TW201408403A - Device for high-density molding and method for high-density molding of mixed powder - Google Patents

Device for high-density molding and method for high-density molding of mixed powder Download PDF

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TW201408403A
TW201408403A TW102114232A TW102114232A TW201408403A TW 201408403 A TW201408403 A TW 201408403A TW 102114232 A TW102114232 A TW 102114232A TW 102114232 A TW102114232 A TW 102114232A TW 201408403 A TW201408403 A TW 201408403A
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powder
mixed powder
mold
density
heating
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TW102114232A
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Chinese (zh)
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Kazuhiro Hasegawa
Yoshiki Hirai
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Aida Eng Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B22F3/03—Press-moulding apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B11/00—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/02—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a ram exerting pressure on the material in a moulding space
    • B30B11/027—Particular press methods or systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • B30B15/30—Feeding material to presses
    • B30B15/302—Feeding material in particulate or plastic state to moulding presses
    • B30B15/304—Feeding material in particulate or plastic state to moulding presses by using feed frames or shoes with relative movement with regard to the mould or moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • B30B15/32—Discharging presses
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C45/00—Amorphous alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C45/00—Amorphous alloys
    • C22C45/02—Amorphous alloys with iron as the major constituent
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy

Abstract

In the present invention, a first die (21D) is filled with a mixed powder (100), which is a mixture of a basic metal powder and a low-melting-point lubricant powder, a first applied pressure is applied to mold a mixed powder intermediate compact (110) with a form having a protruding section (110A) protruding in the direction from which pressure is applied compared to the form of a mixed powder completed compact (120), the mixed powder intermediate compact (110) is heated to actively raise the temperature of the mixed powder intermediate compact (110) to the melting-point-equivalent temperature of the lubricant powder, and the heated mixed powder intermediate compact (110) is subjected to a second applied pressure within a second die (41D) and is pressure molded while subjecting the protruding section (110A); to crushing compression in the direction from which pressure is applied in order to complete a high density mixed powder completed compact (120) having an intended form.

Description

混合粉末的高密度成形方法及高密度成形裝置 High-density forming method of mixed powder and high-density forming device

本發明有關一種高密度成形方法及高密度成形裝置，其可藉由對混合粉末進行二次加壓而成形高密度(例如7.75g/cm3)的粉末壓胚。 The present invention relates to a high-density molding method and a high-density molding apparatus which can form a high-density (for example, 7.75 g/cm 3 ) powder preform by secondary pressurization of a mixed powder.

通常，粉末冶金技術是先對金屬粉末加壓(壓縮)進行成形處理成形規定形狀的粉末壓胚，接著將粉末壓胚加熱到該金屬粉末的熔點附近的溫度並促使粒子間結合(固化)進行燒結處理的一系列技術。由此，可以用低成本製造出形狀複雜尺寸精度高的機械構件。 Generally, the powder metallurgy technique is to pressurize (compress) a metal powder to form a powder preform having a predetermined shape, and then heat the powder compact to a temperature near the melting point of the metal powder and promote bonding (solidification) between the particles. A series of techniques for sintering. Thereby, a mechanical member having a high shape and high dimensional accuracy can be manufactured at low cost.

隨著對機械構件更加小型輕量化的需求，要求提高粉末壓胚的機械強度。另一方面，如果將粉末壓胚暴露在高溫氣氛中則磁性能會降低。因此，在實際生產磁心用粉末壓胚時，有時會省略其後的高溫處理(燒結處理)。換言之，正在摸索一種即使不進行高溫處理(燒結處理)，也能提高機械強度的方法。 With the demand for smaller and lighter mechanical components, it is required to increase the mechanical strength of the powder preform. On the other hand, if the powder compact is exposed to a high temperature atmosphere, the magnetic properties are lowered. Therefore, when the powder preform for magnetic core is actually produced, the subsequent high temperature treatment (sintering treatment) may be omitted. In other words, a method of improving mechanical strength even without performing high temperature treatment (sintering treatment) is being explored.

此處，有人提出機械強度會隨著粉末壓胚密度的增加而得到大幅(雙曲線型)提高。作為有代表性的高密度化 方法，有人提出一種將潤滑劑混合在金屬粉末中以此來減小摩擦阻力並加壓成形的方法(例如專利文獻1)。通常是在基礎金屬粉末中混合約1重量%(1wt%)的潤滑劑成形混合粉末，對混合粉末進行加壓成形。還有人提出了很多旨在進一步提高密度的方案。這些方案大體分為改善潤滑劑本身和改善加壓成形、燒結處理相關的過程。 Here, it has been suggested that the mechanical strength is greatly increased (hyperbolic type) as the density of the powder compact is increased. As a representative high density As a method, a method of mixing a lubricant in a metal powder to reduce frictional resistance and press-forming is proposed (for example, Patent Document 1). Usually, about 1% by weight (1% by weight) of the lubricant-forming mixed powder is mixed in the base metal powder, and the mixed powder is subjected to press forming. Others have proposed a number of programs aimed at further increasing the density. These solutions are broadly divided into processes that improve the lubricant itself and improve the press forming and sintering processes.

作為屬於前者的方案，可以舉出球狀炭分子和板狀炭分子組合在一起的碳分子複合體的方案(例如專利文獻2)；25℃時的穿透度是0.3mm~10mm的潤滑劑的方案(例如專利文獻3)。這些方案均為減小金屬粉末之間、以及金屬粉末和模具間的摩擦阻力的方案。 As a solution belonging to the former, a carbon molecular composite in which spherical carbon molecules and platy carbon molecules are combined can be cited (for example, Patent Document 2); a lubricant having a transmittance of 0.3 mm to 10 mm at 25 ° C is used. Solution (for example, Patent Document 3). These solutions are all solutions for reducing the frictional resistance between metal powders and between metal powder and mold.

作為屬於後者的方案，已知有溫熱成形燒結粉末冶金方法(專利文獻4)、操作方便的前置溫熱成形粉末冶金方法(專利文獻5)、二次壓製-二次燒結粉末冶金方法(例如專利文獻6)，以及一次成形-燒結粉末冶金方法(專利文獻7)。 As a solution belonging to the latter, a warm-forming sintered powder metallurgy method (Patent Document 4), a convenient pre-heating forming powder metallurgy method (Patent Document 5), and a secondary press-secondary sintering powder metallurgy method are known (Patent Document 5) For example, Patent Document 6), and a primary forming-sintering powder metallurgy method (Patent Document 7).

開始的溫熱成形．燒結粉末冶金方法是藉由預熱混合有固體潤滑劑及液體潤滑劑的金屬粉末，使一部分(或全部)潤滑劑熔化並使潤滑劑分散在粒子間。該方法以此降低粒子間及粒子與模具間的摩擦阻力從而提高成形性。操作方便的前置溫熱成形粉末冶金方法，是一種設置有一次成形步驟，以在溫熱成形步驟前對混合粉末進行加壓成形操作方便的低密度(例如密度比低於76%)的一次成形體，以低於使該一次成形體產生藍熱脆性的溫度的低溫狀 態且將一次成形體一次崩解並進行二次成形步驟得到二次成形體(粉末壓胚)的方法。二次壓製-二次燒結粉末冶金方法是一種以在模具內對包含合金成分的鐵粉混合物加壓並生成一次壓縮體，在870℃將該壓縮體(粉末壓胚)預燒結5分鐘並生成預燒結體，藉由加壓該預燒結體而生成已二次壓製的預燒結體，此後在1000℃將已二次壓製的預燒結體燒結5分鐘來生成燒結構件的方法。最後的一次成形-燒結粉末冶金方法是一種提前預熱模具並預先使內表面帶電附著潤滑劑，接著在該模具內填充已加熱的鐵基粉末混合物(鐵基粉末+潤滑劑粉末)，以規定溫度加壓成形製成鐵基粉末成形體，接著對鐵基粉末成形體實施燒結處理，進而進行光亮淬火，之後實施回火處理製造鐵基燒結體的方法。 The beginning of warm forming. The sintered powder metallurgy method is to pre-heat a metal powder mixed with a solid lubricant and a liquid lubricant to melt a part (or all) of the lubricant and disperse the lubricant between the particles. This method reduces the frictional resistance between particles and between the particles and the mold to improve formability. The convenient pre-warm forming powder metallurgy method is a low density (for example, a density ratio lower than 76%) which is provided with a primary forming step to facilitate the pressure forming operation of the mixed powder before the warm forming step. The molded body has a low temperature lower than a temperature at which the primary molded body produces blue hot brittleness In the state, the primary molded body is once disintegrated and subjected to a secondary forming step to obtain a secondary molded body (powder compact). The secondary press-secondary sintering powder metallurgy method is a method of pressurizing an iron powder mixture containing an alloy composition in a mold to form a primary compressed body, and pre-sintering the compressed body (powder compact) at 870 ° C for 5 minutes and generating The pre-sintered body is obtained by pressing the pre-sintered body to form a pre-sintered body which has been twice pressed, and thereafter sintering the pre-sintered body which has been twice pressed at 1000 ° C for 5 minutes to form a sintered member. The last forming-sintering powder metallurgy method is to preheat the mold in advance and electrically attach the inner surface to the lubricant in advance, and then fill the mold with the heated iron-based powder mixture (iron-based powder + lubricant powder) to define The iron-based powder molded body is formed by temperature press molding, and then the iron-based powder molded body is subjected to a sintering treatment to further perform bright quenching, followed by tempering treatment to produce an iron-based sintered body.

像這樣，使用潤滑劑或加壓成形、燒結處理過程相關的任何改善方法，粉末壓胚的密度最高也就是7.4g/cm3(真密度的94%)左右。機械強度不夠。進而，進行燒結處理(高溫氣氛)時，由於氧化隨著溫度、時間而加重，所以粉末粒子塗布狀態的潤滑劑燃燒產生殘渣，導致加壓成形後的粉末壓胚品質降低，因此，實際生產時的密度變為在7.3g/cm3以下。而且，任何改善方法也都複雜且難免會變得成本高昂。操作也麻煩，實用性差。 As such, the density of the powder compact is about 7.4 g/cm 3 (94% of the true density) using any improvement method related to the lubricant or the press forming and sintering process. The mechanical strength is not enough. Further, when the sintering treatment (high-temperature atmosphere) is performed, since the oxidation is increased with temperature and time, the lubricant in the powder particle-coated state is burned to generate a residue, and the quality of the powder preform after the press molding is lowered. Therefore, in actual production, The density becomes 7.3 g/cm 3 or less. Moreover, any improvement method is complicated and inevitably becomes costly. The operation is also troublesome and the practicality is poor.

尤其是考慮到用粉末壓胚製作電磁設備(馬達或變壓器等)用的磁心(磁芯)的話，常被指出這種程度的密度(7.3g/cm3以下)遠不能滿足需要。要減小損耗(鐵損、 磁滯損耗)量提高磁通密度，就需要將粉末壓胚進一步高密度化，例如，從平成21年度粉體粉末冶金協會秋季大會上的演講資料(株式會社豐田中央研究所提供)看就一目了然。磁心密度，例如即便是7.5g/cm3，在實際應用中，也被指出不僅磁特性，其機械強度也不足。 In particular, in consideration of the use of a magnetic core (magnetic core) for electromagnetic equipment (motor, transformer, etc.) by powder compaction, it is often pointed out that such a density (7.3 g/cm 3 or less) is far from satisfactory. In order to reduce the loss (iron loss, hysteresis loss) and increase the magnetic flux density, it is necessary to further increase the density of the powder compact. For example, from the speech of the Autumn Powder Powder Metallurgy Association Autumn Conference (Toyota Co., Ltd.) The Central Research Institute provides) it is clear at a glance. The core density, for example, even 7.5 g/cm 3 , is pointed out in practical applications not only in magnetic properties but also in mechanical strength.

關於該磁心用粉末壓胚的製造，提出一種二次成形-一次燒結(一次退火)的粉末冶金方法(例如專利文獻8)。該專利申請的粉末冶金方法依據的技術內容是：如果在磁性金屬粉末表面預先形成含有矽樹脂和顏料的塗層的話，則其後即便進行高溫處理絕緣性也不會降低。即壓粉磁心的製造方法特徵在於：把表面被覆有含矽樹脂和顏料塗層的磁性粉末預成形製作成預成形體，以500℃以上的溫度對該預成形體實施熱處理成形熱處理體，接著對該熱處理體實施壓縮成形。由於在500℃以下則在其後的壓縮成形時容易產生斷裂，在1000℃以上則會因絕緣塗層分解燒壞絕緣性，所以，熱處理用的溫度設置在500℃~1000℃的範圍內。從防止預成形體氧化的觀點出發，該高溫處理可在真空中、非活性氣體氣氛或還原性氣體氣氛中進行。因而有報導稱可製造出真密度98%(7.7g/cm3)的壓粉磁心。 Regarding the production of the powder compact for the core, a powder metallurgy method of secondary forming-primary sintering (primary annealing) has been proposed (for example, Patent Document 8). The powder metallurgy method of this patent application is based on the technical content that if a coating containing a cerium resin and a pigment is formed in advance on the surface of the magnetic metal powder, the insulating property is not lowered even after high-temperature treatment. That is, the method for producing a powder magnetic core is characterized in that a magnetic powder having a surface coated with a ruthenium resin and a pigment coating layer is preformed into a preform, and the preform is subjected to a heat treatment forming heat treatment at a temperature of 500 ° C or higher, and then The heat-treated body is subjected to compression molding. When the temperature is 500 ° C or lower, the film is likely to be broken during the subsequent compression molding. When the temperature is 1000 ° C or higher, the insulation property is decomposed and burned. Therefore, the temperature for the heat treatment is set in the range of 500 ° C to 1000 ° C. The high temperature treatment can be carried out in a vacuum, an inert gas atmosphere or a reducing gas atmosphere from the viewpoint of preventing oxidation of the preform. Therefore, it has been reported that a dust core having a true density of 98% (7.7 g/cm 3 ) can be produced.

〔習知技術文獻〕 [Practical Technical Literature]

〔專利文獻〕 [Patent Document]

〔專利文獻1〕日本專利公開平1-219101號公報 [Patent Document 1] Japanese Patent Laid-Open No. Hei 1-219101

〔專利文獻2〕日本專利公開2009-280908號公報 [Patent Document 2] Japanese Patent Laid-Open Publication No. 2009-280908

〔專利文獻3〕日本專利公開2010-37632號公報 [Patent Document 3] Japanese Patent Laid-Open Publication No. 2010-37632

〔專利文獻4〕日本專利公開平2-156002號公報 [Patent Document 4] Japanese Patent Laid-Open No. Hei 2-156002

〔專利文獻5〕日本專利公開2000-87104號公報 [Patent Document 5] Japanese Patent Laid-Open Publication No. 2000-87104

〔專利文獻6〕日本專利公開平4-231404號公報 [Patent Document 6] Japanese Patent Laid-Open Publication No. Hei-4-231404

〔專利文獻7〕日本專利公開2001-181701號公報 [Patent Document 7] Japanese Patent Laid-Open Publication No. 2001-181701

〔專利文獻8〕日本專利公開2002-343657號公報 [Patent Document 8] Japanese Patent Publication No. 2002-343657

但是二次成形-一次燒結粉末冶金方法(專利文獻8)與其他專利申請的方法相比，更加複雜化、個別化並且難於實現及實施，導致製造成本大幅度提高。且，必須在500℃以上對預成形體進行熱處理。為防止粉末磁心品質惡化而必須在特殊氣氛中進行，所以不適用於大批量生產。尤其是由於玻璃材質會變質、熔解，所以不適用於被覆玻璃材質塗層的磁性金屬粉末的情況。 However, the secondary forming-primary sintering powder metallurgy method (Patent Document 8) is more complicated, individualized, and difficult to implement and implement than the methods of other patent applications, resulting in a substantial increase in manufacturing costs. Further, the preform must be heat-treated at 500 ° C or higher. In order to prevent deterioration of the quality of the powder core, it must be carried out in a special atmosphere, so it is not suitable for mass production. In particular, since the glass material is deteriorated and melted, it is not suitable for the case of a magnetic metal powder coated with a glass coating.

且，無論在上述任何申請的方法、裝置(專利文獻1~8)中，雖然記載有在相對高溫氣氛內可以實施燒結處理，但有關加壓成形步驟的詳細情況並不明確。與加壓成形機的規格、功能，加壓力和密度的關係或其局限的相關分析也末見有與新的改善相關的報導。 In addition, in the method and apparatus (Patent Documents 1 to 8) of any of the above-mentioned applications, it is described that the sintering treatment can be performed in a relatively high temperature atmosphere, but the details of the press molding step are not clear. Correlation analysis with the specifications, functions, pressure and density of the press forming machine or its limitations is also reported with new improvements.

因而從伴隨小型輕量化而要求更高的機械強度的角度看，當務之急是開發出可切實、穩定並以低成本製造高密 度粉末壓胚(尤其是磁心用高密度粉末壓胚)的方法、裝置。 Therefore, from the perspective of requiring higher mechanical strength with small size and light weight, it is imperative to develop high-density that can be manufactured reliably, stably, and at low cost. A method and apparatus for powder compacting (especially for high density powder compacts for magnetic core).

本發明的目的是提供一種混合粉末的高密度成形方法及高密度成形裝置，其藉由對混合粉末實施加溫前後的二次加壓成形可製造出高密度粉末壓胚，並且可大幅度降低製造成本。 An object of the present invention is to provide a high-density forming method of a mixed powder and a high-density forming apparatus which can produce a high-density powder compact by performing a secondary press forming before and after heating of the mixed powder, and can be greatly reduced manufacturing cost.

