JP2002205131A - Laminate die structure, and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a metal plate laminate die structure which is manufactured in a short period, low-priced, excellent in durability, widely applicable to a press die, a resin die, etc., and easily and automatically manufactured. SOLUTION: The die shape is divided into several bocks in the height direction. Slide data for each plate thickness of metal plates is prepared from three- dimensional CAD data for each block, and the metal plates cut by laser beam are laminated with reference to a reference pin. Gaps between the metal plates are applied or immersed with adhesive and they are pressed together, and the laminated blocks are welded and bound. Or a brazing filler metal is held between the metal plates, and heated, an pressed to a prescribed height in a molten state to weld the metal plates. Holes or grooves for storing the brazing filler metal are made in the laminated plates to improve the strength and sealability. After manufacturing each laminating block, each block is laminated and bound by bolts, welding, etc., to form a die. In order to eliminate any lamination step, the step of the laminated structure is eliminated by heading by a spherical roller, etc., coating resin, or machining by an NC machine.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated die structure in which a plurality of metal plates are laminated in a sheet metal press die or a plastic molding die, and a method of manufacturing the same.

[0002]

2. Description of the Related Art A laminated mold efficiently cuts a metal plate by using a system of three-dimensional CAD data and laser cutting.
By successively laminating them, a die can be manufactured inexpensively and in a short time, so that they have been adopted for a prototype die or a small-lot die (Japanese Patent Application Laid-Open No. Hei 9-150228).
84167). However, the practical range of the lamination mold is limited, and the following problems remain in large press dies and plastic molding dies.

[0003] When press-molding with a laminated mold, an elongated portion or a protruding portion in a plane may be deformed or peeled off by a lateral load due to movement of a work material during molding.
Further, the positioning pin portion and the welded portion have high rigidity, and the other portions have a large elastic deformation, and there is a problem in dimensional accuracy and appearance of the molded product. In the resin mold, if the bonding force between the metal plates is weak, the cooling water leaks, or the resin enters between the metal plates and molding becomes impossible. In addition, even when machining is performed partially, the metal plate is peeled off and cutting is difficult, so that the additional function cannot be enhanced. Since a three-dimensional shape is formed by lamination, a stepped step appears on the product on the slope, and the appearance is reduced. In the case of a press die, the die structure of the lamination is not established.

[0004]

In the above-described press die, the flat and elongated portions and protrusions of the metal plate are weak due to the force in the lateral direction and easily deformed. The problem that the resin material enters the die is a fatal problem of the laminated mold, and it is necessary to strengthen the bonding force between the laminated metal plates. If the bonding strength between the laminated metal plates can be enhanced, machining can be performed, and additional functions can be added to the mold. In addition, the lack of rigidity in the height direction due to the laminated structure must be solved as a decrease in product accuracy and appearance. In order to further improve the appearance and expand the application range of the laminated mold, it is an object of expanding the application range of the laminated mold to remove the step of the shape portion due to lamination in a short time and at low cost.

[0005] It is also necessary to develop a stamping die for press making use of the features of the laminated die.

[0006] The present invention has been made in view of such circumstances, and a laminated mold capable of processing a product having high precision, high rigidity, durability, and good appearance without impairing the advantages of the laminated mold. A laminated mold structure which is inexpensive and can be manufactured in a short period of time, and a method of manufacturing the same.

[0007]

In order to achieve the above object, the present invention takes the following measures. The laminated portion having a three-dimensional shape is divided into several blocks to form a laminated block, accuracy and strength are built for each laminated block, and the laminated blocks are sequentially stacked and joined to form a mold.
In order to increase the bonding force between the laminated metal plates of the laminated block, the metal plates are pressure-bonded to each other. A metal plate having a small planar size is immersed in an adhesive solution after lamination. A large metal plate in a plane is laminated after applying an adhesive, or an adhesive entry hole is added to the metal plate as appropriate and the laminated block laminated is put in a vacuum chamber,
The inside of the room is evacuated and the adhesive is injected, and the adhesive is applied between the metal plates by applying a liquid pressure. After filling the adhesive between the metal plates, the laminated block is bonded by pressing in the laminating direction.

In order to further increase the bonding strength between the metal plates, spot welding is performed by applying electrodes to the upper and lower surfaces of the bonded laminated block. Since the spot welding strength affects the lamination height, the number of laminations, the spot pitch, and the like, the lamination block height is appropriately divided. Further, a welding hole is previously formed in the metal plate, a welding rod is inserted into the welding hole, and a resistance welding power source is supplied with pressure from both ends of the welding rod to weld the metal plate on the upper and lower surfaces of the laminated block. The welding rod is made longer than the height of the laminated block, and holes are machined at both ends to reduce the cross-sectional area to melt both ends. Several metal plates on the upper and lower surfaces of the laminated block increase the welding strength by making both ends of the welding hole large in a countersink shape. It is also possible to use both spot welding and welding with a welding rod.

