US20040238146A1 - Method of manufacturing dies and molds by melting-spray - Google Patents
Method of manufacturing dies and molds by melting-spray Download PDFInfo
- Publication number
- US20040238146A1 US20040238146A1 US10/834,951 US83495104A US2004238146A1 US 20040238146 A1 US20040238146 A1 US 20040238146A1 US 83495104 A US83495104 A US 83495104A US 2004238146 A1 US2004238146 A1 US 2004238146A1
- Authority
- US
- United States
- Prior art keywords
- melting
- prototype
- sprayed
- spray
- die
- Prior art date
- Legal status (The legal status 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 status listed.)
- Abandoned
Links
- 239000007921 spray Substances 0.000 title claims abstract description 37
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 33
- 229910052751 metal Inorganic materials 0.000 claims abstract description 12
- 239000002184 metal Substances 0.000 claims abstract description 12
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 6
- 238000007493 shaping process Methods 0.000 claims abstract description 5
- 239000000463 material Substances 0.000 claims description 15
- 238000000034 method Methods 0.000 claims description 11
- 229910045601 alloy Inorganic materials 0.000 claims description 9
- 239000000956 alloy Substances 0.000 claims description 9
- 238000003754 machining Methods 0.000 claims description 7
- 239000000843 powder Substances 0.000 claims description 6
- 239000000919 ceramic Substances 0.000 claims description 5
- 239000010935 stainless steel Substances 0.000 claims description 5
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
- 238000005266 casting Methods 0.000 claims description 4
- 238000002844 melting Methods 0.000 claims description 4
- 230000008018 melting Effects 0.000 claims description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 3
- 229910001152 Bi alloy Inorganic materials 0.000 claims description 2
- 229910000990 Ni alloy Inorganic materials 0.000 claims description 2
- 229910001297 Zn alloy Inorganic materials 0.000 claims description 2
- 235000012239 silicon dioxide Nutrition 0.000 claims description 2
- 239000000377 silicon dioxide Substances 0.000 claims description 2
- 229910001256 stainless steel alloy Inorganic materials 0.000 claims description 2
- 238000011017 operating method Methods 0.000 abstract description 6
- 229920001971 elastomer Polymers 0.000 abstract description 3
- 239000004033 plastic Substances 0.000 abstract description 3
- 230000003362 replicative effect Effects 0.000 abstract description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- 229910001128 Sn alloy Inorganic materials 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- JWVAUCBYEDDGAD-UHFFFAOYSA-N bismuth tin Chemical compound [Sn].[Bi] JWVAUCBYEDDGAD-UHFFFAOYSA-N 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000007429 general method Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000004904 shortening Methods 0.000 description 2
- 229920002379 silicone rubber Polymers 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000011812 mixed powder Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000010076 replication Effects 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
- B22D23/003—Moulding by spraying metal on a surface
Definitions
- the present invention relates to a method of manufacturing a die and mold used for shaping plastic or metal.
- the basic method of manufacturing a die and mold by melting-spray has a fast manufacturing speed and a low cost.
- a melting-sprayed prototype is generally replicated directly from an original prototype.
- a silicon rubber die is first reproduced from the prototype, and then the melting-sprayed prototype is replicated within the silicon rubber die.
- a melting-spray layer then is formed on the surface of the melting-sprayed prototype, reinforced and finally removed.
- a metal die or mold can be obtained, as described in the 6 th International Tooling Conference Key Note Presentations, Karlstad University 10-13 Sep. 2002 (www.itc 2002.kau.se).
- FIG. 1 is a process flow chart of the conventional method of manufacturing a metal die or mold by melting spray
- FIG. 2 is a process flow chart of the method according to this invention.
- the present invention provides a method of manufacturing die and mold by melting-spray, in which there is no need for the process of replicating a melting-sprayed prototype from the initial prototype, or from a rubber die which is previously reproduced from the prototype. On the contrary, in the present invention the melting-sprayed prototype can be directly manufactured to shorten the overall operating procedure.
- the invention provides a method of manufacturing die and mold by the melting-spray process, including the following steps: (1) directly manufacturing a melting-sprayed prototype; (2) forming a melting-spray layer on the surface of the melting-sprayed prototype; (3) reinforcing the melting-spray layer; and (4) removing the melting-sprayed prototype and then obtaining the die or mold.
- the invention is further characterized in that the melting-sprayed prototype is made by removing material through machining, or by material-accumulated shaping.
- the material of the melting-sprayed prototype may be metal, ceramic powder or mixed powder of both.
