DE102018116773A1 - Method for producing a rotary punching cylinder by means of additive application of at least one punching contour - Google Patents

Abstract

In order to further simplify a method for producing a rotary punching cylinder by means of additive application of at least one punching contour with punching lines to a cylindrical punching base body in such a way that the method can be used more flexibly and the punching contour can be renewed repeatedly, individual layers of the punching contour are applied in sections by applying a metallic one Powder is generated on the curved surface of the punching body and then melted.

Description

The invention relates to a method for producing a rotary punching cylinder by means of additive application of at least one punching contour with punching lines to a cylindrical punching base body.

State of the art

To produce stamping cylinders, pins are usually formed at both ends. In addition, raceways, so-called bearer rings, can be formed from the material on the axial outside of the lateral surface. The punching lines from the cylinder are worked out on the surface of the jacket itself. Depending on the application and the material to be punched / cut, these punching lines differ in depth and geometry. The contours of the punching lines are open or closed contours and form an image of the material to be cut later.

Round steel is usually used for the production of a punching cylinder and machined by means of a lathe. First, the pins and, if necessary, the races are created or milled or turned out of the material. In a further step, the punching lines are worked out using a milling machine.

The DE 10 2014 110 632 A1 describes a method for producing punching tools in the form of punching surfaces and / or punching cylinders for a punching device, the punching tool having a base body and punching lines located thereon and the punching tool being produced at least partially by means of a 3D printing device.

The DE 10 2008 012 063 B4 relates to a method for producing a hybrid molded part which is formed in some areas by a base body which is prefabricated by machining or casting technology and which in some areas is formed by a section which is produced by a laser melting process and is generatively built onto a surface of the base body. A flat powder layer is applied to a curved surface and then selectively solidified using radiation energy.

Presentation of the invention: task, solution, advantages

The object of the invention is to simplify a process for producing a rotary punching cylinder by means of additive application of at least one punching contour with punching lines to a cylindrical punching base body and to design it in such a flexible manner that existing punching contours can be removed in a simple manner and new punching contours can be applied.

1. a) Drehen beziehungsweise Rotieren des Stanzgrundkörpers um dessen Rotationsachse, und
2. b) abschnittsweises Aufbringen eines metallischen Pulvers auf eine gekrümmte Oberfläche des Stanzgrundkörpers mittels einer Pulverbeschichtungseinheit, derart, dass ein Pulverbett mit einer gekrümmten Oberfläche erzeugt wird, und
3. c) abschnittsweises Aufschmelzen des in Schritt b) aufgebrachten metallischen Pulvers mittels eines Lasersystems zur Ausbildung einer ersten Schicht der Stanzkontur, und
4. d) translatorisches Bewegen des Stanzgrundkörpers relativ zur Pulverbeschichtungseinheit und/oder zum Lasersystem, und
5. e) wiederholen der Schritte a) bis c) zur Ausbildung weiterer Schichten der Stanzkontur.

According to the invention, a method for producing a rotary punching cylinder by means of additive application of at least one punching contour with punching lines to a cylindrical punching base body is provided, which comprises at least the following steps:

1. a) rotating or rotating the punch body around its axis of rotation, and
2. b) applying a metallic powder in sections to a curved surface of the punching base body by means of a powder coating unit, such that a powder bed is produced with a curved surface, and
3. c) partial melting of the metallic powder applied in step b) by means of a laser system to form a first layer of the punching contour, and
4. d) translational movement of the punching body relative to the powder coating unit and / or to the laser system, and
5. e) repeating steps a) to c) to form further layers of the punching contour.

According to the invention, the additive application of the stamping contour is to be understood as selective laser melting. For this purpose, a powder layer with the metallic powder is applied to the punching base body in a defined or predetermined thickness and melted by means of a laser, the individual powder particles being partially welded to one another. The powder is applied in the form of a one-component metallic powder. When melting, the material of the metallic powder changes completely into the liquid phase. Optionally, the metallic powder could also be sintered, for example pre-sintered, before and / or during the melting. The volume is created by the repeated application of powder layers and melting. According to the invention, this method is distinguished in particular from laser cladding. In laser cladding, metallic powder is sprayed onto a surface in a weld pool created by the laser using a nozzle. A weld seam is created by moving the nozzle. The volume can then be generated by repeated building.

