JP2005088042A - Structure and manufacturing method of stacked die - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To enhance the strength of a cast die level and the quality of a casting, and to shorten the die manufacturing period by solving disadvantages with a known stacked die of insufficient die strength and poor appearance of the casting. <P>SOLUTION: Portions of insufficient strength and defective appearance quality caused by a stacked portion of a stacked die are formed of thick metal plates. A thin plate part is formed by cutting a metal plate by a laser cutter using the slice data for each thickness of the metal plate out of the three-dimensional CAD data. A thick plate part is roughly machined by an NC machine to the shape level in which the thin metal plate is laser-cut and stacked simultaneously with the laser cutting of the thin plate part. After the rough machining, the plates are successively stacked, and a shape part is formed by NC machining after the binding. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

The present invention relates to a laminated mold structure in which a plurality of metal plates are laminated in a sheet metal press mold or a resin mold and a method for manufacturing the same.

In developing new products, it is important to develop products received in the market in a short period of time ahead of other manufacturers in order to win severe sales competition. In press working and resin molding, shortening the mold production period is the most important issue.
In the production of a mold having a three-dimensional curved surface shape, it was polished from a cast or steel block with a three-dimensional NC machine and then polished. Large press dies are manufactured mainly from castings. As shown in the process of Fig. 2, the period from product data creation to mold design, full mold data creation / processing, casting and casting can be It became a big bottleneck, and further, machining was concentrated after casting, the work was serial, and it was difficult to shorten the production period.

Laminate molds cut thin shapes from 3D CAD data according to slice data for each metal plate thickness with a laser cutter, etc., and stack them one after another to form a 3D shape. It was characterized by being able to be manufactured. However, depending on the product shape, the shape line of the laminated metal plate is transferred to the molded product, and the appearance quality is inferior in appearance, and the thin protrusions are peeled off.
JP 2000-329030 A

  The above-mentioned problems of poor mold strength and poor appearance quality of molded products, which are weak points of the above-mentioned laminated molds in which thin plates are laminated, are raised to the casting mold level, and the production period is shortened by simultaneous parallel processing.

  By changing the method of forming a three-dimensional shape by laminating thin metal plates, a mold structure capable of preparing a material in place of casting in a short time and a manufacturing method thereof are provided. Using general-purpose materials that are always available in the market, such as automotive steel plates and structural steel plates, the metal plate of the laminated mold is divided into a thin plate portion and a portion that cuts the shape from the thick plate according to the product shape, and the thin plate portion is a conventional laser cutter The thick plate part is processed into rough data at a shape level obtained by cutting and stacking thin metal plates with slice data, and rough processing is performed stepwise with an NC processing machine. In the rough machining, the cutting depth is more stable than that of a casting mold, continuous unmanned machining is possible, and the machining time is shortened. After lamination, the metal plates are joined and NC machining is performed unattended by the product shape cutting data. If the slice data can be created as shown in FIG. 2 in the manufacturing process, thin plate laser processing and rough plate processing by a thick plate NC processing machine can be performed simultaneously from general-purpose materials. Casting molds take a long time to cast, require a large amount of NC machining, and require manned roughing and unmanned finishing. All operations are serial and can be laminated in machining. Compared to molds, there is a big difference in production time.

Laser processing of thin plates from general-purpose materials and rough processing on thick plate NC processing machines can be performed in parallel, and in the laminated structure, parts that are problematic in strength and appearance quality are scraped from the thick plate, or the edge of the metal plate Since the parts are welded and integrated, a mold capable of obtaining product quality equivalent to a casting mold can be manufactured at a low cost in a short time.

  In order to obtain a molded product corresponding to a casting mold, a thick metal plate is used for the punch tip, complex shape, and dial part of the laminated mold, or the end of the metal plate is integrated by welding. A manufacturing method in which laser processing and NC processing are performed simultaneously in parallel so that the mold structure can be manufactured in a short period of time.

FIG. 1 is a sectional view of a convex shape according to an embodiment of the present invention. The thick metal plate 2 has a lot of irregularities at the tip of the punch and has a complicated shape, and the laminated structure constitutes a portion having a problem in strength. The thin metal plate group 1 constitutes a portion where the difference in change between the height direction and the plane direction is small. The thick metal plate 4 has a large change in the plane direction with respect to the height direction, and in the laminated structure, the front end of the metal plate has a knife edge shape, which constitutes a problem in terms of mold strength and molded product quality. The thin metal plate group 3 constitutes a portion with little change in shape in the plane direction with respect to the height direction, and a metal plate thicker than the thin metal plate group 1 is used for shortening the manufacturing period. The reference pins 6 and 6a are implanted in the holder 5 and sequentially stacked, and are fastened with bolts 7 and 7a. If necessary, the metal plate can be welded, or the brazing material 8 can be sandwiched between the metal plates during lamination, and the entire plate can be heated and brazed to braze the metal plate to increase the bonding force. After joining the metal plates, the product shape 13 is processed and finished.