In the joining of the metal plates, when laminating the laser cut metal plates, the metal plate and the brazing material foil are alternately laminated,
There is also a method in which the laminated blocks are heated in a heating furnace, and are pressed and welded in a molten state of the brazing material. A stronger bonding force can be obtained by using a metal plate plated with zinc or solder. In addition, slits are formed in a metal plate around a cooling water passage hole or the like that requires particularly tight airtightness and bonding strength, and a paste-like brazing material is filled and welded during lamination.

When the metal plate is joined with the brazing material, the pressure is
Set the stopper height to the target height of the laminated block,
A predetermined pressing force is set by a spring or the like, and is carried into the heating furnace. Alternatively, the brazing material is heated and taken out of the superheating furnace in a molten state, and is pressurized to a predetermined height by a pressing device with a predetermined force.
In the case where the upper surface of the laminated block has a shape with a height difference, the pressure is applied using a block or a holding jig provided with a holding screw according to the height difference.

[0011] The thickness of the upper and lower metal plates constituting the laminated block is made several times to several tens times the thickness of a normal metal plate, and the coupling between the laminated blocks is increased by bolting or welding together. You can also. In addition, the height of the laminated block is set higher than intended, and the height can be accurately adjusted by machining to increase the accuracy. A metal plate having a thickness that cannot be laser-processed is processed by a wire cutter or the like.

[0012] Depending on the part of the mold, wear resistance may be required,
In some cases, thermal conductivity is required for cooling the mold. In this case, a hybrid laminated metal mold combining a plurality of optimal materials such as hard steel materials and aluminum materials and metal plates having a large thickness can be obtained.

The step of the slope portion caused by the lamination is set such that the cutting of the metal plate is set so that the center of the thickness of the metal plate becomes the cutting data, and the excess portion is crushed by the spherical roller to the underfill side, or Hit the surface with a spherical hammer to eliminate steps. A tool that supports a spherical roller via an elastic body is attached to the NC processing machine, and processing is performed on the driven side from the metal plate cutting data. Alternatively, a hammer is attached to a shaker and processed by a robot. Alternatively, the upper surface of the metal plate is cut so as to be cut data, and the underfilled portion is coated with a resin to eliminate a step. Alternatively, the metal plate is cut so that the lower surface side becomes the cutting data, and the excess portion is eliminated by NC grinding to eliminate the step.

The cutting edge of the punching die for pressing is formed by bonding a metal plate which has been heat-treated with high hardness and precision cut into a product cutting shape to one side of a base material roughly cut into a product cutting shape, or a welding rod or screw after bonding. To form a punching die.

As described above, the bonding strength between the metal plates is improved by fixing the laminated metal plates by spot welding or welding rods after pressure bonding, and an adhesive is filled between the metal plates, and And the rigidity in the height direction can be increased. Further, by welding the metal plates with a brazing material, the bonding force between the metal plates becomes stronger, and the rigidity in the height direction is also improved.

By improving the bonding force between the metal plates, the shape portion is not deformed or peeled off by a lateral load due to the movement of the material during press molding, water leakage in the plastic mold, resin between the metal plates, The intrusion problem can be solved. By increasing the rigidity in the height direction, elastic deformation is reduced, and the height accuracy of the product as a whole is improved without locally expanding the reference pin portion and the welded portion. In addition, by improving the bonding force between the metal plates and using thick metal plates on the upper and lower surfaces of the laminated block, machining becomes possible, and the precision can be improved by cutting the upper and lower surfaces of the laminated block. Processing of the tap for lifting the laminated block and embedding of a required precision part, a punch, a die, etc. can be embedded in the laminated part. Bolts can be fastened even when joining the laminated blocks to each other, and sufficient strength can be obtained.

Eliminating the step of the slope portion formed by lamination, the product surface quality approaches that of a normal die, and the applicable range of the lamination die can be expanded. In a press-cutting die, a quenched metal plate is laser-cut and laminated on a rigid base material, so that a die can be manufactured in a short time and at low cost. Further, by laminating metal plates made of a material having excellent wear resistance and heat conductivity depending on the part of the mold, an effect that cannot be obtained with a mold having an integral structure can be expected.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the drawings. FIG. 1 shows a metal plate 11 as a reference pin 1
2 is a cross-sectional view showing a spot welding method of the laminated block 10a fitted and laminated in FIG. 2, and upper and lower surfaces of the laminated block 10a are pressed by electrodes 22 and 23 to conduct electricity. Reference numeral 13 denotes a spot weld.

