TW201325767A - Mold with complex cooling channel and manufacturing method thereof - Google Patents

Abstract

A mold and the manufacturing method thereof are provided. The method comprises steps of: providing a mold prototype; configuring a mold frame around the mold prototype; pouring a refractory material into the mold frame for forming a refractory prototype; configuring a refractory mold frame around the refractory prototype; configuring a cooling channel of the mold along a surface of the refractory prototype; casting a molten metal into the refractory mold frame; and removing the refractory prototype and the refractory mold frame.

Description

Mold with complicated cooling passage and manufacturing method thereof

The present invention relates to a mold and a method of manufacturing the same, and more particularly to a mold having a complicated cooling passage and a method of manufacturing the same.

The conventional rapid mold cooling water channel is formed by drilling a plurality of cooling water passages in the mold body, so that the cooling water can flow in the cooling water passage. The cooling water channel is limited by the development of the current drilling equipment, and only the linear cooling water channel can be drilled in the mold, so that the cooling water channel can only be applied to a mold with a simple shape. However, if the shape of the work object to be made is more complicated, the mold cavity of the mold must have multiple corners, so that the linear cooling water channel cannot follow the corner hole, so the cooling The applicability of waterways is low.

In Taiwan Patent No. 128,062, a method for forming a cooling water channel for casting a rapid mold is disclosed, which is mainly characterized in that the step of setting the ceramic core is carried out, so that the ceramic core and the ceramic which can match the shape of the cavity can be preliminarily accommodated in the mold. At the heart, then, by the implementation of the mold rinsing step, the enamel core is punched out to form a cooling water channel; due to the curved cooling water channel formed in the mold, the size and shape of the mold can be matched to form the state that can take away the most high heat, so the mold The cooling water channel can achieve high applicability and good cooling effect.

However, the curved cooling water channel of the above patent has at least two disadvantages:

1. The curved water channel cannot be set according to the curved surface of the mold. Therefore, when the patent is used for a complicated or small-sized mold (such as an optical lens or a mobile phone case), the heat dissipation is uneven, and the quality of the product is directly affected. characteristic;

2. The curved cooling water channel must be separately fabricated to complete the mold.

Furthermore, the patent fills its cooling water channel with a liquid ceramic core, which must be heated in an alkaline liquid (such as NaOH) for about 5 hours to loosen, and the loosened ceramic core can finally be washed out by high-pressure water. . It can be seen from the above that the process of the patent cooling water channel requires not only a strong alkali solution but also a long process time.

As a result of the job, the inventor, in view of the lack of the prior art, was carefully tested and researched with a perseverance spirit, and finally invented a novel mold with complicated cooling passages and a manufacturing method thereof, which will solve the above-mentioned problems. Disadvantages of the prior art are as follows.

The method of manufacturing the mold in the present invention can ensure that the cooling passage in the mold is accurately fixed along the outer shape (curved surface) of the product or a certain range of distance, so that the heat generated in the stamping or injection process can be uniformly taken away and The quality and precision of the workpiece to be formed is improved.

One of the purposes of the present invention is to provide a mold manufacturing method, the method comprising the steps of: providing a mold prototype, the mold prototype comprising a curved surface; placing a mold frame around the mold prototype; pouring a refractory material into the mold Forming and covering the mold prototype to form a refractory prototype, a surface of the refractory prototype replicating the curved surface; placing a refractory mold frame around the refractory prototype; and providing a cooling along the surface of the refractory prototype a passage; casting a molten metal into the refractory mold frame and covering the surface of the refractory prototype and the cooling passage; and removing the refractory prototype and the refractory mold frame.

Another object of the present invention is to provide a mold for forming a workpiece, comprising: a mold core, comprising a working surface, the working surface having a curved surface, wherein the mold core comprises a cooling passage pre-buried therein, and the mold The distance between the entire cooling path and the working surface is between 10 mm and 50 mm.

Another object of the present invention is to provide a mold manufacturing method comprising: providing a refractory prototype corresponding to the mold; setting a cooling passage of the mold along a surface of the refractory prototype; and arranging a circumference around the refractory prototype a refractory mold frame; casting a molten metal into the refractory mold frame; and removing the refractory prototype and the refractory mold frame.

