CN111452264A - 用于模具组件的经济型塑料工具型芯 - Google Patents
用于模具组件的经济型塑料工具型芯 Download PDFInfo
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Abstract
本发明公开了一种注塑成型工具组件的型芯侧部,其用于与该工具组件的型腔侧部结合使用。该型芯侧部具有以重量百分比表示的下述组分:.25至.55%的碳,.70至1.50%的锰,最多为0.80%的硅,1.40至2.00%的铬,.10至.55%的钼,最多为.040%的铝,最多为.025%的磷,最多为.20%的硫,其余量为铁和不可避免的杂质。
Description
相关申请的交叉引用
本申请是2016年2月1日提交的美国专利申请第14/998,669号的依据美国专利法35U.S.C.§120的部分继续申请。
技术领域
本发明解决了塑料工具工业中与在模具组件上提供无瑕疵的表面相关的问题,该表面在成型时与最终用户可见的零件接触。本发明还解决了为用于以十分经济的成本产出高质量的最终产品的塑料工具组件的型芯和型腔半部提供具有不同合金组分的模具材料的持续性问题。
背景技术
已发现构成塑料工具模具组件的两个半部必须在约为20英寸或更大的材料截面中具有不同的组分和操作特性,从而低成本地生产高质量的零件。具体地,塑料工具组件的型腔侧部一般来说要求为优质钢,以提供模制零件的最终无瑕疵表面。比较来说,工具组件的型芯侧部不需要像工具组件的型腔半部的标准那样严格的表面光洁度标准,但必须匹配所述型芯半部经受的严格的操作条件。
具有下述标称组分:
的标准钢材,诸如P-20,已证明对于工具组件的型腔侧部具有优异表现。然而,这种或类似的品级对于工具组件的型芯侧部中的使用来说是不经济的,因为这种钢材的工作属性实际上超过了工具组件的型芯侧部的属性需求。因此,对于如今的高成本意识环境下的零件制造商来说,为工具组件的型芯侧部使用上述品级与更低成本但是足够有效的合金相比表现出不必要的成本。由于工具零件对于零件制造商来说是高成本因素,因此存在对于一种用于塑料成型工具组件的型芯侧部的合金钢的需求,其比上述合金更便宜,但是会在与上述合金结合使用时有十分令人满意的表现,特别是在工具中具有至少20英寸(20”)的深度。
尤为重要的是,在已经通过工具组件生产了上百零件之后,形成在工具组件型腔上的表面应像炉龄开始时制造的零件一样光洁且无瑕疵。然而,无需对制成型芯侧部的钢进行像型腔侧部一样高程度的抛光,因为型芯侧部不可见。型芯侧部不要求美观优良的光洁度。
已发现,为了维持工具组件的型腔侧部的分模线(即,组件的两个半部之间的分离线),有利的是在组件的型芯侧部的分模线处具有较低的硬度。因此,当发生磨损时,在加压注射塑料之后形成的毛边不会出现在工具组件的型腔侧部上。
在解决这些问题的一种尝试中,已经将具有下述组分的钢应用于工具组件的型芯侧部:
然而,这种组分仅适用于达到约为20英寸的截面。在这种厚度之上,这种组分可能不能在深度上保持预期机械特性。具体地,在大于20英寸的厚度处,这种钢在分模线处表现出过大的硬度下降。这可能归因于对大于20英寸的零件进行淬火时的质量效应。
因此,对于注塑成型工具中截面为20英寸以上的型芯块钢材,对于塑料工具组件的型芯侧部来说需要一种新的组分,其具有20英寸以上的模具工具组件所需的所有物理或机械特性但是具有比现有材料更低的成本。
发明内容
根据本公开的一个方面,公开了一种具有型芯侧部和型腔侧部的钢制注塑工具组件。该组件的型芯侧部具有以重量百分比表示的下述组分:.25至.55%的碳,.70至1.50%的锰,最多为0.80%的硅,1.40至2.00%的铬,.10至.55%的钼,最多为.040%的铝,最多为.025%的磷,最多为.20%的硫,其余量为铁和不可避免的杂质。