根據用燒結冶金技術製造粉末壓胚的慣例，需要在高溫氣氛(例如800℃以上)對加壓成形的粉末壓胚實施燒結處理。但是，燒結用高溫處理不僅會消耗大量的能源，成本負擔巨大，且在保護地球環境上也有很大的害處，需要重新考量。 According to the convention of producing a powder compact by a sintering metallurgy technique, it is necessary to subject a press-formed powder compact to a sintering treatment in a high temperature atmosphere (for example, 800 ° C or higher). However, the high temperature treatment for sintering not only consumes a large amount of energy, but also has a large cost burden, and also has great harm in protecting the global environment, and needs to be reconsidered.

且，以往加壓成形處理是將混合粉確立為具體的形狀，其被認為是高溫燒結處理的前一階段(準備)的機械性處理，並一直是這樣來處理的。但是現狀是只在製造用於電磁設備(電動機、變壓器等)的磁心用粉末壓胚時，例外地省略了用於燒結的高溫處理。這是為了避免高溫處理後的不良影響(磁特性惡化)。即被迫接受機械強度的不足。機械強度不足是由於密度的問題，所以磁特性當然也不夠。 Further, in the conventional press forming treatment, the mixed powder is established into a specific shape, which is considered to be a mechanical treatment in the previous stage (preparation) of the high-temperature sintering treatment, and has been treated as such. However, the current state of the art is to omit high-temperature processing for sintering only when manufacturing a powder preform for a magnetic core (electric motor, transformer, etc.). This is to avoid adverse effects (deterioration of magnetic properties) after high temperature treatment. That is, it is forced to accept the lack of mechanical strength. The lack of mechanical strength is due to the problem of density, so the magnetic properties are of course insufficient.

此處，如果不進行高溫燒結處理而僅以加壓成形處理就可實現粉末壓胚的高密度成形，則應該能夠顯著提高粉末壓胚在產業上的利用及普及。本發明是根據分析同時可 藉由有效利用加壓能力且促進液態潤滑劑的均勻流動而切實製造出高品質粉末壓胚而創造出來的，前述分析是加壓時潤滑劑的有效性、含有潤滑劑粉末的壓縮極限性、潤滑劑粉末在混合粉末內的空間佔有性、對基礎金屬粉末與潤滑劑粉末的空間配置狀態和其特性及潤滑劑的最終處置方式的研究，以及一般的加壓成形機的特性、壓縮極限性及粉末壓胚的密度對強度或磁性的影響的分析。 Here, the high-density molding of the powder compact can be achieved only by the press forming treatment without performing the high-temperature sintering treatment, and the industrial use and spread of the powder compact should be remarkably improved. The invention is based on analysis at the same time It is created by effectively utilizing the pressurizing ability and promoting the uniform flow of the liquid lubricant to effectively produce a high-quality powder compact. The above analysis is the effectiveness of the lubricant during pressurization, and the compression limit of the lubricant powder. The space occupancy of the lubricant powder in the mixed powder, the spatial arrangement state of the base metal powder and the lubricant powder, and the characteristics thereof, and the final disposal manner of the lubricant, as well as the characteristics and compression limit of the general press molding machine And analysis of the effect of density of powdered preforms on strength or magnetic properties.

即本發明將混合粉末填充到第一模具內，前述混合粉末是基礎金屬粉末中混合粉末潤滑劑，維持潤滑劑的粉末狀態並藉由第一加壓步驟成形具有突起部分的中間粉末壓胚，接著藉由加熱潤滑劑使其液化，使中間粉末壓胚內的潤滑方式改變，此後藉由第二加壓步驟在加壓方向上使突起部分潰散、壓縮並進行加壓成形而完成接近真密度的高密度的完成粉末壓胚。換言之，其有關一種脫胎於需要高溫燒結處理的以往燒結冶金技術而創新出的新的粉末冶金技術(潤滑劑液化步驟前後的二次加壓成形)，可提供可切實穩定並低成本地製造高密度粉末壓胚的具有劃時代意義的方法和裝置。 That is, the present invention fills the mixed powder into the first mold, the mixed powder is a mixed powder lubricant in the base metal powder, maintains the powder state of the lubricant, and forms the intermediate powder preform having the protruding portion by the first pressing step, Then, by heating the lubricant to liquefy, the lubrication mode in the intermediate powder preform is changed, and then the protrusion portion is collapsed, compressed, and pressure-formed in the pressing direction by the second pressing step to complete the near true density. The high density of finished powder preforms. In other words, it is a new powder metallurgy technology (secondary press forming before and after the lubricant liquefaction step) that has been invented in the past sintering metallurgy technology that requires high-temperature sintering treatment, and can provide high stability and low cost. A epoch-making method and apparatus for density powder compacts.

(1)具體而言，本發明的一種實施方式有關的混合粉末的高密度成形方法，其特徵在於：在第一模具中填充混合粉末，前述混合粉末基礎金屬粉末與低熔點的潤滑劑粉末混合的混合物，在前述第一模具內向前述混合粉末施加第一加壓力成形混合粉末中間壓縮體，與混合粉末完成壓縮體的形態相比前述混合粉末中間壓縮體具有在加壓方 向上突起的一個或多個突起部分的形態，加熱從前述第一模具取出的前述混合粉末中間壓縮體並積極將前述混合粉末中間壓縮體的溫度升高到相當於該潤滑劑粉末的熔點的溫度，將升溫後的前述混合粉末中間壓縮體裝入第二模具中，在前述第二模具內向前述混合粉末中間壓縮體施加第二加壓力在加壓方向上使突起部分潰散、壓縮並進行加壓成形以高密度完成所期待的形態的混合粉末完成壓縮體。 (1) Specifically, a high-density forming method of a mixed powder according to an embodiment of the present invention is characterized in that a mixed powder is filled in a first mold, and the mixed powder base metal powder is mixed with a low-melting lubricant powder. a mixture of the first pressure-molded mixed powder intermediate compression body applied to the mixed powder in the first mold, and the mixed powder intermediate compression body has a pressurization side as compared with a form in which the mixed powder completes the compressed body a form of the one or more protruding portions protruding upward, heating the mixed powder intermediate compressed body taken out from the first mold and actively raising the temperature of the mixed powder intermediate compressed body to a temperature corresponding to the melting point of the lubricant powder The heated mixed intermediate compressed body is charged into the second mold, and a second pressing force is applied to the mixed powder intermediate compressed body in the second mold to collapse, compress, and pressurize the protruding portion in the pressing direction. Forming the mixed powder in a desired form at a high density to complete the compact.

(2)在上述(1)的發明中，可在混合粉末完成壓縮體是實心且形狀簡單時，將突起部分成形在混合粉末中間壓縮體的平面中央部分。 (2) In the invention of the above (1), when the mixed powder is completed and the compressed body is solid and the shape is simple, the protruding portion can be formed in the central portion of the plane of the mixed powder intermediate compressed body.

(3)在上述(1)或(2)的發明中，可將潤滑劑粉末的熔點設為低熔點，前述低熔點屬於90℃~190℃的溫度範圍內。 (3) In the invention of the above (1) or (2), the melting point of the lubricant powder may be a low melting point, and the low melting point may be in a temperature range of 90 ° C to 190 ° C.

(4)在上述(1)或(2)的發明中，第二模具可在接收前述混合粉末中間壓縮體以前先被預熱到相當於潤滑劑粉末的熔點的溫度。 (4) In the invention of the above (1) or (2), the second mold may be preheated to a temperature corresponding to the melting point of the lubricant powder before receiving the mixed powder intermediate compressed body.

且，(5)在上述(1)或(2)的發明中，第二加壓力可選擇為與第一加壓力等值。 Further, in the invention of the above (1) or (2), the second pressing force may be selected to be equivalent to the first pressing force.

進而，(6)本發明的第二實施方式有關的混合粉末的高密度成形裝置，具有：混合粉末供給機，其可向外部供給填充混合粉末，前述混合粉末是基礎金屬粉末和低熔點的潤滑劑粉末的混合物；第一加壓成形機，其向用該混合粉末供給機填充到第一模具中的前述混合粉末施加第一加壓力成形與混合粉末完成壓縮體的形態相比具有在加壓 方向上突起的一個或多個突起部分的混合粉末中間壓縮體；加熱升溫機，其用於將從前述第一模具取出的前述混合粉末中間壓縮體的溫度升高到相當於該潤滑劑粉末的熔點的溫度；第二加壓成形機，其向已裝入第二模具的已升溫的前述混合粉末中間壓縮體施加第二加壓力在加壓方向上使突起部分潰散、壓縮並進行加壓成形以高密度完成所期待的形態的混合粉末完成壓縮體。 Further, (6) a high-density molding apparatus for a mixed powder according to a second embodiment of the present invention, comprising: a mixed powder supply device that supplies a filling mixed powder to the outside, the mixed powder being a base metal powder and a low melting point lubrication a mixture of powders; a first press molding machine that applies a first press forming to the aforementioned mixed powder filled into the first mold by the mixed powder feeder, and has a pressurization as compared with a form in which the mixed powder completes the compressed body a mixed powder intermediate compression body of one or more protruding portions protruding in the direction; a heating and heating machine for raising the temperature of the aforementioned mixed powder intermediate compression body taken out from the foregoing first mold to correspond to the lubricant powder a temperature at a melting point; a second press molding machine that applies a second pressing force to the heated intermediate body of the mixed powder that has been charged into the second mold to collapse, compress, and press form the protrusion portion in the pressurizing direction The compressed body is completed by mixing the powder of the desired form at a high density.

進而且(7)在上述(6)的發明中，加熱升溫機和第二加壓成形機可由同時具有其二者功能的加熱加壓成形機構成，並且前述加熱加壓成形機由多台加熱加壓成形子機構成且各前述加熱加壓成形子機可在每個週期內選擇依序動作。 (7) In the invention of the above (6), the heating and heating machine and the second press molding machine may be constituted by a heat and pressure molding machine having both functions, and the heating and pressing machine is heated by a plurality of units. The press molding machine is configured and each of the above-described heating and press molding sub-machines can be sequentially operated in each cycle.

(8)在上述(6)的發明中，可具有預熱前述第二模具的預熱裝置。 (8) In the invention of (6) above, the preheating device for preheating the second mold may be provided.

(9)在上述(6)的發明中，還可具有工件移送裝置，其向前述加熱升溫機移送前述第一加壓成形機所成形的前述混合粉末中間壓縮體，將前述加熱升溫機所加熱的前述混合粉末中間壓縮體移送到前述第二加壓成形機，且將前述第二加壓成形機所成形的前述混合粉末完成壓縮體移送到排出部。 (9) In the invention of the above (6), the workpiece transfer device may be further configured to transfer the mixed powder intermediate compression body formed by the first press molding machine to the heating and heating machine, and heat the heating and heating machine. The mixed powder intermediate compressed body is transferred to the second press molding machine, and the mixed powder formed by the second press molding machine is transferred to the discharge portion.

採用上述(1)的發明，可切實穩定地製造高密度粉末壓胚且可大幅度降低製造成本，同時可藉由有效利用加 壓能力且促進液態潤滑劑的均勻流動而順利地實際生產出高品質粉末壓胚。 According to the invention of the above (1), it is possible to stably manufacture a high-density powder compact and to greatly reduce the manufacturing cost, and at the same time, by effectively utilizing The pressure capability and the uniform flow of the liquid lubricant are promoted to smoothly produce a high quality powder compact.

採用上述(2)的發明，可進一步提高從中央部分朝向外側的腔體內壁面的基礎金屬粒子及液態潤滑劑的流動性。即可進一步促進液態潤滑劑的均勻流動且可縮短製造時間。 According to the invention of the above (2), the fluidity of the base metal particles and the liquid lubricant from the central portion toward the outer wall surface of the cavity can be further improved. The uniform flow of the liquid lubricant can be further promoted and the manufacturing time can be shortened.

採用上述(3)的發明，可確保在第一加壓步驟中潤滑劑有充分潤滑作用。而且可有助於抑制氧化，潤滑劑種類的選擇性也廣泛。 According to the invention of the above (3), it is ensured that the lubricant is sufficiently lubricated in the first pressurizing step. Moreover, it can contribute to the suppression of oxidation, and the selectivity of the type of lubricant is also wide.

且，採用上述(4)的發明，可進一步大幅提高在第二加壓成形中的已熔解的潤滑劑的全方向流動性。即除基礎金屬粒子間的摩擦阻力還可大幅減少並維持基礎金屬粒子和第二模具之間的摩擦阻力。 Further, according to the invention of the above (4), the omnidirectional fluidity of the melted lubricant in the second press molding can be further greatly improved. That is, in addition to the frictional resistance between the base metal particles, the frictional resistance between the base metal particles and the second mold can be greatly reduced and maintained.

採用上述(5)的發明，易於進行加壓成形步驟的執行及操作，間接地有助於進一步降低粉末壓胚的製造成本。 According to the invention of the above (5), the execution and operation of the press forming step are facilitated, which indirectly contributes to further reducing the manufacturing cost of the powder compact.

且，採用上述(6)的發明，可切實執行上述(1)~(5)有關的混合粉末的高密度成形方法並易於實現，操作簡單。可進一步提高生產率。 Further, according to the invention of the above (6), the high-density molding method of the mixed powder according to the above (1) to (5) can be reliably carried out, and it is easy to realize, and the operation is simple. Can further increase productivity.

進而且，採用上述(7)的發明，與上述(6)的發明的情況相比，可進一步簡化裝置。也可促進生產線的簡化，操作變得更容易。 Further, according to the invention of the above (7), the apparatus can be further simplified as compared with the case of the invention of the above (6). It also facilitates the simplification of the production line and makes the operation easier.

上述(8)的發明，藉由預熱第二模具，即便在完成粉末壓胚成形開始之前混合粉末中間壓縮體的溫度有可能 下降的情況下，也能將混合粉末中間壓縮體維持在固定的溫度範圍內，所以可得到良好的成形效果。 In the invention of the above (8), by preheating the second mold, it is possible to mix the temperature of the intermediate compressed body of the powder even before the completion of the powder preform forming. In the case of the lowering, the mixed powder intermediate compact can also be maintained in a fixed temperature range, so that a good molding effect can be obtained.

採用上述(9)的發明，藉由具有工件移送裝置，可將工件切實地在從第一加壓成形機到前述加熱升溫機之間，從加熱升溫機到第二加壓成形機之間，以及從第二加壓成形機到排出部之間移送。 According to the invention of the above (9), by having the workpiece transfer device, the workpiece can be reliably passed between the first press molding machine and the heating and heating machine, and between the heating and heating machine to the second press molding machine. And transferring from the second press molding machine to the discharge portion.

另外，可從下文的說明明白上述之外的本發明的結構及效果。 Further, the structure and effects of the present invention other than the above can be understood from the following description.

1‧‧‧高密度成形裝置 1‧‧‧High-density forming device

10‧‧‧混合粉末供給機 10‧‧‧Mixed powder feeder

11‧‧‧中間粉末壓胚 11‧‧‧Intermediate powder preform

12‧‧‧完成粉末壓胚 12‧‧‧Complete powder compact

20‧‧‧第一加壓成形機 20‧‧‧First Press Forming Machine

21‧‧‧下模具 21‧‧‧ Lower mold

21D‧‧‧中空圓筒形模具 21D‧‧‧ hollow cylindrical mold

21PD‧‧‧下沖頭 21PD‧‧‧ lower punch

21PDS‧‧‧上端面 21PDS‧‧‧ upper end

22‧‧‧腔體 22‧‧‧ cavity

23‧‧‧可動構件 23‧‧‧ movable components

24‧‧‧通孔 24‧‧‧through hole

25‧‧‧上模具 25‧‧‧Upper mold

25P‧‧‧上沖頭 25P‧‧‧Upper punch

25PU‧‧‧上沖頭 25PU‧‧‧Upper punch

30‧‧‧加熱升溫機 30‧‧‧heating machine

31‧‧‧噴氣罩 31‧‧‧Air hood

32‧‧‧保持構件 32‧‧‧Retaining components

33‧‧‧排氣循環罩 33‧‧‧Exhaust circulation cover

40‧‧‧第二加壓成形機 40‧‧‧Second press forming machine

41‧‧‧下模具 41‧‧‧ Lower mold

41D‧‧‧下模具 41D‧‧‧ Lower mold

41P‧‧‧下沖頭 41P‧‧‧Under the punch

41PD‧‧‧下沖頭 41PD‧‧‧ lower punch

42‧‧‧腔體 42‧‧‧ cavity

43‧‧‧可動構件 43‧‧‧ movable components

44‧‧‧通孔 44‧‧‧through hole

45‧‧‧上模具 45‧‧‧Upper mold

45P‧‧‧上沖頭 45P‧‧‧Upper punch

45PU‧‧‧上沖頭 45PU‧‧‧Upper punch

47‧‧‧第二預熱裝置 47‧‧‧Second preheating device

48‧‧‧多功能型加熱裝置 48‧‧‧Multifunctional heating device

50‧‧‧工件移送裝置 50‧‧‧Workpiece transfer device

51、52、53‧‧‧移送桿 51, 52, 53‧‧‧Transfer rod

59‧‧‧排出槽 59‧‧‧Drainage trough

70‧‧‧加熱加壓成形機 70‧‧‧heat compression molding machine

70A，70B‧‧‧加熱加壓成形子機 70A, 70B‧‧‧heating and pressing forming machine

100‧‧‧混合粉末 100‧‧‧ mixed powder

110‧‧‧中間粉末壓胚(混合粉末中間壓縮體) 110‧‧‧Intermediate powder preform (mixed powder intermediate compression body)

110A‧‧‧突起部分 110A‧‧‧ protruding part

110B‧‧‧突起部分 110B‧‧‧ protruding part

120‧‧‧完成粉末壓胚(混合粉末完成壓縮體) 120‧‧‧Complete powder compact (mixed powder complete compression body)

120S、120T‧‧‧空間 120S, 120T‧‧‧ space

圖1是用來說明本發明的高密度成形方法的示意圖。 BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic view for explaining a high-density molding method of the present invention.