According to the invention, in step a) the basic punch body is rotated or rotated about its longitudinal axis. The basic punch body can be continuous or sequential, that is in sections, during steps b) and c) are rotated further or rotated.

In step b), the powder is applied by means of the powder coating unit in an axis-parallel and surface-concentric manner to the punching base body on its curved surface. Step b) is carried out during the turning or during the interruption of the turning movement.

In step c), the metallic powder is melted out with a laser of the laser system in such a way that the powder particles are partially welded together. Step c) is carried out during the turning or during a brief interruption of the turning movement.

Steps a), b) and c) can be carried out parallel to one another or else sequentially, that is to say successively at repeated intervals. For example, the punching body could be rotated or rotated continuously while metallic powder was applied to its surface and melted. For this purpose, the powder coating unit and the exposure point could be arranged at a distance from one another in the circumferential direction, so that the last applied powder can be melted immediately afterwards while the punching base body is rotating and at the same time further metallic powder can already be applied to the surface of the punching base body. Alternatively, these steps could be carried out sequentially and metallic powder applied during short breaks.

Curved exposure areas are also generated with the laser system or a scanner unit assigned to the laser system. Thus, both the surface of the punching base body, the surface of the powder bed applied and the generated exposure surface are curved. A constant intensity or power is preferably provided for the exposure on the entire surface of the powder bed applied. This can be achieved, for example, by keeping the distance between the laser system or the scanner unit and the curved powder bed surface always constant.

In step d), the punching base body is changed relative to the powder coating unit and / or to the laser system and / or to the scanner unit, so that the distance between the punching base body and powder coating unit and / or the laser system and / or the scanner unit can be adapted for applying the next layer. The distance is preferably increased by the last powder layer thickness applied. For this purpose, the punching body and / or the powder coating unit and / or the laser system and / or the scanner unit can be moved or moved.

A process chamber is preferably provided for carrying out the production process, in which the punching base body is arranged. The process chamber is particularly preferably designed to be adaptive in order to be able to produce different cylinder lengths and / or diameters in the same system.

As a result of the manufacturing method according to the invention, it is no longer necessary, as in the case of methods known in the prior art, to mill out or to mill out the punching contour from the punching base body. In methods known in the prior art, the stamping base body is usually turned off in a first step, the contours of the pins and bearer rings being prepared and, if appropriate, the diameter of the stamping base body being adapted. The material is then hardened and the pins or bearer rings are ground if necessary. Only then is the punch contour created by milling on the surface of the punch body. Material of the punching base body is removed.

In contrast to this, in the method according to the invention, the punching contour is applied to the curved surface of the punching body by means of selective laser melting. It is therefore no longer necessary to mill the punch contour. It is preferably provided that in step f) after the stamping contours have been produced, they are hardened.

Furthermore, it is preferably provided that, prior to step b), sections are reduced to a defined or predetermined diameter of the punching base body by twisting off the punching body, in particular pins and / or bearer rings being formed on side regions of the punching body. The rough contour and / or the side areas are generated. The actual punching contour is not produced in this step by turning off and / or by grinding and / or milling the basic punching body.

After the layers of the punching contour have been formed, these and / or the bearer rings are preferably ground and / or sharpened.

Furthermore, it is preferably provided that before step b) a punching contour already arranged on the punching base body is turned off and / or ground. This enables a simple and very often repeatable reuse of the punching base body. Since, in contrast to the prior art, the punching contour was not generated by free milling, but by additive application, it can be removed in a simple manner before a new punching contour is created, without significantly reducing the diameter of the actual punching base body.

In step b), the metallic powder is preferably applied from a material that is different from the material of the punching base body. The punching contour can thus be formed, for example, from a higher quality steel compared to the material of the punching base body. In this way, a longer durability of the punching cylinder produced can be ensured without increasing the costs too much. Most of the volume of the punching cylinder, namely that of the punching body, can still be made of inexpensive steel.

