CN101618414B - Deposition manufacturing method of tools and moulds - Google Patents
Deposition manufacturing method of tools and moulds Download PDFInfo
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- CN101618414B CN101618414B CN2009103052967A CN200910305296A CN101618414B CN 101618414 B CN101618414 B CN 101618414B CN 2009103052967 A CN2009103052967 A CN 2009103052967A CN 200910305296 A CN200910305296 A CN 200910305296A CN 101618414 B CN101618414 B CN 101618414B
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- 230000008021 deposition Effects 0.000 title claims abstract description 37
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 26
- 238000000034 method Methods 0.000 claims abstract description 47
- 239000000463 material Substances 0.000 claims abstract description 41
- 238000000151 deposition Methods 0.000 claims abstract description 36
- 238000003754 machining Methods 0.000 claims abstract description 17
- 238000005266 casting Methods 0.000 claims abstract description 11
- 239000000758 substrate Substances 0.000 claims description 52
- 238000007493 shaping process Methods 0.000 claims description 22
- 239000007769 metal material Substances 0.000 claims description 6
- 238000003466 welding Methods 0.000 claims description 6
- 230000006835 compression Effects 0.000 claims description 4
- 238000007906 compression Methods 0.000 claims description 4
- 238000002347 injection Methods 0.000 claims description 4
- 239000007924 injection Substances 0.000 claims description 4
- 229910000838 Al alloy Inorganic materials 0.000 claims description 2
- 229910000975 Carbon steel Inorganic materials 0.000 claims description 2
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 2
- 229910000990 Ni alloy Inorganic materials 0.000 claims description 2
- 239000010962 carbon steel Substances 0.000 claims description 2
- 230000008018 melting Effects 0.000 claims description 2
- 238000002844 melting Methods 0.000 claims description 2
- 239000010935 stainless steel Substances 0.000 claims description 2
- 229910001220 stainless steel Inorganic materials 0.000 claims description 2
- 238000003672 processing method Methods 0.000 abstract 1
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 239000002826 coolant Substances 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 5
- 238000010894 electron beam technology Methods 0.000 description 5
- 238000005516 engineering process Methods 0.000 description 5
- 238000000465 moulding Methods 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- 239000000956 alloy Substances 0.000 description 4
- BIJOYKCOMBZXAE-UHFFFAOYSA-N chromium iron nickel Chemical compound [Cr].[Fe].[Ni] BIJOYKCOMBZXAE-UHFFFAOYSA-N 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 238000003801 milling Methods 0.000 description 3
- 230000002787 reinforcement Effects 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 239000012636 effector Substances 0.000 description 2
- 238000005242 forging Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000000110 selective laser sintering Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 229910001256 stainless steel alloy Inorganic materials 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 102100023774 Cold-inducible RNA-binding protein Human genes 0.000 description 1
- 229910001208 Crucible steel Inorganic materials 0.000 description 1
- 101000906744 Homo sapiens Cold-inducible RNA-binding protein Proteins 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000005094 computer simulation Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
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- 230000007797 corrosion Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
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- 238000000313 electron-beam-induced deposition Methods 0.000 description 1
- 238000010100 freeform fabrication Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000011089 mechanical engineering Methods 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 238000007712 rapid solidification Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
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Abstract
The invention discloses a deposition manufacturing method of tools and moulds, which belongs to a special processing method of tools and moulds and solves the problems of long period, high cost and high risk of the prior manufacturing method of large and middle tools and moulds. The deposition manufacturing method of tools and moulds comprises the following steps: (1) forming: a tool and mould blank is obtained by casting or machining; (2) measuring: the blank is measured and the CAD data of the shape and the size of the blank are obtained; (3) measuring a thickness value: the difference between the CAD data of a required tool and mould and the obtained CAD data of the shape and the size of the blank is computed as the thickness value to be increased; and (4) deposition forming: deposition forming is operated layer by layer by digital gradient material or single material on the surface of the blank according to the thickness value to be increased until the thickness value to be increased is obtained, and then the required tool and mould is obtained. The invention solves the problems of a traditional forming method and the prior quick forming method and is suitable for manufacturing large and middle complicated tools and moulds with high efficiency and quality as well as low cost.
Description
Technical field
The invention belongs to the special process method of tool and mould.
