WO2024035366A1 - Concrete mold system and production method - Google Patents

Concrete mold system and production method Download PDF

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Publication number
WO2024035366A1
WO2024035366A1 PCT/TR2023/050599 TR2023050599W WO2024035366A1 WO 2024035366 A1 WO2024035366 A1 WO 2024035366A1 TR 2023050599 W TR2023050599 W TR 2023050599W WO 2024035366 A1 WO2024035366 A1 WO 2024035366A1
Authority
WO
WIPO (PCT)
Prior art keywords
mold
onto
production
concrete
deposition head
Prior art date
Application number
PCT/TR2023/050599
Other languages
French (fr)
Inventor
Taner Karagöz
Original Assignee
Coşkunöz Kalip Maki̇na Sanayi̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Coşkunöz Kalip Maki̇na Sanayi̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇ filed Critical Coşkunöz Kalip Maki̇na Sanayi̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇
Publication of WO2024035366A1 publication Critical patent/WO2024035366A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/007—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing

Definitions

  • the invention relates to a concrete mold system and production method used in the manufacture of automotive sheet metal forming molds and composite part molds in the defense industry.
  • the invention is particularly related to a concrete mold (formwork) system and production method that enables flexible implementation of mold designs that are limited due to casting constraints and reduces mold costs through incremental manufacturing.
  • Sheet metal molds in the automotive industry are generally made using traditional casting methods with cast iron material.
  • the casting time in traditional casting methods takes a long time due to factors such as cooling.
  • voids (cavities) that may occur during casting cause all the material to become scrap.
  • the mold geometry is limited accordingly.
  • the cost remains at a very high level.
  • styrofoam melts due to the heat generated during the process.
  • the resulting styrofoam melting also causes air pollution.
  • deposition heads are not used in the casting method and the mold production is not carried out by layering the casting material. As a result, there is a risk of voids in the mold.
  • the mentioned deposition heads are used in the fields of concrete and architecture. Therefore, there is a need for a system and method in the known state of the art that eliminates the problems encountered in traditional casting methods.
  • EP1794338B1 can be cited as an example of the state of the art in the research conducted in the literature
  • the mentioned document relates to a method for producing automotive components.
  • a continuous casting machine is used to cast an aluminum alloy in a flat plate form to produce aluminum vehicle structural parts or components.
  • the present invention relates to a concrete mold system and production method that eliminates the disadvantages mentioned above and brings new advantages to the relevant technical field.
  • the main object of the invention is to provide a concrete mold system and production method that enables flexible implementation of mold designs that are limited due to casting constraints in the manufacture of automotive sheet metal forming molds and molds producing composite parts in the defense industry.
  • the object of the invention is to prevent styrofoam melting in productions, since there is no heat during the process, and to ensure rapid curing of the concrete-polymer mixture material with air in the process.
  • Another object of the invention is to reduce mold costs.
  • Another object of the invention is to ensure that the mold becomes immediately usable after production, since there is no cooling time in mold production as in the casting method.
  • Another object of the invention is to ensure that the mold production is carried out with the layering method of the filling material at a certain temperature through the deposition head and eliminate the risk of voids.
  • the invention is a concrete mold system used in the manufacture of automotive sheet metal forming molds and composite part molds in the defense industry.
  • the system includes:
  • a material that will serve as the mold and is processed according to the mold surface A deposition head that deposits filling material by the layer deposition method at the certain temperature onto the material that will serve as the mold.
  • a shell surface of the mold formed by the deposition head depositing the filling material onto the material serving as the mold.
  • a material with high hardness applied onto surface of the mold consisting of the shell surface of the mold and tie piece, which enhances its wear resistance.
  • the invention is also a concrete mold production method used in the manufacture of automotive sheet metal forming molds and composite part molds in the defense industry.
  • the method includes the following steps: a) Preparation of the material serving as the mold by processing it according to the mold model surface, b) Formation of the shell surface of the mold by layering the filling material that comes out of the deposition head onto the material serving as a mold using layer deposition method, c) Formation of the tie piece and obtaining the mold by layering the filling material by layer deposition method onto the shell surface of the mold using the deposition head, d) Application of a material with high hardness onto the surface of the mold to prevent wear during the sheet metal forming process.
  • Figure 1 A representative view of the concrete mold system subject to the invention.
  • Figure 2 A representative view of the spring structures in the concrete mold system subject to the invention.
  • Figure 3 A representative view of the mold in the concrete mold system subject to the invention. Explanation of Part References
  • the invention is related to a concrete mold system used in the manufacture of automotive sheet metal forming molds and composite part molds in the defense industry.
  • the concrete mold system in its most basic form comprises: a material serving as the mold (10), which is processed according to the mold surface; a deposition head (20) that deposits filling material (30) layer by layer onto the material serving as the mold (10) at a certain temperature; a shell surface of the mold (40) formed by the deposition head (20) depositing the filling material (30) onto the material serving as the mold (10); a tie piece (50) formed by layering the filling material (30) onto the shell surface of the mold (40) at a certain temperature using the deposition head (20); and a mold (70) surface consisting of the shell surface of the mold (40) and the tie piece (50) onto which a high hardness material (60) is applied to enhance its wear resistance.
  • the material serving as the mold (10), seen in Figure 1 is used to obtain the shell surface of the mold (40).
  • the material serving as the mold (10) becomes a mold by filling the void formed by melting during production with molten metal.
  • the material serving as the mold (10) is not melted and is used for surface formation purposes.
  • the material serving as the mold (10) is preferably made of polystyrene, but can also be made of wood or similar materials.
  • the deposition head (20) seen in Figure 1 deposits filling material (30) by layer deposition method onto the material serving as the mold (10) at a certain temperature.
  • the filling material (30) is in a fluid state in the deposition head and solidifies quickly on the material serving as the mold (10). Therefore, the process is facilitated. Curing takes place quickly in the air.
  • the tie piece (50) is formed by layering the filling material (30) onto the shell surface of the mold (40) at a certain temperature using the deposition head (20) by layer deposition method, as seen in Figure 2.
  • the material (60) with high hardness applied onto the mold (70) surface consisting of the shell surface of the mold (40) and the tie piece (50), seen in Figure 3, is preferably a polymer to prevent wear during the sheet metal forming process.
  • the material (60) mentioned in the alternative structure of the invention can also be a ceramic or metal material.
  • the process steps of the concrete mold production method subject to the invention are as follows: a) Preparation of the material serving as the mold (10) by processing it according to the model mold surface, b) Formation of the shell surface of the mold (40) by layering the filling material (30) that comes out of the deposition head (20) onto the material serving as the mold (10) using the layer deposition method, c) Formation of the tie piece (50) and obtaining the mold (70) by layering the filling material (30) by layer deposition method onto the shell surface of the mold (40) using the deposition head (20), d) Application of a material (60) with high hardness onto the surface of the mold (70) to prevent wear during the sheet metal forming process, e) Machining the mold (70) with chip removal to achieve high surface tolerance.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

