
|
0.50 |
-5.6 |
21.3°C (24%) |
|
1.0 |
-5.8 |
22.4°C (23%) |
550 g/min |
2.0 |
-8.0 |
21.5°C (24%) |
|
3.0 |
-9.3 |
18.7°C (25%) |
|
4.0 |
-7.6 |
19.1°C (24%) |
|
5.0 |
-6.2 |
19.3°C (24%) |
|
6.0 |
-7.4 |
20.6°C (24%) |
|
7.0 |
-3.9 |
20.4°C (24%) |
|
8.1 |
-5.0 |
19.7°C (24%) |
|
8.0 |
-9.9 |
20.1°C (25%) |
|
9.1 |
-7.4 |
21.6°C (25%) |
|
10.0 |
-5.2 |
21.5°C (25%) |
|
11.0 |
-5.2 |
21.2°C (24%) |
1150 g/min |
12.2 |
-6.4 |
21.2°C (24%) |
|
13.1 |
-5.6 |
20.8°C (25%) |
|
14.1 |
-4.0 |
20.8°C (25%) |
|
15.0 |
-2.0 |
21.3°C (25%) |
|
16.2 |
-2.1 |
21.1°C (25%) |
|
17.1 |
-2.2 |
21.2°C (25%) |
[0102] It was confirmed from the above results that the accumulated amount of static electricity
was decreased by 40% or more simply by supplying as small an amount of water as 0.06
cc/min compared to the value obtained when dry blasting was carried out without supplying
water with the flow control valve 7 fully closed. It was therefore confirmed that
spraying even a relatively small amount of water was highly effective in preventing
the generation of static electricity.
[0103] After that, the accumulated amount of static electricity further decreased as the
water supply amount was increased. The accumulated amount of static electricity decreased
by 90% or more at 15.0 cc/min compared to the value obtained when no water was supplied.
[0104] The abrasive had adhered everywhere in the cabinet including the surface of the workpiece,
the interior walls of the cabinet, rubber hoses and the surface of the blast nozzle
after blasting was carried out without supplying water with the flow control valve
7 fully closed, whereas adhesion of abrasive due to static electricity was not observed
after blasting was carried out by the method of the present invention although accumulation
of abrasive was observed on uneven parts of the walls in the cabinet.
(2) Confirmation of increase in processing amount (cutting speed or rate)
(2-1) Measurement of changes in processing amount with changes in water supply amount
[0105] The blast nozzle shown in FIG. 2A was used, and the opening of the flow control valve
was adjusted to measure how the processing amount (cut amount) for the workpiece changed
with changes in the water supply amount to the blast nozzle.
[0106] Test pieces made of the materials shown in Table 2 below were processed using an
alumina abrasive ("FUJIRUNDUM A#60" manufactured by Fuji Manufacturing Co., Ltd.)
at an ejection distance of 120 mm and an ejection pressure of 0.4 MPa under conditions
shown again in Table 2. The weights of the test pieces before and after the processing
were measured, and the decrease in weight was taken as the cut amount.
[Table 2]
Test pieces and measurement method |
Test pieces |
Dimensions (mm) |
Amount of abrasive used (kg) |
Processing time |
Boron plate (B4C) |
106×60×5.5 |
6 |
60 (min) |
Carbide plate (D-40) |
60×45×7 |
3 |
30 (min) |
Urethane rubber (TR100-70°) |
80×80×10 |
3 |
60 (min) |
Aluminum plate |
80×80×10 |
3 |
30 (min) |
Stainless plate (SUS304) |
100×100×6 |
3 |
30 (min) |
Iron plate (SS41) |
100×100×6 |
3 |
30 (min) |
Acrylic plate (thermoplastic) |
80×80x5 |
3 |
90 (sec) |
Epoxy glass plate (thermosetting) |
80×80×5 |
3 |
90 (sec) |
Granite |
80×80×10 |
3 |
30 (sec) |
[0107] The results of measurement on each test piece are shown in Tables 3 to 11 and FIGS.
6 to 14. The ratio of decrease in Tables 3 to 11 is the ratio of the decrease in weight
to the decrease in weight obtained when processing was carried out without supplying
water.