Background technology
Existing big-and-middle-sized tool and mould, as the big-and-middle-sized stamping die of automotive covering part of complicated shape, basic manufacturing process adopts cast form to obtain leaving the base substrate of suitable allowance mostly earlier; After base substrate machining is removed the surplus of the overwhelming majority, adopt surface hardening heat treatment, make its surface reach requirements such as required hardness, adopt fine finishining to reach the requirement of required size of tool and mould and surface smoothness at last.Yet, for big-and-middle-sized mould, the whole expense height that adopts the high-quality tool die material, machining amount is big, heat treatment technics requires height, has a big risk, blemish such as the intrinsic pore of foundry goods, shrinkage cavity cause scraps etc. and still to be difficult to avoid, and causes the manufacturing cycle of this method long, cost is high, risk is bigger.
For the injection mold of big-and-middle-sized inside gadget of automobile and so on, coolant flow channel is equidistant and be desirable mold cools down mode along with the profile distribution of shapes with the type type of cooling apart from the mold cavity surface.But,, can't obtain with machining with the type coolant flow channel, and mould can only be divided into machinable two parts along coolant flow channel, and adopt machining to obtain this two parts respectively because the profile of this class mould mostly is complex-curved; After runner to be cooled is carried out this two parts seam is got up finally to obtain with complicated mould with the type coolant flow channel.This method need be to a plurality of enforcement complicated shape machinings, and processing capacity is big; The sealing of coolant flow channel, mould and die accuracy etc. are wayward after two parts seam.
Adopting meltallizing (thermal spraying) method, at first is to make heat-resisting prototype, at its surface spraying mold materials, next adopts the backing compression-resistant material to the coating reinforcement then, afterwards prototype is separated with the coating after the reinforcement, finally obtains mould.This method is applicable to the low cost of the big-and-middle-sized mould of trial-production or small lot shaping usefulness, manufacturing fast.But, because of coating is difficult to reach be shaped the in batches required thickness and the requirement of intensity, and coating and metal reinforcement matrix metallurgical binding difficulty, therefore, still be not suitable for the quick manufacturing of the big-and-middle-sized mould of shaping usefulness in enormous quantities.
Directly making metal parts (Direct Rapid Metal Manufacturing) technology fast, is the digitlization stack shaping method that grows up on the basis of RP technique recently.The principle that it disperses/pile up based on the plane, at first in the CAD moulding system, obtain the three-dimensional CAD model of a part, model data is handled, carry out plane " layering " discretization along a certain direction, then by proprietary CAM system (forming machine) with moulding material by the plane successively stack shaping finally obtain the part prototype.The major advantage of this method is not limited by shape.Occurred at present the multiple method of directly making metal parts or mould fast, wherein, the method that can obtain the high-compactness part mainly contains methods such as the high power laser beam shaping of high energy beam, electron beam shaping, beam-plasma shaping.
The high power laser beam shaping is that the metal dust or the silk that adopt high power laser successively will deliver on the planar substrates melt, and rapid solidification finally is shaped, the density of drip molding is apparently higher than the selective laser sintering (SLS) method, see A J.Pinkkerton, L.Li, Effects of Geometry and Composition in Coaxial Laser Deposition of 316L Steel forRapid Protyping Annals of the CIRP, Vol.52,1 (2003), p181-1184.; But exist capacity usage ratio, forming efficiency and stock utilization not high, inaccessible full density, problem such as equipment investment is big.
It is to adopt powerful electron-beam melting dusty material that electron beam is shaped, apply electromagnetic field according to computer model, the motion of control electron beam, on planar substrates, successively scan until whole prototype shaping and finish, forming accuracy is higher, forming quality is better, see Matz JE., Eagar TW.Carbide formation in Alloy 718 during electron-beam solid freeformfabrication.Metallurgical and Materials Transactions A:Physical Metallurgy and Materials Science, 2002, v33 (8): p2559-2567..Yet its process conditions are strict, need carry out in a vacuum, cause forming dimension to be restricted, and the equipment manufacturing cost costliness.
It is the metal dust or the silk material of the good beam-plasma fusing supply synchronously of employing high compression, convergence that beam-plasma is shaped, on planar substrates, successively pile up the technology that forms metal parts, have than high power laser manufacturing process and electron beam deposition method forming efficiency height, be easy to obtain full density, but functionally gradient material (FGM) is shaped equipment and operating cost characteristics such as low far away, but, the forming accuracy of this method is lower than the above two, and the same with preceding two kinds of methods, can only obtain the near-net forming body of part.For this reason, occurred plasma deposition and the compound no molded making method of milling, it promptly is the shaping thermal source with the beam-plasma, in forming process, intersect and carry out the numerical control milling finishing, to realize short flow process, accurately to make (1) Zhang Haiou etc. cheaply, the method and the device thereof of direct quickly manufacturing mould and part, ZL00131288.X.(2) Haiou Zhang, Jipeng Xu, GuilanWang, Fundamental Study on Plasma Deposition Manufacturing, Surface and CoatingTechnology, v.171 (1-3), 2003, pp.112～118. (3) Zhang Haious etc., the compound direct manufacturing high temperature alloy double helix integral wheel of plasma deposition/milling, Chinese mechanical engineering, 2007, Vol18, No.14:P1723～1725.
Yet, for big-and-middle-sized tool and mould, reach several tons full-sized car vehicle body mould as weight, if deposition forming successively from the planar substrates still, even if employing forming efficiency height, the beam-plasma deposition forming technology that size restrictions is little, cost is low, still efficient is lower, cost is higher.Do not see the research report as yet based on the gradient of curved surface layering or homogenous material forming technology and software.Therefore, above-mentioned existing forming and machining method still is not suitable for the big-and-middle-sized batch shaping low cost of tool and mould, quick, high-quality manufacturing.
Summary of the invention
The invention provides a kind of molten long-pending manufacture method of tool and mould, solve the problem that the existing manufacture method cycle of big-and-middle-sized tool and mould is long, cost is high, risk is bigger.
The molten long-pending manufacture method of a kind of tool and mould of the present invention comprises in regular turn:
(1) shaping procedure of processing; Adopt casting to obtain the base substrate of tool and mould, the base substrate precision is in the casting error range; Perhaps with the injection mould or the compression mod base substrate of inner flow passage structure, the base substrate precision is not in the machining error scope for machining;
Described blank of material is required tool die material or tool die material metal material in addition;
(2) measuring process; Measure described base substrate, obtain the cad data of base substrate shape and size;
(3) calculated thickness value step; By the cad data of the cad data of required tool and mould and the base substrate shape and size that obtain, try to achieve both differences, with this difference as the one-tenth-value thickness 1/10 that should increase;
(4) deposition forming step; According to the described one-tenth-value thickness 1/10 that should increase, in described billet surface, adopt required tool die material or tool die material metal material in addition, digitlization functionally gradient material (FGM) or homogenous material be deposition forming successively, until reaching the one-tenth-value thickness 1/10 that should increase, obtain required tool and mould.
After required tool and mould deposition forming is all finished, can apply and grind or polishing, make tool and mould reach the surface quality requirement of design.
Described molten long-pending manufacture method is characterized in that:
In described shaping procedure of processing and the deposition forming step, the metal material beyond the described tool die material is carbon steel, nickel alloy, stainless steel, copper alloy or aluminium alloy.
Described molten long-pending manufacture method is characterized in that:
In the described deposition forming step, described deposition forming method is gas shielded arc welding deposition forming, laser deposition forming.
The problem that cycle is long, cost is high, risk is bigger that the inventive method is made at existing big-and-middle-sized tool and mould, according to the volume size of tool and mould, complex-shaped degree, at first adopt casting or machining to obtain to account for the base substrate of the most of volume of required tool and mould, this base substrate mostly is different shapes such as curved surface; On this billet surface, digitlization gradient or homogenous material be deposition forming successively, up to obtaining wear-resisting, corrosion resistant tool and mould with various complex surfaces or internal structure, and can be fast, economy, high-quality molding; Both solved that traditional casting+machining+the heat treated moulding cycle is long, cost is high, the bigger bottleneck problem of risk that cause because of defectives such as quenching and surface pores and shrinkage cavities, solved again lower based on planar layer and the existing quick forming method piled up because of efficient, cost is higher, be difficult to the curved surface layering is shaped and is not applied to the problem that big-and-middle-sized tool and mould is made as yet, has important application prospects.