圖2是用來說明本發明的第一實施方式的高密度成形裝置(及動作)的主視圖。 Fig. 2 is a front view for explaining a high-density molding apparatus (and operation) according to the first embodiment of the present invention.

圖3A是用來說明本發明的第一實施方式的混合粉末的高密度成形動作的圖，顯示以第一模具成形中間粉末壓胚的狀態。 3A is a view for explaining a high-density molding operation of the mixed powder according to the first embodiment of the present invention, and shows a state in which the intermediate powder preform is formed by the first mold.

圖3B是用來說明本發明的第一實施方式的混合粉末的高密度成形動作的圖，顯示向第一模具內填充下一混合粉末的狀態。 3B is a view for explaining a high-density molding operation of the mixed powder according to the first embodiment of the present invention, and shows a state in which the next mixed powder is filled into the first mold.

圖4是用來說明本發明第一實施方式的加壓力和以該加壓力得到的密度之間的關係的圖表，虛線所示的特性A是顯示第一模具的成形狀態，實線所示的特性B是顯示第二模具的成形狀態。 4 is a graph for explaining the relationship between the pressing force according to the first embodiment of the present invention and the density obtained by the pressing force, and the characteristic A shown by the broken line is a state in which the first mold is formed, as shown by a solid line. Characteristic B is a state in which the second mold is formed.

圖5A是用來說明本發明的第一實施方式的完成粉末 壓胚(中間粉末壓胚)的透視圖，呈圓環形。 Figure 5A is a completed powder for explaining the first embodiment of the present invention A perspective view of the preform (intermediate powder compact) in a circular shape.

圖5B是用來說明本發明的第一實施方式的完成粉末壓胚(中間粉末壓胚)的透視圖，呈圓柱形。 Fig. 5B is a perspective view for explaining a completed powder compact (intermediate powder compact) of the first embodiment of the present invention, which has a cylindrical shape.

圖5C是用來說明本發明的第一實施方式的完成粉末壓胚(中間粉末壓胚)的透視圖，呈細長圓軸形。 Fig. 5C is a perspective view for explaining the completed powder compact (intermediate powder compact) of the first embodiment of the present invention, which has an elongated circular axis shape.

圖5D是用來說明本發明的第一實施方式的完成粉末壓胚(中間粉末壓胚)的透視圖，呈圓盤形。 Fig. 5D is a perspective view for explaining the completed powder compact (intermediate powder compact) of the first embodiment of the present invention, in the shape of a disk.

圖5E是用來說明本發明的第一實施方式的完成粉末壓胚(中間粉末壓胚)的透視圖，呈複雜形狀。 Fig. 5E is a perspective view for explaining a completed powder compact (intermediate powder compact) of the first embodiment of the present invention, in a complicated shape.

圖6是用來說明本發明的第一實施方式中圓盤形完成粉末壓胚所對應的中間粉末壓胚的突起部分的圖。 Fig. 6 is a view for explaining a protruding portion of an intermediate powder preform corresponding to a disc-shaped finished powder compact in the first embodiment of the present invention.

圖7是用來成形設置有本發明的第一實施方式中的突起部分的中間粉末壓胚及圓盤形完成粉末壓胚的第一模具及第二模具的示意圖。 Fig. 7 is a schematic view showing a first mold and a second mold for forming an intermediate powder preform and a disc-shaped finished powder preform provided with the projection portion in the first embodiment of the present invention.

圖8是用來說明本發明的第一實施方式中完成粉末壓胚成形時的液態潤滑劑的流動狀態的圖。 Fig. 8 is a view for explaining a flow state of a liquid lubricant at the time of completion of powder preform forming in the first embodiment of the present invention.

圖9是用於說明本發明的第一實施方式中複雜形狀的完成粉末壓胚所對應的中間粉末壓胚的突起部分的圖。 Fig. 9 is a view for explaining a protruding portion of an intermediate powder preform corresponding to a completed powder preform of a complicated shape in the first embodiment of the present invention.

圖10是本發明的第二實施方式的高密度成形裝置及其動作的主視圖。 Fig. 10 is a front elevational view showing a high-density molding apparatus and an operation thereof according to a second embodiment of the present invention.

以下參照附圖詳細說明本發明的具體實施方式。 Specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

(第一實施方式) (First embodiment)

本混合粉末的高密度成型裝置1，如圖1~圖8所示，具有混合粉末供給機10、第一加壓成形機20、加熱升溫機30及第二加壓成形機40，可穩定切實地實施本混合粉末的高密度成形方法，前述本混合粉末的高密度成形方法有效利用加壓能力且促進基礎金屬粒子及液態潤滑劑的均勻流動而可切實製造出高品質粉末壓胚，前述本混合粉末的高密度成形方法由下述各步驟構成：將混合粉末100填充到第一模具(下模具21)中的混合粉末填充步驟(PR1)，前述混合粉末100是向基礎金屬粉末中混合低熔點的潤滑劑粉末的混合物；在第一模具(下模具21)內藉由安裝於加工成形機20的滑塊5上的上模具25向混合粉末100施加第一加壓力(P1)而成形具有突起部分110A形態的混合粉末中間壓縮體(以下有時也稱為中間粉末壓胚110)的中間粉末壓胚成形步驟(PR2)；加熱從第一模具(下模具21)取出的中間粉末壓胚110使其積極升溫到相當於該潤滑劑粉末的熔點的溫度的加熱升溫步驟(PR3)；將加熱的中間粉末壓胚110裝入第二模具(下模具41)內的步驟(PR4)及在第二模具(下模具41)內藉由安裝於加工成形機40的滑塊5上的上模具45向中間粉末壓胚110施加第二加壓力P2在加壓方向上使突起部分110A潰散、壓縮並進行加壓成形而以高密度完成所期待的形態的混合粉末完成壓縮體(以下有時也稱為完成粉末壓胚120)的完成粉末壓胚成形步驟(PR5)。 As shown in FIGS. 1 to 8 , the high-density molding apparatus 1 of the mixed powder has a mixed powder feeder 10, a first press molding machine 20, a heating and heating machine 30, and a second press molding machine 40, and is stable and practical. The high-density molding method of the mixed powder is carried out, and the high-density molding method of the mixed powder described above can effectively utilize the pressurization ability and promote the uniform flow of the base metal particles and the liquid lubricant, thereby reliably producing a high-quality powder preform. The high-density molding method of the mixed powder is composed of the following steps: a mixed powder filling step (PR1) in which the mixed powder 100 is filled into the first mold (the lower mold 21), and the mixed powder 100 is mixed into the base metal powder. a mixture of melting point lubricant powders; formed in the first mold (lower mold 21) by applying a first pressing force (P1) to the mixed powder 100 by an upper mold 25 attached to the slider 5 of the forming machine 20 Intermediate powder preform forming step (PR2) of the mixed powder intermediate compressed body (hereinafter sometimes referred to as intermediate powder preform 110) in the form of the protruding portion 110A; heating in the middle taken out from the first mold (lower mold 21) The heating step (PR3) of the powder preform 110 to actively raise the temperature to a temperature corresponding to the melting point of the lubricant powder; and the step of loading the heated intermediate powder preform 110 into the second mold (lower mold 41) (PR4) And applying a second pressing force P2 to the intermediate powder preform 110 in the second mold (lower mold 41) by the upper mold 45 attached to the slider 5 of the forming machine 40 to cause the protruding portion 110A in the pressing direction. The completed powder preform forming step (PR5) of the compressed body (hereinafter sometimes referred to as completed powder preform 120) is completed by compaction, compression, and press molding to obtain a mixed powder of a desired form at a high density.

在本說明書中所述的混合粉末100，是指基礎金屬粉末和低熔點的潤滑劑粉末的混合物。且，基礎金屬粉末，是存在：僅由一種主金屬粉末構成的情況，以及由一種主金屬粉末及在其中混合一種或多種合金成分粉末的情況，但無論是什麼情況都可以適用。低熔點是指與基礎金屬粉末的熔點(溫度)相比溫度(熔點)極其低的溫度(熔點)且可大幅抑制基礎金屬粉末的氧化的溫度(溫度)。 The mixed powder 100 described in the present specification means a mixture of a base metal powder and a low melting point lubricant powder. Further, the base metal powder is one in which only one main metal powder is used, and one main metal powder and one or more alloy component powders are mixed therein, but any case can be applied. The low melting point refers to a temperature (melting point) at which the temperature (melting point) is extremely lower than the melting point (temperature) of the base metal powder and the oxidation (base temperature) of the base metal powder can be greatly suppressed.

在顯示高密度成形裝置1的圖2中，配置在高密度成形線的最左側(上游側)的混合粉末供給機10是將混合粉末100供給到構成第一加壓成形機20的一部分的第一模具(下模具21)中並填充到其腔體22內的裝置。具有保留固定量的混合粉末100的功能及定量供給功能，可在初始位置(在圖2、圖3A以實線所示的位置)和第一模具(下模具21)的上方位置(在圖3B以虛線所示的位置)之間有選擇地整體往復移動。 In FIG. 2 showing the high-density molding apparatus 1, the mixed powder feeder 10 disposed on the leftmost (upstream side) side of the high-density molding line supplies the mixed powder 100 to a part constituting a part of the first press molding machine 20. A means in a mold (lower mold 21) and filled into its cavity 22. The function and the dosing function having the fixed amount of mixed powder 100 retained can be in the initial position (the position shown by the solid line in FIGS. 2 and 3A) and the upper position of the first mold (the lower mold 21) (in FIG. 3B). Selectively reciprocatingly moves integrally between the positions indicated by the dashed lines.

由於將混合粉末100均勻且充分地填充到第一模具(下模具21)內的每一處非常重要，所以混合粉末100必須是鬆散狀態。即由於第一模具(下模具21)的內部空間(腔體22)的形狀是與產品形狀相對應的形狀，所以即便產品形狀複雜或是具有狹小部分的形狀，在保證中間粉末壓胚110的尺寸精度上，也最好不要填充不均勻或不充分。 Since it is very important to uniformly and sufficiently fill the mixed powder 100 into each of the first molds (the lower mold 21), the mixed powder 100 must be in a loose state. That is, since the shape of the inner space (cavity 22) of the first mold (the lower mold 21) is a shape corresponding to the shape of the product, even if the shape of the product is complicated or has a narrow shape, the intermediate powder preform 110 is secured. In terms of dimensional accuracy, it is also best not to fill uneven or insufficient.

完成粉末壓胚120(中間粉末壓胚110)的形態(尺寸、形狀)並無特殊限定，例如圖5A~圖5E所示。圖 5A是圓環形、圖5B是圓柱形、圖5C是細長圓軸形、圖5D是圓盤形、圖5E是複雜形狀。 The form (size, shape) of the powder preform 120 (intermediate powder preform 110) is not particularly limited, and is shown, for example, in FIGS. 5A to 5E. Figure 5A is a circular ring shape, FIG. 5B is a cylindrical shape, FIG. 5C is an elongated circular axis shape, FIG. 5D is a disk shape, and FIG. 5E is a complicated shape.

即由於第一加壓成形機20的上模具25(上沖頭25PU)及下模具21的腔體22設置為與中間粉末壓胚110的形態(形狀)對應的形狀，因而在中間粉末壓胚110的形態例如為圖5A~圖5E所示時，變為與之分別對應的形狀。中間粉末壓胚110的形狀如圖5A所示為環形管形狀時，如圖2、圖3A、圖3B所示上模具(上沖頭25PU)25的形狀為圓筒形且下模具21的形狀變為中空環形管形狀。如圖5B所示為圓柱形時，上模具(上沖頭25PU)25的形狀是實心圓筒(圓柱)形且下模具21的形狀變為中空圓筒形。是圖5C的圓盤形、圖5D的細長圓軸形時，也是同樣的形態(但是，存在深淺的差異)。如圖5E所示是複雜形狀時，變為對應的複雜形狀。另外，對第二加壓成形機40的上模具(上沖頭45PU)45及下模具41的腔體42也是同樣地設置。 That is, since the upper mold 25 (upper punch 25PU) of the first press molding machine 20 and the cavity 22 of the lower mold 21 are disposed in a shape corresponding to the form (shape) of the intermediate powder preform 110, the intermediate powder compact For example, when the shape of 110 is as shown in FIG. 5A to FIG. 5E, it has a shape corresponding to each of them. When the shape of the intermediate powder preform 110 is a ring shape as shown in FIG. 5A, the upper mold (upper punch 25PU) 25 has a cylindrical shape and a shape of the lower mold 21 as shown in FIGS. 2, 3A, and 3B. It becomes a hollow annular tube shape. When the cylindrical shape is as shown in Fig. 5B, the shape of the upper mold (upper punch 25PU) 25 is a solid cylinder (cylindrical) shape and the shape of the lower mold 21 becomes a hollow cylindrical shape. When it is the disk shape of FIG. 5C and the elongated circular axis shape of FIG. 5D, it is the same form (however, there is a difference in depth). When it is a complicated shape as shown in FIG. 5E, it becomes a corresponding complex shape. Further, the upper mold (upper punch 45PU) 45 of the second press molding machine 40 and the cavity 42 of the lower mold 41 are also provided in the same manner.

此處，用於減小基礎金屬粉末的粒子間的摩擦阻力及基礎金屬粉末與模具內面的摩擦阻力的潤滑劑在常溫下選擇鬆散狀的固形物(非常小的粒狀)即為粉末狀的物質。例如如果採用液狀的潤滑劑，則由於混合粉末100的黏度增高且流動性降低，所以無法均勻並充分地填充。 Here, the lubricant for reducing the frictional resistance between the particles of the base metal powder and the frictional resistance between the base metal powder and the inner surface of the mold is a powdery form in which a loose solid (very small granular shape) is selected at normal temperature. Substance. For example, if a liquid lubricant is used, the viscosity of the mixed powder 100 is increased and the fluidity is lowered, so that it cannot be uniformly and sufficiently filled.

接著，在常溫下的第一模具(21)內施加第一加壓力P1使中間粉末壓胚成形，在此期間，潤滑劑必須以固體形狀穩定維持規定的潤滑作用。即便存在因第一加壓力 P1的加壓導致溫度有些微上升的情況，但仍應同樣穩定維持。 Next, the first pressing force P1 is applied to the first mold (21) at normal temperature to form the intermediate powder preform, and during this period, the lubricant must be stably maintained in a solid shape to maintain a predetermined lubricating action. Even if there is a first pressure The pressurization of P1 causes a slight increase in temperature, but it should be maintained equally stable.

另一方面，從與中間粉末壓胚成形後實施的加熱升溫步驟(PR3)的關係及抑制基礎金屬粉末的氧化來看，潤滑劑粉末的熔點需要設為與該基礎金屬粉末的熔點相比非常地低的熔點(低熔點)。 On the other hand, from the viewpoint of the relationship between the heating and heating step (PR3) performed after the intermediate powder preform molding and the oxidation of the base metal powder, the melting point of the lubricant powder needs to be set to be very high compared with the melting point of the base metal powder. Low melting point (low melting point).

在該實施方式中，潤滑劑粉末的熔點選擇為低熔點，前述低熔點屬於90℃~190℃的溫度範圍內。下限溫度(90℃)設為相比中間粉末壓胚成形過程中即便發生某種程度的溫度上升估計也達不到該溫度的值(例如70℃~80℃)的上限溫度(80℃)仍充裕的值(例如90℃)，進而看其他的金屬皂的熔點(例如110℃)來進行選擇。即徹底消除了在中間粉末壓胚的加壓成形過程中潤滑油粉末熔解(液化)並流出的危險。 In this embodiment, the melting point of the lubricant powder is selected to be a low melting point, and the low melting point is in a temperature range of 90 ° C to 190 ° C. The lower limit temperature (90 ° C) is set to an upper limit temperature (80 ° C) which is less than the value (for example, 70 ° C to 80 ° C) which is estimated to be less than the temperature rise during the intermediate powder preform forming process. Ample values (e.g., 90 ° C) are used to select the melting point of other metal soaps (e.g., 110 ° C) for selection. That is, the danger of the lubricating oil powder melting (liquefying) and flowing out during the press forming process of the intermediate powder compact is completely eliminated.

上限溫度(例如190℃)選擇從潤滑劑粉末的種類相關的選擇性放大的角度看是最小值，而在加熱升溫步驟時從抑制基礎金屬粉末的氧化的角度看為最大值。即希望理解為該溫度範圍(90℃~190℃)的下限溫度和上限溫度不是極限值而是邊界值。 The upper limit temperature (for example, 190 ° C) is selected to be the minimum value from the viewpoint of the selective amplification related to the kind of the lubricant powder, and is the maximum value from the viewpoint of suppressing the oxidation of the base metal powder at the heating and heating step. That is, it is desirable to understand that the lower limit temperature and the upper limit temperature of the temperature range (90 ° C to 190 ° C) are not limit values but boundary values.

因而可選擇性地採用屬於金屬皂的很多物質(硬脂酸鋅、硬脂酸鎂等)作為潤滑劑粉末。另外，由於潤滑劑必須是粉末狀態，所以不能採用有黏性的液體如辛酸鋅等。 Therefore, many substances (zinc stearate, magnesium stearate, etc.) belonging to the metal soap can be selectively used as the lubricant powder. In addition, since the lubricant must be in a powder state, a viscous liquid such as zinc octoate or the like cannot be used.