- the material for forming the melting-spray layer may be carbide alloy or wear resistant metal, and the material for reinforcing the melting-spray layer may be casting alloy.
- the ceramic powder used by the melting-sprayed prototype may be alumina or silicon dioxide; the material for forming the melting-spray layer may be tungsten carbide alloy, stainless steel or nickel alloy, and the material used for reinforcement may be bismuth alloy or zinc alloy.
- the operating procedure of the present invention is shortened and thus has the following advantages: (1) the speed of manufacturing the die or mold is increased, because the shortening of overall operating procedure reduces the time for manufacturing the die or mold; (2) the cost is lowered due to eliminating the need for using the prototype and the rubber die, and thus the material for manufacturing the die or mold and the labor cost are reduced; (3) the precision of the manufacture of the die or mold is improved, because the shortening of the operating procedure eliminates the precision loss caused by replication during the die manufacturing.
- a metallic copper powder and binding agent are mixed together and agitated to be uniform, following by being poured in a pouring frame; and then waiting until the uniform mixture in the pouring frame is solidified to the blank whose shape can be fixed.
- Tungsten carbide alloy powder is melting-sprayed on the surface of the melting-sprayed prototype, forming a tungsten carbide alloy layer with the thickness of about 0.3 mm.
- Melting-sprayed layer is reinforced by the use of bismuth-tin alloy casting.
- a cooling pipeline may be provided in the reinforced part.
- the melting-spray prototype is not finished by piling-up and accumulating material on a base plate until the desired shape of the prototype is formed. After preheating, the surface of the melting-spray prototype is melting-sprayed, thereby forming the desired melting-spray layer.
- the melting-sprayed layer is reinforced by the use of bismuth-tin alloy casting.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
A method of manufacturing die and mold by melting-spray relates to a method of manufacturing die and mold used for plastic or metal shaping, in which there is no need for the operating procedure of replicating a melting-sprayed prototype from a prototype or from a rubber die which is reproduced from the prototype. The present invention includes the following steps: (1) directly manufacturing the melting-sprayed prototype; (2) forming a melting-spray layer on the surface of the melting-sprayed prototype; (3) reinforcing the melting-spray layer; and (4) removing the melting-sprayed prototype and then obtaining the die or mold. With this invention, the fast manufacturing speed, the low cost and the improved precision are obtained, and the existent operating procedure for manufacturing die and mold by melting-spray is shortened, thereby it is suitable for manufacturing die and mold used for plastic or metal shaping.
Description
- This application claims priority to China Patent Application No. 03119035.9, entitled “Method of Manufacturing Die and Mould by Melting Spray”, to Zhang, et al., filed on 5 May 2003, and the specification thereof is incorporated herein by reference.
- 1. Field of the Invention (Technical Field)
- The present invention relates to a method of manufacturing a die and mold used for shaping plastic or metal.
- 2. Background Art
- The basic method of manufacturing a die and mold by melting-spray, such as thermal spray, has a fast manufacturing speed and a low cost. In current melting-spray techniques, a melting-sprayed prototype is generally replicated directly from an original prototype. Alternatively, a silicon rubber die is first reproduced from the prototype, and then the melting-sprayed prototype is replicated within the silicon rubber die. A melting-spray layer then is formed on the surface of the melting-sprayed prototype, reinforced and finally removed. As a result, a metal die or mold can be obtained, as described in the 6 th International Tooling Conference Key Note Presentations, Karlstad University 10-13 Sep. 2002 (www.itc 2002.kau.se).
- The “Sprayform Tooling Process.” A method for manufacturing a metal die or mold by melting-spay is disclosed in Chinese Patent No. 9911649.0, in which a metal die or mold with high quality and durability can be made by changing the material of the melting-sprayed prototype, followed by changing the material of the melting-sprayed layer. However, a prototype still must be made first to replicate a melting-sprayed prototype from the prototype.
- The accompanying drawings, which are incorporated into and form a part of the specification, illustrate several embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating a preferred embodiment of the invention and are not to be construed as limiting the invention. In the drawings:
- FIG. 1 is a process flow chart of the conventional method of manufacturing a metal die or mold by melting spray; and
- FIG. 2 is a process flow chart of the method according to this invention.
- The present invention provides a method of manufacturing die and mold by melting-spray, in which there is no need for the process of replicating a melting-sprayed prototype from the initial prototype, or from a rubber die which is previously reproduced from the prototype. On the contrary, in the present invention the melting-sprayed prototype can be directly manufactured to shorten the overall operating procedure.