The specific embodiment
Embodiment 1:
(1) adopt casting to obtain the base substrate of required drawing and shaping mold, the base substrate precision is in the casting error range, and blank of material is the cast iron materials of required mould; (2) by measuring described base substrate, obtain the cad data of the shape and size of this base substrate; (3) by the cad data of die needed cad data and the base substrate shape and size that measure, try to achieve both differences, with this difference as the one-tenth-value thickness 1/10 that should increase.With the lip-deep spill cone of the die of this mould is example, the size of this spill cone is as follows: the diameter at cone upper end open place is that the diameter of 130mm, bottom, lower end is 100mm, dark 15mm, and in the relevant position of the billet surface of this mould, the diameter that records a upper end open place is that the diameter of 140mm, bottom, lower end is the spill cone part of 110mm, dark 20mm, then on the recessed cone surface of this base substrate, the one-tenth-value thickness 1/10 that should increase is 5mm; (4) according to the described one-tenth-value thickness 1/10 that should increase, on this recessed cone surface of described billet surface, employing is installed in the molten long-pending rifle of consumable electrode gas-arc on the end effector of robot, the setting welding current is 40A～80A, digitlization is deposition forming drawing and shaping mold steel material successively, until reaching the 5mm one-tenth-value thickness 1/10 that should increase; Also by the one-tenth-value thickness 1/10 that should increase of trying to achieve after measuring, digitlization is the deposition forming die steel material successively, finally obtains the mould of required size for the other parts of described base substrate.After shaping is finished, apply a small amount of following process, make it reach the requirement of the surface quality of mould design.
Embodiment 2:
(1) adopt casting to obtain the base substrate of required drawing and shaping mold, the base substrate precision is in the casting error range, and blank of material is the cast steel material of required mould; (2) by measuring described base substrate, obtain the cad data of the shape and size of this base substrate; (3) by the cad data of die needed cad data and the base substrate shape and size that obtain, try to achieve both differences, with this difference as the one-tenth-value thickness 1/10 that should increase.On the die surface as this mould, the groove surface that a long 100mm, wide 50mm, dark 10mm are arranged, and on the relevant position of the billet surface of this mould, record the groove body portion of a long 106mm, wide 56mm, dark 13mm, then on the groove surface of this base substrate, the one-tenth-value thickness 1/10 that should increase is 3mm; (4) according to the described one-tenth-value thickness 1/10 that should increase, on described billet surface, adopt the molten long-pending rifle of the consumable electrode gas-arc that is installed on the deposition forming Digit Control Machine Tool processing head, welding current is 50～80A, digitlization is deposition forming iron-nickel-chromium material successively, until reaching the 3mm one-tenth-value thickness 1/10 that should increase; Also by the one-tenth-value thickness 1/10 that should increase of trying to achieve after measuring, digitlization is deposition forming iron-nickel-chromium material successively, finally obtains the mould of required size for the other parts of described base substrate.After shaping is finished, apply a small amount of following process, make it reach the requirement of the surface quality of mould design.
Embodiment 3:
(1) adopt machining to obtain the base substrate of required die casting, the base substrate precision is in the machining error scope, and blank of material is No. 50 forging steel; (2) by measuring described base substrate, obtain the cad data of the shape and size of this base substrate; (3) by the cad data of die needed cad data and the base substrate shape and size that obtain, try to achieve both differences, with this difference as the one-tenth-value thickness 1/10 that should increase.It is the half recessed ball portion of 20mm, dark 20mm that a radius is arranged in the die as this mould, and on the relevant position of the base substrate of this mould, recording a radius is the half recessed spheroid part of 23mm, dark 23mm, and then on half recessed ball surface of this base substrate, the one-tenth-value thickness 1/10 that should increase is 3mm; (4) according to the described one-tenth-value thickness 1/10 that should increase, in described billet surface, adopt the molten long-pending rifle of the plasma arc that is installed in the non-consumable gas shielded arc welding on the end effector of robot, welding current 50～80A, digitlization is deposition forming iron-nickel-chromium material successively, until reaching the one-tenth-value thickness 1/10 that should increase; Also by the one-tenth-value thickness 1/10 that should increase of trying to achieve after measuring, digitlization is deposition forming iron-nickel-chromium material successively, finally obtains the mould of required size for the other parts of described base substrate.After shaping is finished, apply a small amount of following process, make it reach the requirement of the surface quality of mould design.