Furthermore, the punching base body is preferably rotated or rotated continuously at least during steps b) and c). It is thus possible to carry out steps b) and c), namely the powder application and the subsequent melting, in parallel and continuously layer by layer.

In step c), at least one laser beam of the laser system is preferably aligned in the longitudinal direction of the punching base body by means of at least one scanner unit, and the power of the laser beam is regulated or adjusted. The longitudinal direction of the punching base body is to be understood as an axis-parallel movement or alignment. Several lasers and / or scanner units can optionally also be used, for example depending on the length of the punching base body. For example, two or more lasers and scanner units arranged one behind the other could be provided along the length of a punching base body, so that even long punching base bodies can be processed in a simple manner along their entire length.

In step a), the metallic powder according to steps b) and c) is preferably applied continuously in sections and then melted while the punching base body is being rotated or rotated.

According to the invention, a rotary punching cylinder with a punching contour applied to a cylindrical punching base body is further provided, the punching cylinder having been produced according to a previously described method.

According to the invention, a production system for producing a rotary punching cylinder by means of additive application of at least one punching contour to a cylindrical punching base body according to a previously described method is also provided, the manufacturing system comprising at least one powder coating unit, one laser system and one drive or several drives for rotating or rotating and translationally moving the Has punch body relative to the powder coating unit and / or to the laser system and / or to the scanner unit.

The production system preferably also has an adaptive process chamber in order to be able to produce different cylinder lengths and / or diameters in the same system.

Brief description of the drawings

The invention is explained below by way of example using preferred embodiments.

• 1: einzelne Schritte eines Verfahrens zur Herstellung eines rotativen Stanzzylinders,
• 2: eine perspektivische Ansicht eines rotativen Stanzzylinders, und
• 3: eine Herstellungsanlage zur Herstellung eines rotativen Stanzzylinders.

They show schematically:

• 1 : individual steps of a method for producing a rotary punching cylinder,
• 2 : a perspective view of a rotary punch cylinder, and
• 3 : a manufacturing plant for the manufacture of a rotary punching cylinder.

Preferred embodiments of the invention

In 1 are individual steps of a method for producing a rotary punching cylinder 100 by means of an additive application of a punching contour 10 with punch lines on a cylindrical punch body 11 shown. In step S1 becomes the cylindrical punch body 11 mechanically turned, that means the diameter is adjusted and the pins are on the lateral ends 19 and bearers 20 created.

In the next step S2 becomes the punch contour 10 using selective laser melting onto the surface 13 of the punch body 11 applied. The stamping base body 11 continuously rotated, the metallic powder 12 on the curved surface 13 of the punch body 11 by means of a powder coating unit 11 applied such that a powder bed 23 is created with a curved surface. The applied metallic powder 12 is then using a laser system 15 melted. These sub-steps can be repeated several times to add more layers of the punching contour 10 train.

In further steps S3 and S4 become the side pegs 19 and bearers 20 ground as well as the stamped contour applied 10 hardened. These two steps S3 and S4 can be carried out simultaneously or in succession.

In a next step S5 becomes the punch contour 10 or the punching lines are sharpened and / or reworked.

In 2 is a perspective view of a punch cylinder 100 with a punched contour applied according to the previously described method 10 shown. The rotary punching cylinder has on the side areas 100 spigot 19 , Bearer rings 20 and a gear 27 on.

3 shows a sectional view through a schematic diagram for a manufacturing plant 200 for the production of a rotary punching cylinder 100 , The manufacturing facility 200 has an adaptive process chamber 22 in which the punching body 11 is used.

The punching body 11 is about its longitudinal axis 21 rotated or rotated. In the meantime, in the upper area, i.e. shortly before the apex of the punching body 11 by means of a powder coating unit 14 metallic powder 12 on the curved surface 13 of the punch body 11 applied. The metallic powder 12 is applied in such a way that a powder bed 23 with a curved surface.

In the area of the apex of the basic punch body 11 is supplied with protective gas 26 using a laser system 15 and a scanner unit 18 the applied metallic powder 12 melted. For this a laser beam is used 25 by means of the laser system 15 generated and via the scanner unit 18 deflected or aligned. The individual particles of the metallic powder 12 are caused by the energy supply by means of the laser beam 25 melted and welded together. This creates a first layer 24 the punching contour 10 on the surface of the punching base body 11 generated.

