{ "slug": "deburring-methods", "title": "CNC部品のバリ取り方法：15工程の比較", "description": "十五のバリ取り工程を、エッジ形状、バリ寸法、エッジ半径、Raへの影響、コスト階層で比較し、サイクルタイムの計算例と交差穴加工の選定指針を示します。", "lang": "ja", "tables": [ { "caption": "バリ取り・エッジブレーク方法の比較（15工程）", "columns": [ "方法", "エッジ形状", "材質", "最大バリ寸法", "エッジブレーク／R", "Raへの影響", "コスト階層", "設備要件", "出典" ], "rows": [ { "方法": "Manual (file / scraper / blade)", "エッジ形状": "外周エッジ、固定角度の面取り。薄肉、内部交差穴、厳格な半径には適用不可", "材質": "すべての金属", "最大バリ寸法": "no unified limit (gap)", "エッジブレーク／R": "edge break 0.2–0.5 mm; skilled ±0.05 mm", "Raへの影響": "手研磨によるエッジブレーク ≤ 0.01 mm。Raは工具に依存", "コスト階層": "2", "設備要件": "低。手工具 €10–50", "出典": "S1, S19" }, { "方法": "CNC in-machine chamfer / edge tool", "エッジ形状": "外周エッジ、ボア入口、工具が到達できるエッジ", "材質": "すべての金属", "最大バリ寸法": "not specified (gap)", "エッジブレーク／R": "90° chamfer 0.1–2.0 mm; ball end mill R 0.1–0.5 mm", "Raへの影響": "刃物に依存。Raの変化は最小", "コスト階層": "2", "設備要件": "中。CNCとプログラミングが必要", "出典": "S19" }, { "方法": "Rotary brush (incl. in-machine)", "エッジ形状": "外周、ねじ、狭いコーナー、軽微な内部形状", "材質": "すべての金属", "最大バリ寸法": "light burrs only (gap)", "エッジブレーク／R": "fine brush edge break 0.01–0.02 mm", "Raへの影響": "Raを改善。マイクロブラシは1,000–3,000 rpm", "コスト階層": "2", "設備要件": "低–中。CNCのツールチェンジャーに装着可能", "出典": "S1" }, { "方法": "Barrel tumbling", "エッジ形状": "小物部品の外周エッジ", "材質": "金属、一部のプラスチック", "最大バリ寸法": "small burrs (gap)", "エッジブレーク／R": "larger edge radius; numeric R not given", "Raへの影響": "振動バレルより粗い。Ra範囲は記載なし", "コスト階層": "3", "設備要件": "中。回転バレル20–45 rpm", "出典": "S10" }, { "方法": "Vibratory finishing", "エッジ形状": "外周＋メディアが到達できる内部、スロット、交差穴", "材質": "すべての金属", "最大バリ寸法": "stainless burr ≈ 75–80 µm (retrieval-index transcription)", "エッジブレーク／R": "controlled edge R 0.05–0.3 mm", "Raへの影響": "Ra 3.2 → 0.8 µm。範囲0.4–1.6 µm", "コスト階層": "3", "設備要件": "中。サイクル20–120 min", "出典": "S9, S10, S42" }, { "方法": "Centrifugal barrel", "エッジ形状": "小型精密部品、外周", "材質": "金属", "最大バリ寸法": "small–medium burrs", "エッジブレーク／R": "numeric R not given", "Raへの影響": "Ra 0.2–0.8 µm", "コスト階層": "3", "設備要件": "中–高。バリ取り15–45 min", "出典": "S10, S13" }, { "方法": "Centrifugal disc", "エッジ形状": "小型部品、大量生産", "材質": "金属", "最大バリ寸法": "small burrs", "エッジブレーク／R": "numeric R not given", "Raへの影響": "Ra 0.2–0.8 µm。低Ra仕上げ", "コスト階層": "3", "設備要件": "中–高。バリ取り約2 h、自動取出し", "出典": "S14, S15" }, { "方法": "Drag finishing", "エッジ形状": "切削工具の外周エッジ、円筒部品", "材質": "超硬、焼入れ鋼", "最大バリ寸法": "micro edge burrs", "エッジブレーク／R": "60 min: Ø6 mm tool R ≈ 18 µm; Ø8 mm ≈ 20 µm", "Raへの影響": "粗さ改善率が報告されている", "コスト階層": "3", "設備要件": "中–高。治具でメディア中を引き抜き", "出典": "S16" }, { "方法": "Abrasive flow machining (AFM)", "エッジ形状": "内部流路、交差穴、深いキャビティ", "材質": "すべての金属", "最大バリ寸法": "thin burrs (gap)", "エッジブレーク／R": "uniform edge R 0.02–0.05 mm", "Raへの影響": "微細な内部Ra。