根据本公开的另一个方面,公开了一种注塑成型工具组件的型芯侧部,其用于与该工具组件的型腔侧部结合使用。该型芯侧部具有以重量百分比表示的下述组分:.25至.55%的碳,.70至1.50%的锰,最多为0.80%的硅,1.40至2.00%的铬,.10至.55%的钼,最多为.040%的铝,最多为.025%的磷,最多为.20%的硫,其余量为铁和不可避免的杂质。
本公开的这些及其他方面和特征在结合附图进行阅读时将更易理解。
附图说明
图1是塑料工具组件的型芯侧部的立体图;
图2是所述塑料工具组件的型腔侧部的立体图;
图3是简化的模具组件的部分的剖视图;
图4是图3的细节4的放大图;并且
图5是塑料工具组件的型芯侧部的制造中可涉及的一系列步骤的流程图。
具体实施方式
首先参考图1,整体上用10表示塑料工具组件的型芯侧部,型芯表示为11,并且分模线平面表示为12。
接下来参考图2,整体上用20表示塑料工具组件的型腔侧部,型腔表示为21,并且分模线平面表示为22。应理解的是,当型芯侧部10和型腔侧部20成型接合时,分模线平面12和22将抵接形成分模线23(见图3),并且型芯侧部11将接收在型腔21中。
由于型芯11的尺寸略微小于型腔21的尺寸,因此将在型芯与型腔之间的空间24(见图4)中形成零件。两个半部10和20在被工业上熟知的合适工具(未示出)闭合时将会被确实地保持在固定位置。
现在具体参考图4,将看出分模线23在型芯侧部10的表面与型腔侧部20的表面接触时形成了清晰的边界线。当熔融塑料的射流在相当大的压力下被注入到成型腔体24中时,所述塑料将与型芯侧部10和型腔侧部20二者的表面接触。然而,由于型芯侧部10由比型腔侧部20的钢更软的钢形成,因此所述型芯侧部10将比型腔侧部20更早受到腐蚀。在所示实施方式中,型芯侧部10的受腐蚀区域在图4中表示为13。虽然图中示出了均匀的腐蚀深度,但是应理解某些位置可能比临近位置更软并因此使受腐蚀区域从点到点深度不规则。然而,形成型芯侧部10的钢总是比形成型腔侧部20的钢更软并因此比型腔的钢更易受腐蚀。结果,型芯侧部在多个周期之后总是会具有毛边。然而,由于模制零件的型芯侧表面对观察者不可见,因此型芯侧部10的区域13所表示的毛边在商业上是可接受的。
现在仅参考型芯10,本发明的所述型芯由具有以重量百分比表示的下述广泛组分的钢形成:
.25至.55%的碳
.70至1.50%的锰
最多为0.80%的硅
1.40至2.00%的铬
.10至.55%的钼
最多为.040%的铝
最多为.025%的磷
最多为.20%的硫
其余量为铁和不可避免的杂质
在上述范围内,以重量百分比表示的型芯10的组分可以是如下:
.30至.50%的碳
1.05至1.45%的锰
最多为0.60%的硅
1.50至2.00%的铬
.10至.45%的钼
最多为.035%的铝
最多为.020%的磷
.05至.15%的硫
其余量为铁和不可避免的杂质
在上述范围内,以重量百分比表示的型芯10的组分可以是如下:
.30至.45%的碳
1.15至1.35%的锰
最多为0.40%的硅
1.50至1.90%的铬
.10至.30%的钼
最多为.030%的铝
最多为.015%的磷
.05至.10%的硫
其余量为铁和不可避免的杂质
碳是提供所需硬度和抗磨损性所必要的。如果碳在重量上明显大于0.55%,则模具块体将表现出较低的可加工性和抛光特性。优选地,重量上最大为0.50%的碳用于确保良好的可加工性。如果使用了实际上重量小于0.25%的碳,则抗磨损性和机械特性将不适用于模具块体所经受的使用条件。优选地,重量上最小为.30%的碳用于确保可接受的抗磨损性、硬度和机械特性。最优选地,应使用重量上在0.35%至0.45%的范围内且目标是0.40%的碳。