Embodiment 4:
(1) adopt machining to obtain the base substrate of required injection mold, the base substrate precision is in the machining error scope, and blank of material is No. 45 forging steel; (2) by measuring described base substrate, obtain the cad data of the shape and size of this base substrate; (3) by the cad data of die needed cad data with the base substrate shape and size that obtain, try to achieve both differences, with this difference as the one-tenth-value thickness 1/10 that should increase, the semicircle projection section that in the die as this mould a radius to be arranged be 20mm, high 20mm, and the semicircle projection section that to record a radius in the relevant position of the base substrate of this mould be 18mm, high 18mm, then on the semicircle boss surface of this base substrate, the one-tenth-value thickness 1/10 that should increase is 2mm; (4) according to the described one-tenth-value thickness 1/10 that should increase, in described billet surface, the voltage that employing is installed on the deposition forming Digit Control Machine Tool processing head is 420v～480v, frequency is the laser beam that 10 hertz YAG solid state laser sends, digitlization is the deposition forming stainless steel alloy material successively, until reaching the one-tenth-value thickness 1/10 that should increase; Also by the one-tenth-value thickness 1/10 that should increase of trying to achieve after measuring, digitlization is the deposition forming stainless steel alloy material successively for the other parts of described base substrate, finally obtain required size, band is with the mould of type coolant flow channel.After shaping is finished, apply a small amount of following process, make it reach the requirement of the surface quality of mould design.
Claims (3)
1. melting of a tool and mould amassed manufacture method, comprises in regular turn:
(1) shaping procedure of processing; Adopt casting to obtain the base substrate of tool and mould, the base substrate precision is in the casting error range; Perhaps with the injection mould or the compression mod base substrate of inner flow passage structure, the base substrate precision is not in the machining error scope for machining;
Described blank of material is required tool die material or tool die material metal material in addition;
(2) measuring process; Measure described base substrate, obtain the cad data of base substrate shape and size;
(3) calculated thickness value step; By the cad data of the cad data of required tool and mould and the base substrate shape and size that obtain, try to achieve both differences, with this difference as the one-tenth-value thickness 1/10 that should increase;
(4) deposition forming step; According to the described one-tenth-value thickness 1/10 that should increase, in described billet surface, adopt required tool die material or tool die material metal material in addition, carry out digitlization functionally gradient material (FGM) or homogenous material deposition forming successively, until reaching the one-tenth-value thickness 1/10 that should increase, obtain required tool and mould.
2. molten long-pending manufacture method as claimed in claim 1 is characterized in that:
In described shaping procedure of processing and the deposition forming step, the metal material beyond the described tool die material is carbon steel, nickel alloy, stainless steel, copper alloy or aluminium alloy.
3. molten long-pending manufacture method as claimed in claim 1 or 2 is characterized in that:
In the described deposition forming step, the deposition forming method is gas shielded arc welding deposition forming or laser deposition forming.
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| CN2009103052967A CN101618414B (en) | 2009-08-06 | 2009-08-06 | Deposition manufacturing method of tools and moulds |
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| CN2009103052967A CN101618414B (en) | 2009-08-06 | 2009-08-06 | Deposition manufacturing method of tools and moulds |
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Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2011212841A (en) * | 2010-03-16 | 2011-10-27 | Panasonic Corp | Molding machine, method for producing mold motor using molding machine, and mold motor produced by the method |
| CN102116933A (en) * | 2011-02-28 | 2011-07-06 | 许小曙 | Laser scanning method for selective laser firing |
| CN104028725B (en) * | 2014-05-15 | 2016-04-13 | 泰州市万达轮业制造有限公司 | A kind of three-dimensional piles up the die casting mold technology for making of shaping gradient-structure |
| CN105503201A (en) * | 2015-12-09 | 2016-04-20 | 机械科学研究总院先进制造技术研究中心 | Digital forming method of precision ceramic parts |
| DE102016203195A1 (en) * | 2016-02-29 | 2017-08-31 | Ford Global Technologies, Llc | Method for producing a forming tool |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB681887A (en) * | 1950-05-04 | 1952-10-29 | Goodyear Aircraft Corp | Method of making metal molds |
| CN1651593A (en) * | 2005-02-23 | 2005-08-10 | 华中科技大学 | Mould surface modifying and repairing method |
| CN101362272A (en) * | 2008-09-17 | 2009-02-11 | 华中科技大学 | No-mold fusion stacking manufacture method of parts or mold |
-
2009
- 2009-08-06 CN CN2009103052967A patent/CN101618414B/en active Active
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB681887A (en) * | 1950-05-04 | 1952-10-29 | Goodyear Aircraft Corp | Method of making metal molds |
| CN1651593A (en) * | 2005-02-23 | 2005-08-10 | 华中科技大学 | Mould surface modifying and repairing method |
| CN101362272A (en) * | 2008-09-17 | 2009-02-11 | 华中科技大学 | No-mold fusion stacking manufacture method of parts or mold |
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