CN105128227A - 3D precision shaping method of conformal cooling structure of injection mold - Google Patents
3D precision shaping method of conformal cooling structure of injection mold Download PDFInfo
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- CN105128227A CN105128227A CN201510675385.6A CN201510675385A CN105128227A CN 105128227 A CN105128227 A CN 105128227A CN 201510675385 A CN201510675385 A CN 201510675385A CN 105128227 A CN105128227 A CN 105128227A
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Abstract
Provided is a 3D precision shaping method of a conformal cooling structure of an injection mold. Based on heat transfer calculation, an efficient heat exchange conformal cooling flow channel three-dimensional model is established for the cavity face contour of the injection mold, layered structural division is performed on the conformal cooling flow channel three-dimensional model, corresponding structures in different layers are machined through a machining method, a laser method or a chemical etching method, and the structures in different layers are stacked and positioned according to corresponding sequence. The layered structures are welded through a diffusion welding method achieved by adding an intermediate layer, and 3D precision shaping of a conformal cooling flow channel is achieved; finally, a mold cavity is machined in a diffusion welding solid surface through a machining method, and 3D precision shaping of the conformal cooling structure of the injection mold is completed. By means of the method, the design space can be greatly expanded, and conformal cooling structures in any complicated shape can be manufactured. High strength and high precision of the conformal cooling structure is guaranteed, production cost is low, production efficiency is high, and the requirement for batch industrial production can be met.
Description
Technical field
The invention belongs to technology of die manufacturing field, be specifically related to a kind of 3D method for precisely forming of injection mold conformal cooling structure.
Background technology
In the design of traditional injection moulding mold cools down water channel, owing to manufacturing the restriction of means, simple cooling water channel (as carried out car, milling, plane, brill, mill, galvanic corrosion etc. to metal blank) can only be adopted, and can not produce as 3 D complex cooling systems such as follow-cooling passageways.
Point out in document " key technology of injection mould cooling system and progress ", cooling system is on the impact of plastic parts moulding significantly and be mainly manifested in: in a injection molding process, account for molding cycle 50% ~ 80% cool time, the raising of improvement to production efficiency of cooling system is most important; The rational cooling system of b can make the temperature at each position of mould keep evenly, improving plastic surface quality; The rational cooling system of c can keep constant mold temperature, thus improves the dimensional accuracy of plastic; The rational cooling system of d can improve the temperature field of mould inside effectively, reduces plastic internal stress, thus strengthens plastic mechanical property.
Follow-cooling passageway is by arranging cooling line from a distance, mold cavity surface, and cooling line changes along with the change of mold cavity structure.Point out in document " TheDesignofConformalCoolingChannelsinInjectionMoldingToo ling ", compared with the traditional moulds type of cooling, conformal cooling mode generally can shorten its injection cycle about 20%, and the distortion of injection-moulded plastic part simultaneously reduces 15%.
The manufacture of current follow-cooling passageway realizes mainly through rapid shaping technique, as direct metal deposition, direct metal laser sintering, selective laser sintering, selective laser thawing etc.Above-mentioned technology is all adopt metal dust to carry out rapid shaping, utilize discrete-pile up principle to make shapingly to enter inside parts, but it all exists that manufacturing cost is high, machinable material kind is limited, production efficiency is low, surface quality of workpieces the is not good enough shortcoming such as (not reaching precision and surface roughness that traditional diamond-making technique realizes) and forming part low strength (not reaching the intensity that traditional diamond-making technique realizes).
Except adopting above-mentioned metal dust quick molding method, adopt laminated solid body diffusion welding method also can realize the manufacture of injection mold follow-cooling passageway.Laminated solid body diffusion welding (DW) is a kind of rapid shaping technique, and its core concept is discrete dynamics models, namely does moulding with laminate or thin slice, can process certain structure, then multi-layered sheet is stacked assembling, Diffusion Welding, thus complete entity manufacture according to design on thin plate.The advantage of the method is: a breaches the restriction of the complex-shaped degree of part geometry, can manufacture the part of any labyrinth; B is particularly suitable for manufacturing the part with inner flow passage or cavity; C can meet the industrial needs of mass.
