JP3187896B2 - Manufacturing method of press-type combined model and die material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a press-type model and a mold material. More specifically, the present invention relates to a method for manufacturing a model that can be used as a model for casting or copying, a press die for performing bending, deep drawing, overhanging, and the like, and a material for the die.

[0002]

2. Description of the Related Art Castings are generally made by pouring a molten metal into a sand mold. A model is required to make this sand mold. This model is a model of which various types are known, but which can usually be separated into vertically divided halves. This model is made from materials such as wood, clay, and wax. Also,
After pouring the molten metal into the sand mold, the casting is cooled and shrunk, so the model is made larger by the size considering this shrinkage.

On the other hand, a die for drawing having a complicated curved surface such as an automobile body is often processed by a milling machine by copying and manufactured. The model that is a sample of the copying used in this processing has dimensions close to the shape of the final product. In that sense, the model used at this time cannot be shared unlike the model for casting. At the time of this milling process, a cutter mark and a feed mark are attached to the surface of the mold, and therefore, after the milling process, it is necessary to polish manually or by copying.

[0004] For example, mufflers for automobiles, motorcycles, etc. are made of sheet metal due to their thin wall thickness, and their center lines are complex curves derived from experiments and theory from the relationship between engine combustion and exhaust. It is elongated and its cross-sectional structure is not uniform. In order to manufacture this muffler, in the case of mass production, a mold is made, a half muffler is made by drawing with this mold, and this is joined and welded.

[0005] However, in the case of trial production or small-scale production, processing using a mold requires a large number of steps, and there is a problem in terms of processing time and cost. That is, preparing the mold requires time and cost for processing the mold first. Therefore,
Usually, a wooden mold is made, and a molten metal such as aluminum, zinc, casting or the like is poured into the wooden mold to make a desired product. This method has problems such as a large number of processing steps, such as a need to consider the shrinkage of the casting, and the need to remove burrs after casting, and a long processing time.

That is, since the above-mentioned muffler and the like extend in a complicated curve and have a non-uniform cross-sectional shape, the desired accuracy can be easily reproduced in consideration of shrinkage of a casting and a shape error of a sand mold. I can't do it, and there are many man-hours for that.

[0007]

In recent years, with the sophistication of life, multi-product small-quantity production has been increasing, mainly for consumables. In this multi-product small-quantity production, it is better to reduce the processing requiring a mold as much as possible for the reasons described above. This is because, in the case of mass production, the depreciation cost per piece is low, which is not a problem. However, in the case of small-volume production, the cost is high and the production cost is improved.

In order to perform small-volume production and high-precision machining with a muffler such as that described above, it is more desirable to employ drawing or bending using a press than plastic working, that is, plastic working. In addition, it is desirable to perform processing with as few steps as possible in order to reduce the cost. The present invention has been invented in such a technical background and achieves the following objects.

It is an object of the present invention to provide a method of manufacturing a press-type model which is optimal for small-quantity production, and a material for the die.

It is another object of the present invention to provide a method of manufacturing a press die and a model which can reduce the number of sheet metal processing steps, and a die material thereof.

[0011]

The following means are employed to solve the above-mentioned problems.

The method of manufacturing the press-type combined model is as follows: a. A machining step of machining the mold to form grooves, which are edges and corners of the workpiece to be molded; b. Pouring a liquid mold material of a component comprising an adhesive and a metal powder into the groove to enhance mechanical strength over the material of the mold; c. After the mold material has solidified, a machining step of machining a necessary contour shape and leaving the mold material on the edge is performed.

It is preferable to use a material mainly composed of a synthetic resin as the material of the mold. In the mold material, it is preferable that the adhesive is an epoxy resin, the metal powder is an aluminum powder, and a ceramic powder is further added. Further, in the mold material, it is preferable that the adhesive is an epoxy resin, the metal powder is an aluminum powder, and a ceramic powder is further added.

[0014]

Embodiments of the present invention will be described below with reference to the drawings. A method of manufacturing a deep drawing die that is also used as a model for processing a flanged pipe will be described as an example. FIG. 1 shows a flanged pipe. The flanged pipe 1 includes a straight portion 2, a flange portion 3, and a bent portion 4. The wall thickness of the flanged pipe 1 is made of a steel plate of about 1 mm. After being separately made of halves of a shape cut at a plane including the center line, they are butt-joined and joined. It has been joined.

A method for manufacturing a die for deep drawing this flanged pipe 1 will be described below. First, a commercially available plate material is prepared as a model material. Dice 10
Is an artificial composition mainly composed of a synthetic resin. In this example, Sanyo Chemical Industry Co., Ltd. (Kyoto, Kyoto)
Sun module (trade name, N07V) was used.
SunModule is a sphere of polyurethane resin and phenolic resin (Micro Balloon, Sta., Ohio, USA)
ndard Co. Is a trade name of Emers
on & Cuming), a composition in which an inorganic pigment is mixed. Therefore, this material has better machinability than metals and the like, and has better mechanical strength characteristics than wood.

As shown in FIG. 2, the material of the die 10 is N
The groove 12 is cut by the end mill 11 of the C milling machine. The groove 12 cuts into a portion of the flanged pipe 1 that only contacts the seam 5 and the flange portion 3. This is because stress is concentrated on these portions when used as a deep drawing die, and therefore only these portions are replaced with the following mold material to enhance mechanical strength such as wear resistance. When the processing of the groove 12 is completed, a liquid mold material 13 composed of the following components is injected and filled into the groove 12 (see FIG. 3).

[0017]Mold material 1  a. Liquid epoxy resin (trade name-Adeka Resin EP-4530, manufactured by Asahi Denka Kogyo Co., Ltd.) 1.0 (weight ratio) b. Aluminum powder (manufactured by Nippon Sangyo Co., Ltd., particle size 300 #, trade name-ALG-300) 1.0 to 2.0 (weight ratio) c. Ceramics (Al_TwoO_Three)) Powder having a particle size of 600 # (trade name-zircon flour, manufactured by Nippon Sangyo Co., Ltd.)
Aluminum powder to improve wear resistance
Ceramic powder was mixed for the purpose. This sera
The mixed powder is a silicon dioxide type (S) other than the alumina type.
iO_Two) And other ceramics alone or in combination
Things are fine.

After the mold material 13 has hardened, it is processed by a ball end mill 14. The trajectory of the ball end mill 14 is processed into a desired shape while zigzag as shown in FIG. This tool path is automatically programmed by a CAD / CAM system. When this process is completed,
As shown in FIG. 5, the shape of the die 10 is processed. The die 10 has a high mechanical strength because the edge 15 and the corner 16 where the stress during the processing during the deep drawing of the sheet metal is concentrated are made of the mold material 13.

A punch 21 as shown in FIG. 6 is manufactured based on the same concept. That is, the edge portion 22 where the stress of the drawing process of the punch 21 is concentrated is also formed of the above-described mold material. The punch 21 is manufactured in the same process as the die 10 integrally with the punch holder 20 as in the case of the die 10. The muffler 1 is manufactured by mounting a sheet metal member W such as a steel plate, SPCC, an aluminum plate, a stainless steel plate, or a titanium plate member on the die 10 and then drawing the sheet metal member W by lowering the punch 21.

At this time, the flange portion 3 of the muffler 1 undergoes severe shrinkage flange deformation, but the material of the cylindrical portion 2 is formed by relatively easy bending deformation. However, since this severe portion, that is, the green corner, is mounted with the mold material 13 described above, it exhibits properties close to those of the mold without deformation and wear.

[Second Embodiment] The distribution ratio of the mold material in the first embodiment is as described above, but is not limited to the above ratio. The following formulation examples may be used. This mold material 2
Has low abrasion resistance because it does not contain ceramic powder, but can sufficiently withstand use.

[0022]Mold material 2  a. Liquid epoxy resin (trade name-Adeka Resin EP-4530, manufactured by Asahi Denka Kogyo Co., Ltd.) 1.0 (weight ratio) b. Aluminum powder (manufactured by Nippon Sangyo Co., Ltd., particle size 300 #, trade name: ALG-300) 1.0 to 2.0 (weight ratio) [Other Examples] The above examples are press dies for deep drawing.
Met. Also, the shape can be applied in other shapes.
FIG. 7 shows a sectional view of an aperture die according to another embodiment.
You. A wider mold material 23 is arranged around the punch 21a.
It is an example. The die 10 is also widened corresponding to the mold material 23.
The mold material 13a is arranged. This is an example
And between the parts 23 and 13a even in deep drawing
It plays the role of removing wrinkles.

Although the above embodiment is a deep drawing type,
It may be used for other processing such as bending and overhanging. Since the dimensions of the die and punch are the same as the inner and outer diameters of the product, it can be used as a model for milling a die. In the above-described embodiment, the synthetic resin is used as the material of the die and the punch. However, other materials such as synthetic wood may be used as long as the mechanical strength is good. The dies and pons and these holders may be made of different materials as shown in FIG. 7 and assembled later.

[0024]

As described above, the present invention can be used both as a model and as a press die for small-scale production. Therefore, for small-scale production of sheet metal products,
Improvements in processing accuracy and cost reduction have become possible. Also,
In addition, it is possible to process hard sheet metal such as titanium. Also, if the press material is processed by leaving the mold material at the edges and corners, the mold material is more resistant to abrasion than other parts, so the edges and corners that are most likely to wear as the press mold are less likely to wear. .

[Brief description of the drawings]

FIG. 1 is an external view showing an example of a workpiece.

FIG. 2 is a view showing a case where grooves are formed by milling for die processing.

FIG. 3 is a view showing a state in which a liquid mold material is injected into a groove.

FIG. 4 is a diagram showing a situation in which a die is being machined by an end mill.

FIG. 5 is a diagram showing an appearance of a completed die. .

FIG. 6 is an external view showing a die and a punch.

FIG. 7 is a sectional view of a deep drawing die and a punch according to another embodiment.

[Explanation of symbols]

1 ... pipe with flange, 2 ... straight line, 3 ... flange part,
4 ... Bent part, 5 ... Seam

Claims (3)

(57) [Claims] 1. A method according to claim 1, A machining step of machining the mold to form grooves, which are edges and corners of the workpiece to be molded; b. The groove has a greater mechanical strength than the material of the mold.
Pouring a liquid mold material of a component consisting of an adhesive and a metal powder for c. And forming a necessary contour shape after the mold material is solidified , and leaving the mold material at the edges and corners . 2. A press-type combined model according to claim 1 .
A molding method , wherein the material of the mold is mainly composed of a synthetic resin, the mold material, the adhesive is an epoxy resin,
Metal powder consists of aluminum powder, and ceramic powder
A method for producing a press-type combined model, characterized by adding powder . 3. A press-type combined model according to claim 1 .
A mold material used in a manufacturing method, wherein the mold material is an epoxy resin, the metal powder is an aluminum powder, and a ceramic powder is further added. Mold material.