锰对于淬透性来说是重要的,并且在炼钢工序中作为脱氧剂。其还在前述操作中用于控制硫化物。与其他合金元件组合,如果存在重量明显大于1.50%的情况,则会有存在残余奥氏体的风险。如果存在重量明显小于0.70%的锰的情况,则模具块体的淬透性将会降低。另外,为了确保对硫的控制,锰含量应为硫含量的至少20倍。锰还有助于抗磨损性,虽然与其他碳化物形成元素相比略差。优选地,锰的重量将在1.05%至1.45%的范围内,最优选重量在1.15%至1.35%的范围内。
硅在炼钢工序中专门利用其脱氧能力。如果比指定的量更多,则将具有最终产品脆化的倾向。
铬是碳化物形成、硬化以及抗磨损性所必要的。如果实际上存在重量最大为2.00%的铬,则淬火温度对于常规生产热处理工序来说将会过高。铬的重量低于指定的最小值1.40%,将会不利地影响抗磨损性。优选地,铬重量为1.50%至2.00%,最优选重量为1.50%至1.90%。
钼是有助于淬透性和抗磨损性的关键元素,因为其是强碳化物形成元素。其重量在0.10%至0.55%的范围内表现出其有益效果,但优选的是其重量保持在0.10%至0.45%的较低范围内,最优选重量在0.10%至0.30%的范围内。
铝对晶粒细化是有利的,但是在铝酸盐具有不期望的杂质的情况下会对钢质量产生不利影响。因此,重要的是在最终熔体组分中将铝的添加量减小到最大占重量的0.040%。最优选地,铝的目标重量为0.020%将实现晶粒细化。
磷会提高可加工性但是该元素在工具钢中具有不利影响,例如增大韧脆转变温度,超过了有益效果。因此,磷含量应不超过规定的重量最大值0.025%,最优选重量小于0.015%。
硫是可加工性的关键元素,并且通常认为工具钢中大于0.045%的含量将实现可接受的可加工性。然而,为了在工序中保持对硫化物的控制,有必要避免硫的含量在重量上超过0.20%。硫的重量应在0.05%至0.15%,并且最优选重量在0.05%至0.10%的范围内,目标是重量为0.07%。
重要的是,最终组分经过水淬,以实现所需操作特性。然而,型芯和型腔截面必须具有不同硬度,以确保工具组件的型芯侧部具有比型腔侧部更低的硬度。
因此,假设型芯侧部的硬度总是低于型腔侧部的硬度,则型腔侧部合适的硬度范围为277至321BHN,并且型芯侧部合适的硬度范围为269至277BHN。通过使型芯半部比型腔半部更软而在两个半部之间保持不同的硬度,维持了型腔的分模线;即,更期望型芯侧部的分模线受磨损而不是型腔侧部的分模线。因此,将在最终模制产品中产生光洁无瑕疵的型腔侧表面,从而需要最少的或不需要零件的型腔侧后成型工序。
现在参考图5,一种制造用于20英寸以上厚度的模具或模子的型芯侧部的低合金钢块体的方法如下:
通过下述步骤在电弧炉中制备钢熔体:
a.熔化含有大部分合金成分的主要钢组分,以产生适于引入到容器中的钢熔体(框202),
b.之后对一炉钢水进行加热、合金化以及精炼,以使该一炉钢水具有其最终组分(框204),
c.对齿轮进行真空脱气、铸造以及通过底部浇铸法进行浇铸,以形成铸锭(框206),
d.对铸锭进行热加工,以形成低合金模具或模子块体(框208),以及
e.之后通过水淬及回火对模具或模子块体进行热处理,以形成热加工产品(框210)。
应理解的是,在通过上述方法处理钢之后,热加工产品应在800℃与900℃之间的温度下进行奥氏体化(austenitizing)(框212),在水中进行淬火(框214),以及在500℃与700℃之间的温度下进行回火(框216)。
在所述处理之后,得到的产品将显现出主要含有贝氏体并且可能含有贝氏体与珍珠岩的混合物的微结构,其深度将大于块体厚度的四分之一。
Claims (9)
1.一种具有型芯侧部和型腔侧部的钢制注塑工具组件,所述组件的所述型芯侧部具有以重量百分比表示的下述组分:
.25至.55%的C,
.70至1.50%的Mn,