But when adopting the direct connecting mold steel of diffusion welding method, there will be the large and low two large problems of strength of joint of welding deformation amount, be specially:
When adopting diffusion welding method to weld mould steel workpiece, needing to apply certain pressure to workpiece, making the rough and uneven in surface place of its welding surface microcosmic produce plastic deformation and reaching close contact.In allowed band, when welding pressure is larger, strength of joint is higher; More hour, strength of joint is lower for welding pressure.Therefore the acquisition of high-strength joint, need to adopt large welding pressure.
But when welding pressure is larger, welding deformation amount can be caused large, especially when welding complex multilayer (as curved-surface structure, hollow-core construction etc.), the inhomogeneities of welding pressure is born owing to there is labyrinth, can cause subsiding, going here and there chamber etc., welding deformation amount is large, has had a strong impact on surface accuracy; And when welding pressure is less, linkage interface is obvious, strength of welded joint is lower.
Summary of the invention
In order to overcome above-mentioned the deficiencies in the prior art, the object of this invention is to provide a kind of 3D method for precisely forming of injection mold conformal cooling structure, namely add intermediate layer at diffusion weld interface, but postwelding joint intermediate layer disappearing completely.Its bonding machine is shaped with two kinds: first metallic intermediate layer does not react with mother metal, welding insulating process in, the metallic intermediate layer of molten state along mother metal crystal boundary to its diffusion inside, until intermediate layer disappears completely; It two is that metallic intermediate layer can react with mother metal, in welding insulating process, metallic intermediate layer to the diffusion of mother metal matrix, reaction, until intermediate layer disappears completely.
To achieve these goals, the technical solution used in the present invention is:
A 3D method for precisely forming for injection mold conformal cooling structure, comprises the following steps:
1) first for molding mold cavity facial contour, based on Calculation of Heat Transfer, the follow-cooling passageway threedimensional model that High Efficiency Thermal exchanges is set up;
2) based on the basic principle being easy to process, Rotating fields division is carried out to the threedimensional model of follow-cooling passageway, adopt the method for machining, laser or chemical etching to process corresponding each Rotating fields, each Rotating fields is stacked according to the order of correspondence, locates;
3) adopt subsequently and add the diffusion welding method in intermediate layer, under certain welding condition, Rotating fields is welded, choose Cu, Au, Mn, Sn or Zn wherein a certain simple metal as intermediate layer, realize the 3D precise forming of follow-cooling passageway;
Described welding condition, welding vacuum is not less than 10
-2pa, temperature is higher than metallic intermediate layer fusing point or Fe-metallic intermediate layer binary phase diagraml eutectic point 30 ~ 100 DEG C, and pressure is 0.1 ~ 1MPa, and temperature retention time is 0.5 ~ 1.5h; Be below using Ni metal, Au, Mn, Sn or Zn wherein a certain simple metal as the welding procedure in intermediate layer:
A, employing Ni metal are as intermediate layer, and welding vacuum is not less than 10
-2pa, is increased to 1113 ~ 1183 DEG C by welding temperature subsequently, pressurization 0.1 ~ 1MPa, insulation duration 0.5 ~ 1.5h;
B, employing metal A u are as intermediate layer, and welding vacuum is not less than 10
-2pa, is increased to 1094 ~ 1164 DEG C by welding temperature subsequently, pressurization 0.1 ~ 1MPa, insulation duration 0.5 ~ 1.5h;
C, employing metal M n are as intermediate layer, and welding vacuum is not less than 10
-2pa, passes into 1000Pa argon gas, prevents the volatilization loss of Mn after vacuumizing end in vacuum diffusion welding body of heater, raises welding temperature to 1276 ~ 1346 DEG C subsequently, pressurization 0.1 ~ 1MPa, insulation 0.5 ~ 1.5h;
D, employing metal Sn are as intermediate layer, and welding vacuum is not less than 10
-2pa, raises welding temperature to 1160 ~ 1230 DEG C subsequently, pressurization 0.1 ~ 1MPa, insulation 0.5 ~ 1.5h;
E, employing Metal Zn are as intermediate layer, and welding vacuum is not less than 10
-2pa, passes into 1000Pa argon gas, prevents the volatilization loss of Zn after vacuumizing end in vacuum diffusion welding body of heater, raises welding temperature to 812 ~ 882 DEG C subsequently, pressurization 0.1 ~ 1MPa, insulation 0.5 ~ 1.5h;
4) finally adopt machining process at diffusion welding (DW) solid object surface processing mold die cavity, complete the 3D precise forming of injection mold conformal cooling structure.
Described intermediate layer thickness is 1 ~ 10mm, adopts the preparation of foil, metal dust, surface coating.