在該實施方式中，採用熔點120℃的硬脂酸鋅粉末作為潤滑劑粉末。另外，在本發明中，否定了像專利文獻7 的發明那樣使用溫度比加壓成形時模具溫度還低的(熔點)潤滑劑且從最初使潤滑劑熔解(液化)並進行加壓成形的方法。因為在中間粉末壓胚110成形結束以前如熔解的潤滑劑流出，則容易出現中途潤滑不足的部位，所以無法切實且穩定地進行充分的加壓成形。 In this embodiment, zinc stearate powder having a melting point of 120 ° C is used as the lubricant powder. In addition, in the present invention, it is denied like Patent Document 7 In the invention, a method of using a (melting point) lubricant having a temperature lower than that of the mold at the time of press molding and melting (liquefying) the lubricant from the beginning is used. Since the melted lubricant flows out before the completion of the formation of the intermediate powder preform 110, the portion where the lubrication is insufficient in the middle is likely to occur, so that sufficient press forming cannot be performed reliably and stably.

潤滑劑粉末的量設為根據實驗研究及實際生產中的經驗來選擇的值。在與該實施方式有關的中間粉末壓胚成形步驟(PR2)的關係中，潤滑劑粉末的量設為混合粉末總量的0.23wt%~0.08wt%。0.08wt%是到中間粉末壓胚110成形結束為止可擔保潤滑作用的下限值，0.23wt%是在從混合粉末100變為中間粉末壓胚110時為了獲得前述壓縮比而必要的上限值。 The amount of the lubricant powder is set to a value selected based on experimental research and experience in actual production. In the relationship of the intermediate powder preform forming step (PR2) relating to this embodiment, the amount of the lubricant powder is set to be 0.23 wt% to 0.08 wt% of the total amount of the mixed powder. 0.08 wt% is the lower limit value of the lubricating action to the end of the formation of the intermediate powder preform 110, and 0.23 wt% is the upper limit value necessary for obtaining the aforementioned compression ratio when the mixed powder 100 is changed to the intermediate powder preform 110. .

接著，實際生產中潤滑劑粉末的量應定為可保證在第一模具(下模具21)內施加第一加壓力成形的中間粉末壓胚110的真密度比的值及在第二模具(下模具41)內的出汗現象的量。此時，必須考慮到防止液化潤滑劑從模具向外部滲出導致作業環境惡化的滴漏(滴漏現象)出現。在該實施方式中，由於將中間粉末壓胚110的真密度比(對真密度100%的比)的值設為80%~90%，所以潤滑劑粉末的量設為0.2wt%~0.1wt%。上限值(0.2wt%)從可防止滴漏現象出現的角度來決定，下限值(0.1wt%)從可避免出現不足或剩餘而只出現必要的出汗現象的角度出發來決定。相比上述以往申請例子(1wt%)的情況只是很少量，卻可大幅提高工業上的使用性。 Next, the amount of the lubricant powder in the actual production should be set to ensure that the value of the true density ratio of the first pressure-molded intermediate powder preform 110 is applied in the first mold (the lower mold 21) and in the second mold (below The amount of sweating phenomenon in the mold 41). At this time, it is necessary to take into consideration the occurrence of dripping (drip phenomenon) which causes the liquefied lubricant to leak out from the mold to the outside to cause deterioration of the working environment. In this embodiment, since the value of the true density ratio (ratio of 100% to true density) of the intermediate powder preform 110 is set to 80% to 90%, the amount of the lubricant powder is set to 0.2 wt% to 0.1 wt. %. The upper limit value (0.2 wt%) is determined from the viewpoint of preventing the occurrence of dripping, and the lower limit value (0.1 wt%) is determined from the viewpoint of avoiding the occurrence of insufficient or surplus and only the necessary sweating phenomenon. Compared with the above-mentioned prior application example (1 wt%), the amount is only a small amount, but the industrial usability is greatly improved.

防止發生滴漏現象對實際生產極為重要。在計畫或研究階段，由於為了減少加壓時的摩擦力而擔心潤滑劑的量會不足而傾向於混入極過量的潤滑劑。例如，完全不在乎從能否製造出超過7.3g/cm3的高密度的試錯階段開始，就有過量的潤滑劑液化流出的情況。甚至都意識不到滴漏現象。即液化潤滑劑的滴漏會因潤滑劑使用量增加而導致成本上升，會因工作環境惡化而使生產效率降低或增加操作人員的負擔，如果不加以解決不但缺乏實用性而且也難於普及擴大。 Preventing the occurrence of dripping is extremely important for actual production. In the planning or research stage, since the amount of the lubricant is insufficient in order to reduce the friction at the time of pressurization, it tends to be mixed with a very large amount of the lubricant. For example, there is a case where an excessive amount of lubricant liquefies and flows out from the start of a trial and error phase in which a high density of more than 7.3 g/cm 3 can be produced. Not even aware of the phenomenon of dripping. That is, the dripping of the liquefied lubricant may increase the cost due to the increase in the amount of the lubricant, and the production efficiency may be lowered or the burden on the operator may be increased due to the deterioration of the working environment. If it is not solved, it is not only practical but also difficult to spread.

將0.2wt%的混合粉末100壓縮到真密度比80%的中間粉末壓胚110的情況，是一旦在加熱升溫步驟(PR3)將該潤滑劑粉末積極升溫到熔點溫度，則中間粉末壓胚110內散佈的粉末潤滑劑熔化充滿金屬粉末粒子間的孔，接著經過金屬粉末粒子間液狀潤滑劑均勻地在中間粉末壓胚110的表面滲出(噴出)。即誘發出汗現象。在第二模具(下模具41)內向該中間粉末壓胚110施加第二加壓力P2進行壓縮時，可大幅降低基礎金屬粉末和腔體內壁面的摩擦阻力。 The case where 0.2 wt% of the mixed powder 100 is compressed to the intermediate powder preform 110 having a true density ratio of 80% is that once the lubricant powder is actively heated to the melting point temperature in the heating and heating step (PR3), the intermediate powder compact 110 The powder lubricant dispersed therein melts the pores between the metal powder particles, and then uniformly bleeds (sprays) on the surface of the intermediate powder preform 110 through the liquid lubricant between the metal powder particles. That is, it induces sweating. When the second pressing force P2 is applied to the intermediate powder preform 110 for compression in the second mold (lower mold 41), the frictional resistance between the base metal powder and the inner wall surface of the cavity can be greatly reduced.

同樣，將0.1wt%的混合粉末100壓縮到真密度比為90%的中間粉末壓胚110的情況，和將超過0.1wt%不滿0.2wt%範圍內的混合粉末100壓縮到真密度比不滿90%且超過80%範圍內的值的中間粉末壓胚110，也能發現出汗現象。可防止出現滴漏現象。 Similarly, 0.1% by weight of the mixed powder 100 is compressed to an intermediate powder preform 110 having a true density ratio of 90%, and the mixed powder 100 in a range exceeding 0.1% by weight to less than 0.2% by weight is compressed to a true density ratio less than 90%. Excessive sweat pressure was also observed in the intermediate powder compact 110 of % and values in the range of more than 80%. It can prevent dripping.

因此可高密度成形，製造出滿足磁特性及機械強度的 粉末壓胚(例如磁心)。也可消除對模具受損的擔心。而且，可大幅削減潤滑劑的消耗量，使液狀潤滑劑不再從第二模具(下模具41)滴漏出來，改善作業環境。整體上由於可提高生產效率及降低粉末壓胚製造成本所以可顯著地提高在工業生產上的可使用性。 Therefore, it can be formed at a high density to produce magnetic properties and mechanical strength. Powder preforms (eg magnetic cores). It also eliminates the fear of mold damage. Further, the amount of lubricant consumed can be greatly reduced, and the liquid lubricant can no longer leak from the second mold (lower mold 41), thereby improving the working environment. As a whole, the usability in industrial production can be remarkably improved because the production efficiency can be improved and the manufacturing cost of the powder compact can be reduced.

在上述任意一種以往方法、裝置(專利文獻1~8)中對潤滑劑的含有率與混合粉末的壓縮率的關係、潤滑劑的多少導致的滴漏現象、出汗現象均無認識。 In any of the above conventional methods and apparatuses (Patent Documents 1 to 8), there is no known knowledge of the relationship between the content ratio of the lubricant and the compression ratio of the mixed powder, the dripping phenomenon caused by the amount of the lubricant, and the sweating phenomenon.

尤其是即便在熱成形粉末冶金方法(專利文獻5)中，雖然可以理解為了便於操作而成形密度比不足76%的一次成形體這一點，但對高密度成形的技術依據及可實施的事項均無公開。更別說從其後一度使一次成形體潰散在成形二次成形體這一點看，只能否定其藉由一次成形、二次成形的累積來實現高密度化的技術思想。 In particular, even in the thermoforming powder metallurgy method (Patent Document 5), it is understood that the primary molded body having a density ratio of less than 76% is formed for the convenience of handling, but the technical basis and implementable matters for the high-density molding are No publicity. In addition, from the viewpoint that the primary molded body is once broken to form the secondary molded body, the technical idea of achieving high density by the accumulation of primary molding and secondary molding can be denied.

第一加壓成形機20是使用混合粉末供給機10向填充到第一模具(下模具21)的混合粉末100施加第一加壓力P1成形混合粉末中間壓縮體(中間粉末壓胚110)的裝置，該實施方式是壓製機械結構。 The first press molding machine 20 is a device that applies a first pressing force P1 to the mixed powder 100 filled into the first mold (the lower mold 21) by using the mixed powder feeder 10 to form a mixed powder intermediate compressed body (intermediate powder preform 110). This embodiment is a press mechanical structure.

在圖2中第一模具裝置由工作臺側的下模具21(模具21D)和滑塊5側的上模具25(上沖頭25PU)構成。下模具21的腔體22形狀設置為與圖5A所示中間粉末壓胚110的形態(環形形態)對應的形狀(環形管形狀)。即上模具25(上沖頭25PU)設置為可擠壓進下模具21(腔體22)內的狀態(圖2、圖3A，圖3B所示的環形管 形狀)，靠滑塊5做升降運動。腔體22的下方在上下方向可移動地嵌裝有可動構件23。 In Fig. 2, the first mold device is composed of a lower mold 21 (mold 21D) on the table side and an upper mold 25 (upper punch 25PU) on the slider 5 side. The cavity 22 of the lower mold 21 is shaped like a shape (annular tube shape) corresponding to the form (annular shape) of the intermediate powder preform 110 shown in Fig. 5A. That is, the upper mold 25 (the upper punch 25PU) is set to be squeezable into the lower mold 21 (cavity 22) (the annular tube shown in Fig. 2, Fig. 3A, Fig. 3B) Shape), the slider 5 is used for lifting movement. The movable member 23 is movably fitted in the up and down direction below the cavity 22.

可動構件23通過貫穿設置在底面高度GL以下的通孔24向上突起的頂出桿(圖示省略)移動到上方。即可把第一模具〔下模具21(腔體22)〕內的中間粉末壓胚110上推到移送面HL。從外部看，具有作為將第一模具(下模具21)內的中間粉末壓胚110取出到外部(HL)的第一取出裝置的功能。中間粉末壓胚110被移送到加熱升溫機30側後，可動構件43與頂出桿一同返回初始位置。另外，也可用其他特殊裝置形成第一取出裝置。 The movable member 23 is moved upward by an ejector rod (not shown) that protrudes upward through a through hole 24 provided at a bottom surface height GL or less. The intermediate powder preform 110 in the first mold [lower mold 21 (cavity 22)] can be pushed up to the transfer surface HL. Viewed from the outside, it has a function as a first take-out device that takes out the intermediate powder preform 110 in the first mold (lower mold 21) to the outside (HL). After the intermediate powder preform 110 is transferred to the side of the heating and heating machine 30, the movable member 43 returns to the initial position together with the ejector rod. Alternatively, the first take-out device can be formed by other special means.

參照圖4說明第一加壓成形機20中的加壓力(第一加壓力P1)和與之對應得到中間粉末壓胚110的真密度比(密度ρ)的關係。橫軸以指數顯示加壓力P。在該實施方式中的最大能力(加壓力P)是10Ton/cm2，其設為橫軸指數100。Pb是模具損壞壓力，為橫軸指數140(14Ton/cm2)。縱軸以指數顯示真密度比(密度ρ)。縱軸指數(100)相當於真密度比(密度ρ)是97%(7.6g/cm3)。 The relationship between the pressing force (first pressing force P1) in the first press molding machine 20 and the true density ratio (density ρ) of the intermediate powder preform 110 corresponding thereto will be described with reference to FIG. The horizontal axis shows the applied pressure P by an index. The maximum capacity (pressure P) in this embodiment is 10 Ton/cm 2 which is set to the horizontal axis index of 100. Pb is the mold damage pressure and has a horizontal axis index of 140 (14 Ton/cm 2 ). The vertical axis shows the true density ratio (density ρ) by an index. The vertical axis index (100) corresponds to a true density ratio (density ρ) of 97% (7.6 g/cm 3 ).

在該實施方式中，基礎金屬粉末設為磁心用玻璃材質絕緣塗層被覆鐵粉末(真密度是7.8g/cm3)，潤滑劑粉末選擇是在0.2wt%~0.1wt%的範圍內的硬脂酸鋅粉末且是第一加壓力P1將混合粉末中間壓縮體壓縮到相當於縱軸指數82~92〔相當於密度ρ(6.24g/cm3~7.02g/cm3)〕的真密度比80%~90%的物質。 In this embodiment, the base metal powder is coated with iron powder coated with a glass material for magnetic core (true density is 7.8 g/cm 3 ), and the lubricant powder is selected to be hard in the range of 0.2 wt% to 0.1 wt%. zinc stearate powder and the first pressure P1 corresponds to the longitudinal axis of the body is compressed to 82 to 92 [index corresponding to the density ρ (6.24g / cm 3 ~ 7.02g / cm 3) ] the true density of the intermediate compression ratio of the mixed powder 80% to 90% of the substance.

同時，縱軸指數102相當於密度ρ(7.75g/cm3)，真密度比(密度ρ)相當於99%。 Meanwhile, the vertical axis index 102 corresponds to the density ρ (7.75 g/cm 3 ), and the true density ratio (density ρ) corresponds to 99%.

另外，作為基礎金屬粉末，也可選擇磁心用鐵系非晶粉末(磁心用Fe-Si合金粉末)、磁心用鐵系非晶粉末、磁心用Fe-Si合金粉末、機械構件用純鐵粉末等。 In addition, as the base metal powder, iron-based amorphous powder for magnetic core (Fe-Si alloy powder for magnetic core), iron-based amorphous powder for magnetic core, Fe-Si alloy powder for magnetic core, pure iron powder for mechanical member, and the like may be selected. .

一旦提高第一加壓力P1，則藉由第一加壓成形機20得到的密度ρ隨著以虛線(曲線)顯示的特性A而升高。在第一加壓力P1(橫軸指數100)時，密度ρ變為7.6g/cm3。真密度比是97%。即便使第一加壓力P1上升到這以上的值，密度ρ的提高也是微小的。模具損壞的可能性很大。 Once the first pressing force P1 is increased, the density ρ obtained by the first press molding machine 20 rises with the characteristic A shown by a broken line (curve). At the first pressing force P1 (horizontal axis index 100), the density ρ becomes 7.6 g/cm 3 . The true density ratio is 97%. Even if the first pressing force P1 is raised to a value higher than this, the increase in the density ρ is minute. There is a high possibility of mold damage.

以往，在以加壓成形機(壓製機械)的最大能力來加壓得到的密度ρ無法滿足需要時，必須裝備更大型的壓製機械。但是，即便是大型化例如將最大能力變為1.5倍，密度ρ的提高也是微小的。因此，現在的情況是勉強接受以現有的壓製機械得到的低密度ρ(例如7.5g/cm3)。 Conventionally, when the density ρ obtained by pressurizing the maximum capacity of a press molding machine (pressing machine) cannot be satisfied, it is necessary to equip a larger pressing machine. However, even if the enlargement is, for example, the maximum capacity is changed to 1.5 times, the increase in the density ρ is minute. Therefore, the current situation is to reluctantly accept the low density ρ (for example, 7.5 g/cm 3 ) obtained by the existing pressing machine.

此處，現在直接使用壓製機械，如可從縱軸指數100(7.6g/cm3)提高到102(7.75g/cm3)，則可理解為具有劃時代的意義。即如果可將密度ρ提高2%，則可大幅提高磁性能(雙曲線地)且可使機械強度的提高飛躍地實現。而且，由於可徹底去除高溫氣氛下的燒結處理，所以可大幅抑制粉末壓胚的氧化(可防止磁心性能降低)。 Here, the use of a pressing machine directly, such as an increase from a vertical axis index of 100 (7.6 g/cm 3 ) to 102 (7.75 g/cm 3 ), can be understood as having an epoch-making significance. That is, if the density ρ can be increased by 2%, the magnetic properties can be greatly improved (hyperbolic) and the improvement in mechanical strength can be achieved. Further, since the sintering treatment in a high-temperature atmosphere can be completely removed, the oxidation of the powder preform can be greatly suppressed (the core performance can be prevented from being lowered).

為實現上述方式，可藉由加熱由第一加壓成形機20成形的中間粉末壓胚110促使潤滑劑熔解(液化)，此後 以第二加壓成形機40進行第二次加壓成形處理。如果在第二加壓成形機40中對中間粉末壓胚110進行加壓，則如圖4的特性B(實線)所示，可達到相當於縱軸指數102的高密度(7.75g/cm3)。將在第二加壓成形機40的說明中追述詳細情況。 In order to achieve the above, the lubricant can be melted (liquefied) by heating the intermediate powder preform 110 formed by the first press molding machine 20, and thereafter the second press molding process is performed by the second press molding machine 40. If the intermediate powder preform 110 is pressurized in the second press molding machine 40, as shown by the characteristic B (solid line) of FIG. 4, a high density (7.75 g/cm) corresponding to the vertical axis index 102 can be achieved. 3 ). The details will be described in the description of the second press molding machine 40.