押出圧力10–200 bar", "コスト階層": "5", "設備要件": "高。専用機＋工具", "出典": "S1, S17, S23" }, { "方法": "Electrochemical deburring (ECD)", "エッジ形状": "内部交差穴、到達困難な交差部", "材質": "導電性金属のみ", "最大バリ寸法": "up to 0.5 mm", "エッジブレーク／R": "edge R 0.05–0.2 mm (single secondary source); control ±0.05 mm", "Raへの影響": "Ra 2–4 µm。機械的力なし", "コスト階層": "4", "設備要件": "高。電源＋専用陰極", "出典": "S6, S7, S21" }, { "方法": "Thermal energy method (TEM)", "エッジ形状": "内部・外部のすべてのエッジを同時に", "材質": "鋼、ステンレス、鋳鉄が最適。アルミ／ほとんどのプラスチックは不適", "最大バリ寸法": "thin burrs / flash", "エッジブレーク／R": "edge break 0.02–0.05 mm", "Raへの影響": "酸化残渣の後洗浄が必要", "コスト階層": "5", "設備要件": "高。チャンバー設備 €300k–800k", "出典": "S1, S3, S19" }, { "方法": "Laser deburring (SLD)", "エッジ形状": "板金の外周エッジ、規定半径", "材質": "金属", "最大バリ寸法": "thin burrs remelted", "エッジブレーク／R": "minimum achievable R ≈ 0.55 mm", "Raへの影響": "再溶融エッジ。工具摩耗なし", "コスト階層": "4", "設備要件": "高。レーザー光源＋光学系＋治具", "出典": "S33, S34" }, { "方法": "High-pressure water jet (HPW)", "エッジ形状": "交差穴、深穴、タップ穴（視線が通る場合）", "材質": "すべての金属。延性バリでは限界あり", "最大バリ寸法": "loose / light-adhering only", "エッジブレーク／R": "no R value; firm burrs remain", "Raへの影響": "熱的／化学的応力なし。洗浄と一体化", "コスト階層": "4", "設備要件": "高。ポンプ＋NC多軸ノズル", "出典": "S19, S24, S26" }, { "方法": "Chemical deburring (electroless)", "エッジ形状": "複雑な小型部品、到達困難な部位", "材質": "鋼、アルミ、ステンレス（液種による）", "最大バリ寸法": "up to a few tenths of mm", "エッジブレーク／R": "leveling; no fixed R", "Raへの影響": "凸部と凹部の電位差による表面平坦化", "コスト階層": "3", "設備要件": "中。タンク＋薬液管理", "出典": "S36, S37, S38" }, { "方法": "Cryogenic + shot blast", "エッジ形状": "外周のバリ／フラッシュ", "材質": "ゴム、プラスチック、ダイカスト金属", "最大バリ寸法": "thin flash; precision to 0.01 mm", "エッジブレーク／R": "clean flash break; part dimensions retained", "Raへの影響": "母材表面では最小〜なし", "コスト階層": "4", "設備要件": "高。断熱チャンバー＋ブラストホイール", "出典": "S28, S30, S31, S52" } ] }, { "caption": "熟練の手作業バリ取り作業者が安定的に維持できるエッジブレークはどの程度ですか？", "columns": [ "バリ寸法クラス", "バリ高さ", "代表的なシナリオ", "出典" ], "rows": [ { "バリ寸法クラス": "Precision burr", "バリ高さ": "< 0.02 mm", "代表的なシナリオ": "航空宇宙／医療のクリティカルエッジ", "出典": "S2" }, { "バリ寸法クラス": "Minor burr", "バリ高さ": "0.02–0.05 mm", "代表的なシナリオ": "一般的な精密加工", "出典": "S2" }, { "バリ寸法クラス": "Moderate burr", "バリ高さ": "0.05–0.15 mm", "代表的なシナリオ": "標準的なフライス／穴加工エッジ", "出典": "S2" }, { "バリ寸法クラス": "Heavy burr", "バリ高さ": "> 0.15 mm", "代表的なシナリオ": "工具摩耗／延性材／重切削", "出典": "S2" } ] }, { "caption": "ねじと狭いコーナーで最小のエッジブレークが得られるバリ取り方法はどれですか？", "columns": [ "エッジ位置", "第一選択", "代替案", "推奨しない", "出典" ], "rows": [ { "エッジ位置": "External straight edge / fixed chamfer", "第一選択": "CNC in-machine chamfer tool", "代替案": "manual, rotary brush", "推奨しない": "TEM for a simple edge (over-cost)", "出典": "S19" }, { "エッジ位置": "External 3D freeform edge", "第一選択": "ball end mill / disc brush", "代替案": "robotic compliant spindle", "推奨しない": "rigid chamfer tool", "出典": "S19" }, { "エッジ位置": "Bore entrance / bore internal surface", "第一選択": "Flex-Hone (Ø4–960 mm)", "代替案": "rotary brush", "推奨しない": "rigid tool (cannot follow bore)", "出典": "S19" }, { "エッジ位置": "Cross-hole / intersection", "第一選択": "ECD or Flex-Hone", "代替案": "TEM, AFM, HPW", "推奨しない": "manual (inconsistent), rigid tool", "出典": "S19, S21" }, { "エッジ位置": "Deep cavity / internal passage", "第一選択": "AFM", "代替案": "TEM, ECD", "推奨しない": "brush / belt (cannot reach)", "出典": "S1, S17" }, { "エッジ位置": "Hidden / inaccessible burr", "第一選択": "TEM", "代替案": "ECD", "推奨しない": "line-of-sight methods", "出典": "S3, S19" }, { "エッジ位置": "Screw / thread edge", "第一選択": "fine rotary brush", "代替案": "ECD", "推奨しない": "aggressive belt (damages thread)", "出典": "S1" } ] }, { "caption": "振動研磨はエッジ半径と表面粗さをどのように変化させますか？", "columns": [ "パラメータ", "値", "出典" ], "rows": [ { "パラメータ": "Ceramic media standard cycle", "値": "40–60 min, edge R 0.05–0.15 mm", "出典": "S9" }, { "パラメータ": "Extended cycle for R up to 0.3 mm", "値": "90–120 min", "出典": "S9" }, { "パラメータ": "Aluminium edge break 0.10–0.20 mm, 10 mm ceramic", "値": "30–60 min", "出典": "S11" }, { "パラメータ": "Deburring cycle range", "値": "20–60 min", "出典": "S12" }, { "パラメータ": "Radiusing cycle range", "値": "30–90 min", "出典": "S12" }, { "パラメータ": "Material removal, ceramic", "値": "0.01–0.05 mm per surface", "出典": "S9" }, { "パラメータ": "Material removal, plastic media", "値": "0.002–0.01 mm per surface", "出典": "S9" }, { "パラメータ": "Media-to-part volume ratio", "値": "3:1–5:1 (precision up to 6:1+)", "出典": "S9, S10" }, { "パラメータ": "Bowl load fill", "値": "60%–70%", "出典": "S9" }, { "パラメータ": "Stainless burr the process is sized for", "値": "≈ 75–80 µm (retrieval-index transcription, not directly verified)", "出典": "S42" }, { "パラメータ": "Removal from part diameter or thickness", "値": "7–25 µm", "出典": "S42" }, { "パラメータ": "Rotary brush, aluminium", "値": "1,000–1,500 rpm, 15–30 µm compound", "出典": "S1" }, { "パラメータ": "Rotary brush, hardened steel", "値": "2,000–3,000 rpm, 3–9 µm diamond", "出典": "S1" } ] }, { "caption": "振動処理が想定するステンレスバリの厚さは通常どの程度ですか？", "columns": [ "選定パラメータ", "値", "出典" ], "rows": [ { "選定パラメータ": "Typical stainless burr", "値": "≈ 75–80 µm (76 µm in the retrieval index; not directly verified)", "出典": "S42" }, { "選定パラメータ": "Removal per cycle", "値": "7–25 µm", "出典": "S42" }, { "選定パラメータ": "Centrifugal barrel vs vibratory, same work", "値": "15–45 min vs 4–24 h", "出典": "S13" }, { "選定パラメータ": "Centrifugal disc deburr", "値": "about 2 h, auto-unload", "出典": "S14, S15" } ] }, { "caption": "電気化学バリ取りはどの程度のバリを除去でき、どの半径を残しますか？", "columns": [ "パラメータ", "従来のECD", "交差穴の研究", "出典" ], "rows": [ { "パラメータ": "Applied voltage", "従来のECD": "12–24 V (DC supply 8–30 V)", "交差穴の研究": "50–100 V", "出典": "S6" }, { "パラメータ": "Current density", "従来のECD": "5–10 A/cm²", "交差穴の研究": "30–200 A/cm²", "出典": "S6" }, { "パラメータ": "Interelectrode gap", "従来のECD": "0.1–0.3 mm", "交差穴の研究": "0.1–0.7 mm", "出典": "S6" }, { "パラメータ": "Time", "従来のECD": "5–100 s", "交差穴の研究": "—", "出典": "S6" }, { "パラメータ": "Typical cycle", "従来のECD": "30–45 s; about 20 s multi-hole", "交差穴の研究": "—", "出典": "S6, S21" }, { "パラメータ": "Electrolyte pressure", "従来のECD": "0.3–0.5 MPa", "交差穴の研究": "—", "出典": "S6" }, { "パラメータ": "Burr height removed", "従来のECD": "up to 0.5 mm", "交差穴の研究": "—", "出典": "S6" }, { "パラメータ": "Edge radius left", "従来のECD": "R 0.05–0.2 mm (single secondary source — see note above)", "交差穴の研究": "—", "出典": "S6" } ] }, { "caption": "電気化学バリ取りの代表的な電圧と電流密度はどのくらいですか？", "columns": [ "被加工材", "電解液", "出典" ], "rows": [ { "被加工材": "Carbon / low-carbon steel", "電解液": "5%–15% or 2%–2.5% NaNO3", "出典": "S6" }, { "被加工材": "Copper alloys", "電解液": "5%–15% NaNO3", "出典": "S6" }, { "被加工材": "Aluminium alloys", "電解液": "5%–20% NaNO3", "出典": "S6" }, { "被加工材": "Stainless steels", "電解液": "5% NaNO3 + 0.5% NaCl", "出典": "S6" }, { "被加工材": "Electrolyte supply pressure", "電解液": "0.3–0.5 MPa; tool gap 0.1–0.3 mm; tip overlap 1.5–2 mm", "出典": "S6" } ] }, { "caption": "熱エネルギ法（TEM）のサイクルはどのくらい速いですか？", "columns": [ "パラメータ", "値", "出典" ], "rows": [ { "パラメータ": "Combustion temperature", "値": "2,500–3,500 °C, milliseconds", "出典": "S3" }, { "パラメータ": "Fuel gas", "値": "methane + oxygen, pressurized chamber", "出典": "S3, S4" }, { "パラメータ": "Cycle excluding load/unload", "値": "less than 1 minute; active burn < 1 s", "出典": "S3, S1" }, { "パラメータ": "Edge break", "値": "0.02–0.05 mm; over-burn can round to 0.05 mm", "出典": "S1" }, { "パラメータ": "Removed burr amount set by", "値": "gas volume, burr thickness, material heat-transfer rate, fuel-oxygen ratio", "出典": "S3" } ] }, { "caption": "熱バリ取りに適さない材質はどれですか？", "columns": [ "材質", "推奨方法", "注意／制約", "出典" ], "rows": [ { "材質": "Carbon / low-carbon steel", "推奨方法": "CNC tool, vibratory, ECD, TEM, chemical", "注意／制約": "化学浴では素材減肉の許容を見込む必要あり", "出典": "S6, S36" }, { "材質": "Stainless steel", "推奨方法": "vibratory, ECD, TEM, AFM", "注意／制約": "化学法は硝酸を使用。TEMは洗浄が必要な酸化物を残す", "出典": "S3, S38" }, { "材質": "Aluminium", "推奨方法": "plastic media, rotary brush, Flex-Hone, chemical (NaOH)", "注意／制約": "TEMは一般に不適。