FIG. 2 shows a welding hole 15 in the laminated block 10b.
Then, a welding rod 16 longer than the height of the laminated block 10b is inserted, and a resistance welding power source is supplied and pressurized by the electrodes 24 and 25 to be welded to the metal plate 21 as shown in FIG. FIG. 3 shows the details of the portion A in FIG. 2. The welding rod 16 is formed with holes at both ends to reduce the cross-sectional area and hasten the melting of the ends. In order to increase the welding strength of the welding rod, the both ends of the welding hole 15 are countersunk, and the diameters of the welding holes of the upper and lower metal plates are increased.
Is inflated as shown in FIG. 13 can be used in combination with spot welding.

In the embodiment shown in FIG. 4, the adhesive is injected into the chamber 31 for injecting the adhesive between the metal plates of the laminated block 10b in which the adhesive injection hole 17 has been machined. After sealing with the cover 32, the valve 37 is opened and the vacuum is opened. The air is exhausted from the exhaust port 36 leading to the pump. When the degree of vacuum rises, the valve 37 is closed, the valve 39 is opened to suck the adhesive 18 from the suction port 34, and when the required liquid level is reached, the valve 39 is closed and the valve 38 is opened to compress the compressed air from the compressed air supply port 35. It takes in air and pressurizes it to help the adhesive enter. The compressed air supply port 35 is set to the atmospheric pressure, the valve 39 is opened, the adhesive 18 is returned to the tank, and the laminated block 10b is taken out. After injecting the adhesive between the metal plates, the laminated block is pressed and bonded in the laminating direction.

The embodiment of FIG. 5 eliminates the step-like steps formed on the slope by lamination. FIG.
1b is cut so that the center of the plate thickness becomes the product shape 1 at the time of cutting, and the spherical roller 27 is pressed in the direction of the arrow by an NC processing machine pivotally supported via an elastic body, and the excess portion is cut off as indicated by 2 To eliminate the steps. FIG. B shows the metal plate 11c cut so that the upper surface side of the metal plate has the product shape 1, and the underfilled portion is ground after finishing the resin. Fig. C shows the metal plate 11d cut so that the lower surface side of the metal plate has a product shape 1 and the excess portion is ground by an NC machine.

In the embodiment shown in FIG. 6, the laminated block 10 is machined to form a punch 41, a punching die 42, and burials 43 and 44 of the required precision parts. An example is shown in which taps are machined and fastened with bolts. The bolt holes may be machined before lamination with the adhesive injection holes 17 in countersink shape.

The embodiment shown in FIG. 7 is an example of a punching die having a laminated structure, in which a die-side base material 54 gas-cut larger than the product cut shape and a punch-side base material gas cut smaller than the product cut shape are used. 53 are fixed to the holders facing each other, and a die-side cutting edge 52 obtained by laser-cutting a metal plate for a cutting edge heat-treated to a high hardness of about 2 to 6 mm into a product cutting shape is cut into a die-side base material 54 and a punch-side cut. The blade 51 is positioned and adhered to the punch-side base material 53 with the knock pin 55.

In the embodiment shown in FIG. 8, a metal plate 71 plated with solder and a 0.1 mm solder foil 79 are alternately laminated and set on a pressing device 60, and a stopper 62 is set at a target height of the laminated block 70a. With the pressure screw 63 tightened with a predetermined force via a spring 65, the screw is carried into a heating furnace, heated to a predetermined temperature, cooled, and taken out. Thick plates are used for the metal plates 71a and 71b on the upper and lower surfaces of the laminated block so that they can be machined.

The embodiment shown in FIG. 9 shows a pressing device 80 using a pressing jig 90 in which the holding block 91 and the holding screw 92 are adjusted according to the height difference when the stacked block 70b has a height difference. . The pressurizing device 80 takes in the brazing material heated in a molten state in a heating furnace, and pressurizes with a hydraulic cylinder 81 until the slide 82 comes into contact with a stopper 83 whose height has been set.

The embodiment shown in FIG. 10 shows a convex side section of a mold having a cooling water channel 76. FIG. 2B shows a metal plate 72 having laminated cooling water passages 76 and slits 77 and 78 for brazing filler metal provided at corners of the shape, and FIG.
Indicates a metal plate 73 having no slit, and a metal plate 73 having a slit and a slit having no slit are alternately laminated.
Reference numeral 12a denotes a reference hole. In addition, the joint surface between the holder 56 and the laminated block is welded with a brazing material to improve the bonding force and prevent water leakage.