加熱升溫機30是加熱從第一模具(下模具21)取出的混合粉末中間壓縮體(中間粉末壓胚110)將該中間粉末壓胚110的溫度積極升溫到該潤滑劑粉末的相當於熔點的溫度的裝置。在圖2中，加熱升溫機30包含末圖示的暖風產生源、噴氣罩31、排氣循環罩33等，藉由向定位在絲網狀保持構件32上的中間粉末壓胚110噴出暖風加熱，將其溫度升溫到潤滑劑粉末的相當於熔點的溫度(例如120℃)。 The heating and heating machine 30 heats the mixed powder intermediate compressed body (intermediate powder preform 110) taken out from the first mold (lower mold 21) to actively raise the temperature of the intermediate powder preform 110 to the melting point of the lubricant powder. Temperature device. In FIG. 2, the heating and heating machine 30 includes a warm air generating source (not shown), a gas hood 31, an exhaust gas recirculation cover 33, and the like, and is sprayed to the intermediate powder preform 110 positioned on the mesh-like holding member 32. The air is heated and its temperature is raised to a temperature corresponding to the melting point of the lubricant powder (for example, 120 ° C).

該低溫加熱處理的技術意義將在與第一加壓成形處理的關係中加以說明。如果觀察填充在下模具21(腔體22)內的混合粉末100，則可知在與基礎金屬粉末的關係中潤滑劑粉末的存在較稀疏的部分(稀疏部分)和較緻密的部分(緻密部分)。緻密部分可減少基礎金屬粉末的粒子間摩擦阻力及基礎金屬粉末和模具內面的摩擦阻力。稀疏部分應該可以使這些摩擦阻力變大。 The technical significance of this low temperature heat treatment will be explained in relation to the first press forming process. If the mixed powder 100 filled in the lower mold 21 (cavity 22) is observed, it is understood that the lubricant powder is present in a relatively sparse portion (sparse portion) and a denser portion (dense portion) in relation to the base metal powder. The dense portion reduces the interparticle frictional resistance of the base metal powder and the frictional resistance of the base metal powder and the inner surface of the mold. The sparse part should make these frictional resistances larger.

在第一加壓成形機20的加壓過程中，緻密部分由於摩擦小所以壓縮性優越，易於進行壓縮化。稀疏部分由於摩擦大所以壓縮性差，壓縮化緩慢。無論是哪種，都會出現與預先設定的第一加壓力P1的值對應的壓縮進行困難 的現象。即出現壓縮極限。放大觀察在該狀態下從第一模具(下模具21)的中間粉末壓胚110的斷裂面，則作為上述緻密部分的部分為基礎金屬粉末整體壓接。但是，也混有潤滑劑粉末。作為稀疏部分的部分在壓接的基礎金屬粉末間殘留有微小間隙(空間)。幾乎看不到潤滑劑粉末。 In the pressurization process of the first press molding machine 20, the dense portion is excellent in compressibility due to small friction, and is easily compressed. The sparse part is poor in compressibility due to large friction, and the compression is slow. In either case, it is difficult to perform compression corresponding to the value of the preset first applied pressure P1. The phenomenon. That is, the compression limit appears. When the fracture surface of the intermediate powder preform 110 from the first mold (lower mold 21) is observed in this state, the portion as the dense portion is integrally pressed against the base metal powder. However, a lubricant powder is also mixed. As a portion of the sparse portion, a small gap (space) remains between the pressed base metal powders. Almost no lubricant powder is visible.

因此，如從作為緻密部分的部分去除潤滑劑粉末的話，則產生可壓縮的間隙。如可向作為稀疏部分的部分間隙補充潤滑劑的話，則可提高該部分的壓縮性。 Therefore, if the lubricant powder is removed from the portion as the dense portion, a compressible gap is generated. If the lubricant can be replenished to a part of the gap which is a sparse part, the compressibility of the part can be improved.

即提高第一加壓成形結束後加熱中間粉末壓胚110升溫到相當於潤滑劑粉末的熔點的溫度(例如120℃)，使潤滑劑粉末熔解(液化)提高其流動性。從作為緻密部分的部分開始熔化的潤滑劑滲到周圍且補充到是稀疏部分的部分。從而，可減小基礎金屬粉末的粒子間摩擦阻力，也可壓縮潤滑劑粉末所占的空間。也可減小基礎金屬粉末的粒子和模具內面的摩擦阻力。即利用液態潤滑劑的流動性並施加第二加壓成形處理。 That is, after the end of the first press molding, the temperature of the intermediate powder preform 110 is raised to a temperature corresponding to the melting point of the lubricant powder (for example, 120 ° C), and the lubricant powder is melted (liquefied) to improve the fluidity. The lubricant which starts to melt from the portion which is the dense portion penetrates to the periphery and is added to the portion which is the sparse portion. Thereby, the intergranular frictional resistance of the base metal powder can be reduced, and the space occupied by the lubricant powder can also be compressed. It is also possible to reduce the frictional resistance of the particles of the base metal powder and the inner surface of the mold. That is, the fluidity of the liquid lubricant is utilized and a second press forming treatment is applied.

接著，第二加壓成形機40是用於向裝入第二模具(下模具41)的已升溫的中間粉末壓胚110施加第二加壓力P2成形高密度的完成粉末壓胚120的裝置。 Next, the second press molding machine 40 is a device for applying a second pressing force P2 to the heated intermediate powder preform 110 loaded in the second mold (the lower mold 41) to form a high-density finished powder preform 120.

在本實施方式中，給第二模具(下模具41)設置預熱功能。但是如果能將已升溫好的中間粉末壓胚110的溫度控制為在第二模具(下模具41)內到施加了第二加壓力P2的完成粉末壓胚成形開始時刻為止不妨礙成形的固 定的溫度範圍內的話，則不預熱第二模具(下模具41)也能實施本發明的高密度成形。 In the present embodiment, the second mold (lower mold 41) is provided with a warm-up function. However, if the temperature of the intermediate powder preform 110 which has been heated can be controlled to be in the second mold (lower mold 41) until the completion of the completion of the powder compact forming of the second pressing force P2, the solidification does not hinder the molding. Within the predetermined temperature range, the high-density molding of the present invention can be carried out without preheating the second mold (lower mold 41).

但是，中間粉末壓胚110的熱容量小時，則到達第二模具的移送時間或移送路徑長時，則根據混合粉末100的組成或中間粉末壓胚110的形態等，在到已升溫好的中間粉末壓胚110開始完成粉末壓胚成形時刻為止溫度有可能下降時，加熱第二模具(下模具41)可得到更好的成形效果。後文所說的第二預熱裝置47是為此而設的。 However, when the heat capacity of the intermediate powder preform 110 is small, when the transfer time to the second mold or the transfer path is long, the intermediate powder which has been heated up is obtained according to the composition of the mixed powder 100 or the form of the intermediate powder preform 110. When the preform 110 starts to complete the powder preform forming time, the temperature may be lowered, and the second mold (the lower mold 41) is heated to obtain a better forming effect. The second preheating device 47, which will be described later, is provided for this purpose.

另外，該實施方式中的第二加壓成形機40的最大加壓能力(加壓力P)與第一加壓成形機20的情況相同是10Ton/cm2。因此，第一加壓成形機20和第二加壓成形機40構成為一台壓製機械，由圖2所示的共用的滑塊5同步升降各上模具25、45。從這一點看，裝置更經濟，可降低完成粉末壓胚120的製造成本。 Further, the maximum pressurization capacity (pressure P) of the second press molding machine 40 in this embodiment is 10 Ton/cm 2 as in the case of the first press molding machine 20. Therefore, the first press molding machine 20 and the second press molding machine 40 are configured as a single pressing machine, and the upper molds 25, 45 are simultaneously raised and lowered by the common slider 5 shown in FIG. From this point of view, the device is more economical and can reduce the manufacturing cost of completing the powder compact 120.

在圖2中，第二模具裝置由工作臺側的下模具41(模子41D)和滑塊5側的上模具(沖頭)45構成。下模具41的腔體42設置為下部與完成粉末壓胚120的形狀(環形)相對應的形狀(環形管形狀)，上部為可接收中間粉末壓胚110的略大的形態。上模具45設置為可擠壓入下模具41(腔體42)內的形態，藉由滑塊5進行升降運動。在腔體42的下方，可動構件43嵌裝為可在上下方向移位。另外，第二模具(下模具41)和第一模具(下模具21)設置為可進行相當於與壓縮物件(中間粉末壓胚110和完成粉末壓胚120))在上下方向尺寸差的高度 (位置)調整。 In Fig. 2, the second mold device is composed of a lower mold 41 (mold 41D) on the table side and an upper mold (punch) 45 on the slider 5 side. The cavity 42 of the lower mold 41 is disposed in a shape in which the lower portion corresponds to the shape (annular shape) of the completed powder compact 120 (annular tube shape), and the upper portion is a slightly larger form capable of receiving the intermediate powder preform 110. The upper mold 45 is provided in a form squeezable into the lower mold 41 (cavity 42), and is moved up and down by the slider 5. Below the cavity 42, the movable member 43 is fitted to be displaceable in the vertical direction. Further, the second mold (the lower mold 41) and the first mold (the lower mold 21) are disposed to be capable of performing a height difference corresponding to the size of the compressed article (the intermediate powder preform 110 and the completed powder preform 120) in the up and down direction. (Location) adjustment.

可動構件43通過貫穿設置在底面高度GL以下的通孔44向上突起的頂出桿(圖示省略)移動到上方。即可把第二模具〔下模具41(腔體42)〕內的完成粉末壓胚120上推到移送面HL。從外部看，具有作為將第二模具內的完成粉末壓胚120取出到外部(HL)的第二取出裝置的功能。另外，也可用其他特殊裝置形成第二取出裝置。完成粉末壓胚120被排出到排出槽59中，從加熱升溫機30接收新的中間粉末壓胚110後，可動構件43與頂出桿一同返回初始位置。 The movable member 43 is moved upward by an ejector rod (not shown) that protrudes upward through a through hole 44 provided at a bottom surface height GL or less. The completed powder preform 120 in the second mold [lower mold 41 (cavity 42)] can be pushed up to the transfer surface HL. Viewed from the outside, it has a function as a second take-out device that takes out the completed powder compact 120 in the second mold to the outside (HL). Alternatively, other special means may be used to form the second take-up means. The completed powder preform 120 is discharged into the discharge tank 59, and after receiving the new intermediate powder preform 110 from the heating warmer 30, the movable member 43 returns to the initial position together with the ejector rod.

在第二模具(下模具41)中安裝有可變更設定溫度的第二預熱裝置47。該第二預熱裝置47在接收中間粉末壓胚110(被裝入)之前，將第二模具〔下模具41(腔體42)〕加熱(預熱)到相當於潤滑劑粉末(硬脂酸鋅)的熔點的溫度(120℃)。對已升溫的中間粉末壓胚110可不冷卻而接收。由此，可防止先前熔解(液化)的潤滑劑再次固化並確保潤滑作用。另外，第二預熱裝置47在本實施方式中設置為電熱加熱方式(加熱器)，但也可用熱油或熱水循環預熱的循環方式的加熱裝置來進行。 A second preheating device 47 that can change the set temperature is attached to the second mold (lower mold 41). The second preheating device 47 heats (preheats) the second mold [the lower mold 41 (cavity 42)] to the lubricant powder (stearic acid) before receiving the intermediate powder preform 110 (loaded) The temperature of the melting point of zinc (120 ° C). The intermediate powder preform 110 that has been heated can be received without cooling. Thereby, it is possible to prevent the previously melted (liquefied) lubricant from solidifying again and to ensure lubrication. Further, although the second preheating device 47 is provided as an electrothermal heating method (heater) in the present embodiment, it may be performed by a heating device of a circulation type in which hot oil or hot water is preheated.

在該意義上，第二預熱裝置47設為可在完成粉末壓胚120加壓成形結束之前持續加熱。由於如此可進一步提高加壓成形中已熔解的潤滑劑向所有方向的流動性，因而不僅可將粒子間也可將粒子與模具〔下模具41(腔體42)〕間的摩擦阻力大幅減小並保持之。 In this sense, the second preheating device 47 is configured to continue to heat before the completion of the press forming of the powder compact 120. Since the fluidity of the melted lubricant in the press forming in all directions can be further improved, the frictional resistance between the particles and the mold (the lower mold 41 (cavity 42)) can be greatly reduced. And keep it.

與之相關，在該實施方式中，設置有用於預熱第一模具(下模具21)的末圖示的預熱功能。但是，在升溫加熱步驟前無需預熱第一模具(下模具21)預備升溫中間粉末壓胚110也可實施本發明的高密度成形加工。 In connection with this, in this embodiment, a preheating function for preheating the last illustration of the first mold (lower mold 21) is provided. However, the high-density forming process of the present invention can be carried out without preheating the first mold (lower mold 21) to warm the intermediate powder preform 110 before the heating and heating step.

但是，在混合粉末100的組成或中間粉末壓胚110的形態特殊時、中間粉末壓胚110的熱容量大時、無法安裝大的加熱升溫機30時、或作業環境溫度低時，中間粉末壓胚110的加熱升溫可能要花費很長時間。在這樣的情況下，較佳是預熱第一模具(下模具21)。為此，在該實施方式中會預熱第一模具(下模具21)。 However, when the composition of the mixed powder 100 or the form of the intermediate powder preform 110 is special, when the heat capacity of the intermediate powder preform 110 is large, when the large heating and heating machine 30 cannot be attached, or when the working environment temperature is low, the intermediate powder compacts The heating up of 110 may take a long time. In such a case, it is preferred to preheat the first mold (the lower mold 21). To this end, the first mold (lower mold 21) is preheated in this embodiment.

即第一模具〔下模具21(腔體22)〕上也設置由可改變設定溫度的第一預熱裝置(圖示省略)，在中間粉末壓胚110的成形結束後傳遞到加熱升溫機30以前可預熱第一模具(下模具21)預先加熱潤滑劑粉末。藉由這樣設置，可減少加熱升溫時間，縮短生產週期。 That is, the first mold (the lower mold 21 (cavity 22)) is also provided with a first preheating device (not shown) which can change the set temperature, and is transferred to the heating and heating machine 30 after the formation of the intermediate powder preform 110 is completed. The first mold (lower mold 21) can be preheated to previously heat the lubricant powder. With this arrangement, the heating rise time can be reduced and the production cycle can be shortened.

第二加壓成形機40得到的密度ρ如實線所示的特性B。即與第一加壓成形機20的情況〔特性A(虛線)〕不同，密度ρ並非隨著第二加壓力P2提高而漸漸升高。即到超過第一加壓成形步驟中最終的第一加壓力P1(例如橫軸指數50、75或85)之前密度ρ不會升高。第二加壓力P2一旦超過最終的第一加壓力P1，則密度ρ即一下子升高。第二加壓成形可理解為好像連續不斷地進行第一加壓成形的方式。 The density ρ obtained by the second press molding machine 40 is a characteristic B as indicated by a solid line. That is, unlike the case of the first press molding machine 20 [characteristic A (dashed line)], the density ρ does not gradually increase as the second pressing force P2 increases. That is, the density ρ does not rise until the final first pressing force P1 (for example, the horizontal axis index 50, 75 or 85) in the first press forming step is exceeded. Once the second applied pressure P2 exceeds the final first applied pressure P1, the density ρ rises at a time. The second press forming can be understood as a manner in which the first press forming is continuously performed.

因而在第一加壓成形步驟中，變為可以不用在任何時 候都將第一加壓力P1上升直到與最大能力相對應的值(橫軸指數100)。即可排除在壓縮極限以後繼續進行第一加壓成形時浪費的時間、消耗的能量。使製造成本降低。且，由於變得易於避免超過橫軸指數100的超負荷運轉，所以不必擔心模具破損。整體上運轉操作容易並可安全且穩定地運用。 Therefore, in the first press forming step, it becomes unnecessary to be used at any time. The first applied pressure P1 is raised until the value corresponding to the maximum capacity (horizontal axis index 100). It is possible to eliminate the time and energy consumed when the first press forming is continued after the compression limit. Reduce manufacturing costs. Moreover, since it becomes easy to avoid overload operation exceeding the horizontal axis index 100, there is no need to worry about mold breakage. The overall operation is easy and safe and stable.

工件移送裝置50設置為可將第一取出裝置(可動構件23、通孔24)從第一模具(下模具21)取出的中間粉末壓胚110移送到加熱升溫機30內的規定位置，可將升溫後的中間粉末壓胚110從加熱升溫機30內移送到第二模具(下模具41)，可將靠第二取出裝置(43、44)的功能從第二模具(下模具41)取出的完成粉末壓胚120移送到向高密度成形裝置1外排出的排出部，例如排出槽59。工件移送裝置50可在從第一加壓成形機20到加熱升溫機30之間、從加熱升溫機30到第二加壓成形機40之間、以及從第二加壓成形機40到排出槽59之間切實移送工件。 The workpiece transfer device 50 is provided to transfer the intermediate powder preform 110 taken out from the first mold (the movable mold 23, the through hole 24) from the first mold (the lower mold 21) to a predetermined position in the heating and heating machine 30, which can be The intermediate powder preform 110 after the temperature rise is transferred from the heating and heating machine 30 to the second mold (the lower mold 41), and the function of the second take-up device (43, 44) can be taken out from the second mold (the lower mold 41). The completed powder preform 120 is transferred to a discharge portion that is discharged to the outside of the high-density forming device 1, for example, a discharge tank 59. The workpiece transfer device 50 can be between the first press molding machine 20 and the heating warmer 30, from the heating warmer 30 to the second press molding machine 40, and from the second press molding machine 40 to the discharge tank The workpiece is actually transferred between 59.