- The invention provides a method of manufacturing die and mold by the melting-spray process, including the following steps: (1) directly manufacturing a melting-sprayed prototype; (2) forming a melting-spray layer on the surface of the melting-sprayed prototype; (3) reinforcing the melting-spray layer; and (4) removing the melting-sprayed prototype and then obtaining the die or mold.
- According to general methods of manufacturing die and mold by melting-spray, the invention is further characterized in that the melting-sprayed prototype is made by removing material through machining, or by material-accumulated shaping.
- According to the inventive method of manufacturing die and mold by melting-spray, the material of the melting-sprayed prototype may be metal, ceramic powder or mixed powder of both.
- According to the inventive method of manufacturing die and mold by melting-spray, the material for forming the melting-spray layer may be carbide alloy or wear resistant metal, and the material for reinforcing the melting-spray layer may be casting alloy.
- According to the inventive method of manufacturing die and mold by melting-spray, the ceramic powder used by the melting-sprayed prototype may be alumina or silicon dioxide; the material for forming the melting-spray layer may be tungsten carbide alloy, stainless steel or nickel alloy, and the material used for reinforcement may be bismuth alloy or zinc alloy.
- Compared with the conventional method of manufacturing die and mold by melting-spray, the operating procedure of the present invention is shortened and thus has the following advantages: (1) the speed of manufacturing the die or mold is increased, because the shortening of overall operating procedure reduces the time for manufacturing the die or mold; (2) the cost is lowered due to eliminating the need for using the prototype and the rubber die, and thus the material for manufacturing the die or mold and the labor cost are reduced; (3) the precision of the manufacture of the die or mold is improved, because the shortening of the operating procedure eliminates the precision loss caused by replication during the die manufacturing.
- Embodiment 1
- (1) A metallic copper powder and binding agent are mixed together and agitated to be uniform, following by being poured in a pouring frame; and then waiting until the uniform mixture in the pouring frame is solidified to the blank whose shape can be fixed.
- (2) Removal-type machining is applied to the blank, according to the desired shape of the prototype, to obtain the melting-spray prototype. After preheating, the surface of the melting-spray prototype can be melting-sprayed, thereby forming the melting-spray layer with the desired performances.
- (3) Tungsten carbide alloy powder is melting-sprayed on the surface of the melting-sprayed prototype, forming a tungsten carbide alloy layer with the thickness of about 0.3 mm.
- (4) Melting-sprayed layer is reinforced by the use of bismuth-tin alloy casting. To improve the effect of cooling, a cooling pipeline may be provided in the reinforced part.
- (5) The melting-sprayed prototype is broken and separated from the melting-spray layer, thereby yielding the die or mold which has the surface of tungsten carbide alloy. Sequential finish machining can be carried out by the use of general methods, such as machining.
- Embodiment 2
- (1) An alumina powder and binding agent are mixed together and agitated to a uniform mixture.
- (2) Through an extrusion device, the melting-spray prototype is not finished by piling-up and accumulating material on a base plate until the desired shape of the prototype is formed. After preheating, the surface of the melting-spray prototype is melting-sprayed, thereby forming the desired melting-spray layer.
- (3) Stainless steel powder is melting-sprayed on the surface of the melting-sprayed surface, and a stainless steel layer with the thickness of about 0.5 mm is formed.
- (4) With the same method as that of embodiment 1 above, the melting-sprayed layer is reinforced by the use of bismuth-tin alloy casting.
- (5) The melting-sprayed prototype is broken and separated from the melting-spray layer, so that a die or mold having a surface of stainless steel is obtained. Sequential finish machining can be carried out by the use of generally known methods, such as machining.
Claims (6)
1. A method of manufacturing die or mold by a melting-spray process, comprising:
directly manufacturing a melting-sprayed prototype;
forming a melting-spray layer on the surface of the melting-sprayed prototype;
reinforcing the melting-spray layer; and
removing the melting-sprayed prototype and then obtaining the die or mold.
2. The method of manufacturing die or mold according to claim 1 , characterized in that the melting-sprayed prototype is manufactured by removal-type machining,
3. The method of manufacturing die or mold according to claim 1 , characterized in that the melting-sprayed prototype is manufactured by material-accumulated shaping.
4. A method of manufacturing die and mold according to claim 1 , characterized in that the material of the melting-sprayed prototype is selected from the group consisting of metal, ceramic power, and a powder of mixed metal and ceramic.