The embodiment shown in FIG. 11 is an example in which the material and the thickness of the metal plate are optimized depending on the part of the die.
7, punch tip 85, corner 84, and blank holder upper surface 86 are made of a carbon steel plate having high abrasion resistance. In order to ensure the height and parallelism of the laminated block, the lower surface is cut, tapped and bolted.

[0028]

Since the present invention is constructed as described above, it has the following effects.

By pressing and bonding the laminated block, spot welding or a welding rod is inserted into the laminated block in a state where the adhesive is filled between the metal plates and the gap is further narrowed, and both ends are welded and fixed. Alternatively, by welding with a brazing material between metal plates, the bonding force between the metal plates is improved, and the problem of deformation or peeling of the shape portion due to movement of the material during press forming is eliminated. It also solves the problems of water leakage in the plastic mold and the penetration of resin between metal plates.

As described above, the rigidity in the laminating direction is improved, and the accuracy of the press-formed product is also improved. In addition, since the laminated block approaches the integrated metal, machining can be performed, and the filling of the required precision portion, a punch, and a die can be embedded, so that the application range of the laminated mold can be expanded.

The surface quality of the product can be improved by removing the steps formed in the shape by the lamination, and the application range of the lamination mold can be further expanded.

The punching die of the press can be realized by lamination, and blanking processing for medium-volume production can compete with laser processing.

[Brief description of the drawings]

FIG. 1 is a sectional view of a laminated block having a laminated mold structure according to the present invention.

FIG. 2 is a sectional view of a laminated block having a laminated mold structure according to the present invention.

FIG. 3 shows details of a portion A in FIG. 2;

FIG. 4 is a cross-sectional view showing a method of injecting an adhesive into a laminated block.

FIG. 5 is a partial side view showing a method of removing a step of a laminated block.

FIG. 6 is a sectional view showing a press die having a laminated structure.

FIG. 7 is a sectional view showing a punching die having a laminated structure.

FIG. 8 is a side sectional view in which a laminated block is pressed by a pressing device.

FIG. 9 is a side sectional view in which the laminated block is pressed by a pressing device using a pressing jig.

FIG. 10 is a side sectional view of a laminated mold having a cooling water channel and a cut shape of a laminated metal plate.

FIG. 11 is a cross-sectional view in which metal plates of different materials and plate thicknesses are laminated depending on the part of the mold.

[Explanation of symbols]

1 Product shape line 2, 3 Shaped part with steps removed 10, 10a, 10b, 10c, 10d, 10e, 70
a, 70b laminated blocks 11, 21, 71, 71a, 72, 73, 84, 85,
86, 87, 88 Metal plate 12 Reference pin 13 Spot welding portion 14 Welding bar connection portion 16 Welding bar 18 Adhesive liquid 19 Coating resin 22, 23, 24, 25 Electrode 27 Spherical roll 28 Cutter 31 Chamber 41 Drilling punch 42 Drilling Dies 43, 44 Filling 51 Punch-side cutting edge 52 Die-side cutting edge 60, 80 Pressing device 62, 83 Stopper 76 Cooling water channel 90 Pressing jig

Claims (22)