該實施方式的工件移送裝置50由圖3B所示的同步運轉的三個移送桿51、52、53構成。移送桿51、52、53在要求移送時從圖3A的紙面深處側向近前(圖3B)的移送線上推進，從左向右移動後退回到原始位置。裝入裝置(移送桿52、可動構件43、通孔44)將已升溫的混合粉末中間壓縮體110裝入已預熱到相當於潤滑劑熔點溫度的第二模具〔下模具41(腔體42)〕中。 The workpiece transfer device 50 of this embodiment is constituted by three transfer levers 51, 52, and 53 which are synchronously operated as shown in Fig. 3B. The transfer levers 51, 52, and 53 are pushed from the deep side of the paper surface of FIG. 3A toward the front (FIG. 3B) transfer line when the transfer is requested, and are moved back to the original position from the left to the right. The loading device (transfer rod 52, movable member 43, through hole 44) loads the heated mixed powder intermediate compression body 110 into a second mold that has been preheated to a temperature equivalent to the melting point of the lubricant [the lower mold 41 (cavity 42) )〕in.

另外，工件移送裝置50也可由包含向二維或三維方向驅動的機械手臂等，將工件依序移送到各模具等的移送裝置等構成。 Further, the workpiece transfer device 50 may be configured by a transfer device that sequentially transfers the workpiece to each mold or the like, including a robot arm that is driven in a two-dimensional or three-dimensional direction.

在此處，對這樣的技術事項進行說明，其可用來促進為進一步普及推廣而導入的加壓能力的有效利用及液態潤滑劑的均勻流動並製造完成更好的高品質粉末壓胚。另外，完成粉末壓胚120(中間粉末壓胚110)的形態(尺寸、形狀)雖無特殊限定，但為方便說明，以圖6(B)、圖7(B2)所示的圓盤形來進行說明。 Here, such technical matters are explained, which can be used to promote the effective utilization of the pressurizing ability introduced for further popularization and the uniform flow of the liquid lubricant and to manufacture a better high quality powder compact. In addition, the form (size, shape) of the powder preform 120 (intermediate powder preform 110) is not particularly limited, but for convenience of explanation, the disk shape shown in FIG. 6(B) and FIG. 7(B2) is used. Be explained.

首先，第二加壓成形機40製作如圖6(B)所示的圓盤形完成粉末壓胚120時，以實心圓筒狀的上模具45PU作為圖7(B1)所示的上模具，以中空圓筒形的模具41D及實心圓柱形的下沖頭41PD為下模具。由於第一加壓成形機20基本上是製作完成粉末壓胚120之前階段的中間壓縮體110的，所以只需與第二加壓成形機40的情況相同，以實心圓柱形的上沖頭25PU為圖7(A1)所示的上模具，由中空圓筒形模具21D及中空圓柱形的下沖頭21PD構成下模具即可。另外，下沖頭21PD的上端面21PDS製作成將在後文詳述的朝上的凹形。 First, when the second press molding machine 40 is formed into a disc-shaped finished powder compact 120 as shown in Fig. 6(B), the upper cylindrical mold 45PU having a solid cylindrical shape is used as the upper mold shown in Fig. 7 (B1). A hollow cylindrical mold 41D and a solid cylindrical lower punch 41PD are used as the lower mold. Since the first press molding machine 20 is basically the intermediate compression body 110 at the stage before the completion of the powder preform 120, it is only necessary to be the same as the case of the second press molding machine 40, with a solid cylindrical upper punch 25PU. In the upper mold shown in Fig. 7 (A1), the lower mold may be constituted by the hollow cylindrical mold 21D and the hollow cylindrical lower punch 21PD. Further, the upper end surface 21PDS of the lower punch 21PD is formed in a concave shape which will be described later in detail.

且，第二加壓成形機40內的中間粉末壓胚110的上面與上沖頭45PU的整個面抵接並且下面與41PD的整個面抵接。即施加在上下面任意一個部位的單位面積的按壓力是固定的，其值根據第二加壓力P2的值決定。申請人認為。要縮短從中間粉末壓胚110到完成粉末壓胚120成 形結束所期待的的成形時間，可以考慮藉由加大第二加壓力P2，提高基礎金屬粒子及液態潤滑劑的流動性。但是，從節省設備及使用成本上的問題(不利)角度看，無限增加第二加壓力P2很難得到認同。 Further, the upper surface of the intermediate powder preform 110 in the second press molding machine 40 abuts against the entire surface of the upper punch 45PU and the lower surface abuts against the entire surface of the 41PD. That is, the pressing force per unit area applied to any one of the upper and lower portions is fixed, and the value is determined according to the value of the second pressing force P2. The applicant believes. To shorten the intermediate powder preform 110 to complete the powder preform 120 It is conceivable to increase the fluidity of the base metal particles and the liquid lubricant by increasing the second pressing force P2 in order to complete the desired forming time. However, from the viewpoint of the problem of equipment saving and the cost of use (unfavorable), it is difficult to obtain an infinite increase in the second pressing force P2.

接著，考察中間粉末壓胚110的液態潤滑劑的流動性。在接近中間粉末壓胚110的外周面的部位，液態潤滑劑應該可以快速向腔體內壁面流動。靠近中央部的液態潤滑劑可向三維的所有方向中的任意一個方向流動，但實際上如果存在於其行進方向上所要到的各處的液態潤滑劑不先流動，靠近中央部的液態潤滑劑是沒辦法開始流動的。因此為了提高行進方向上所要到之處的流動性，想到只要積極地推動中央部的液態潤滑劑，增強其流動性即可。此時，也會因為需要加設複雜且大型的結構、裝置而使工業生產上的利用性降低。 Next, the fluidity of the liquid lubricant of the intermediate powder preform 110 was examined. At a portion close to the outer peripheral surface of the intermediate powder preform 110, the liquid lubricant should be able to flow rapidly toward the inner wall surface of the chamber. The liquid lubricant near the center can flow in any of the three-dimensional directions, but in fact, if there is a liquid lubricant that is present everywhere in the direction of travel, the liquid lubricant does not flow first, and the liquid lubricant near the center There is no way to start flowing. Therefore, in order to improve the fluidity in the traveling direction, it is thought that the liquid lubricant in the center portion can be actively promoted to enhance the fluidity. At this time, the utilization in industrial production is also lowered because of the need to add complicated and large structures and devices.

在本發明中，將第二加壓力P2固定，並在壓縮開始時向中間粉末壓胚110的一部分局部施加大的壓縮力。藉由在中間粉末壓胚110的形態上想辦法即可實現。具體而言，與完成粉末壓胚120的形態相比，在中間粉末壓胚110上設置在加壓方向(壓製負載方向)上突起的1個或多個突起部分，將中間粉末壓胚110的形態設置得不同於完成粉末壓胚120的形狀。例如在中間粉末壓胚110的下面側，設置如圖6(A)、圖7(A2)所示的在加壓方向(朝下方向)上突起的突起部分110A，此時的突起部分110A為山形，但也可為其他形狀。且，也可在上面側設 置突起部分110A。 In the present invention, the second pressing force P2 is fixed, and a large compressive force is locally applied to a part of the intermediate powder preform 110 at the start of compression. This can be achieved by the method of the intermediate powder preform 110. Specifically, one or more protruding portions protruding in the pressing direction (pressing load direction) are provided on the intermediate powder compact 110 as compared with the form of the completed powder preform 120, and the intermediate powder preform 110 is The morphology is set differently than the shape of the finished powder compact 120. For example, on the lower surface side of the intermediate powder preform 110, a projection portion 110A which protrudes in the pressing direction (downward direction) as shown in Figs. 6(A) and 7(A2) is provided, and the projection portion 110A at this time is Yamagata, but can also be other shapes. Also, it can be set on the upper side The protruding portion 110A is placed.

即當完成粉末壓胚120的形態是如圖6(B)、圖7(B2)所示的實心且形狀簡單的形態(圓盤形等)時，較佳是將圖6(A)、圖7(B2)所示的突起部分110A設置在中間粉末壓胚110的平面中央部分。將與第二加壓成形時的粉末壓胚和模具(下沖頭41PD)上面的加壓方向正交方向的接觸面積設置為開始小並漸漸增大。可在開始增強按壓流動，之後促進流動的平均順暢。 That is, when the form of the powder compact 120 is completed in a solid and simple shape as shown in FIG. 6(B) and FIG. 7(B2) (a disk shape or the like), FIG. 6(A) and FIG. The protruding portion 110A shown in 7 (B2) is disposed at a central portion of the plane of the intermediate powder preform 110. The contact area in the direction orthogonal to the pressing direction of the powder blank and the mold (the lower punch 41PD) at the time of the second press forming is set to be small at the beginning and gradually increased. The press flow can be enhanced at the beginning, and then the flow is averaged smoothly.

另外，當完成粉末壓胚120的形態例如是圖9(B)所示的複雜形狀時，由於液態潤滑劑也可向空間120S、120T流動，所以也可如圖9(A)所示在接近腔體內壁面的各突起圓弧部分的下方設置向加壓方向上突出的突起部分110B。 Further, when the form of the powder compact 120 is, for example, the complex shape shown in Fig. 9(B), since the liquid lubricant can flow to the spaces 120S and 120T, it can be approached as shown in Fig. 9(A). A protruding portion 110B that protrudes in the pressing direction is provided below the arcuate portion of each of the inner wall surfaces of the cavity.

為了在中間粉末壓胚110上設置突起部分110A，第一加壓成形機20如上所述，由圖7(A1)的實心圓柱形的上沖頭25PU、中空圓筒形的模具21D及實心圓柱形的下沖頭21PD構成。下沖頭21PD的形態(上端面21PDS)預先成形朝上的凹形。這樣一來，用第一加壓成形機20，可成形具有突起部分110A的中間粉末壓胚110，前述突起部分110A如圖7(A2)所示在加壓方向(朝下方向)突起。 In order to provide the protruding portion 110A on the intermediate powder compact 110, the first press molding machine 20 is as described above, from the solid cylindrical upper punch 25PU of FIG. 7 (A1), the hollow cylindrical mold 21D, and the solid cylinder. The shape of the lower punch 21PD is formed. The form of the lower punch 21PD (upper end surface 21PDS) is previously formed into a concave shape that faces upward. Thus, the intermediate powder preform 110 having the projection portion 110A can be formed by the first press molding machine 20, and the projection portion 110A projects in the pressing direction (downward direction) as shown in Fig. 7 (A2).

在第二加壓成形機40中，如圖7(B1)所示中間粉末壓胚110的上面側在整個平面上與上沖頭45PU的下面全面抵接。其下面側為只有突起部分110A與下沖頭41PD 的上面中央部部分抵接。其餘下面則不與下沖頭41PD的上面抵接。即在第二加壓開始時，與通常情況相比增加施加在中間粉末壓胚110上的第二加壓力P2。可以理解為這是巧妙而有效地利用了加壓能力(第二加壓力P2)。 In the second press molding machine 40, the upper side of the intermediate powder preform 110 as shown in Fig. 7 (B1) abuts completely on the lower surface of the upper punch 45PU over the entire plane. The lower side is only the protruding portion 110A and the lower punch 41PD The upper central portion of the upper part abuts. The rest below does not abut the upper surface of the lower punch 41PD. That is, at the start of the second pressurization, the second pressing force P2 applied to the intermediate powder compact 110 is increased as compared with the usual case. It can be understood that this is a clever and effective utilization of the pressurizing ability (second applied pressure P2).

因此如藉由滑塊下降從上沖頭45PU施加第二加壓力P2，則向中間粉末壓胚110的上面和突起部分110A施加很大的壓縮力，在加壓方向上壓縮中間粉末壓胚110。向此時的中央部分(突起部分110A)施加的單位面積的加壓力增大，中間粉末壓胚110的液態潤滑劑被擠壓而流動。即如圖8所示從上面中央點Pu向所有方向且向斜下方擠壓流動，從下面中央點Pd向所有方向且向斜上方擠壓流動。該均勻流動有助於實現穩定而迅速的壓縮效果。突起部分110A漸漸潰散並變為接近圓盤形的平面形狀。隨著突起部分110A的潰散，單位面積的加壓力漸漸降低。 Therefore, if the second pressing force P2 is applied from the upper punch 45PU by the slider lowering, a large compressive force is applied to the upper surface of the intermediate powder preform 110 and the protruding portion 110A, and the intermediate powder preform 110 is compressed in the pressing direction. . The pressing force per unit area applied to the central portion (projecting portion 110A) at this time is increased, and the liquid lubricant of the intermediate powder compact 110 is pressed and flows. That is, as shown in Fig. 8, the flow is pressed from the upper center point Pu in all directions and obliquely downward, and the flow is squeezed from the lower central point Pd in all directions and obliquely upward. This uniform flow helps achieve a stable and rapid compression. The protruding portion 110A gradually collapses and becomes a planar shape close to a disk shape. As the protruding portion 110A collapses, the pressing force per unit area gradually decreases.

另外，第一模具(下模具21)的內部空間(腔體22)的形態成形與中間粉末壓胚110的形態相對應的形態，第二模具(下模具41)的內部空間(腔體42)的形態設置為與完成粉末壓胚120的形態相對應的形態。是圓盤形粉末壓胚(中間粉末壓胚110、完成粉末壓胚120)時，可將各粉末壓胚110、120的各形狀按該各外部尺寸(直徑d1、d2)設置，將各腔體22、42的各形態按該各內部尺寸(直徑d1、d2)設置。當然，與第一模具〔下模具21(腔體22)〕的內部尺寸d1相比，第二模具〔下 模具41(腔體42)〕的內部尺寸d2可選擇更大。原因是需要將直徑d1的中間粉末壓胚110***並裝在內部尺寸d2的第二模具(下模具41)內。即如果難於***並裝在第二模具(下模具41)內而需要花費很長時間的話，則會直接導致生產率下降。 Further, the form of the internal space (cavity 22) of the first mold (the lower mold 21) is shaped corresponding to the form of the intermediate powder preform 110, and the internal space of the second mold (the lower mold 41) (cavity 42) The form is set to correspond to the form in which the powder preform 120 is completed. When the disc-shaped powder preform (the intermediate powder preform 110 and the powder compact 120) is completed, each shape of each of the powder preforms 110 and 120 may be set according to the respective outer dimensions (diameters d1 and d2), and each cavity is provided. The respective forms of the bodies 22 and 42 are set for the respective internal dimensions (diameters d1 and d2). Of course, compared with the inner dimension d1 of the first mold [the lower mold 21 (cavity 22)], the second mold [below The inner dimension d2 of the mold 41 (cavity 42) can be selected to be larger. The reason is that it is necessary to insert the intermediate powder preform 110 of the diameter d1 and fit it in the second mold (lower mold 41) of the inner dimension d2. That is, if it is difficult to insert and fit in the second mold (the lower mold 41) and it takes a long time, the productivity is directly lowered.

以與完成粉末壓胚120的形態相對應的第二模具(模具41D)的腔體42的內部尺寸d2為100%時，設置第一模具(模具21D)的腔體22的內部尺寸d1與第二模具(下模具41)的腔體42的內部尺寸d2相比小1%~5%={〔(d2-d1)/d2〕×100%}。如果超過5%，則粉末壓胚上產生龜裂。如果不足1%，則會有超載、模具破損問題。在該實施方式中，由於設置為小2.5%，所以可切實防止龜裂發生。 When the internal dimension d2 of the cavity 42 of the second mold (mold 41D) corresponding to the form of the completed powder preform 120 is 100%, the internal dimension d1 of the cavity 22 of the first mold (mold 21D) is set and the first The internal dimension d2 of the cavity 42 of the second mold (the lower mold 41) is 1% to 5% smaller than {[(d2-d1)/d2]×100%}. If it exceeds 5%, cracks are generated on the powder compact. If it is less than 1%, there will be problems with overload and mold breakage. In this embodiment, since it is set to be 2.5% smaller, it is possible to reliably prevent cracking from occurring.

在此種實施方式的混合粉末的高密度成形裝置1中，可藉由下述步驟實施高密度成形。 In the high-density molding apparatus 1 of the mixed powder of this embodiment, high-density molding can be performed by the following procedure.

(混合粉末的製備) (Preparation of mixed powder)

將基礎金屬粉末(磁心用玻璃材質絕緣塗層被覆鐵粉末)和0.2wt%的潤滑劑粉末(硬脂酸鋅粉末)混合製備出鬆散狀態的混合粉末100。以規定量補給到混合粉末供給機10中(圖1的步驟PR0)。 The base metal powder (magnetic insulating glass coated iron powder for magnetic core) and 0.2 wt% of lubricant powder (zinc stearate powder) were mixed to prepare a mixed powder 100 in a loose state. It is supplied to the mixed powder feeder 10 in a predetermined amount (step PR0 of Fig. 1).

(混合粉末的填充) (filling of mixed powder)

在規定的時間，混合粉末供給機10如圖3B所示從規 定位置(實線)移動到補給位置(虛線)。接著打開混合粉末供給機10的供給口，向第一加壓成形機20的空的下模具21(腔體22)內填充定量的混合粉末100(圖1的步驟PR1)。例如可在2秒鐘內填充。填充後關閉供給口，混合粉末供給機10返回規定位置(實線)。如圖7(A1)所示時，填充的混合粉末100的下方部變為與下沖頭21PD的上面形狀(上端面21PDS)對應的倒山形，上部是藉由切削形成水平形狀。 At a prescribed time, the mixed powder feeder 10 is as shown in FIG. 3B. The fixed position (solid line) moves to the replenishment position (dashed line). Then, the supply port of the mixed powder feeder 10 is opened, and the empty mixed mold 100 (cavity 22) of the first press molding machine 20 is filled with the quantitative mixed powder 100 (step PR1 of FIG. 1). For example, it can be filled in 2 seconds. After filling, the supply port is closed, and the mixed powder feeder 10 returns to a predetermined position (solid line). As shown in Fig. 7 (A1), the lower portion of the filled mixed powder 100 has an inverted mountain shape corresponding to the upper shape (upper end surface 21PDS) of the lower punch 21PD, and the upper portion is formed into a horizontal shape by cutting.