The metallic powder 12 in sections on the curved surface 13 of the punch body 11 applied. In particular, the metallic powder 12 applied at the places where the punching contour 10 should arise. The process is repeated several times to add more layers (for the sake of clarity in 3 not shown) on the punch body 11 to create. This is done after a full revolution of the punch body 11 this relative to the powder coating unit 14 moved in the translatory direction. Either the basic die body can be used 11 or the powder coating unit 14 be moved. The only important thing is that the distance between the powder coating unit 14 and the punch body 11 is adjusted before applying a next layer. The powder coating unit comprises a powder inflow or a powder reservoir and a coater. For example, for the adjustment of the distance, the entire powder coating unit or only the coater can be moved in a translational direction relative to the punching base body. The distance between the punching base body is also the same 11 and the laser system 15 or the scanner unit 18 customized.

LIST OF REFERENCE NUMBERS

100

Rotary punch cylinder

200

manufacturing plant

10

dieline

11

Punch body

12

Metallic powder

13

Surface of the punch body

14

Powder coating unit

15

laser system

16

drive

17

temperature control

18

scanner unit

19

spigot

20

Schmitz rings

21

Longitudinal axis of the punch body

22

process chamber

23

powder bed

24

First layer of the punch contour

25

laser beam

26

protective gas

27

gear

28

Translatory direction

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• DE 102014110632 A1 [0004]
• DE 102008012063 B4 [0005]

Claims (11)

Method for producing a rotary stamping cylinder (100) by means of additive application of at least one stamping contour (10) with stamping lines to a cylindrical stamping base body (11), the method comprising at least the following steps: a) rotating the punching body (11) about its axis of rotation, and b) applying a metallic powder (12) in sections to a curved surface (13) of the punching base body (11) by means of a powder coating unit (14) such that a powder bed with a curved surface is produced, and c) melting the metal powder (12) applied in step b) in sections by means of a laser system (15) to form a first layer of the punching contour (10), and d) translatory movement of the punching base body (11) relative to the powder coating unit (14) and / or to the laser system (15), and e) repeating steps a) to c) to form further layers of the punching contour (10). Procedure according to Claim 1 , characterized in that in a step f) after the layers of the punching contour (10) have been formed, the punching contour (10) is hardened. Procedure according to Claim 1 or 2 , characterized in that before step b) a diameter of the punching base body (11) is reduced in sections by twisting and / or grinding off the punching base body (11), in particular pins (19) and / or bearer rings (20) on side areas of the punching base body (11 ) be formed. Method according to one of the preceding claims, characterized in that after the layers of the punching contour (10) have been formed, the punching contour (10) and / or the bearer rings (10) are ground and / or sharpened. Method according to one of the preceding claims, characterized in that before step b) a punching contour (10) already arranged on the punching base body (11) is turned off and / or ground off. Method according to one of the preceding claims, characterized in that in step b) the metallic powder (12) is applied from a material different from the material of the punching base body (11). Method according to one of the preceding claims, characterized in that the punching base body (11) is continuously rotated at least during step b) and / or step c). Method according to one of the preceding claims, characterized in that in step c) at least one laser beam is aligned and metered in the longitudinal direction of the punching base body (11) by means of at least one scanner unit (18). Method according to one of the preceding claims, characterized in that during the turning of the punching base body (11) in step a) the metallic powder (12) according to steps b) and c) is continuously applied in sections and then melted. Rotary punching cylinder (100) with a punching contour (10) applied to a cylindrical punching base body (11), characterized in that the punching cylinder (100) was produced using a method according to one of the preceding claims. Manufacturing plant (200) for producing a rotary punching cylinder (100) by means of additive application of at least one punching contour (10) to a cylindrical punching base body (11) according to a method according to one of the Claims 1 to 9 , characterized in that the production plant (200) has at least one powder coating unit (14), a laser system (15) and a drive (16) or a plurality of drives for rotating and translating the punching base body (11) relative to the powder coating unit (14) and / or to the laser system (16).

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