The case can be further explained by the following detailed explanation:

The invention will be further described in detail by the following preferred embodiments and the accompanying drawings.

Please refer to the first figure, which is a workpiece prototype 10 of the first embodiment of the mold of the present invention. The workpiece prototype 10 is machined and has the same size and shape as the workpiece to be formed. Preferably, the workpiece (workpiece prototype 10) has a curved surface. The workpiece prototype 10 in this embodiment is merely an example, and the present invention is also applicable to products of various highly complex curved surfaces.

Please refer to the second figures (a)-(g), which are schematic views of the manufacturing method of the first embodiment of the mold of the present invention.

Referring to the second figure (a), the first embodiment of the present invention first makes a mold prototype 20 with a material such as gypsum, paraffin, polymer material or wood, and sets a mold frame around the mold prototype 20. 21, wherein the mold prototype 20 replicates a partial shape of the workpiece prototype 10, in particular, the surface of the mold prototype 20 replicates a curved surface of the workpiece prototype 10, and the mold prototype 20 may be a solid or hollow thin shell structure. The height of the mold frame 21 must be higher than the height of the mold prototype 20 and made of materials such as acrylic, wood or steel. Next, a high temperature resistant refractory material is poured into the space enclosed by the mold frame 21 and the upper surface of the mold prototype 20 to form a refractory prototype 22 (as shown in the second diagram (b)), wherein the refractory prototype 22 The partial shape of the workpiece prototype 10 is reproduced, and in particular, the surface of the refractory prototype 22 replicates the curved surface of the workpiece prototype 10. The refractory material is made of a material of a foundry sand mold, preferably cast sand or natural sand (for example, sea sand, mountain sand, etc.) containing a binder. Cast sand is divided into two types according to the mineral composition: 石灰 sand and non-矽 sand. Non-矽 sand includes limestone sand, zircon sand, magnesia, chromite ore, corundum sand, alumina sand (Malay sand) and olivine sand. Wait. The above-mentioned binder may be an inorganic binder such as clay, refractory clay, cement or sodium citrate, or an organic binder such as oil, starch, sugar, natural resin or synthetic resin. Different sands may also be mixed as the refractory material for a specific use.

After the refractory prototype 22 is formed, the mold frame 21 and the mold prototype 20 shown in the second figure (b) are removed (as shown in the second figure (c)). Next, a refractory plate (refractory frame) 23 is disposed around the four sides of the refractory prototype 22 (as shown in the second figure (d)). The height of the refractory plate 23 must be higher than the height of the refractory prototype 22, and is also made of the above refractory material, which may have the same composition or different composition as the refractory prototype. Thereafter, one or more metal tubes 24 are disposed along the surface of the refractory prototype 22 (as shown in the second diagram (e)). The metal tube 24 can be a plurality of parallel or disconnected tubes or a single tube. The material of the metal pipe 24 may be various metals such as copper. In addition, the metal tube 24 can be secured to a particular location above the surface of the refractory prototype 22 using any suitable fixture (e.g., wire) (not shown). Because the closer the distance between the metal tube 24 and the surface of the refractory prototype 22 is, the cooling effect of the mold is better. Therefore, it is preferable that the distance between the metal tube 24 and the surface of the refractory prototype 22 is in the range of 10 mm to 50 mm; more preferably, the metal is The distance between the tube 24 and the surface of the refractory prototype 22 is in the range of 10 mm to 20 mm. Alternatively, one or more of the metal tubes 24 may be disposed to be equal in distance from the surface of the refractory prototype 22.

It will be appreciated by those skilled in the art that the step of providing a refractory plate (refractory frame) 23 around the four sides of the refractory prototype 22 (as shown in Figure 2(d)) can be performed after the metal tube 24 is disposed.