The invention relates to a concrete mold system and production method that enables the flexible implementation of mold designs for sheet metal forming molds for automotive and composite parts molds for defense industry, which are limited by casting constraints, using additive manufacturing.

Description

CONCRETE MOLD SYSTEM AND PRODUCTION METHOD
Technical Field
The invention relates to a concrete mold system and production method used in the manufacture of automotive sheet metal forming molds and composite part molds in the defense industry.
The invention is particularly related to a concrete mold (formwork) system and production method that enables flexible implementation of mold designs that are limited due to casting constraints and reduces mold costs through incremental manufacturing.
Known State of the Art
Sheet metal molds in the automotive industry are generally made using traditional casting methods with cast iron material.
In the current technique, the casting time in traditional casting methods takes a long time due to factors such as cooling. However, voids (cavities) that may occur during casting cause all the material to become scrap. Due to some constraints in the casting method, the mold geometry is limited accordingly. Especially in the molds that produced for low parts, the cost remains at a very high level. Additionally, in the current mold production process, styrofoam melts due to the heat generated during the process. The resulting styrofoam melting also causes air pollution. Furthermore, deposition heads are not used in the casting method and the mold production is not carried out by layering the casting material. As a result, there is a risk of voids in the mold. The mentioned deposition heads are used in the fields of concrete and architecture. Therefore, there is a need for a system and method in the known state of the art that eliminates the problems encountered in traditional casting methods.
The document numbered EP1794338B1 can be cited as an example of the state of the art in the research conducted in the literature The mentioned document relates to a method for producing automotive components. In the invention, a continuous casting machine is used to cast an aluminum alloy in a flat plate form to produce aluminum vehicle structural parts or components.
As a result, the existence of the aforementioned problems and the inadequacy of existing solutions have made it necessary to make a development in the relevant technical field.
Objective of the Invention
The present invention relates to a concrete mold system and production method that eliminates the disadvantages mentioned above and brings new advantages to the relevant technical field.
The main object of the invention is to provide a concrete mold system and production method that enables flexible implementation of mold designs that are limited due to casting constraints in the manufacture of automotive sheet metal forming molds and molds producing composite parts in the defense industry.
The object of the invention is to prevent styrofoam melting in productions, since there is no heat during the process, and to ensure rapid curing of the concrete-polymer mixture material with air in the process.
Another object of the invention is to reduce mold costs.
Another object of the invention is to ensure that the mold becomes immediately usable after production, since there is no cooling time in mold production as in the casting method.
Another object of the invention is to ensure that the mold production is carried out with the layering method of the filling material at a certain temperature through the deposition head and eliminate the risk of voids.
To achieve all the objectives stated above and those that can be inferred from the detailed description, the invention is a concrete mold system used in the manufacture of automotive sheet metal forming molds and composite part molds in the defense industry. The system includes:
A material that will serve as the mold and is processed according to the mold surface. A deposition head that deposits filling material by the layer deposition method at the certain temperature onto the material that will serve as the mold. A shell surface of the mold formed by the deposition head depositing the filling material onto the material serving as the mold.
The tie piece (50) formed by deposition filling material (30) at a certain temperature onto the shell surface of the mold (40) using the deposition head (20) by layer deposition method,
A material with high hardness applied onto surface of the mold consisting of the shell surface of the mold and tie piece, which enhances its wear resistance.