硬いセラミックメディアは軟らかい表面を傷つける可能性", "出典": "S1, S38" }, { "材質": "Copper / brass", "推奨方法": "plastic / steel media, ECD, vibratory", "注意／制約": "軟らかい真ちゅうに粗いセラミックは避ける", "出典": "S6, S10" }, { "材質": "Hardened steel / carbide", "推奨方法": "diamond brush, drag finishing, AFM, ECD", "注意／制約": "微細砥粒が必要（3–9 µmダイヤモンド）", "出典": "S1, S16" }, { "材質": "Titanium", "推奨方法": "AFM, ECD, fine media", "注意／制約": "低導電率／低反応性のため電解液の調整が必要", "出典": "S17" }, { "材質": "Rubber / elastomer", "推奨方法": "cryogenic + shot", "注意／制約": "温度は材料のTg以下に下げる必要あり", "出典": "S31" }, { "材質": "Plastic / nylon", "推奨方法": "cryogenic, fine brush, HPW", "注意／制約": "TEMはプラスチックを燃焼させる。ECDは非導電性のため不可", "出典": "S19, S30" }, { "材質": "Die-cast metal", "推奨方法": "cryogenic (warm range), plastic media", "注意／制約": "多孔質の鋳造表皮をめっき前に保護する", "出典": "S29, S51" } ] }, { "caption": "高圧水バリ取りでは通常どの程度の圧力を使いますか？", "columns": [ "出典／設備", "圧力範囲", "備考" ], "rows": [ { "出典／設備": "HPWD typical (S26)", "圧力範囲": "5,000–7,500 psi (34–52 MPa), up to 15,000 psi (103 MPa)", "備考": "検索インデックスからの転記で、直接検証なし。レポートBDX-613-2421（1980）をDOIで引用" }, { "出典／設備": "Sugino JCC (S24)", "圧力範囲": "up to 50 MPa", "備考": "CNCノズル、交差／深／タップ穴" }, { "出典／設備": "Sugino JDM (S25)", "圧力範囲": "up to 70 MPa", "備考": "交差穴、歯車" }, { "出典／設備": "PrecisionPro (S19)", "圧力範囲": "300–2,500 bar (30–250 MPa)", "備考": "バリ取り階層。遊離または軽く付着したバリのみ。強固なバリは残る" }, { "出典／設備": "Sinobakr (S27)", "圧力範囲": "5–50 MPa stepless", "備考": "除去率99%。1–5 µmろ過。自動車部品" }, { "出典／設備": "WOMA UHP (S55)", "圧力範囲": "up to 4,000 bar (400 MPa; 58,000 psi)", "備考": "UHPポンプの上限。切断／重洗浄階層で、バリ取りの常用パラメータではない" } ] }, { "caption": "レーザーバリ取りで達成できる最小エッジ半径はどのくらいですか？", "columns": [ "パラメータ", "値", "出典" ], "rows": [ { "パラメータ": "Laser source", "値": "5 kW diode / 5 kW Nd:YAG", "出典": "S33, S35" }, { "パラメータ": "Feed rate", "値": "up to 9 m/min", "出典": "S33" }, { "パラメータ": "Minimum achievable edge radius", "値": "about 0.55 mm (PDF not re-verified online)", "出典": "S34" }, { "パラメータ": "Edge forming capacity, high-strength steel", "値": "increased by more than 240%", "出典": "S33" } ] }, { "caption": "化学バリ取りと電気化学バリ取りはどう違いますか？", "columns": [ "工程", "駆動力", "標準サイクル", "適用範囲" ], "rows": [ { "工程": "Chemical deburring (electroless)", "駆動力": "bath chemistry, no power", "標準サイクル": "about 60 s", "適用範囲": "" }, { "工程": "Electrochemical deburring (ECD)", "駆動力": "DC supply + targeted cathodes + electrolyte", "標準サイクル": "20–45 s per cycle", "適用範囲": "" }, { "工程": "Terminology conflict", "駆動力": "some pages call ECD chemical deburring", "標準サイクル": "—", "適用範囲": "" }, { "工程": "Chemical solutions", "駆動力": "acid or alkali per alloy", "標準サイクル": "—", "適用範囲": "" } ] }, { "caption": "バリ取りは陽極酸化の前に行うべきですか、後に行うべきですか？", "columns": [ "工程", "作業内容" ], "rows": [ { "工程": "1", "作業内容": "CNC machine to drawing dimensions" }, { "工程": "2", "作業内容": "Deburr and clean" }, { "工程": "3", "作業内容": "Pre-treatment (etch, de-smut)" }, { "工程": "4", "作業内容": "Anodize to specified type and thickness" }, { "工程": "5", "作業内容": "Dye (optional)" }, { "工程": "6", "作業内容": "Seal" }, { "工程": "7", "作業内容": "Inspect" } ] }, { "caption": "バリ取りは部品総コストのどの程度を占めますか？", "columns": [ "出典", "占有率", "対象範囲" ], "rows": [ { "出典": "SpecForge / IQS (S39)", "占有率": "about 30%", "対象範囲": "precision aerospace" }, { "出典": "SpecForge (S39)", "占有率": "15%–20%", "対象範囲": "automotive" }, { "出典": "Ramachandran survey (S41, JMPT 44(1–2) 1994, DOI 10.1016/0924-0136(94)90033-7)", "占有率": "5%–15%", "対象範囲": "average edge/surface finishing" }, { "出典": "Dingzhu / AFS (S43)", "占有率": "5%–12%", "対象範囲": "castings" } ] }, { "caption": "CNC一体型のブラシまたはFlex-Honeによるバリ取りは、どの生産量から手作業に対して採算が合いますか？", "columns": [ "生産量", "推奨アプローチ", "損益分岐の考え方", "出典" ], "rows": [ { "生産量": "Prototype / one-off (< 50 pcs)", "推奨アプローチ": "manual blade / file", "損益分岐の考え方": "投資不要、柔軟", "出典": "S19" }, { "生産量": "Small batch (about 50 pcs/month up)", "推奨アプローチ": "CNC-integrated Flex-Hone / brush", "損益分岐の考え方": "月約50個で手作業に対する損益分岐", "出典": "S19" }, { "生産量": "Medium batch (hundreds)", "推奨アプローチ": "vibratory / centrifugal batch finishing", "損益分岐の考え方": "一バッチ~20個を超えると一個あたり人工費が低下", "出典": "S9" }, { "生産量": "High volume (>10,000/day)", "推奨アプローチ": "TEM or dedicated deburring system", "損益分岐の考え方": "一サイクルで全エッジに作用。高いスループット", "出典": "S19" }, { "生産量": "Continuous flow (e.g. crankshafts)", "推奨アプローチ": "linear continuous vibrator", "損益分岐の考え方": "一個あたり1 min未満、60+ pcs/h", "出典": "S44" } ] }, { "caption": "低温デフラッシングは部品寸法と表面にどのような影響を与えますか？", "columns": [ "パラメータ", "値", "出典" ], "rows": [ { "パラメータ": "Machine cooling range", "値": "−130 °C to +50 °C; operating down to about −150 °C", "出典": "S29, S30" }, { "パラメータ": "Liquid nitrogen boiling point", "値": "about −196 °C", "出典": "S30" }, { "パラメータ": "EPDM glass-transition Tg", "値": "−55 °C", "出典": "S31" }, { "パラメータ": "SBR Tg", "値": "−40 °C", "出典": "S31" }, { "パラメータ": "NBR Tg", "値": "−30 °C", "出典": "S31" }, { "パラメータ": "Example batch", "値": "7 kg, −70 °C, 8 min, wheel 6,500 rpm, basket 20 rpm, 1.0 mm media", "出典": "S28" } ] }, { "caption": "月20,000個のアルミハウジングでバリ取りを自動化すると何が節約できますか？", "columns": [ "項目", "根拠", "値" ], "rows": [ { "項目": "Monthly volume", "根拠": "case input (S2)", "値": "20,000 pcs" }, { "項目": "Manual cycle", "根拠": "case input (S2)", "値": "90 s/pc" }, { "項目": "Automated rotary brush cycle", "根拠": "case input (S2)", "値": "22 s/pc" }, { "項目": "Original monthly machine time", "根拠": "20,000 × 90 s ÷ 3,600", "値": "500 h" }, { "項目": "New monthly machine time", "根拠": "20,000 × 22 s ÷ 3,600", "値": "122.2 h" }, { "項目": "Theoretical cycle-time