(中間粉末壓胚的成形1) (Formation of intermediate powder preforms 1)

開始第一加壓成形處理，第一加壓成形機20的上模具25與圖2的滑塊5一同下降，以第一加壓力P1加壓下模具21(腔體22)內的混合粉末100。固態潤滑劑發揮充分的潤滑作用。已壓縮的中間粉末壓胚110的密度ρ隨圖4的特性A(虛線)而升高。第一加壓力P1一達到與橫軸指數(例如30)對應的壓力(3.0Ton/cm2)，則真密度比升高到85%即密度ρ升高到6.63g/cm3(相當於縱軸指數87)。例如8秒鐘的加壓成形一結束，則如圖3A所示在第一模具(下模具21)內成形中間粉末壓胚110(圖1的步驟PR2)。其後上模具25靠滑塊5上升。且，在第二加壓成形機40中可同步進行與之前的中間粉末壓胚110相關的第二加壓成形處理。 The first press forming process is started, and the upper die 25 of the first press molding machine 20 is lowered together with the slider 5 of FIG. 2, and the mixed powder 100 in the lower die 21 (cavity 22) is pressurized by the first pressing force P1. . Solid lubricants provide adequate lubrication. The density ρ of the compressed intermediate powder compact 110 increases with the characteristic A (dashed line) of FIG. When the first applied pressure P1 reaches a pressure corresponding to the horizontal axis index (for example, 30) (3.0Ton/cm 2 ), the true density ratio is increased to 85%, that is, the density ρ is increased to 6.63 g/cm 3 (corresponding to vertical Axis index 87). For example, when the press forming of 8 seconds is completed, the intermediate powder preform 110 is formed in the first mold (lower mold 21) as shown in Fig. 3A (step PR2 of Fig. 1). Thereafter, the upper mold 25 is raised by the slider 5. Further, the second press forming process associated with the previous intermediate powder preform 110 can be simultaneously performed in the second press molding machine 40.

(中間粉末壓胚的成形2) (Formation of intermediate powder preform 2)

如圖7(A1)所示的第一加壓成形時，形成具有圖7(A2)所示的突起部分110A的形態的中間粉末壓胚110。 At the time of the first press molding as shown in Fig. 7 (A1), the intermediate powder preform 110 having the form of the projection portion 110A shown in Fig. 7 (A2) is formed.

(中間粉末壓胚的取出) (Extraction of intermediate powder preform)

第一取出裝置(可動構件23)啟動，中間粉末壓胚110被推高到傳遞面HL。即從下模具21取出。於是如圖3B所示工件移送裝置50啟動，靠其移送桿51將中間粉末壓胚110向加熱升溫機30移送。在該階段，可動構件23返回到下方的初始位置。移送後的中間粉末壓胚110被定位在圖3A所示的絲網狀保持構件32上。 The first take-up device (movable member 23) is activated, and the intermediate powder compact 110 is pushed up to the transfer surface HL. That is, it is taken out from the lower mold 21. Then, the workpiece transfer device 50 is activated as shown in Fig. 3B, and the intermediate powder preform 110 is transferred to the heating and warming machine 30 by the transfer rod 51. At this stage, the movable member 23 returns to the initial position below. The transferred intermediate powder compact 110 is positioned on the wire-like holding member 32 shown in Fig. 3A.

(加熱升溫) (heating and heating)

在圖3A中，加熱升溫機30啟動。從噴氣罩31噴出的熱風將中間粉末壓胚110升溫到相當於潤滑劑粉末的熔點的溫度(120℃)(圖1的步驟PR3)。即潤滑劑熔解，靠其流動使中間粉末壓胚110內的潤滑劑分佈變為均勻。加熱升溫時間例如是8~10秒。另外，熱風可通過絲網狀保持構件32、排氣循環罩33而循環再次使用。中間粉末壓胚110是具有圖7(A2)所示的突起部分的110A時也同樣進行加熱升溫。 In Fig. 3A, the heating warming machine 30 is started. The hot air ejected from the air hood 31 raises the intermediate powder preform 110 to a temperature (120 ° C) corresponding to the melting point of the lubricant powder (step PR3 of Fig. 1). That is, the lubricant is melted, and the flow of the lubricant in the intermediate powder compact 110 becomes uniform by the flow thereof. The heating and heating time is, for example, 8 to 10 seconds. Further, the hot air can be recycled and reused by the mesh-like holding member 32 and the exhaust gas recirculation cover 33. When the intermediate powder preform 110 is 110A having the protruding portion shown in Fig. 7 (A2), the heating is also performed in the same manner.

(已升溫的中間粉末壓胚的裝入) (Loading of intermediate powder preforms that have been heated)

已升溫的中間粉末壓胚110如圖3B所示靠工件移送 裝置50(移送桿52)傳動到第二加壓成形機40，定位在下模具41的上方，裝到在下模具41(腔體42)內的可動構件43上(圖1的步驟PR4)。是圖7(B1)時，上模具是上沖頭45P，下模具是模具41D及下沖頭41P。 The heated intermediate powder preform 110 is transferred by the workpiece as shown in FIG. 3B. The device 50 (transfer rod 52) is driven to the second press molding machine 40, positioned above the lower mold 41, and attached to the movable member 43 in the lower mold 41 (cavity 42) (step PR4 of Fig. 1). In the case of Fig. 7 (B1), the upper mold is the upper punch 45P, and the lower mold is the mold 41D and the lower punch 41P.

(模具的預熱) (preheating of the mold)

在第二加壓成形機40中，選擇了啟動時，第二預熱裝置47啟動。在接收中間粉末壓胚110(被裝入)以前，將模具(模具41D)的溫度加熱到相當於潤滑劑粉末的熔點的溫度(120℃)。可防止之後接收的已升溫的中間粉末壓胚110內的潤滑劑的再次固化。是圖7(B1)時，可預先在模具41D上設置第二預熱裝置(加熱器)47。 In the second press molding machine 40, when the startup is selected, the second preheating device 47 is activated. The temperature of the mold (mold 41D) is heated to a temperature (120 ° C) corresponding to the melting point of the lubricant powder before receiving the intermediate powder preform 110 (loaded). The re-solidification of the lubricant in the heated intermediate powder preform 110 that is received later can be prevented. In the case of Fig. 7 (B1), a second preheating device (heater) 47 may be provided in advance on the mold 41D.

(完成粉末壓胚的成形1) (Complete the formation of powder preforms 1)

上模具45如圖3A所示與圖2的滑塊5一同下降，開始以第二加壓力P2對下模具41(腔體42)內的中間粉末壓胚110加壓。液態的潤滑劑充分起到潤滑作用。尤其是出現出汗現象，隨著加壓成形的進行潤滑劑向所有方向流出。不僅能高效減輕基礎金屬粒子間也能高效減輕粒子和模具間的摩擦阻力。已壓縮的中間粉末壓胚110的密度ρ隨著圖4的特性B而升高。即第二加壓力P2一旦超過橫軸指數(例如30...加壓力3.0Ton/cm2)，則密度ρ從6.63g/cm3急速升高到與縱軸指數102相當的密度ρ (7.75g/cm3)。一將第二加壓力P2上升到橫軸指數100(10Ton/cm2)，則密度ρ(7.75g/cm3)整體變均勻。例如8秒鐘的第二加壓成形處理一結束，則完成粉末壓胚120在第二模具(下模具41)內成形(圖1的步驟PR5)。其後，上模具45靠滑塊5來上升。另外，在第一加壓成形機20中可同步進行與後續的中間粉末壓胚110相關的第一加壓成形處理。 The upper mold 45 is lowered together with the slider 5 of Fig. 2 as shown in Fig. 3A, and the intermediate powder preform 110 in the lower mold 41 (cavity 42) is started to be pressurized by the second pressing force P2. The liquid lubricant is fully lubricated. In particular, sweating occurs, and the lubricant flows out in all directions as the pressure is formed. Not only can it effectively reduce the frictional resistance between the particles and the mold, but also effectively reduce the friction between the particles and the mold. The density ρ of the compressed intermediate powder preform 110 increases with the characteristic B of FIG. That is, once the second pressing force P2 exceeds the horizontal axis index (for example, 30...plus pressure 3.0Ton/cm 2 ), the density ρ rapidly increases from 6.63 g/cm 3 to a density ρ corresponding to the vertical axis index 102 (7.75). g/cm 3 ). When the second pressing force P2 is raised to the horizontal axis index of 100 (10 Ton/cm 2 ), the density ρ (7.75 g/cm 3 ) becomes uniform as a whole. For example, when the second press forming process of 8 seconds is completed, the completion of the powder preform 120 in the second mold (lower mold 41) (step PR5 of Fig. 1). Thereafter, the upper mold 45 is raised by the slider 5. Further, the first press forming process associated with the subsequent intermediate powder preform 110 can be simultaneously performed in the first press molding machine 20.

(完成粉末壓胚的成形2) (Complete the formation of powder preform 2)

是圖7(B1)時，如藉由滑塊下降從上沖頭45PU向下沖頭41PD側施加第二加壓力P2，則如圖8所示的中間粉末壓胚110的上面側和下面側的突起部分110A之間施加大的壓縮力。由於向中央部分(突起部分110A)上施加的單位面積的加壓力大，所以中間粉末壓胚110的基礎金屬粒子及液態潤滑劑從上面中央點Pu向所有方向且向斜下方擠壓流動，從下面中央點Pd向所有方向且向斜上方擠壓流動。因而，可保障均勻切實地流動。可有助於實現穩定且迅速的壓縮效果。突起部分110A逐漸潰散並接近圓盤形狀，最終可按如圖7(B2)〔圖6(B)〕所示的規定形狀完成高品質完成粉末壓胚120。 In the case of Fig. 7 (B1), if the second pressing force P2 is applied from the upper punch 45PU to the lower punch 41PD side by the slider lowering, the upper side and the lower side of the intermediate powder preform 110 as shown in Fig. 8 A large compressive force is applied between the protruding portions 110A. Since the pressing force per unit area applied to the central portion (protrusion portion 110A) is large, the base metal particles and the liquid lubricant of the intermediate powder compact 110 are squeezed from the upper central point Pu in all directions and obliquely downward. The lower center point Pd is pressed to flow in all directions and obliquely upward. Therefore, it is possible to ensure uniform and reliable flow. Can help achieve a stable and rapid compression effect. The protruding portion 110A is gradually broken and approaches the shape of the disk, and finally the high-quality finished powder compact 120 can be completed in a prescribed shape as shown in Fig. 7 (B2) [Fig. 6 (B)].

(產品取出) (product removal)

第二取出裝置(43)啟動，完成粉末壓胚120被推高到移送面HL。即從下模具41取出。於是如圖3B所示， 工件移送裝置50啟動，靠其移送桿53將完成粉末壓胚120移送到排出槽59。在這一階段，可動構件43返回到下方的初始位置。相當於縱軸指數102的密度ρ(7.75g/cm3)的完成粉末壓胚120由於潤滑劑粉末熔點低所以玻璃材質不會變質、熔解。因此，渦流損耗小，可高效地製造磁通密度高的高品質磁心用粉末壓胚。 The second take-up device (43) is activated to complete the powder compact 120 being pushed up to the transfer surface HL. That is, it is taken out from the lower mold 41. Then, as shown in Fig. 3B, the workpiece transfer device 50 is activated, and the finished powder preform 120 is transferred to the discharge groove 59 by its transfer lever 53. At this stage, the movable member 43 returns to the initial position below. The finished powder preform 120 corresponding to the density ρ (7.75 g/cm 3 ) of the vertical axis index 102 does not deteriorate or melt the glass material because the melting point of the lubricant powder is low. Therefore, the eddy current loss is small, and a high-quality core powder compact for high magnetic flux density can be efficiently manufactured.

(製造週期) (manufacturing cycle)

由於採用以上各步驟的高密度成形方法，可對依序供給填充的金屬粉末(混合粉末100)同步實施第一加壓成形處理、加熱升溫處理及第二加壓成形處理，所以可在最長的加熱升溫處理時間(例如10秒)上加上工件移送時間(例如2~4秒)後得到的12~14秒的週期時間內製造出高密度粉末壓胚(完成粉末壓胚120)。理解為即便是與以往例中30分鐘以上的高溫燒結處理時間相比，製造、生產時間仍顯著節約。例如可穩定供給小型輕量複雜形狀機械強度高的汽車用構件或磁特性及機械強度優越的電磁設備，還可對降低這些產品的生產成本做出很大貢獻。 According to the high-density molding method of the above steps, the first press molding process, the heating temperature rising process, and the second press molding process can be simultaneously performed on the sequentially supplied filled metal powder (mixed powder 100), so that it can be the longest. A high-density powder compact (completed powder compact 120) is produced in a cycle time of 12 to 14 seconds obtained by adding a workpiece transfer time (for example, 2 to 4 seconds) to the heating and heating treatment time (for example, 10 seconds). It is understood that the manufacturing and production time are significantly saved even in comparison with the high-temperature sintering treatment time of 30 minutes or more in the conventional example. For example, it is possible to stably supply small-sized, lightweight, and complex-shaped automotive members with high mechanical strength, electromagnetic materials having excellent magnetic properties and mechanical strength, and contribute greatly to reducing the production cost of these products.

這樣，由於高密度成形方法採用該實施方式可向第一模具(下模具21)中裝填混合粉末100，前述混合粉末100是基礎金屬粉末中混合低熔點的潤滑劑粉末的混合物，在第一模具內施加第一加壓力P1成形在加壓方向上突起的突起部分110A的中間粉末壓胚110，將加熱並積 極升溫到相當於潤滑劑粉末的熔點的溫度的中間粉末壓胚110裝入第二模具(下模具41)且施加第二加壓力P2使突起部分110A在加壓方向上潰散、壓縮並加壓成形，以高密度完成所期待的形態的完成粉末壓胚120的高密度成形方法，所以可切實穩定地製造高密度粉末壓胚並可大幅降低製造成本，可有效利用加壓能力並促進液態潤滑劑的均勻流動，以此可順利地實際製造出高品質粉末壓胚。 Thus, since the high-density forming method employs this embodiment, the first mold (the lower mold 21) can be filled with the mixed powder 100, which is a mixture of the low-melting lubricant powder mixed in the base metal powder, in the first mold. Applying the first pressing force P1 to form the intermediate powder preform 110 of the protruding portion 110A protruding in the pressing direction, and heating and accumulating The intermediate powder preform 110 whose temperature is extremely raised to a temperature equivalent to the melting point of the lubricant powder is loaded into the second mold (lower mold 41) and the second pressing force P2 is applied to cause the protruding portion 110A to collapse, compress and pressurize in the pressurizing direction. The high-density molding method for completing the powder compact 120 in a desired form is completed at a high density, so that a high-density powder compact can be reliably produced and the manufacturing cost can be greatly reduced, and the pressurizing ability can be effectively utilized and liquid lubrication can be promoted. The uniform flow of the agent makes it possible to smoothly manufacture a high quality powder compact.

從藉由有效利用加壓能力而強化基礎金屬粒子及液態潤滑劑的流動性，由此可完成規定的高密度、高品質的完成粉末壓胚120的角度看，可以說可減輕在第二加壓成形機的設計階段的加壓能力。即壓製機械等可以小容量、小型化。 By enhancing the fluidity of the base metal particles and the liquid lubricant by effectively utilizing the pressurizing ability, the predetermined high-density, high-quality finished powder preform 120 can be completed, and it can be said that the second addition can be alleviated. Pressurization capability at the design stage of the press forming machine. That is, the press machine or the like can be small in capacity and small in size.

且，由於可去除高溫下長時間的燒結處理，所以不僅可大幅抑制粉末壓胚110、120的氧化，且可實現能耗的高利用率及製造成本的大幅降低。在保護地球環境方面也受到歡迎。 Further, since the sintering treatment at a high temperature for a long period of time can be removed, not only the oxidation of the powder preforms 110 and 120 can be greatly suppressed, but also the high utilization rate of energy consumption and the manufacturing cost can be greatly reduced. It is also welcomed in protecting the global environment.

且，由於當完成粉末壓胚120是如圖6(B)所示的實心且形狀簡單時，設置為在中間粉末壓胚110的平面中央部分成形如圖6(A)所示的突起部分110A，所以可進一步提高從中央部分向外側腔體內壁面的基礎金屬粒子及液態潤滑劑的流動性。也可縮短製造時間。 Further, since the finished powder preform 120 is solid and has a simple shape as shown in Fig. 6(B), it is provided to form the protruding portion 110A as shown in Fig. 6(A) at the central portion of the plane of the intermediate powder preform 110. Therefore, the fluidity of the base metal particles and the liquid lubricant from the central portion to the inner wall surface of the outer cavity can be further improved. It also reduces manufacturing time.

由於潤滑劑粉末的熔點屬於90℃~190℃的溫度範圍內的低熔點，所以可有助於抑制第一加壓步驟中的潤滑劑的氧化且可保證充分的潤滑作用。並且潤滑劑的選擇性更 加廣泛。 Since the melting point of the lubricant powder belongs to a low melting point in the temperature range of 90 ° C to 190 ° C, it can contribute to suppressing oxidation of the lubricant in the first pressurizing step and ensuring sufficient lubricating action. And the selectivity of the lubricant is more Plus wide.