The invention is also a concrete mold production method used in the manufacture of automotive sheet metal forming molds and composite part molds in the defense industry. The method includes the following steps: a) Preparation of the material serving as the mold by processing it according to the mold model surface, b) Formation of the shell surface of the mold by layering the filling material that comes out of the deposition head onto the material serving as a mold using layer deposition method, c) Formation of the tie piece and obtaining the mold by layering the filling material by layer deposition method onto the shell surface of the mold using the deposition head, d) Application of a material with high hardness onto the surface of the mold to prevent wear during the sheet metal forming process.
The structural and characteristic features of the invention and all its advantages will be understood more clearly through the detailed description provided with the figures and references to these figures. Therefore, the evaluation should be made taking into account these figures and the detailed description.
Figures to Help Understand the Invention
Figure 1 : A representative view of the concrete mold system subject to the invention.
Figure 2: A representative view of the spring structures in the concrete mold system subject to the invention.
Figure 3: A representative view of the mold in the concrete mold system subject to the invention. Explanation of Part References
10. Material serving as the mold
20. Deposition head
30. Filling material
40. Shell surface of the mold
50. Tie piece
60. Material
70. Mold
Detailed Description of the Invention
In this detailed description, preferred alternatives of the concrete mold system and method subject to the invention are explained only for a better understanding of the subject matter and without creating any limiting effect.
The invention is related to a concrete mold system used in the manufacture of automotive sheet metal forming molds and composite part molds in the defense industry. The concrete mold system in its most basic form comprises: a material serving as the mold (10), which is processed according to the mold surface; a deposition head (20) that deposits filling material (30) layer by layer onto the material serving as the mold (10) at a certain temperature; a shell surface of the mold (40) formed by the deposition head (20) depositing the filling material (30) onto the material serving as the mold (10); a tie piece (50) formed by layering the filling material (30) onto the shell surface of the mold (40) at a certain temperature using the deposition head (20); and a mold (70) surface consisting of the shell surface of the mold (40) and the tie piece (50) onto which a high hardness material (60) is applied to enhance its wear resistance.
In the concrete mold system subject to the invention, the material serving as the mold (10), seen in Figure 1 , is used to obtain the shell surface of the mold (40). In the current technique, the material serving as the mold (10) becomes a mold by filling the void formed by melting during production with molten metal. In our invention, the material serving as the mold (10) is not melted and is used for surface formation purposes. The material serving as the mold (10) is preferably made of polystyrene, but can also be made of wood or similar materials.
The deposition head (20) seen in Figure 1 deposits filling material (30) by layer deposition method onto the material serving as the mold (10) at a certain temperature. The filling material (30) is in a fluid state in the deposition head and solidifies quickly on the material serving as the mold (10). Therefore, the process is facilitated. Curing takes place quickly in the air.
The tie piece (50) is formed by layering the filling material (30) onto the shell surface of the mold (40) at a certain temperature using the deposition head (20) by layer deposition method, as seen in Figure 2.
The material (60) with high hardness applied onto the mold (70) surface consisting of the shell surface of the mold (40) and the tie piece (50), seen in Figure 3, is preferably a polymer to prevent wear during the sheet metal forming process. The material (60) mentioned in the alternative structure of the invention can also be a ceramic or metal material.
The process steps of the concrete mold production method subject to the invention are as follows: a) Preparation of the material serving as the mold (10) by processing it according to the model mold surface, b) Formation of the shell surface of the mold (40) by layering the filling material (30) that comes out of the deposition head (20) onto the material serving as the mold (10) using the layer deposition method, c) Formation of the tie piece (50) and obtaining the mold (70) by layering the filling material (30) by layer deposition method onto the shell surface of the mold (40) using the deposition head (20), d) Application of a material (60) with high hardness onto the surface of the mold (70) to prevent wear during the sheet metal forming process, e) Machining the mold (70) with chip removal to achieve high surface tolerance.