[Table 3]
Changes in processing amount with changes in water supply amount (boron plate) |
|
Water supply amount (cc/min) |
Weight of test piece (g) |
Before processing |
After processing |
Decrease in weight (ratio of decrease) |
Comparative example |
0 |
79.59 |
78.54 |
-1.05 (1) |
|
0.1 |
82.15 |
81.00 |
-1.15 (1.1) |
|
0.5 |
78.97 |
77.45 |
-1.52 (1.45) |
|
2.0 |
81.56 |
78.86 |
-2.70 (2.57) |
|
3.0 |
83.56 |
80.50 |
-3.06 (2.91) |
Example |
5.0 |
83.37 |
80.33 |
-3.04 (2.89) |
7.0 |
83.91 |
80.86 |
-3.05 (2.90) |
|
10.0 |
83.50 |
80.41 |
-3.09 (2.94) |
|
13.0 |
79.14 |
76.14 |
-3.00 (2.86) |
|
18.0 |
78.85 |
75.84 |
-3.01 (2.87) |
|
24.0 |
83.54 |
80.56 |
-2.98 (2.84) |
[Table 4]
Changes in processing amount with changes in water supply amount (carbide plate) |
|
Water supply amount (cc/min) |
Weight of test piece (g) |
Before processing |
After processing |
Decrease in weight (ratio of decrease) |
Comparative example |
0 |
254.84 |
244.94 |
-9.90 (1) |
|
1.0 |
273.13 |
262.53 |
-10.60 (1.07) |
|
3.0 |
265.34 |
254.24 |
-11.10(1.12) |
Example |
5.0 |
273.24 |
261.86 |
-11.35 (1.15) |
|
12.0 |
262.53 |
250.93 |
-11.60 (1.17) |
|
20.0 |
260.30 |
248.16 |
-12.14 (1.22) |
|
28.0 |
206.02 |
193.45 |
-12.57 (1.27) |
[Table 5]
Changes in processing amount with changes in water supply amount (urethane rubber
plate) |
|
Water supply amount (cc/min) |
Weight of test piece (g) |
Before processing |
After processing |
Decrease in weight (ratio of decrease) |
Comparative example |
0 |
74.61 |
74.50 |
-0.11 (1) |
|
3.0 |
74.78 |
74.58 |
-0.20 (1.82) |
|
8.0 |
74.75 |
73.76 |
-0.99 (9.00) |
Example |
16.0 |
74.81 |
72.73 |
-2.08 (18.91) |
|
28.0 |
75.19 |
72.31 |
-2.88 (26.18) |
|
40.0 |
74.57 |
71.31 |
-3.26 (29.64) |
|
50.0 |
75.13 |
71.96 |
-3.17 (28.82) |
|
60.0 |
74.43 |
71.25 |
-3.18 (28.91) |
[Table 6]
Changes in processing amount with changes in water supply amount (aluminum plate) |
|
Water supply amount (cc/min) |
Weight of test piece (g) |
Before processing |
After processing |
Decrease in weight (ratio of decrease) |
Comparative example |
0 |
166.36 |
163.93 |
-2.43 (1) |
|
3.0 |
164.98 |
160.40 |
-4.58 (1.88) |
|
8.0 |
165.24 |
160.09 |
-5.15 (2.12) |
|
16.0 |
165.22 |
159.90 |
-5.32 (2.19) |
|
32.0 |
165.00 |
159.40 |
-5.60 (2.30) |
Example |
50.0 |
164.71 |
158.98 |
-5.73 (2.36) |
|
70.0 |
165.89 |
160.05 |
-5.84 (2.40) |
|
100.0 |
166.17 |
160.50 |
-5.67 (2.33) |
|
130.0 |
166.04 |
160.39 |
-5.65 (2.33) |
|
150.0 |
167.67 |
162.11 |
-5.56 (2.29) |
[Table 7]
Changes in processing amount with changes in water supply amount (stainless plate) |
|
Water supply amount (cc/min) |
Weight of test piece (g) |
Before processing |
After processing |
Decrease in weight (ratio of decrease) |
Comparative example |
0 |
450.59 |
445.18 |
-5.41 (1) |
|
1.0 |
449.89 |
443.65 |
-6.24 (1.15) |
|
3.0 |
450.99 |
443.46 |
-7.53 (1.39) |
|
5.0 |
450.20 |
442.45 |
-7.75 (1.43) |
|
8.0 |
449.76 |
442.04 |
-7.72 (1.43) |
Example |
12.0 |
450.94 |
443.18 |
-7.76 (1.43) |
|
20.0 |
450.88 |
442.99 |
-7.89 (1.46) |