Referring to the second drawing (f), a molten metal 25 is slowly cast along the inner wall of the refractory plate 23 into the space surrounded by the surface of the refractory plate 23 and the refractory prototype 22. The metal 25 may be a metal suitable for producing a metal mold such as steel, cast iron, or aluminum alloy. After the refractory prototype 22 and the refractory plate 23 are removed, the sand surface of the refractory prototype 22 may have unevenness. In order to make the manufactured mold more precise, it is preferably controlled by Computer Numerical Control (CNC). a surface finishing process to form a metal mold 27 having a pre-embedded cooling passage 26 (as shown in the second diagram (g)), wherein the metal mold 27 replicates a partial shape of the workpiece prototype 10, in particular, the metal mold The surface of the workpiece 27 replicates the surface of the workpiece prototype 10. It will be understood by those skilled in the art that the surface finishing process can be omitted as appropriate.

Referring to the third figure, in the manufacturing method of the first embodiment, it is preferable to fill the metal tube 24 in advance before setting one or more metal tubes 24 (as shown in the second figure (e)). Refractory sand 30. As the refractory sand 30, a material similar to the foregoing refractory material such as foundry sand or natural sand may be used, except that the refractory sand 30 filled therein does not contain a binder, that is, has no bonding property. When the metal tube 24 can withstand a lower temperature than the molten metal 25 of the metal mold 27, after casting the molten metal 25 over the refractory prototype 22 (as shown in the second diagram (f)), the metal tube 24 may be partially dissolved. In this case, the refractory sand 30 filled in the metal pipe 24 at this time helps to maintain the reserved space of the cooling passage. After the metal mold 27 is formed, only the refractory sand 30 must be poured or sucked out to present one or more cooling passages preset in the metal mold 27.

The metal mold 27 shown in the first preferred embodiment is only a lower mold (or a female mold), and a person skilled in the art can manufacture a corresponding upper mold (or a convex mold) of the lower mold according to the foregoing steps to utilize the upper mold. The workpiece is molded in the same manner as the workpiece prototype 10.

Since the metal pipe (cooling passage) of the present invention can be disposed along the curved surface of the refractory prototype, the thickness or the number of the cooling passages in a specific region can be adjusted according to the thickness of the product, so that the heat generated in the process of manufacturing the product by the mold can be used. The cooling passage is taken away, which can effectively improve the distance between the cooling pipe and the mold surface in the conventional linear drilling method, resulting in uneven cooling. Furthermore, the method of the present invention for making a mold is particularly suitable for the manufacture of precision molds for producing thick and uneven or highly complex curved products. The products of the highly complex curved surface are, for example, optical lenses, lenses, golf balls, and the like; the uneven thickness products are, for example, 3C shells (such as mobile phone cases), bicycle seat cushions, and the like. When the accuracy of the product is improved by the mold proposed in this case, the value of the product naturally increases. Furthermore, in this case, the use of refractory sand to fill the metal tube is easy to remove, so that the process of mold manufacturing can be simplified. Based on the above, the present invention can have advantages such as improvement in production efficiency, improvement in product quality, and reduction in defective rate.

Example:

A mold manufacturing method comprising: providing a mold prototype, the mold prototype comprising a curved surface; placing a mold frame around the mold prototype; pouring a refractory material into the mold frame, and covering the mold prototype, To form a refractory prototype, a surface of the refractory prototype replicates the curved surface; a refractory mold frame is disposed around the refractory prototype; a cooling passage of the mold is disposed along the surface of the refractory prototype; and a molten metal is cast And refracting the surface of the refractory prototype and the cooling passage; and removing the refractory prototype and the refractory mold frame.

2. The method of embodiment 1, before providing the mold prototype, further comprising: providing a workpiece prototype that is identical to a workpiece to be formed, the workpiece prototype having the curved surface.

3. The method of any of the preceding embodiments, further comprising: filling a refractory sand in the cooling passage.

4. The method of any of the preceding embodiments, after the refractory prototype is formed, further comprising: removing the mold frame.

5. The method of any of the above embodiments, after casting the molten metal into the refractory mold frame, further comprising: removing refractory sand in the cooling passage.

6. The method of any of the preceding embodiments, after removing the refractory prototype and the refractory mold frame, further comprising: performing a surface finishing step.

7. The method of any of the preceding embodiments, wherein the mold prototype is made of a material selected from the group consisting of gypsum, paraffin, a piece of wood, and a polymeric material.