saving", "根拠": "500 − 122.2", "値": "377.8 h" }, { "項目": "Cycle reduction ratio", "根拠": "(90 − 22) ÷ 90", "値": "75.6%" }, { "項目": "Defective pcs", "根拠": "20,000 × 3.0% → × 0.2%", "値": "600 → 40 pcs" }, { "項目": "Reported labour saving / cost change", "根拠": "source-reported (S2)", "値": "60 h/month; −8%" } ] }, { "caption": "月15,000個のステンレスバルブボディで交差穴バリ取りをすると何が節約できますか？", "columns": [ "項目", "根拠", "値" ], "rows": [ { "項目": "Monthly volume", "根拠": "case input (S2)", "値": "15,000 pcs" }, { "項目": "Manual / new cycle", "根拠": "case input (S2)", "値": "4.8 / 1.2 min per pc" }, { "項目": "Original monthly time", "根拠": "15,000 × 4.8 min = 72,000 min; ÷ 60", "値": "1,200 h" }, { "項目": "New monthly time", "根拠": "15,000 × 1.2 min = 18,000 min; ÷ 60", "値": "300 h" }, { "項目": "Labour time saving (theoretical, full load)", "根拠": "1,200 − 300", "値": "900 h" }, { "項目": "Caliber note", "根拠": "theoretical machine time vs reported capacity", "値": "reported +18% includes bottleneck/scheduling — not interconvertible" }, { "項目": "Cycle reduction ratio", "根拠": "(4.8 − 1.2) ÷ 4.8", "値": "75%" }, { "項目": "Leak-failure pcs", "根拠": "15,000 × 2.6% → × 0.3%", "値": "390 → 45 pcs" }, { "項目": "Failure reduction", "根拠": "390 − 45", "値": "345 pcs (−88.5%)" }, { "項目": "Complaints", "根拠": "source-reported (S2)", "値": "11 → 2 per quarter" } ] }, { "caption": "交差穴のバリ取り方法はどのように比較できますか？", "columns": [ "方法", "到達機構", "サイクル", "エッジ制御", "副作用", "最適用途", "出典" ], "rows": [ { "方法": "Flex-Hone", "到達機構": "柔軟なグローブがボアをたどって交差部に到達", "サイクル": "short, CNC-integrable", "エッジ制御": "plateau finish + radius", "副作用": "最低コスト。極小または硬いバリでは限界あり", "最適用途": "ほとんどの一般的な交差穴", "出典": "S19" }, { "方法": "ECD", "到達機構": "専用陰極がバリを溶解", "サイクル": "about 20 s, dozens of holes at once", "エッジ制御": "R 0.05–0.2 mm, ±0.05 mm (single secondary source)", "副作用": "導電性部品のみ。ワーク専用の陰極が必要", "最適用途": "油圧バルブボディ、複数交差部", "出典": "S6, S21" }, { "方法": "TEM", "到達機構": "ガスがすべての流路を満たし、すべてのバリを燃焼", "サイクル": "< 1 s active, all locations", "エッジ制御": "edge break 0.02–0.05 mm", "副作用": "酸化層。薄肉リスク。アルミには不適", "最適用途": "複雑で隠れた交差部、鋼／ステンレス", "出典": "S3, S19" }, { "方法": "AFM", "到達機構": "砥粒メディアを流路に強制圧送", "サイクル": "3–10 min per batch", "エッジ制御": "uniform R 0.02–0.05 mm", "副作用": "低速、高コスト、メディア治具が必要", "最適用途": "高精度なクリティカル交差部、高価値部品", "出典": "S17, S23" }, { "方法": "HPW", "到達機構": "CNCノズルを交差穴に向ける", "サイクル": "seconds per feature", "エッジ制御": "removes loose burrs", "副作用": "強固なバリは残る。乾燥が必要", "最適用途": "切り屑＋遊離バリ、深穴／タップ穴", "出典": "S24, S19" }, { "方法": "Abrasive micro-blast", "到達機構": "ブラストノズルを小径ボアに挿入。0.056 inまでの穴に到達", "サイクル": "manual / automated", "エッジ制御": "fine blasted texture", "副作用": "—", "最適用途": "薄く脆いバリ", "出典": "S21" } ] } ] }