|
30.0 |
450.27 |
442.34 |
-7.93 (1.47) |
|
40.0 |
449.54 |
441.57 |
-7.97 (1.47) |
|
50.0 |
450.66 |
442.76 |
-7.90 (1.46) |
|
60.0 |
450.23 |
442.22 |
-8.01 (1.48) |
[Table 8]
Changes in processing amount with changes in water supply amount (iron plate) |
|
Water supply amount (cc/min) |
Weight of test piece (g) |
|
Before processing |
After processing |
Decrease in weight (ratio of decrease) |
Comparative example |
0 |
462.72 |
457.90 |
-4.82 (1) |
|
1.0 |
462.86 |
456.90 |
-5.96 (1.24) |
|
3.0 |
462.20 |
455.02 |
-7.18 (1.49) |
|
5.0 |
462.40 |
455.11 |
-7.29 (1.51) |
|
8.0 |
462.46 |
455.22 |
-7.24 (1.50) |
Example |
12.0 |
462.94 |
455.55 |
-7.39 (1.53) |
|
20.0 |
462.20 |
454.65 |
-7.55 (1.57) |
|
30.0 |
461.73 |
454.02 |
-7.71 (1.60) |
|
40.0 |
463.07 |
455.24 |
-7.83 (1.62) |
|
50.0 |
462.63 |
454.50 |
-8.13 (1.69) |
|
60.0 |
462.38 |
454.13 |
-8.25 (1.71) |
[Table 9]
Changes in processing amount with changes in water supply amount (acrylic plate) |
|
Water supply amount (cc/min) |
Weight of test piece (g) |
|
Before processing |
After processing |
Decrease in weight (ratio of decrease) |
Comparative example |
0 |
37.92 |
37.37 |
-0.55 (1) |
|
1.0 |
37.90 |
37.19 |
-0.71 (1.29) |
|
3.0 |
37.91 |
36.93 |
-0.98 (1.78) |
|
6.0 |
37.92 |
36.72 |
-1.20 (2.18) |
|
10.0 |
37.91 |
36.55 |
-1.26 (2.29) |
Example |
15.0 |
37.93 |
36.59 |
-1.34 (2.44) |
|
20.0 |
36.76 |
35.44 |
-1.32 (2.40) |
|
30.0 |
36.66 |
35.34 |
-1.32 (2.40) |
|
40.0 |
36.67 |
35.32 |
-1.35 (2.45) |
|
50.0 |
36.62 |
35.20 |
-1.42 (2.58) |
|
60.0 |
36.56 |
35.11 |
-1.45 (2.64) |
[Table 10]
Changes in processing amount with changes in water supply amount (epoxy glass plate) |
|
Water supply amount (cc/min) |
Weight of test piece (g) |
|
Before processing |
After processing |
Decrease in weight (ratio of decrease) |
Comparative example |
0 |
61.90 |
60.04 |
-1.86 (1) |
|
1.0 |
61.81 |
60.00 |
-1.81 (0.97) |
|
3.0 |
61.83 |
59.38 |
-2.45 (1.32) |
|
6.0 |
61.91 |
59.00 |
-2.91 (1.56) |
|
10.0 |
61.78 |
59.00 |
-3.06 (1.65) |
Example |
15.0 |
61.83 |
58.64 |
-3.19 (1.72) |
|
20.0 |
61.77 |
58.58 |
-3.19 (1.72) |
|
30.0 |
61.74 |
58.51 |
-3.23 (1.74) |
|
40.0 |
61.85 |
58.44 |
-3.41 (1.83) |
|
50.0 |
61.92 |
58.49 |
-3.43 (1.84) |
|
60.0 |
61.91 |
58.47 |
-3.44 (1.85) |
[Table 11]
Changes in processing amount with changes in water supply amount (granite) |
|
Water supply amount (cc/min) |
Weight of test piece (g) |
|
Before processing |
After processing |
Decrease in weight (ratio of decrease) |
Comparative example |
0 |
185.22 |
182.34 |
-2.88 (1) |
|
1.0 |
180.55 |
177.12 |
-3.43 (1.19) |
Example |
5.0 |
191.26 |
187.67 |
-3.59 (1.25) |
|
10.0 |
187.87 |
184.35 |
-3.52 (1.22) |
|
25.0 |
187.06 |
183.47 |
-3.59 (1.25) |
|
40.0 |
192.97 |
189.34 |
-3.63 (1.26) |
[0108] According to the above results, it was confirmed that the cut amount could be increased
compared to the value obtained when blasting was carried out without supplying water
(comparative example) regardless of the material of the test piece processed.