5. A method of manufacturing die and mold according to claim 4 , characterized in that the material for forming the melting spray is selected from the group consisting of carbide alloy and wear resistant metal, and the material for reinforcing the melting spray layer comprises casting alloy.
6. A method of manufacturing die and mold according to claim 5 , wherein the ceramic power used in the melting-sprayed prototype is selected from the group comprising alumina and silicon dioxide, the material for forming the melting-spray layer is selected from the group comprising tungsten carbide alloy, stainless steel and nickel alloy, and the material for reinforcing is selected fro the group comprising bismuth alloy and zinc alloy.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB031190359A CN100413638C (en) | 2003-05-05 | 2003-05-05 | Method of making mold by fusion injection |
| CN03119035.9 | 2003-05-05 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20040238146A1 true US20040238146A1 (en) | 2004-12-02 |
Family
ID=28684386
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US10/834,951 Abandoned US20040238146A1 (en) | 2003-05-05 | 2004-04-28 | Method of manufacturing dies and molds by melting-spray |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US20040238146A1 (en) |
| CN (1) | CN100413638C (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20040011495A1 (en) * | 2000-05-24 | 2004-01-22 | Jonathon Fischers | Mold material processing device, method and apparatus for producing same |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112795813B (en) * | 2021-01-06 | 2021-12-21 | 中南大学 | A kind of additive manufacturing method of high hardness zinc alloy mold blank |
| CN113172728B (en) * | 2021-04-21 | 2022-07-19 | 连云港东睦新材料有限公司 | Method for duplicating parts from original parts by adopting powder injection molding |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3683722A (en) * | 1969-10-09 | 1972-08-15 | Edward Alexander Pears | Press tools and dies |
| US4231982A (en) * | 1975-05-20 | 1980-11-04 | Ab Volvo | Method for the production of tools for deep drawing, moulding, extruding and the like |
| US5817267A (en) * | 1995-11-13 | 1998-10-06 | General Magnaplate Corporation | Fabrication of tooling by thermal spraying |
| US6447704B1 (en) * | 2000-05-23 | 2002-09-10 | Gmic, Corp. | Thermal-sprayed tooling |
| US6517773B1 (en) * | 1999-09-23 | 2003-02-11 | Innovative Technology Licensing, Llc | Direct metal fabrication of parts with surface features only |
| US6800234B2 (en) * | 2001-11-09 | 2004-10-05 | 3M Innovative Properties Company | Method for making a molded polymeric article |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1093452C (en) * | 1999-04-27 | 2002-10-30 | 张海鸥 | Smelting-ejecting technology for manufacturing metallic mould |
-
2003
- 2003-05-05 CN CNB031190359A patent/CN100413638C/en not_active Expired - Fee Related
-
2004
- 2004-04-28 US US10/834,951 patent/US20040238146A1/en not_active Abandoned
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3683722A (en) * | 1969-10-09 | 1972-08-15 | Edward Alexander Pears | Press tools and dies |
| US4231982A (en) * | 1975-05-20 | 1980-11-04 | Ab Volvo | Method for the production of tools for deep drawing, moulding, extruding and the like |
| US5817267A (en) * | 1995-11-13 | 1998-10-06 | General Magnaplate Corporation | Fabrication of tooling by thermal spraying |
| US6517773B1 (en) * | 1999-09-23 | 2003-02-11 | Innovative Technology Licensing, Llc | Direct metal fabrication of parts with surface features only |
| US6447704B1 (en) * | 2000-05-23 | 2002-09-10 | Gmic, Corp. | Thermal-sprayed tooling |
| US6800234B2 (en) * | 2001-11-09 | 2004-10-05 | 3M Innovative Properties Company | Method for making a molded polymeric article |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20040011495A1 (en) * | 2000-05-24 | 2004-01-22 | Jonathon Fischers | Mold material processing device, method and apparatus for producing same |
| US7044191B2 (en) * | 2000-05-24 | 2006-05-16 | Mold-Masters Limited | Mold material processing device, method and apparatus for producing same |
Also Published As
| Publication number | Publication date |
|---|---|
| CN100413638C (en) | 2008-08-27 |
| CN1450194A (en) | 2003-10-22 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AS | Assignment |
Owner name: HUAZHONG UNIVERSITY OF SCIENCE & TECHNOLOGY, CHINA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ZHANG, HAIOU;WANG, GUILAN;REEL/FRAME:014921/0734 Effective date: 20040618 |
|
| STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |