CN108034944B - 一种烧结永磁铁氧体磁体模具下冲的制作方法 - Google Patents

一种烧结永磁铁氧体磁体模具下冲的制作方法 Download PDF

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CN108034944B
CN108034944B CN201711219670.2A CN201711219670A CN108034944B CN 108034944 B CN108034944 B CN 108034944B CN 201711219670 A CN201711219670 A CN 201711219670A CN 108034944 B CN108034944 B CN 108034944B
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陈辉明
石亮亮
卢晓强
张筝
黄华为
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Abstract

本发明涉及磁瓦成型模具技术领域,尤其涉及一种烧结永磁铁氧体磁体模具下冲的制作方法,包括以下步骤:(1)打磨毛刺,清洗预热;(2)在下冲基体上表面焊接非磁性合金层;(3)将硬质合金粉末预处理得到自熔性合金粉末;(4)在下冲基体和非磁性合金层的接触面外缘四周表面喷涂自熔性合金粉末;(6)溶覆形成超硬耐磨损层;(7)采用磁控溅射工艺在非磁性合金层的表面沉积类金刚石碳涂层。本发明有效降低冲头四周平面相应的磨损量,成倍提高模具核心零部件下冲的使用寿命;成倍的提升整套模具的耐磨损与耐腐蚀的性能,延长模具的使用寿命;工艺合理,节能降耗,成型稳定,高效高产,产品的品质优越,市场竞争优势明显。

Description

一种烧结永磁铁氧体磁体模具下冲的制作方法
技术领域
本发明涉及磁瓦成型模具技术领域,尤其涉及一种烧结永磁铁氧体磁体模具下冲的制作方法。
背景技术
永磁铁氧体干法或者湿法生产磁体的工艺过程中,成型的模具是决定最终成品的形状和磁性表现特征的基础工序。磁体在上下冲头与凹模型腔的包覆下成型,上下冲的制作对成型体的外观、成型体的成品率有极大的影响。一般的冲头与型腔的配合间隙在双边0.02~0.04mm。中国专利文献上公开了“瓦形永磁铁氧体的成型模具的下凸模”,其公告号为CN2754778Y;中国专利文献上公开了“磁瓦下凸模”,其公告号为CN201136056Y;参照上述两篇专利文献,发现传统的成型磁体模具冲头的制作,在长期的模具使用过程与生产反馈跟踪过程中,传统制作方式存在许多的缺点:下凸模基体与下凸模基体端的耐磨不导磁层之间的焊接部分外四周平面耐磨损性能差,一般不能够超出50万模的使用寿命,特别是在冲头部设计产品倒角结构时。
传统的结构设计特点是:1)冲头表面镶非磁性体;2)非磁性体的硬度在HRC20~42;3)冲头的基体材料为强磁材料。此类设计及制作工艺方式结构由于表层材料的硬度相对较低,存在产品毛坯体粘模现象,产品脱模之后表面粗糙度差,更进一步产品的成型密度分布不均匀,引起烧结后坯体开裂纹的倾向增加。中国专利文献上公开了“磁材湿压自动注料双面吸水模具”,其公告号为CN201036887Y,该实用新型采用双面的吸水方式解决冲头面的开裂问题,但是其建议是用于磁体毛坯超出15mm厚度以上。
再者,永磁铁氧体干压与湿压法生产磁体的工艺过程中,模具的使用环境恶劣、高湿、腐蚀,以及粉末颗粒细微而且硬度高,另外磁性材料磁体成型模具的特殊性,在模具下冲头(强磁材料)基材45#钢上须要焊接非磁性材料层,一般选择焊接硬度HRC40左右的无磁合金材料,但是二种焊接在一起的材料在热处理过程中容易开裂,而且热处理后基体与合金材料交界处外四周平面硬度无法提高到HRC40~55的水平,大都是HRC32左右,因为成型的粉料颗粒在0.003~0.01mm左右,所以在不断的模具成型使用过程中,由于模具配合间隙的存在,有粉末颗粒会进入模具配合缝隙,在模具使用压制约10万次左右,磨粒磨损引起的下冲与型腔的配合间隙迅速加大,使得模具精度减低,引起模具下冲报废。
发明内容
本发明为了克服传统模具下冲四周耐磨损性能差和基体与合金材料交界处外四周平面硬度无法提高的问题,提供了一种降低冲头四周平面相应的磨损量,成倍提高模具核心零部件下冲的使用寿命的烧结永磁铁氧体磁体模具下冲的制作方法。
为了实现上述目的,本发明采用以下技术方案:
一种烧结永磁铁氧体磁体模具下冲的制作方法,包括以下步骤:
(1)采用250目砂纸对下冲基体进行打磨毛刺,再用丙酮和无水酒精清洗,并且预热至400℃;
(2)在步骤(1)处理后的下冲基体上表面,采用氧乙炔火焰焊接非磁性合金层,再进行表面精密磨削加工,形成厚度为0.05~0.1mm的非磁性合金层,不限于下冲基体与非磁性合金层相互结合线为弧形的造型,可以为公知的磁瓦下冲,或者方块磁体、磁钢的下冲;
(3)将硬质合金粉末置于干燥箱中于110~130℃烘干,保温2h以上,得到自熔性合金粉末;
(4)采用粉末喷焊枪,嘴孔径1.9mm,采用的气泵气体压0.35Mpa,用氧乙炔火焰对下冲基体和非磁性合金层的接触面外缘四周加热到450~550℃,然后使喷嘴离工件表面120~150mm,把自熔性合金粉末均匀地喷涂于下冲基体和非磁性合金层的接触面外缘四周表面,再经过火焰熔融至表面出现镜面反光后,逐渐移动熔融位置,使自熔性合金粉末与工件母材互相熔敷,相互扩散形成牢固的结合层,熔覆过程完成后,用石棉布对工件表面进行保护保温,再冷却至室温;
(6)溶覆过程试样冷却完成后进行精密磨削,将工件磨至成品尺寸,在下冲基体和非磁性合金层的接触面外缘四周形成厚度为0.05~0.5mm的超硬耐磨损层;
(7)采用磁控溅射工艺,于80~150℃条件下在非磁性合金层的表面做离子束清洗及沉积,形成类金刚石碳涂层,增加表面涂层,可以成倍的提升整套模具的耐磨损与耐腐蚀的性能,延长模具的使用寿命。
类金刚石碳涂层的主要成分为碳,是一种兼有高硬度和优异摩擦性能的非晶体硬质薄膜,由石墨与金刚石组成。特别在无润滑剂情况下,摩擦系数也很低(µ=0.005~0.2)。涂层摩擦系数小,抗粘附性好,硬度高,耐磨性优良,可以极大的减低模具压制过程中的皂化油使用浓度与使用量。
作为优选,步骤(1)中,所述下冲基体的材料为45#钢。
作为优选,步骤(2)中,所述非磁性合金层由以下重量份的成分组成:C 1~1.5份,Cr 26~33份,Fe 2~3份,Mn 0.5~1份,Ni 2~3份和W 4~5.5份。
作为优选,步骤(3)中,所述硬质合金粉末中含有质量百分含量50%的碳化钨(WC)。
作为优选,步骤(4)中,氧乙炔火焰焊的温度控制到2100℃,氧乙炔焊接枪的移动速度控制在3mm~5mm/s。
由于WC颗粒在特定温度3500~3700℃才能够充分熔化,氧乙炔火焰焊的温度调节,控制到2100℃是关键;经过进行多次实验,不断总结发现喷涂技巧,在氧乙炔焊接枪的移动速度控制在3mm~5mm/s时,形成的超硬耐磨损层均匀并且能够充分熔化,不产生凸凹现象,同时能够提升硬质合金粉末的利用率,节约材料。
作为优选,步骤(7)中,所述类金刚石碳涂层的摩擦系数为0.05~0.2,最高耐热温度为300℃。
涂层最高耐热温度300℃,工件在涂层前运用丙酮及酒精清洗技术,然后对工件表面进行超声波再次深度清洗,同时活化工件表面,使类金刚石碳涂层与下冲基体有更好的结合力。
作为优选,所述非磁性合金层的硬度为HRC40~45,所述超硬耐磨损层的硬度为HRC55~60,所述类金刚石碳涂层的硬度为HV1500~4000。
因此,本发明具有如下有益效果:
(1)通过超硬耐磨损层设计,有效降低冲头四周平面相应的磨损量,成倍提高模具核心零部件下冲的使用寿命;
(2)通过增加表面涂层,成倍的提升整套模具的耐磨损与耐腐蚀的性能,延长模具的使用寿命;
(3)工艺合理,节能降耗,成型稳定,高效高产,产品的品质优越,市场竞争优势明显。
附图说明
图1是本发明烧结永磁铁氧体磁体模具下冲的结构示意图。
图中:下冲基体1,非磁性合金层2,超硬耐磨损层3,类金刚石碳涂层4。
具体实施方式
下面通过具体实施例,并结合附图1,对本发明的技术方案作进一步具体的说明。
在本发明中,若非特指,所有设备和原料均可从市场购得或是本行业常用的,下述实施例中的方法,如无特别说明,均为本领域常规方法。
实施例1
(1)采用250目砂纸对材质为强磁材料45#钢的下冲基体1进行打磨毛刺,再用丙酮和无水酒精清洗,并且预热至400℃;
(2)在步骤(1)处理后的下冲基体上表面,采用氧乙炔火焰焊接非磁性合金层,再进行表面精密磨削加工,形成厚度为0.05mm的非磁性合金层2,非磁性合金层由以下重量份的成分组成:C 1份,Cr 26份,Fe 2份,Mn 0.5份,Ni 2份和W 4份;
(3)将含有质量百分含量50%的碳化钨的硬质合金粉末置于干燥箱中于110℃烘干,保温2h以上,得到自熔性合金粉末;
(4)采用粉末喷焊枪,嘴孔径1.9mm,采用的气泵气体压0.35Mpa,用氧乙炔火焰对下冲基体和非磁性合金层的接触面外缘四周加热到450℃,氧乙炔火焰焊的温度控制到2100℃,氧乙炔焊接枪的移动速度控制在3mm/s,然后使喷嘴离工件表面120mm,把自熔性合金粉末均匀地喷涂于下冲基体和非磁性合金层的接触面外缘四周表面,再经过火焰熔融至表面出现镜面反光后,逐渐移动熔融位置,使自熔性合金粉末与工件母材互相熔敷,相互扩散形成牢固的结合层,熔覆过程完成后,用石棉布对工件表面进行保护保温,再冷却至室温;
(6)溶覆过程试样冷却完成后进行精密磨削,将工件磨至成品尺寸,在下冲基体和非磁性合金层的接触面外缘四周形成厚度为0.05mm的超硬耐磨损层3;
(7)采用磁控溅射工艺,于80℃条件下在非磁性合金层的表面做离子束清洗及沉积,形成类金刚石碳涂层4,其摩擦系数为0.05,最高耐热温度为300℃;
经工件硬度测试打表,测得各部件的硬度分别为:非磁性合金层的硬度为HRC40,超硬耐磨损层的硬度为HRC55,类金刚石碳涂层的硬度为HV1500。
实施例2
(1)采用250目砂纸对材质为强磁材料45#钢的下冲基体1进行打磨毛刺,再用丙酮和无水酒精清洗,并且预热至400℃;
(2)在步骤(1)处理后的下冲基体上表面,采用氧乙炔火焰焊接非磁性合金层,再进行表面精密磨削加工,形成厚度为0.1mm的非磁性合金层2,非磁性合金层由以下重量份的成分组成:C 1.5份,Cr 33份,Fe 3份,Mn 1份,Ni 3份和W 5.5份;
(3)将含有质量百分含量50%的碳化钨的硬质合金粉末置于干燥箱中于130℃烘干,保温2h以上,得到自熔性合金粉末;
(4)采用粉末喷焊枪,嘴孔径1.9mm,采用的气泵气体压0.35Mpa,用氧乙炔火焰对下冲基体和非磁性合金层的接触面外缘四周加热到550℃,氧乙炔火焰焊的温度控制到2100℃,氧乙炔焊接枪的移动速度控制在5mm/s,然后使喷嘴离工件表面150mm,把自熔性合金粉末均匀地喷涂于下冲基体和非磁性合金层的接触面外缘四周表面,再经过火焰熔融至表面出现镜面反光后,逐渐移动熔融位置,使自熔性合金粉末与工件母材互相熔敷,相互扩散形成牢固的结合层,熔覆过程完成后,用石棉布对工件表面进行保护保温,再冷却至室温;
(6)溶覆过程试样冷却完成后进行精密磨削,将工件磨至成品尺寸,在下冲基体和非磁性合金层的接触面外缘四周形成厚度为0.5mm的超硬耐磨损层3;
(7)采用磁控溅射工艺,于150℃条件下在非磁性合金层的表面做离子束清洗及沉积,形成类金刚石碳涂层4,其摩擦系数为0.2,最高耐热温度为300℃;
经工件硬度测试打表,测得各部件的硬度分别为:非磁性合金层2的硬度为HRC45,超硬耐磨损层3的硬度为HRC60,类金刚石碳涂层4的硬度为HV4000。
实施例3
(1)采用250目砂纸对材质为强磁材料45#钢的下冲基体1进行打磨毛刺,再用丙酮和无水酒精清洗,并且预热至400℃;
(2)在步骤(1)处理后的下冲基体上表面,采用氧乙炔火焰焊接非磁性合金层,再进行表面精密磨削加工,形成厚度为0.5mm的非磁性合金层2,非磁性合金层由以下重量份的成分组成:C 1.2份,Cr 30份,Fe 2.5份,Mn 0.8份,Ni 2.5份和W 5份;
(3)将含有质量百分含量50%的碳化钨的硬质合金粉末置于干燥箱中于120℃烘干,保温2h以上,得到自熔性合金粉末;
(4)采用粉末喷焊枪,嘴孔径1.9mm,采用的气泵气体压0.35Mpa,用氧乙炔火焰对下冲基体和非磁性合金层的接触面外缘四周加热到500℃,氧乙炔火焰焊的温度控制到2100℃,氧乙炔焊接枪的移动速度控制在4mm/s,然后使喷嘴离工件表面130mm,把自熔性合金粉末均匀地喷涂于下冲基体和非磁性合金层的接触面外缘四周表面,再经过火焰熔融至表面出现镜面反光后,逐渐移动熔融位置,使自熔性合金粉末与工件母材互相熔敷,相互扩散形成牢固的结合层,熔覆过程完成后,用石棉布对工件表面进行保护保温,再冷却至室温;
(6)溶覆过程试样冷却完成后进行精密磨削,将工件磨至成品尺寸,在下冲基体和非磁性合金层的接触面外缘四周形成厚度为0.25mm的超硬耐磨损层3;
(7)采用磁控溅射工艺,于100℃条件下在非磁性合金层的表面做离子束清洗及沉积,形成类金刚石碳涂层4,其摩擦系数为0.1,最高耐热温度为300℃;
经工件硬度测试打表,测得各部件的硬度分别为:非磁性合金层2的硬度为HRC42,超硬耐磨损层3的硬度为HRC58,类金刚石碳涂层4的硬度为HV2000。
本发明通过超硬耐磨损层设计,有效降低冲头四周平面相应的磨损量,成倍提高模具核心零部件下冲的使用寿命;通过增加表面涂层,成倍的提升整套模具的耐磨损与耐腐蚀的性能,延长模具的使用寿命;工艺合理,节能降耗,成型稳定,高效高产,产品的品质优越,市场竞争优势明显。
以上所述仅为本发明的较佳实施例,并非对本发明作任何形式上的限制,在不超出权利要求所记载的技术方案的前提下还有其它的变体及改型。

Claims (6)

1.一种烧结永磁铁氧体磁体模具下冲的制作方法,其特征在于,包括以下步骤:
(1)采用250目砂纸对下冲基体进行打磨毛刺,再用丙酮和无水酒精清洗,并且预热至400℃;
(2)在步骤(1)处理后的下冲基体上表面,采用氧乙炔火焰焊接非磁性合金层,再进行表面精密磨削加工,形成厚度为0.05~0.1mm的非磁性合金层;所述非磁性合金层由以下重量份的成分组成:C 1~1.5份,Cr 26~33份,Fe 2~3份,Mn 0.5~1份,Ni 2~3份和W 4~5.5份;所述非磁性合金层的硬度为HRC40~45;
(3)将硬质合金粉末置于干燥箱中于110~130℃烘干,保温2h以上,得到自熔性合金粉末;
(4)采用粉末喷焊枪,嘴孔径1.9mm,采用的气泵气体压0.35MPa,用氧乙炔火焰对下冲基体和非磁性合金层的接触面外缘四周加热到450~550℃,然后使喷嘴离工件表面120~150mm,把自熔性合金粉末均匀地喷涂于下冲基体和非磁性合金层的接触面外缘四周表面,再经过火焰熔融至表面出现镜面反光后,逐渐移动熔融位置,使自熔性合金粉末与工件母材互相熔覆,相互扩散形成牢固的结合层,熔覆过程完成后,用石棉布对工件表面进行保护保温,再冷却至室温;氧乙炔焊接枪的移动速度控制在3mm~5mm/s;
(5)熔覆过程试样冷却完成后进行精密磨削,将工件磨至成品尺寸,在下冲基体和非磁性合金层的接触面外缘四周形成厚度为0.05~0.5mm的超硬耐磨损层,所述超硬耐磨损层的硬度为HRC55~60;
(6)采用磁控溅射工艺,于80~150℃条件下在非磁性合金层的表面做离子束清洗及沉积,形成类金刚石碳涂层。
2.根据权利要求1所述的一种烧结永磁铁氧体磁体模具下冲的制作方法,其特征在于,步骤(1)中,所述下冲基体的材料为强磁材料45#钢。
3.根据权利要求1所述的一种烧结永磁铁氧体磁体模具下冲的制作方法,其特征在于,步骤(3)中,所述硬质合金粉末中含有质量百分含量50%的碳化钨。
4.根据权利要求1所述的一种烧结永磁铁氧体磁体模具下冲的制作方法,其特征在于,步骤(4)中,氧乙炔火焰焊的温度控制到2100℃。
5.根据权利要求1所述的一种烧结永磁铁氧体磁体模具下冲的制作方法,其特征在于,步骤(6)中,所述类金刚石碳涂层的摩擦系数为0.05~0.2,最高耐热温度为300℃。
6.根据权利要求1-5任一所述的一种烧结永磁铁氧体磁体模具下冲的制作方法,其特征在于,步骤(6)中,所述类金刚石碳涂层的硬度为HV1500~4000。
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