[0109] While the cut amount increased as the water supply amount was increased, the cut
mount did not further increase but remained constant even if the water supply amount
was increased after the cut amount had increased to a certain level.
[0110] This indicates that ejecting a relatively small amount of liquid together with an
abrasive as in the blasting method of the present invention has the unexpected effect
of increasing the processing amount in addition to the above-mentioned antistatic
effect.
[0111] In addition, it was confirmed that this effect could be obtained regardless of the
material of the workpiece.
(2-2) Confirmation of effect of different abrasives on processing amount
[0112] The results of processing performed on stainless test pieces (SUS304) by ejecting
zircon grid ("FZG 60" manufactured by Fuji Manufacturing Co., Ltd., particle diameter:
0.125 to 0.250 mm) using the blast nozzle shown in FIG. 5 and the results of processing
performed on test pieces by ejecting an alumina abrasive ("FUJIRUNDUM A #60" manufactured
by Fuji Manufacturing Co., Ltd., average particle diameter: 230 µm) are shown in Tables
12 and 13, respectively.
[Table 12]
Changes in processing amount depending on whether water is supplied (FZG-60) |
|
Comparative example |
Example |
Valve opening |
0/8 (Full closed) |
3/8 |
Water supply amount (cc/min) |
0 |
3.0 |
Decrease in weight of test piece (g/20 min) |
(1)-2.9 |
(1)-4.8 |
(2)-3.4 |
(2)-5.6 |
(Average: -3.15) |
(Average: -5.2) |
[Table 13]
Changes in processing amount depending on whether water is supplied (FUJIRUNDUM A#60) |
|
Comparative example |
Example |
Water supply amount (cc/min) |
0 |
2.0 |
3.6 |
Decrease in weight of test piece (g/1H) |
-11.52 |
-15.93 |
-16.19 |
[0113] It was confirmed from the above results that the processing amount increased both
when zircon grid (FZG-60) was used as the abrasive and when an alumina abrasive ("FUJIRUMDUM
A #60" manufactured by Fuji Manufacturing Co., Ltd., particle diameter: 250 to 212
µm) was used. It was therefore confirmed that the processing amount increasing effect
of the present invention could be still obtained even when the type of abrasive used
was different.
[0114] The increase in processing amount was more than 1.5 times for the zircon grid (FZG-60)
and 1.3 to 1.4 times for the alumina abrasive ("FUJIRUNDUM A #60" manufactured by
Fuji Manufacturing Co., Ltd.). It was therefore confirmed that a significant increase
in processing amount could be achieved.
(3) Confirmation of abrasive sticking or lodging state
[0115] The components at the center of the processed region of the urethane rubber plate,
stainless plate, iron plate, acrylic plate and epoxy glass plate of the test pieces
processed as described in "(2)(2-1) Measurement of changes in processing amount with
changes in water supply amount" were measured with an EDX (energy dispersive X-ray
analysis) device (INCA Energy manufactured by Oxford Instruments), and the mass concentration
of aluminum as a primary component of the alumina abrasive used ("FUJIRUNDUM A #60"
manufactured by Fuji Manufacturing Co., Ltd.) was evaluated as the amount of abrasive
stuck in the test piece.
[0116] The results of measurements are shown in Tables 14 to 18 and FIGS. 15 to 19. The
Al mass concentration ratio in Tables 14 to 18 is the ratio of the Al mass concentration
to the Al mass concentration obtained without water supply.