The form parameter of described follow-cooling passageway, as distance, diameter, centre-to-centre spacing apart from moulding mold cavity surface, based on Calculation of Heat Transfer, can carry out free design according to the different cooling requirement of reality.
Rotating fields surface to be welded surface roughness is between 0.01 ~ 1mm.
Compared with prior art, the invention has the beneficial effects as follows:
1) according to heat exchange demand, the follow-cooling passageway of almost complicated shape arbitrarily can be manufactured and designed, improves temperature homogeneity and the cooling effectiveness of injection mold.
2) intensity and the precision of the conformal cooling structure prepared by are high.
3) production cost is low, and production efficiency is higher, can meet the industrial needs of mass.
Accompanying drawing explanation
Fig. 1 is the three-dimensional model diagram of the structure 1 that technical scheme of the present invention is implemented;
Wherein, 1.1 is semi-circular section of follow-cooling passageway; 1.2 is the straightway of follow-cooling passageway, and 2 is mold cavity, and 3 is cooling medium entrance, and 4 is cooling medium outlet.
Fig. 2 is the Rotating fields dividing mode of follow-cooling passageway threedimensional model in Fig. 1 structure;
Wherein, threedimensional model will be divided into Rotating fields 5,6,7,8,9,10 along the cross-section of five semi-circular runners 1.1.
Fig. 3 is the three-dimensional model diagram of the structure 2 that technical scheme of the present invention is implemented;
Wherein, 11 is cooling medium entrance, and 12 is cooling medium outlet, and 13 is mold cavity, and 14.1 is round section of follow-cooling passageway, and 14.2 is the oblique line section of follow-cooling passageway.
Fig. 4 is the Rotating fields dividing mode of follow-cooling passageway threedimensional model in Fig. 3 structure;
Wherein, threedimensional model will be divided into Rotating fields 15,16,17,18,19 along the cross-section of four round runners 14.1.
Detailed description of the invention
Below in conjunction with embodiment and accompanying drawing, the present invention is described further, but the present invention is not limited to following examples.
Below in conjunction with the follow-cooling passageway of two profiles cavity configuration and Cu, Au, Mn, Sn or Zn wherein a certain simple metal as the diffusion welding (DW) in intermediate layer, the present invention will be further described.
Embodiment 1
Adopt Cu as the 3D method for precisely forming of the injection mold conformal cooling structure in diffusion welding (DW) intermediate layer, step is as follows:
Mould steel kind selects P20.
For the facial contour of molding mold cavity, based on Calculation of Heat Transfer, set up the follow-cooling passageway threedimensional model that High Efficiency Thermal exchanges, specifically as shown in Figure 1, set up the threedimensional model of follow-cooling passageway according to mold cavity 2 semi-circular in Fig. 1.Cooling medium enters from entrance 3, realizes three-dimensional serial runner along follow-cooling passageway (1.1 and 1.2), and the final cooling medium that arrives exports 4.
Based on the basic principle being easy to process, Rotating fields division is carried out to the threedimensional model of follow-cooling passageway, specifically as shown in Figure 2, along the cross-section of five semi-circular runners 1.1, entity is carried out to the division of Rotating fields, be five Rotating fields by entity division, be respectively 5,6,7,8,9,10.Black heavy line is cut-off rule, and adopts two kinds of different filling modes to be distinguished.
According to above-mentioned design, adopt numerical control mill and Drilling operation to combine, laminate 5,6,7,8,9,10 corresponding in Fig. 2 can be processed.
Laminate surface to be welded after corase grind, fine grinding, makes its surface roughness reach 0.1mm by employing grinding machine.
Clear up surface to be welded before weldering, adopt 1500# fine sandpaper to polish to surface to be welded, clean surface to be welded with acetone subsequently, cold wind dries up.
Before weldering, the interlayer Cu paper tinsel that 5m is thick is cleared up.Be processed into and surface to be welded same shape by Cu paper tinsel, and adopt 1500# fine sandpaper to carry out two-sided polishing to Cu paper tinsel, clean Cu paper tinsel with acetone subsequently, cold wind dries up.
Each Rotating fields is stacked according to the order of correspondence, locates (making locating hole).And while stacking, locating, Cu paper tinsel is positioned over each solder side as intermediate layer.