  FIG. 2 shows a manufacturing process of the laminated mold of the present invention and a general casting mold. In the laminated mold, a commercially available material is used, and laser processing of the thin plate portion, NC rough processing of the thick plate portion, and processing of the holder portion can be performed simultaneously in parallel. In the case of a casting mold, the period until the casting is made is long, and thereafter, machining is concentrated and operations are serial.

  FIG. 3 shows a method for manufacturing a laminated mold of the present invention. In the thin metal plate groups 1 and 3, a commercially available steel plate is processed by a laser cutter based on slice data. Thick metal plates 2 and 4 are obtained by gas cutting a commercially available steel plate with slice data 11 on the maximum surplus side, machining upper and lower surfaces, reference holes, and fastening holes, and attaching them to the jig plate 10 according to the rough machining data 12 NC machining. The holder 5 is made of a commercially available steel material and milled with a face and a hole. After the lamination and fastening, NC processing is performed by the product shape cutting data 13 to finish the shape portion.

  4 (a) is a slanted portion with a gentle product shape, and the portion where the tip of the metal plate has a knife edge shape is a 2-6 mm metal plate, and is sliced as shown in detail view (b) of portion A. Laser cutting is performed with the data 11, and the end of the metal plate is welded 9 after lamination and fastening, and NC machining is performed with the product shape cutting data 13. As shown in the figure (C), when there are small irregularities 13a on the product shape surface, a rough shape is created by the overlay welding 14, and then NC processing is performed by the product shape cutting data 13 to finish the shape portion.

  It can be widely used regardless of the level of appearance quality, as a prototype for sheet metal pressing and resin molding, or as a small-to-volume production die.

The convex cross-sectional structure of the laminated metal mold | die of this invention is shown. (Example 1) The manufacturing process of the laminated metal mold | die of this invention and a general casting metal mold | die is shown. Sectional drawing which shows the manufacturing method of the laminated metal mold | die of this invention. Sectional drawing of the lamination metal mold | die of this invention. (Example 2)

Explanation of symbols

1, 3 Thin metal plate group Thick metal plate 5 Holder 6, 6a, 6b Reference pin 7, 7a Bolt 8 Raw material 12 Roughing slice data 13 Product shape 14 Overlay welding

Claims (3)

Cut the metal plate from the 3D CAD data with slice data for each thickness of the metal plate, stack the metal plate and brazing material alternately, press and heat to join the metal plate, finish the step and finish the product shape In the laminated mold to be formed, when laminating thin metal plates depending on the product shape, the shape line of the metal plate is transferred to the molded product, and the thin convex portions are peeled off, which causes problems in appearance quality and mold strength. Laminated metal molds that are composed of thick metal plates of 10 mm or more at the locations, and are laminated one after the other, then joined together by a combination of bolting, welding, and brazing, and NC processed into a product shape.   For thin metal plates, shape lines and reference holes / bolt holes are cut with a laser cutter using slice data for each metal plate thickness from 3D CAD data. In the concave mold, after cutting by gas cutting etc. with the slice data on the minimum side and processing the upper and lower surfaces and reference holes / bolt fastening holes, the thin plate is cut with slice data and then roughed with an NC processing machine, The method for manufacturing a laminated mold according to claim 1, wherein the laminated molds are sequentially laminated, combined by a combination of bolting, welding, brazing, and the like, and then processed into a product shape by an NC processing machine using product shape cutting data. Cut the metal plate with slice data for each thickness of the metal plate from the 3D CAD data, and sequentially stack the metal plate and the brazing material, pressurize and heat to join the metal plate, finish the step and finish the product shape In the laminated mold to be formed, the sloped part with a gentle product shape and the part where the tip of the metal plate has a knife edge shape at the R part are welded to the edge of the metal plate after laminating and joining one after another. Laminated molds where the part with the shape is laminated and joined, and overlay welding is performed to create a rough shape, which is processed into the product shape by an NC processing machine using the product shape cutting data.

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