[Table 14]
Changes in amount of abrasive stuck in test piece with changes in water supply amount
(urethane rubber) |
|
Water supply amount (cc/min) |
Al mass concentration (%) |
Al mass concentration ratio |
Comparative example |
0 |
13.62 |
1 |
|
3.0 |
7.99 |
0.59 |
|
5.0 |
6.38 |
0.47 |
|
12.0 |
4.09 |
0.30 |
Example |
20.0 |
2.17 |
0.16 |
28.0 |
2.11 |
0.15 |
|
40.0 |
2.09 |
0.15 |
|
50.0 |
2.19 |
0.16 |
|
60.0 |
1.80 |
0.13 |
[Table 15]
Changes in amount of abrasive stuck in test piece with changes in water supply amount
(stainless) |
|
Water supply amount (cc/min) |
Al mass concentration (%) |
Al mass concentration ratio |
Comparative example |
0 |
12.12 |
1 |
|
5.0 |
11.21 |
0.92 |
|
12.0 |
9.95 |
0.82 |
Example |
20.0 |
8.36 |
0.69 |
|
30.0 |
5.79 |
0.48 |
|
40.0 |
6.08 |
0.50 |
|
50.0 |
5.82 |
0.48 |
|
60.0 |
6.04 |
0.50 |
[Table 16]
Changes in amount of abrasive stuck in test piece with changes in water supply amount
(iron) |
|
Water supply amount (cc/min) |
Al mass concentration (%) |
Al mass concentration ratio |
Comparative example |
0 |
12.35 |
1 |
|
3.0 |
11.57 |
0.94 |
|
8.0 |
10.40 |
0.84 |
Example |
16.0 |
10.04 |
0.81 |
|
25.0 |
8.5 |
0.69 |
|
40.0 |
6.82 |
0.55 |
|
60.0 |
5.21 |
0.42 |
[Table 17]
Changes in amount of abrasive stuck in test piece with changes in water supply amount
(acrylic) |
|
Water supply amount (cc/min) |
Al mass concentration (%) |
Al mass concentration ratio |
Comparative example |
0 |
2.02 |
1 |
|
1.0 |
0.79 |
0.39 |
|
6.0 |
0.71 |
0.35 |
Example |
10.0 |
0.75 |
0.37 |
|
20.0 |
0.71 |
0.35 |
|
30.0 |
0.68 |
0.34 |
|
40.0 |
0.69 |
0.34 |
|
50.0 |
0.73 |
0.36 |
|
60.0 |
0.67 |
0.33 |
[Table 18]
Changes in amount of abrasive stuck in test piece with changes in water supply amount
(epoxy glass) |
|
Water supply amount (cc/min) |
Al mass concentration (%) |
Al mass concentration ratio |
Comparative example |
0 |
2.49 |
1 |
|
3.0 |
1.43 |
0.57 |
|
6.0 |
1.42 |
0.57 |
Example |
10.0 |
1.54 |
0.62 |
|
20.0 |
1.43 |
0.57 |
|
30.0 |
1.61 |
0.65 |
|
40.0 |
1.49 |
0.60 |
|
50.0 |
1.59 |
0.64 |
|
60.0 |
1.61 |
0.65 |
[0117] It was confirmed from the above results that sticking or lodging of abrasive decreases
when a liquid was supplied compared to when blasting was carried out without supplying
water.
[0118] Sticking or lodging of abrasive can be reduced even when processing is carried out
by a known wet blasting method. However, because the cut amount decreases in known
wet blasting compared to dry blasting as described before, good processing performance
and the reduction of sticking or lodging of abrasive cannot be achieved by wet blasting
at the same time.
[0119] In contrast to this, the method of the present invention has the unexpected effect
of being able to improve the cut amount compared not only to conventional wet blasting
but also to blasting without involving water supply as described above and prevent
sticking or lodging of abrasive at the same time.
(4) Results of measurements of amount of consumption and particle size of abrasive
[0120] Test pieces made of SUS304 were subjected to blasting at an ejection pressure of
0.5 MPa using zircon beads ("FZB-60" manufactured by Fuji Manufacturing Co., Ltd.,
average diameter: 200 µm) as the abrasive by the blasting method of the present invention,
which used the blast nozzle shown in FIG. 2A (example) and, a dry blasting method,
which used a known blast nozzle (having a structure obtained by removing the liquid
introduction path 88 from the blast nozzle shown in FIG. 2A) (comparative example).