Treat that weldment entirety is placed in Vacuum diffusion bonding furnace by what assemble, close fire door, body of heater vacuum is evacuated to 10
-3pa.Subsequently welding temperature is increased to 1133 DEG C, pressurization 0.5MPa, insulation 1h.Insulation terminates rear release, with stove cooling weldment.Realize the precision of each Rotating fields, high strong ties.
Finally adopt CNC milling machine at diffusion welding (DW) solid object surface processing mold die cavity 2, complete the 3D precise forming of injection mold follow-cooling passageway structure.
Embodiment 2
Adopt Au as the 3D method for precisely forming of the injection mold conformal cooling structure in diffusion welding (DW) intermediate layer, be with the difference of embodiment 1:
Diffusion welding (DW) intermediate layer is the Au paper tinsel that 5mm is thick.
Treat that weldment entirety is placed in Vacuum diffusion bonding furnace by what assemble, close fire door, body of heater vacuum is evacuated to 10
-3pa.Subsequently welding temperature is increased to 1094 DEG C, pressurization 0.5MPa, insulation 1h.Insulation terminates rear release, with stove cooling weldment.Realize the precision of each Rotating fields, high strong ties.
Embodiment 3
Adopt Mn as the 3D method for precisely forming of the injection mold conformal cooling structure in diffusion welding (DW) intermediate layer, be with the difference of embodiment 1:
For molding mold cavity facial contour, based on Calculation of Heat Transfer, set up the follow-cooling passageway threedimensional model that High Efficiency Thermal exchanges, specifically as shown in Figure 3, set up the threedimensional model of follow-cooling passageway according to mold cavity 13 round in Fig. 3.Cooling medium enters from entrance 11, realizes three-dimensional serial runner along follow-cooling passageway (14.1 and 14.2), and the final cooling medium that arrives exports 12.
Based on the basic principle being easy to process, Rotating fields division is carried out to the threedimensional model of follow-cooling passageway.Specifically as shown in Figure 4.Along the cross-section of five round runners 14.1, entity is carried out to the division of Rotating fields, be five Rotating fields by entity division, be respectively 15,16,17,18,19.Black heavy line is cut-off rule, and adopts two kinds of different filling modes to be distinguished.
According to above-mentioned design, adopt numerical control mill and Drilling operation to combine, laminate 15,16,17,18,19 corresponding in Fig. 2 can be processed.
Diffusion welding (DW) intermediate layer is the Mn powder that about 5mm is thick, first with alcohol, Mn powder is made pasty state, and while stacking, locating by pasty state Mn powder uniform spreading in each solder side.
Treat that weldment entirety is placed in Vacuum diffusion bonding furnace by what assemble, close fire door, body of heater vacuum is evacuated to 10
-3pa, applying argon gas to 100Pa, to prevent the volatilization loss of Mn in welding high temperature.Subsequently welding temperature is increased to 1276 DEG C, pressurization 0.5MPa, insulation 1h.Insulation terminates rear release, with stove cooling weldment.Realize the precision of each Rotating fields, high strong ties.
Embodiment 4
Adopt Sn as the 3D method for precisely forming of the injection mold conformal cooling structure in diffusion welding (DW) intermediate layer, be with the difference of embodiment 3:
Diffusion welding (DW) intermediate layer is the Sn paper tinsel that 5mm is thick.
Treat that weldment entirety is placed in Vacuum diffusion bonding furnace by what assemble, close fire door, body of heater vacuum is evacuated to 10
-3pa, is increased to 1160 DEG C by welding temperature subsequently, pressurization 0.5MPa, insulation 1h.Insulation terminates rear release, with stove cooling weldment.Realize the precision of each Rotating fields, high strong ties.
Embodiment 5
Adopt Zn as the 3D method for precisely forming of the injection mold conformal cooling structure in diffusion welding (DW) intermediate layer, be with the difference of embodiment 3:
Adopt electroplating device to prepare the thick diffusion welding (DW) intermediate layer Zn film of 5mm on surface to be welded surface, and surface roughness is remained on about 0.1mm.
Treat that weldment entirety is placed in Vacuum diffusion bonding furnace by what assemble, close fire door, body of heater vacuum is evacuated to 10
-3pa, applying argon gas to 1000Pa, to prevent the volatilization loss of Zn in welding high temperature.Subsequently welding temperature is increased to 812 DEG C, pressurization 0.5MPa, insulation 1h.Insulation terminates rear release, with stove cooling weldment.Realize the precision of each Rotating fields, high strong ties.