由於可藉由第二預熱裝置47在接收中間粉末壓胚11前預熱第二模具(下模具41)，所以可進一步大幅提高第二加壓成形中已熔解的潤滑劑向所有方向的流動性。即不僅可以大幅減少基礎金屬粒子間而且可以減少粒子和第二模具(下模具41、模具41D)間的摩擦阻力並加以保持。 Since the second mold (the lower mold 41) can be preheated by the second preheating device 47 before receiving the intermediate powder compact 11, the flow of the melted lubricant in the second press forming can be further greatly increased in all directions. Sex. That is, not only the amount of the base metal particles can be greatly reduced but also the frictional resistance between the particles and the second mold (the lower mold 41 and the mold 41D) can be reduced and maintained.

且，由於將第二加壓力P2的值設為與第一加壓力P的值相等，所以容易進行加壓成形步驟的實施及其操作，既可以間接有助於進一步降低粉末壓胚的製造成本，並且在實現裝置時也可以例如以一台壓製機械為基礎簡化構造。 Further, since the value of the second pressing force P2 is set to be equal to the value of the first pressing force P, it is easy to carry out the operation of the press forming step and the operation thereof, which can indirectly contribute to further reducing the manufacturing cost of the powder compact. In the case of a device, the construction can also be simplified, for example on the basis of a pressing machine.

且，即便將基礎金屬粉末變更為磁心用玻璃質絕緣塗層被覆鐵粉末、磁心用鐵基非晶粉末、磁心用Fe-Si合金粉末的任意一種，其他條件相同，也可高效地製造與基礎金屬粉末的種類對應的具有優越磁特性的磁心構件。 In addition, even if the base metal powder is changed to any one of the iron-based insulating coating-coated iron powder for the core, the iron-based amorphous powder for the core, and the Fe-Si alloy powder for the core, the other conditions are the same, and the base can be efficiently manufactured and manufactured. A magnetic core member having superior magnetic properties corresponding to the type of metal powder.

綜上所述，依靠現有裝置(例如壓製機械)的能力(圖4的橫軸指數100)將密度升高到相當於縱軸指數100以上是不可能的；反之，採用本發明可以用同一裝置升高到相當於縱軸指數102的密度。這一事實在該技術領域被讚譽為具有劃時代的意義。 In summary, it is impossible to increase the density to a value corresponding to a vertical axis index of 100 or more depending on the capability of the existing device (for example, a pressing machine) (the horizontal axis index of FIG. 4); conversely, the same device can be used with the present invention. Raised to a density corresponding to the vertical axis index 102. This fact is acclaimed in this technical field as epoch-making.

進而，由於高密度化裝置1由混合粉末供給機10、第一加壓成形機20、加熱升溫機30以及第二加壓成形機40構成，所以可切實穩定地實施上述的高密度化方法。 Further, since the high-density device 1 is composed of the mixed powder feeder 10, the first press molding machine 20, the heating and heating machine 30, and the second press molding machine 40, the above-described high-density method can be reliably and stably performed.

當是例如圖9(B)所示的複雜形狀時，如預先進一步增大突起部分110B增加混合粉末100的填充量的話，則與其他部分比較，可增大各突起圓弧部分的密度(強度)。 When it is a complicated shape as shown, for example, in FIG. 9(B), if the amount of filling of the mixed powder 100 is increased by further increasing the protruding portion 110B in advance, the density (intensity) of the circular arc portion of each protrusion can be increased as compared with other portions. ).

(第二實施方式) (Second embodiment)

該實施方式如圖10所示。與第一實施方式的情況相比，其特徵在於混合粉末供給機10及第一加壓成形機20照原樣設置，加熱升溫機30和第二加壓成形機40一體構成。 This embodiment is shown in FIG. Compared with the case of the first embodiment, the mixed powder feeder 10 and the first press molding machine 20 are provided as they are, and the heating and heating machine 30 and the second press molding machine 40 are integrally formed.

即高密度成形裝置1由一體組裝有第一實施方式時的加熱升溫機30的功能和第二加壓成形機40的功能的加熱加壓成形機70形成。加熱加壓成形機70由多台(在該實施方式中是兩台)加熱加壓成形子機70A、70B形成，各加熱加壓成形子機70A、70B設置為藉由末圖示的控制裝置在每個製造週期內可選擇依序動作。 In other words, the high-density molding apparatus 1 is formed by a heating and press molding machine 70 in which the function of the heating and heating machine 30 in the first embodiment and the function of the second press molding machine 40 are integrally assembled. The heating and press molding machine 70 is formed of a plurality of (two in this embodiment) heating and press molding machines 70A and 70B, and each of the heating and pressing molding machines 70A and 70B is provided as a control device shown by the end. The sequential actions can be selected during each manufacturing cycle.

各加熱加壓成形子機70A(70B)的基本構造設置為與第一實施方式中第二加壓成形機40相同。且，各加熱加壓成形子機70A(70B)中，安裝有具備與第一實施方式的加熱升溫機30及第二預熱裝置47的各功能對應的複合功能的多功能型加熱裝置48。 The basic structure of each of the heat and pressure forming sub-machines 70A (70B) is set to be the same as that of the second press molding machine 40 in the first embodiment. Further, in each of the heating and press molding machine 70A (70B), a multi-function heating device 48 having a composite function corresponding to each function of the heating and heating device 30 and the second preheating device 47 of the first embodiment is attached.

即多功能型加熱裝置48設置為具有設定溫度切換功能的電熱方式。可事先(在接收中間粉末壓胚110以前)將下模具41預熱到相當於潤滑劑熔點的溫度(120℃)。 接收中間粉末壓胚110後，可藉由加大切換將中間粉末壓胚110整體加熱升溫到相當於潤滑劑熔點的溫度(120℃)的發熱量。也可選擇切換加熱部位。在該加熱升溫結束後與第一實施方式的第二加壓成形機40的情況相同進行第二加熱成形處理。多功能型加熱裝置48工作，可在第二加熱成形處理中將中間粉末壓胚110的溫度保持在相當於潤滑劑熔點的溫度(120℃)以上。 That is, the multi-function type heating device 48 is provided as an electric heating mode having a set temperature switching function. The lower mold 41 may be preheated (before receiving the intermediate powder compact 110) to a temperature (120 ° C) corresponding to the melting point of the lubricant. After receiving the intermediate powder preform 110, the intermediate powder preform 110 can be heated and heated to a temperature corresponding to the melting point of the lubricant (120 ° C) by increasing the switching. You can also choose to switch the heating area. After the completion of the heating and heating, the second heat forming process is performed in the same manner as in the case of the second press molding machine 40 of the first embodiment. The multifunctional heating device 48 operates to maintain the temperature of the intermediate powder preform 110 at a temperature (120 ° C) or higher corresponding to the melting point of the lubricant in the second heat forming process.

如圖10所示，各加熱加壓成形子機20、70A、70B設置為獨立壓製機械結構，各滑塊5、5A、5B靠各機器用電動機的旋轉控制驅動其分別做升降運動。即各加熱加壓成形子機70A、70B的一個(另一個)進行加壓成形動作時另一個(一個)為預熱，不做加壓成形動作。考慮到加熱加壓成形機70與製造週期時間的關係即便設置為由三台以上的加熱加壓成形子機形成的情況也是一樣。 As shown in Fig. 10, each of the heating and press forming sub-machines 20, 70A, 70B is provided as an independent pressing mechanical structure, and each of the sliders 5, 5A, 5B is driven to perform a lifting movement by the rotation control of each of the machine motors. In other words, when one (the other) of each of the heating and press molding sub-machines 70A and 70B performs the press forming operation, the other one (one) is preheated, and the press forming operation is not performed. The same applies to the case where the relationship between the heating press molding machine 70 and the manufacturing cycle time is set to be formed by three or more heating and press forming sub-machines.

像此種實施方式的裝置，在以第一加熱成形機20對第3個中間粉末壓胚110進行加壓成形期間，一個加熱加壓成形子機70A(或70B)加熱升溫第2個中間粉末壓胚110而另一個加熱加壓成形子機70B(或70A)正在將第一個中間粉末壓胚110成形完成粉末壓胚120。 In the apparatus of this embodiment, during the press molding of the third intermediate powder preform 110 by the first heat molding machine 20, one heating and pressing molding machine 70A (or 70B) heats up the second intermediate powder. The preform 110 and the other heated and pressed forming machine 70B (or 70A) are forming the first intermediate powder preform 110 to complete the powder preform 120.

這樣，採用該實施方式，由於只需將加熱加壓成形機70構建為由同一結構的多台加壓成形子機70A、70B構成，所以與第一實施方式時相比可使裝置簡化。即可促進生產線的簡單化，又變得更容易操作。 As described above, according to this embodiment, since the heating and press molding machine 70 is only required to be constituted by a plurality of press molding sub-machines 70A and 70B having the same configuration, the apparatus can be simplified as compared with the case of the first embodiment. It simplifies the production line and makes it easier to operate.

當然，與第一實施方式的情況(圖6~圖9)相同， 施加第一加壓力P1成形中間粉末壓胚110，前述中間粉末壓胚110具有在加壓方向上突起的突起部分110A，向已升溫的中間粉末壓胚110施加第二加壓力P2使突起部分110A在加壓方向上潰散、壓縮並加壓成型，即可以高密度完成所期待的形態的完成粉末壓胚120。 Of course, the same as the case of the first embodiment (FIGS. 6 to 9), The intermediate pressing preform 110 is formed by applying a first pressing force P1, the intermediate powder preform 110 having a protruding portion 110A protruding in the pressing direction, and applying a second pressing force P2 to the heated intermediate powder preform 110 to cause the protruding portion 110A The powder preform 120 in a desired form can be completed at a high density by being collapsed, compressed, and pressure molded in the pressurizing direction.

另外，也可用一台壓製機械設置成第一加壓成形機20和加熱加壓成形子機70A(或70B)或第一加壓成形機20及各加熱加壓成形子機70A、70B。 Further, the first press molding machine 20 and the heat and pressure forming sub-machine 70A (or 70B) or the first press molding machine 20 and the respective heat and pressure forming sub-machines 70A and 70B may be provided by a single pressing machine.

10‧‧‧混合粉末供給機 10‧‧‧Mixed powder feeder

21D‧‧‧中空圓筒形模具 21D‧‧‧ hollow cylindrical mold

21PD‧‧‧下沖頭 21PD‧‧‧ lower punch

21PDS‧‧‧上端面 21PDS‧‧‧ upper end

25PU‧‧‧上沖頭 25PU‧‧‧Upper punch

41D‧‧‧下模具 41D‧‧‧ Lower mold

41PD‧‧‧下沖頭 41PD‧‧‧ lower punch

45PU‧‧‧上沖頭 45PU‧‧‧Upper punch

100‧‧‧混合粉末 100‧‧‧ mixed powder

110‧‧‧中間粉末壓胚 110‧‧‧Intermediate powder preform

110A‧‧‧突起部分 110A‧‧‧ protruding part

120‧‧‧完成粉末壓胚 120‧‧‧Complete powder compact

Claims (9)

一種混合粉末的高密度成形方法，其特徵在於：將混合粉末填充到第一模具中，前述混合粉末是基礎金屬粉末和低熔點潤滑劑粉末的混合物；在第一模具內向混合粉末施加第一加壓力成形與混合粉末完成壓縮體的形狀相比具有在加壓方向上突起的一個或多個突起部分的形狀的混合粉末中間壓縮體；加熱從第一模具取出的混合粉末中間壓縮體，將混合粉末中間壓縮體的溫度積極升高到相當於該潤滑劑粉末的熔點的溫度；將已升溫的混合粉末中間壓縮體裝入第二模具中；在第二模具內向前述混合粉末中間壓縮體施加第二加壓力使前述突起部分在加壓方向上潰散、壓縮並加壓成形，以高密度完成所期待的形狀的混合粉末完成壓縮體。 A high-density forming method of a mixed powder, characterized in that a mixed powder is filled into a first mold, the mixed powder is a mixture of a base metal powder and a low-melting lubricant powder; and a first addition is applied to the mixed powder in the first mold Press-forming a mixed powder intermediate compressed body having a shape of one or more protruding portions protruding in a pressurizing direction as compared with a shape in which the mixed powder is completed; heating the mixed powder intermediate compressed body taken out from the first mold, mixing The temperature of the intermediate compressed body of the powder is actively raised to a temperature corresponding to the melting point of the lubricant powder; the intermediate compressed body of the heated mixed powder is charged into the second mold; and the intermediate compressed body is applied to the mixed powder in the second mold. The two-pressing pressure causes the aforementioned protruding portion to be collapsed in the pressurizing direction, compressed and press-formed, and the mixed powder of the desired shape is completed at a high density to complete the compressed body. 如申請專利範圍第1項所述之混合粉末的高密度成形方法，其中，前述混合粉末完成壓縮體是實心且形狀簡單時，前述突起部分成形在該混合粉末壓縮體的平面中央部分。 The high-density molding method of the mixed powder according to the first aspect of the invention, wherein, when the mixed powder is solid and the shape is simple, the protruding portion is formed in a central portion of the plane of the mixed powder compact. 如申請專利範圍第1或2項所述之混合粉末的高密度成形方法，其中，前述潤滑劑粉末的熔點設為低熔點，熔點溫度在90℃~190℃的範圍內。 The high-density molding method of the mixed powder according to claim 1 or 2, wherein the lubricant powder has a melting point of a low melting point and a melting point temperature of 90 ° C to 190 ° C. 如申請專利範圍第1或2項所述之混合粉末的高密度成形方法，其中， 前述第二模具在接收前述混合粉末中間壓縮體以前先被預熱到相當於該潤滑劑粉末的熔點的溫度。 A high-density forming method of the mixed powder according to claim 1 or 2, wherein The foregoing second mold is preheated to a temperature corresponding to the melting point of the lubricant powder before receiving the mixed powder intermediate compressed body. 如申請專利範圍第1或2項所述之混合粉末的高密度成形方法，其中，前述第二加壓力選擇與前述第一加壓力等值。 The high-density molding method of the mixed powder according to claim 1 or 2, wherein the second pressing force is selected to be equal to the first pressing force. 一種混合粉末的高密度成形裝置，包括：混合粉末供給機，其向外部供給填充混合粉末，前述混合粉末是基礎金屬粉末和低熔點的潤滑劑粉末的混合物；第一加壓成形機，其向用該混合粉末供給機填充到第一模具中的混合粉末施加第一加壓力成形與混合粉末完成壓縮體的形狀相比具有在加壓方向上突起的一個或多個突起部分的混合粉末中間壓縮體；加熱升溫機，用於使從第一模具取出的混合粉末中間壓縮體的溫度升高到相當於該潤滑劑粉末的熔點的溫度；以及第二加壓成形機，其向已裝入第二模具中的已升溫的混合粉末中間壓縮體施加第二加壓力使前述突起部分在加壓方向上潰散、壓縮並加壓成形，以高密度完成所期待的形狀的混合粉末完成壓縮體。 A high-density forming apparatus for a mixed powder, comprising: a mixed powder feeder that supplies a filling mixed powder to the outside, the mixed powder being a mixture of a base metal powder and a low-melting lubricant powder; and a first press molding machine The mixed powder filled into the first mold by the mixed powder feeder is subjected to a first press forming to compress the mixed powder having one or more protruding portions protruding in the pressurizing direction as compared with the shape of the mixed powder to complete the compressed body. a heating and heating machine for raising the temperature of the mixed powder intermediate compressed body taken out from the first mold to a temperature corresponding to the melting point of the lubricant powder; and a second press forming machine, which has been loaded into the first The heated mixed powder intermediate compressed body in the two molds is subjected to a second pressing force to cause the above-mentioned protruding portion to be collapsed in the pressurizing direction, compressed and press-formed, and the mixed powder of the desired shape is completed at a high density to complete the compressed body. 如申請專利範圍第6項所述之混合粉末的高密度成形裝置，其中，由一體組裝有具有前述加熱升溫機的功能和前述第二加壓成形機功能的加熱加壓成形機構成，並且加熱加壓成 形機由多台加熱加壓成形子機構成，且各加熱加壓成形子機設置為在每個週期可選擇依序動作。 The high-density molding apparatus of the mixed powder according to the sixth aspect of the invention, wherein the heating and press molding machine having the function of the heating and heating machine and the function of the second press molding machine are integrally assembled and heated Pressurize The machine is composed of a plurality of heating and press forming sub-machines, and each of the heating and press forming sub-machines is arranged to be sequentially operated in each cycle. 如申請專利範圍第6項所述之混合粉末的高密度成形裝置，其中，還具有預熱前述第二模具的預熱裝置。 The high-density forming apparatus of the mixed powder according to claim 6, wherein the preheating means for preheating the second mold is further provided. 如申請專利範圍第6項所述之混合粉末的高密度成形裝置，其中，還具有工件移送裝置，其將前述第一加壓成形機所成形的前述混合粉末中間壓縮體移送到前述加熱升溫機，將用前述加熱升溫機加熱後的前述混合粉末中間壓縮體移送到前述第二加壓成形機，且將前述第二加壓成形機所成形的前述混合粉末完成壓縮體移送到排出部。 The high-density molding apparatus of the mixed powder according to claim 6, further comprising a workpiece transfer device that transfers the mixed powder intermediate compression body formed by the first press molding machine to the heating and heating machine The mixed powder intermediate compressed body heated by the heating and heating machine is transferred to the second press molding machine, and the mixed powder formed by the second press molding machine is transferred to the discharge portion.
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