最多为0.80%的Si,
1.40至2.00%的Cr,
.10至.55%的Mo,
最多为.040%的Al,
最多为.025%的P,
最多为.20%的S,以及
其余量为Fe和不可避免的杂质。
2.根据权利要求1所述的钢制注塑工具组件,其中,所述组件的所述型芯侧部具有以重量百分比表示的下述组分:
.30至.50%的C,
1.05至1.45%的Mn,
最多为0.60%的Si,
1.50至2.00%的Cr,
最多为.10至.45%的Mo,
最多为.035%的Al,
最多为.020%的P,
.05至.15%的S,以及
其余量为Fe和不可避免的杂质。
3.根据权利要求1所述的钢制注塑工具组件,其中,所述组件的所述型芯侧部具有以重量百分比表示的下述组分:
.35至.45%的C,
1.15至1.35%的Mn,
最多为0.40%的Si,
1.50至1.90%的Cr,
.10至.30%的Mo,
最多为.030%的Al,
最多为.015%的P,
.05至.10%的S,以及
其余量为Fe和不可避免的杂质。
4.一种注塑成型工具组件的型芯侧部,其用于与所述工具组件的型腔侧部结合使用,所述型芯侧部具有以重量百分比表示的下述组分:
.25至.55%的C,
.70至1.50%的Mn,
最多为0.80%的Si,
1.40至2.00%的Cr,
.10至.55%的Mo,
最多为.040%的Al,
最多为.025%的P,
最多为.20%的S,以及
其余量为Fe和不可避免的杂质。
5.根据权利要求4所述的注塑成型工具组件的型芯侧部,其中,所述型芯侧部具有以重量百分比表示的下述组分:
.30至.50%的C,
1.05至1.45%的Mn,
最多为0.60%的Si,
1.50至2.00%的Cr,
.10至.45%的Mo,
最多为.035%的Al,
最多为.020%的P,
.05至.15%的S,以及
其余量为Fe和不可避免的杂质。
6.根据权利要求5所述的注塑成型工具组件的型芯侧部,其中,所述型芯侧部具有以重量百分比表示的下述组分:
.35至.45%的C,
1.15至1.35%的Mn,
最多为0.40%的Si,
1.50至1.90%的Cr,
.10至.30%的Mo,
最多为.030%的Al,
最多为.015%的P,
.05至.10%的S,以及
其余量为Fe和不可避免的杂质。
7.根据权利要求4所述的注塑成型工具组件的型芯侧部,其中,所述型芯侧部的深度至少为20英寸。
8.根据权利要求7所述的注塑成型工具组件的型芯侧部,其中,所述型芯侧部通过下述步骤经由在电弧炉中制备的钢熔体制备而成:
a.熔化含有大部分合金成分的主要钢组分,以产生适于引入到容器中的钢熔体,
b.之后对一炉钢水进行出钢、加热、合金化以及精炼,以使所述一炉钢水具有其最终组分,
c.对所述一炉钢水进行真空脱气、铸造以及通过底部浇铸法进行浇铸,以形成铸锭,
d.对所述铸锭进行热加工,以形成低合金模具或模子块体,以及
e.之后通过水淬及回火对所述模具或模子块体进行热处理,以形成最终热加工产品。
9.根据权利要求8所述的注塑成型工具组件的型芯侧部,其中,所述最终热加工产品随后进行:
在800℃与900℃之间的温度下进行奥氏体化,
在水中进行淬火,以及
在500℃与700℃之间的温度下进行回火,以形成主要含有贝氏体或贝氏体与珍珠岩的混合物的微结构,所述微结构的深度大于形成所述型芯侧部的所述块体的厚度的四分之一。
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CN108724620A (zh) * | 2017-04-14 | 2018-11-02 | 芬可乐父子公司 | 用于塑模和冲模套件的经济性塑料加工工具型芯 |
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