In conjunction with above-mentioned five embodiments, appearance and size test and hydraulic pressure test are carried out to five group welding pieces, as can be seen from following table test data, by adding the method in welding intermediate layer, can effectively control welding deformation amount between 0.01 ~ 0.1%, and hydraulic pressure test can reach 3MPa and not produce leakage.Above-mentioned welding deformation amount is less than the welding deformation amount of direct diffusion welding (DW) mould steel, is about 1% ~ 3%, and intensity is suitable with direct diffusion welding (DW) mould steel.As can be seen from test result, the inventive method both ensure that injection mold conformal cooling structure welding intensity, turn improved dimensional accuracy.
。
Claims (4)
1. a 3D method for precisely forming for injection mold conformal cooling structure, is characterized in that, comprise the following steps:
1) first for molding mold cavity facial contour, based on Calculation of Heat Transfer, the follow-cooling passageway threedimensional model that High Efficiency Thermal exchanges is set up;
2) based on the basic principle being easy to process, Rotating fields division is carried out to the threedimensional model of follow-cooling passageway, adopt the method for machining, laser or chemical etching to process corresponding each Rotating fields, each Rotating fields is stacked according to the order of correspondence, locates;
3) adopt subsequently and add the diffusion welding method in intermediate layer, under certain welding condition, Rotating fields is welded, choose Cu, Au, Mn, Sn or Zn wherein a certain simple metal as intermediate layer, realize the 3D precise forming of follow-cooling passageway;
Described welding condition, welding vacuum is not less than 10
-2pa, temperature is higher than metallic intermediate layer fusing point or Fe-metallic intermediate layer binary phase diagraml eutectic point 30 ~ 100 DEG C, and pressure is 0.1 ~ 1MPa, and temperature retention time is 0.5 ~ 1.5h; Be below using Ni metal, Au, Mn, Sn or Zn wherein a certain simple metal as the welding procedure in intermediate layer:
A, employing Ni metal are as intermediate layer, and welding vacuum is not less than 10
-2pa, is increased to 1113 ~ 1183 DEG C by welding temperature subsequently, pressurization 0.1 ~ 1MPa, insulation duration 0.5 ~ 1.5h;
B, employing metal A u are as intermediate layer, and welding vacuum is not less than 10
-2pa, is increased to 1094 ~ 1164 DEG C by welding temperature subsequently, pressurization 0.1 ~ 1MPa, insulation duration 0.5 ~ 1.5h;
C, employing metal M n are as intermediate layer, and welding vacuum is not less than 10
-2pa, passes into 1000Pa argon gas, prevents the volatilization loss of Mn after vacuumizing end in vacuum diffusion welding body of heater, raises welding temperature to 1276 ~ 1346 DEG C subsequently, pressurization 0.1 ~ 1MPa, insulation 0.5 ~ 1.5h;
D, employing metal Sn are as intermediate layer, and welding vacuum is not less than 10
-2pa, raises welding temperature to 1160 ~ 1230 DEG C subsequently, pressurization 0.1 ~ 1MPa, insulation 0.5 ~ 1.5h;
E, employing Metal Zn are as intermediate layer, and welding vacuum is not less than 10
-2pa, passes into 1000Pa argon gas, prevents the volatilization loss of Zn after vacuumizing end in vacuum diffusion welding body of heater, raises welding temperature to 812 ~ 882 DEG C subsequently, pressurization 0.1 ~ 1MPa, insulation 0.5 ~ 1.5h;
4) finally adopt machining process at diffusion welding (DW) solid object surface processing mold die cavity, complete the 3D precise forming of injection mold conformal cooling structure.
2. the 3D method for precisely forming of a kind of injection mold conformal cooling structure according to claim 1, it is characterized in that, described intermediate layer thickness is 1 ~ 10mm, adopts the preparation of foil, metal dust, surface coating.
3. the 3D method for precisely forming of a kind of injection mold conformal cooling structure according to claim 1, it is characterized in that, the form parameter of described follow-cooling passageway, as distance, diameter, centre-to-centre spacing apart from moulding mold cavity surface, based on Calculation of Heat Transfer, free design can be carried out according to the different cooling requirement of reality.
4. the 3D method for precisely forming of a kind of injection mold conformal cooling structure according to claim 1, it is characterized in that, Rotating fields surface to be welded surface roughness is between 0.01 ~ 1mm.
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