The amount of consumption of abrasive was measured and the condition of particles
of the abrasive was observed after the blasting.
[0121] The ejection was carried out in a continuous manner (in an abrasive circulating-type
blasting apparatus shown in FIG. 1). The weight of the abrasive introduced into the
abrasive tank of the blasting apparatus before starting the measurement and the weight
of abrasive recovered were measured, and the decrease in weight was evaluated as the
amount of consumption.
[0122] The blasting time was 45 minutes and water was introduced at a rate of 6 cc/min in
the blasting method of the present invention.
[0123] The results of measurements of the amount of consumption of abrasive are shown in
Table 19 and the conditions of the particles of the abrasive after use are shown in
FIG. 20.
[Table 19]
Results of measurements of amount of consumption of abrasive |
|
Example (after drying) |
Comparative example |
Water supply amount |
6cc/min |
0cc/min |
Continuous ejection method |
-130.0g |
-225.3g |
[0124] It was confirmed from the above results that the blasting method of the present invention
could reduce the amount of consumption of abrasive compared to the known dry blasting
method.
[0125] According to the results of observation of the particle size of the recovered abrasive
(see FIG. 20), the abrasive used in the dry blasting method underwent rapid crushing
compared to the abrasive used in the blasting method of the present invention and
therefore had a smaller particle diameter. In this respect, it was confirmed that
there was a large difference in the consumption of abrasive.
(5) Measurement of surface temperature of workpiece
(5-1) Temperature measurement with thermocouple
[0126] Zircon beads ("FZB-400" manufactured by Fuji Manufacturing Co., Ltd., particle diameter:
<0.05 mm) as an abrasive was ejected onto copper plates with a size of 15 mm × 15
mm × 0.5 mm at an ejection distance of 100 mm and an ejection pressure of 0.3 MPa
or 0.5 MPa, and the changes in temperature of the copper plates were measured.
[0127] The temperature measurement was carried out by attaching a thermocouple-type thermometer
to a backside of each copper plate so that the change in temperature could be read,
and the abrasive was ejected for several seconds using the blast nozzle shown in FIG.
2A while the water supply amount was being varied. The highest temperature displayed
while the abrasive was being ejected was employed as the measurement value. The results
of measurements are shown in Table 20.
[Table 20]
Processing pressure |
0.3MPa |
0.5MPa |
|
Comparative example |
Example |
Comparative example |
Example |
Water supply amount (cc/min) |
0 |
1.4 3.6 |
0 |
1.5 |
3.1 |
Temperature (°C) |
54 |
36 26 |
56 |
42 |
29 |
[0128] It was confirmed from the above results that the blasting method of the present invention
could significantly reduce the temperature rise of the workpiece compared to a dry
blasting method.
(5-2) Confirmation of heat generating state
[0129] The temperature measured in the above test was the temperature of the backside of
a copper plate as a processing object measured while the abrasive was being ejected
for as fairly short a period as several seconds, and it is expected that the temperature
of the surface where the strike with abrasive occurs instantaneously rises to a level
high enough to soften the surface of the workpiece.
[0130] Thus, the blasting method of the present invention and a dry blasting method were
applied to paint stripping from PC (polycarbonate) resin products and deburring of
PPS (polyphenylene sulfide) resin products and the post-processing states were compared
so that the difference in surface temperature of the workpiece between the blasting
method of the present invention and the dry blasting method could be understood instinctively.
[0131] The paint stripping from the PC resin products was carried out by ejecting a high-purity
alumina abrasive ("FUJIRUNDUM WA #600" manufactured by Fuji Manufacturing Co., Ltd.)
at a processing pressure of 0.4 MPa and a nozzle distance of 70 mm using the blast
nozzle shown in FIG. 2A. The processing was carried out with a water supply amount
of 5 cc/min in the method of the present invention (example) and without supplying
water in the comparative example.