Claims

CLAIMS A concrete mold system used in the production of sheet metal forming molds for automotive and the production of composite parts molds for defense industry, characterized by comprising:
The material serving as the mold (10), which is processed according to the model mold surface,
The deposition head (20) that layers filling material (30) onto the material serving as the mold (10) using the layer deposition method at a certain temperature,
The shell surface of the mold (40), which is formed by the deposition head (20) layering filling material (30) onto the material serving as the mold (10), The tie piece (50) formed by deposition filling material (30) at a certain temperature onto the shell surface of the mold (40) using the deposition head (20) by layer deposition method, a material (60) with high hardness applied onto surface of the mold (70) consisting of the shell surface of the mold (40) and the tie piece (50), which enhances its wear resistance. The concrete mold production system in according the claim 1 , characterized in that; the material serving as the mold (10) is made of styrofoam, wood or similar materials. A concrete mold production method used in the production of sheet metal forming molds for automotive and the production of composite parts molds for defense industry, characterized by comprising: a) Preparation of the material serving as the mold (10) by processing it according to the model mold surface, b) Formation of the shell surface of the mold (40) by layering the filling material (30) that comes out of the deposition head (20) onto the material serving as the mold (10) using the layer deposition method, c) Formation of the tie piece (50) and obtaining the mold (70) by layering the filling material (30) by layer deposition method onto the shell surface of the mold (40) using the deposition head (20), d) Application of a material (60) with high hardness onto the surface of the mold (70) to prevent wear during the sheet metal forming process. The concrete mold production method in according the claim 3, characterized in that; the material (60) applied onto the surface of the mold (70) in step (d) is a polymer. The concrete mold production method in according the claim 3, characterized in that; the material (60) applied onto the surface of the mold (70) in step (d) is a ceramic or metal material. The concrete mold production method in according the claim 3, characterized by comprising; the step of machining the mold (70) with chip removal to achieve high surface tolerance after step (d).
PCT/TR2023/050599 2022-08-10 2023-06-20 Concrete mold system and production method WO2024035366A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR2022/012636A TR2022012636A2 (en) 2022-08-10 2022-08-10 Concrete formwork system and production method
TR2022/012636 2022-08-10

Publications (1)

Publication Number Publication Date
WO2024035366A1 true WO2024035366A1 (en) 2024-02-15

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PCT/TR2023/050599 WO2024035366A1 (en) 2022-08-10 2023-06-20 Concrete mold system and production method

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WO (1) WO2024035366A1 (en)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4231982A (en) * 1975-05-20 1980-11-04 Ab Volvo Method for the production of tools for deep drawing, moulding, extruding and the like
US20040134588A1 (en) * 2002-11-19 2004-07-15 Andreas Gerken Method for the manufacture of a molded body firmly bonded to a grained or structured molded skin and a device for performing the method
WO2017210509A1 (en) * 2015-06-05 2017-12-07 Collider, Inc. Apparatus and method for hybrid manufacturing

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4231982A (en) * 1975-05-20 1980-11-04 Ab Volvo Method for the production of tools for deep drawing, moulding, extruding and the like
US20040134588A1 (en) * 2002-11-19 2004-07-15 Andreas Gerken Method for the manufacture of a molded body firmly bonded to a grained or structured molded skin and a device for performing the method
WO2017210509A1 (en) * 2015-06-05 2017-12-07 Collider, Inc. Apparatus and method for hybrid manufacturing

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Publication number Publication date
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