8. The method of any of the preceding embodiments, wherein the mold prototype is a hollow thin shell structure.

9. The method of any of the preceding embodiments, wherein the mold frame is made of a mold frame material selected from the group consisting of an acrylic, a wood, and a steel.

10. The method of any of the preceding embodiments, wherein the cooling passage is disposed at a fixed distance from the surface.

The method of any of the preceding embodiments, wherein the fixed distance is a distance selected from 10 mm to 50 mm.

12. The method of any of the preceding embodiments, wherein the cooling passage is disposed in a range of distances from the surface.

13. The method of any of the preceding embodiments, wherein the distance ranges from 10 mm to 50 mm.

The method of any of the preceding embodiments, wherein the distance ranges from 10 mm to 20 mm.

15. A mold for forming a workpiece, comprising: a mold core comprising a work surface having a curved surface, wherein the mold core includes a cooling passage pre-buried therein, and the entire passage of the cooling passage The distance between the working surfaces is the same.

16. A mold for forming a workpiece, comprising: a mold core comprising a work surface having a curved surface, wherein the mold core includes a cooling passage pre-buried therein, and the entire passage of the cooling passage The distance between the working surfaces is between 10 mm and 50 mm.

17. The mold of embodiment 16 wherein the distance between the entire path of the cooling passage and the working surface is between 10 mm and 20 mm.

18. A method of manufacturing a mold comprising: providing a refractory prototype corresponding to the mold; disposing a cooling passage along the surface of the refractory prototype; placing a refractory frame around the refractory prototype; casting a molten metal into the refractory mold frame; and removing the refractory prototype and the refractory mold frame.

However, the above description is only the preferred embodiment of the present invention, and the scope of the present invention is not limited thereto, and the equivalent structural changes of the present specification and the illustrated contents are all included in the same. Within the scope of the invention, it is given to Chen Ming.

10. . . prototype

20. . . Mold prototype

twenty one. . . Die frame

twenty two. . . Refractory prototype

twenty three. . . Refractory board

twenty four. . . Metal tube

25. . . Molten metal

26. . . Cooling path

27. . . Metal mold

30. . . Refractory sand

First: a schematic diagram of a prototype of a first embodiment of the mold of the present invention;

Second Figures (a) - (g): Schematic diagrams of the method of making the first embodiment of the mold of the present invention;

Third drawing: Schematic diagram of the metal tube in the second drawing (e) of the present invention.

26. . . Cooling path

27. . . Metal mold

Claims (10)

A mold manufacturing method comprising: providing a mold prototype, the mold prototype comprising a curved surface; placing a mold frame around the mold prototype; pouring a refractory material into the mold frame and covering the mold prototype to make Forming a refractory prototype, a surface of the refractory prototype replicating the curved surface; placing a refractory mold frame around the refractory prototype; providing a cooling passage along the surface of the refractory prototype; casting a molten metal to the refractory mold frame And covering the surface of the refractory prototype and the cooling passage; and removing the refractory prototype and the refractory mold. The method of claim 1, wherein before providing the mold prototype, the method further comprises: providing a workpiece prototype completely conforming to a workpiece to be formed, the workpiece prototype having the curved surface. The method of claim 1, further comprising: filling a refractory sand in the cooling passage. The method of claim 3, after casting the molten metal into the refractory mold frame, further comprising: removing the refractory sand in the cooling passage. The method of claim 1, after removing the refractory prototype and the refractory mold frame, further comprising: performing a surface finishing step. The method of claim 1, wherein the mold prototype is made of a material selected from the group consisting of a gypsum, a paraffin, a wood, and a polymeric material. The method of claim 1, wherein the mold prototype is a hollow thin shell structure. The method of claim 1, wherein the cooling passage is disposed at a fixed distance from the surface. A mold for forming a workpiece, comprising: a mold core, comprising a working surface, the working surface having a curved surface, wherein the mold core comprises a cooling passage embedded therein, and the whole process of the cooling passage and the work The distance between the surfaces is between 10 mm and 50 mm. A mold manufacturing method comprising: providing a refractory prototype corresponding to the mold; providing a cooling passage along the surface of the refractory prototype; placing a refractory mold frame around the refractory prototype; casting a melting Metal to the refractory mold frame; and removing the refractory prototype and the refractory mold frame.