[0132] The deburring of the PPS (polyphenylene sulfide) resin products was carried out by
ejecting nylon beads ("FNB-0303" manufactured by Fuji Manufacturing Co., Ltd.) using
the blast nozzle shown in FIG. 2A at a processing pressure of 0.4 MPa and a nozzle
distance of 20 to 30 mm. The processing was carried out with a water supply amount
of 3 cc/min in the method of the present invention (example) and without supplying
water in the comparative example.
[0133] The results of measurements of surface roughness of the PC products after the paint
stripping are shown in FIG. 21, and the results of measurements of surface roughness
of the PPS products after the deburring are shown in FIG. 22.
[0134] It can be understood from the processing results that the surface roughness of the
resin product processed by the method of the present invention (see FIG. 21A and FIG.
22A) was lower than that of the resin product processed by the dry method of the comparative
example (see FIG. 21B and FIG. 22B) in either case. From these results, it is believed
that the surfaces underwent significant deformation caused by thermal softening in
the dry blasting.
[0135] In addition, the surfaces of the resin products processed by the dry blasting had
been burnt dark whereas no burning was observed on the resin products processed by
the method of the present invention. In this respect, it was confirmed that the method
of the present invention could effectively prevent the workpiece from generating heat.
[0136] Such burning occurs not only when resin products are processed but also when products
made of a metal such as aluminum are processed. The method of the present invention
can also prevent occurrence of burning in the processing of such metal products.
[0137] In addition, it took 11 to 12 seconds to carry out the paint stripping by dry blasting
whereas the method of the present invention was able to reduce the time to 6 to 7
seconds. It was therefore confirmed that the paint stripping efficiency could be improved
when blasting was carried out by the method of the present invention.
[0138] The same effect was observed not only in paint stripping from a surface of a resin
base material but also in paint stripping from a surface of a metal base material
such as aluminum alloy, magnesium alloy, zinc alloy, brass alloy or iron.
[0139] In the deburring, even burrs that could not be removed by dry blasting could be removed
by the blasting of the present invention. It was therefore confirmed that the blasting
of the present invention was also effective in deburring.
[0140] The differences are believed to be due to the fact that the surface temperature of
the workpiece rises until the coated film or burrs become soft enough to absorb the
impact of strike of the abrasive and make their stripping or removal difficult in
dry blasting, whereas the surface of the workpiece is cooled and the coated film or
burrs are prevented from becoming soft and remain hard (and thus brittle) enough to
be easily stripped or removed by strike of the abrasive in the method of the present
invention.
(6) Confirmation of warpage occurrence state
[0141] Almen strips (A strips) were processed using the blast nozzle shown in FIG. 2A and
using a zircon shot ("FZB-425" manufactured by Fuji Manufacturing Co., Ltd. (Median
particle diameter: 425µm to 600 µm, average diameter: 513 µm)) as the abrasive.
[0142] The processing was carried out at processing pressures of 0.3 MPa and 0.5 MPa for
20 seconds. The arc height value (the height to which the test piece was curved) was
measured at various water supply amounts and evaluated as "warpage." The results of
measurements are shown in Table 21.
[Table 21]
Result of confirmation of warpage occurrence state |
Ejection pressure |
Water supply amount (cc/min) |
Arc height |
0.3MPa |
0 |
0.163 mmA |
1.4 |
0.158 mmA |
3.6 |
0.158 mmA |
0.5MPa |
0 |
0.244 mmA |
1.5 |
0.238 mmA |
3.1 |
0.238 mmA |
* The "A" in "mmA" indicates the use of an A strip. |
[0143] It was confirmed from the above results that warpage of the workpiece could be slightly
reduced when blasting was carried out by the method of the present invention.
Descriptions of reference numerals
1 |
Blasting apparatus |
82 |
Nozzle tip |
2 |
Cabinet |
82a |
Conical inner surface |
21 |
Processing chamber |
83 |
Rear nozzle |
3 |
Abrasive tank (cyclon) |
84 |
Abrasive introduction port |
5 |
Dust collector |
85 |
Abrasive introduction chamber |
6 |
Exhauster |
86 |
Compressed gas flow path |
7 |
Flow control valve |
88 |
Liquid introduction path |
8 |
Blast nozzle |
88a |
Distal end (of Liquid introduction path) |
81 |
Body |
91 |
Abrasive recovery pipe |
|
|