[Claims] 1. A method of joining a metal plate and a metal plate of a laminated mold in which metal plates cut by slice data for each thickness of a metal plate from three-dimensional CAD data are sequentially laminated based on a reference pin. Laminated mold structure characterized by being divided into several laminated blocks, applying or dipping and injecting an adhesive between metal plates for each laminated block, and then press-fitting, and then applying spot welding to electrodes on the upper and lower surfaces of the laminated block. . 2. A method of joining a metal plate and a metal plate of a laminated mold in which metal plates cut by slice data for each thickness of a metal plate from three-dimensional CAD data are sequentially laminated based on a reference pin. After dividing into several laminated blocks, applying or dipping and injecting an adhesive between the metal plates for each laminated block, pressing and bonding, a welding rod is inserted into a welding hole drilled in the laminated block, and at both ends of the welding rod A laminated mold structure characterized in that both ends of a welding rod are welded to a metal plate by applying a pressure / resistance welding power source while applying an electrode. 3. The laminated mold structure according to claim 1, wherein spot welding and welding with a welding rod are used in combination. 4. The laminated mold structure according to claim 2, wherein both ends of the welding holes of the laminated block are counterbored. 5. A welding rod for a lamination die in which holes are machined at both ends of the welding rod to reduce the cross-sectional area and to be longer than the height of the laminated block to be welded. 6. A laminated block in which a hole for adhering an adhesive is appropriately formed in a laminated metal plate is put into a vacuum chamber, and the chamber is evacuated to inject the adhesive, pressurize the adhesive, remove the adhesive, and pressurize the laminated block. 5. The method for manufacturing a laminated mold according to claim 1, wherein the laminated mold is bonded by bonding. 7. When cutting a metal plate with slice data for each thickness of the metal plate from the three-dimensional CAD data, the center of the thickness of the metal plate is set to be the cutting data, and the remaining of the stacked and crimped stacked blocks is set. 7. The method according to claim 1, wherein the step of eliminating the step is performed by crushing the meat portion to the underfilled side with a spherical roller or hitting with a spherical hammer. 8. When cutting a metal plate with slice data for each thickness of the metal plate from the three-dimensional CAD data, the upper surface side of the metal plate is set to be the cutting data, and the cut data is formed in the cutout portion of the laminated block that has been laminated and pressed. 7. The laminated mold structure according to claim 1, wherein a step is eliminated by coating a resin. 9. When cutting a metal plate with slice data for each thickness of the metal plate from the three-dimensional CAD data, the lower surface side of the metal plate is set to be the cutting data, and the excess portion of the laminated / compressed laminated block is set. 7. The method according to claim 1, wherein the step is removed by grinding. 10. The laminated mold structure according to claim 1, wherein the laminated block and the laminated block are joined by a bolt or an adhesive and a bolt. 11. The laminated mold structure according to claim 1, wherein the laminated block is machined into the precision-required portion or the cut portion to embed a metal block. 12. A die-cut laminated metal having a cutting edge formed by bonding or mechanically bonding a hardened heat-treated cutting edge material laser-processed based on product cutting shape data onto a base material having strength. Type structure. 13. A metal plate cut by slice data for each thickness of a metal plate from three-dimensional CAD data and sequentially stacked with reference to a reference pin. Put the brazing material such as solder between the metal plates of each whole block or several laminated blocks, heat in a heating furnace, pressurize with the pressing means in the molten state of the brazing material, and then cool the metal plate Patent application title: Laminated mold structure in which gaps are bonded and method for producing the same. 14. The method according to claim 13, wherein the pressurizing means uses a pressurizing device capable of setting a stopper height at a target height of the laminated block to be processed and setting a predetermined pressing force. 15. When the laminated block has a shape with a height difference on the upper surface side, a predetermined pressure height and pressure are set using a pressure jig in which a block or a set screw is adjusted according to the height difference. 14. The method according to claim 13, wherein a pressurizing device is used. 16. The laminated mold structure according to claim 13, wherein a metal plate having a surface plated with zinc, solder, copper, lead or the like is used. 17. The laminated mold structure according to claim 13, wherein a hole for accumulating a brazing material is formed in the metal plate to be laminated, and the brazing material is filled and welded. 18. A laminated mold having a cooling water passage,
A metal plate in which a discontinuous brazing filler hole is machined single or multiple around the cooling passage hole and a metal plate processed only in the cooling passage hole are alternately laminated, and the brazing filler hole is filled with brazing material. The laminated mold structure according to any one of claims 13 to 17, which is welded, and a method of manufacturing the same. 19. A metal plate and a metal plate of a lamination mold in which metal plates cut by slice data for each thickness of the metal plate from the three-dimensional CAD data are sequentially stacked with reference to a reference pin, and a laminated portion is formed. Divided into several laminated blocks, the upper and lower surfaces of each laminated block usually use a metal plate having a thickness of several times to several tens times the thickness of the laminated metal plate, and the connection between each laminated block is bolted or 18. The laminated mold structure according to claim 13, which is welded or bolted and then welded. 20. The method according to claim 19, wherein the height of each laminated block is made higher than a target dimension, and one or both of the upper and lower surfaces of the laminated block are machined after the metal plates are joined. 21. A laminated mold structure in which a joining surface of a laminated block having upper and lower mold halves and a shape portion constituting a laminated mold is filled with a metal material. 22. In the joining of a metal plate and a metal plate of a lamination die in which metal plates cut by slice data for each thickness of the metal plate from the three-dimensional CAD data are sequentially laminated based on a reference pin, a laminated portion is formed. A laminated mold structure in which the material of the metal plate constituting the laminated block is divided into the whole or several laminated blocks, and the material is optimally laminated depending on the material in terms of wear resistance, thermal conductivity for mold cooling, and the like.