JP2011207143A - Hybrid mold - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a hybrid mold which unites characteristics of high strength of steel material and high heat conduction of a nonferrous metal body (copper alloy body).SOLUTION: The hybrid mold is characterized in that at least a heat exchange range of the forming mold 1 is formed of the nonferrous metal body 3 (copper alloy body 3A), the nonferrous metal body is provided with a cavity E and a product relating part 7, a load concentration range which is susceptible to damage in a product-forming surface (e) of the cavity and a cavity continuous part 3a of a parting line PL of the product relating part are thinned into a thickness of several millimeters or less, the build-up welding of a ferrous material F having a fusion temperature higher than that of the nonferrous metal body is performed to form a ferrous build-up part 4 on a thin thickness part 13 by using a heat source of high energy density, a finish-processed iron material layer 4A is disposed on the build-up part surface 4a and the load concentration range susceptible to damage of the nonferrous metal body in the iron material layer is protected. Further, by constituting the forming mold 1 with a steel material mold 10 and a nesting mold 20 made of the nonferrous metal body, the same characteristics can be obtained.

Description

  The present invention relates to a mold used for molding various products, and more particularly, to a hybrid mold using a non-ferrous metal mold, particularly a copper alloy mold as a base material.

As molds, synthetic resin molding molds, rubber molding molds, die casting molds, glass molds and the like are known. In addition, these machines require expensive machine tools and specialized operators.In particular, the final finishing process requires hand polishing by skilled workers, which requires a large amount of cost and production days. It is also known that
On the other hand, a steel material is often used as a mold material, especially as a mold material for molding a synthetic resin, and the use of non-ferrous metals other than the steel material is extremely limited. The reason for this is that steel materials are rich in technology and experience, such as high strength, various types, low cost, and high quality (particularly made in Japan).

However, in the mold, thermal conductivity is also an important indispensable element (the mold is not only a resin product molding but also a heat exchanger for cooling and solidifying high temperature resin), but the steel mold is a non-ferrous metal While it is stronger than metal molds, its thermal conductivity is significantly inferior.
As a result, the molten resin injected into the steel mold does not “cool and solidify” quickly and uniformly, resulting in a longer cooling time and a longer molding cycle than non-ferrous metals.
This is a major issue at the manufacturing site because it causes a reduction in the product forming speed due to the cooling speed of the steel mold, a reduction in cost competitiveness associated therewith, and an adverse effect on the appearance of the product. .
Furthermore, since the heat balance is difficult to achieve, the mold temperature is not stable, and as a result, deformation and sink marks of the molded product occur, and there are significant problems in quality and productivity. (The mold is a heat exchanger)
Therefore, in the design of steel molds, it is important to enhance the cooling circuit, but the thermal conductivity of steel is several times inferior to non-ferrous metals such as zinc alloy, aluminum alloy, copper alloy, It is not easy to sufficiently cover the thermal conductivity.
Therefore, there has been no alternative technique to deal with design changes, processing errors, damage due to accidents at the molding stage, deterioration such as wear, etc. other than partially or entirely remodeling.

Japanese Patent Laid-Open No. 08-118049 Japanese Patent Laid-Open No. 10-85972 JP 2000-153380 A JP 2008-80388 A JP 2009-6191 A Japanese Patent No. 2509125 Japanese Utility Model Publication No. 07-19667

Therefore, high-strength copper alloys with excellent thermal conductivity were developed, and some or all of the molds were replaced with copper alloys and used.
However, even though it is a high-strength copper alloy, it does not have a strength comparable to that of steel, and the die life is inferior.
Furthermore, it is known that overlay welding by TIG, which is generally performed for steel materials, is very difficult and impossible with copper alloys.
On the other hand, as overlay welding, YAG laser welding (yttrium, aluminum, garnet laser) has recently attracted attention, and is showing remarkable development.
This has led to significant progress in mold repair technology.
Technology for joining dissimilar steel materials to copper alloy molds has not yet been established, and if that technology can be established, it will be possible to manufacture hybrid molds made of copper alloys and steel materials with excellent heat conduction and strength, and a new industry Can be sent to the world.
In other words, if a hybrid mold that combines the characteristics of a copper alloy with excellent heat conduction and a steel material with excellent strength and cost can be produced, it becomes an innovative technology.

  The inventor found that when repairing a copper alloy mold by micro YAG laser welding, the steel alloy wire was accidentally welded to the copper alloy body with unexpected soundness. Inspired by the idea, a hybrid mold having the features of “high strength of steel” and “high thermal conductivity of copper alloy” can be arbitrarily created as needed.

In order to achieve the above object, a hybrid mold according to the present invention includes, as claimed in claim 1, at least a heat exchange range of a molding mold made of a non-ferrous metal body, the non-ferrous metal body including a cavity and a product-related portion, An iron-based material with a melting point higher than the non-ferrous metal body by using a heat source with a high energy density in the thin-walled portion, where the load concentration range on the product forming surface of the cavity is thinner than the specified finish thickness. Is built-up welded to form an iron-based built-up part, and a finished iron layer is provided on the surface of the built-up part, which protects the load concentration range where the product formation surface is easily damaged by the iron layer. And
According to a second aspect of the present invention, in the hybrid mold according to the first aspect, the product-related portion is a cavity continuous portion of a nonferrous metal parting line (hereinafter referred to as PL), and the substantially continuous portion is less than a predetermined finish thickness. An iron material layer that has been thinned to a thickness of a few millimeters and overlaid and welded an iron-based material to the thin-walled portion using a heat source with a high energy density to form an iron-based built-up portion and finish the surface of the built-up portion And a continuous cavity portion of PL is formed in the iron material layer.

Here, the hybrid mold refers to a mold composed of a light metal body having good heat conductivity and a durable iron-based material.
Here, the cavity refers to an empty part for forming a molded product provided in the molding die, an empty part for containing molten resin, an empty part through which the molten resin passes, and the like.
Here, the iron-based built-up portion refers to a part formed by overlay welding of an iron-based material, and the finish processing refers to cutting or polishing processing on the surface of the iron-based built-up portion, and the iron material layer Means an iron-based overlay that has been finished.
Here, the heat exchange range is a range in which the heating state and the cooling state are alternately repeated, and particularly a range in which the heat exchange must be frequently performed in a short time. This refers to the product formation surface on the opposite side of the direct gate, the cavity corner where the molten metal hits strongly, the shape suddenly changing portion, etc. Say department.

Claim 3 is the hybrid mold according to claim 1 or 2, wherein the product-related portion is a sliding body that reciprocates toward the cavity, and a sliding body receiving portion that guides the sliding body slidably. The receiving part is thinned at least at the inlet side to a thickness within a few millimeters of the predetermined finish thickness, and an iron-based material is welded to the thin-walled part using a high energy density heat source to form an iron-based built-up part And the iron material layer finished by the process is provided in the surface of the build-up part, and the entrance side of the sliding body receiving part is protected by the iron material layer.
According to a fourth aspect of the present invention, in the hybrid mold according to the third aspect, the sliding body is formed of a non-ferrous metal body, and at least the head thereof is thinned to a thickness within several millimeters, and a high energy density heat source is provided in the thin-walled portion. Using the overlay welding of iron-based material, forming an iron-based overlay, providing a finished iron layer on the surface of the overlay, and protecting the sliding body head with the iron layer And

Here, the molding die refers to a die composed of a fixed die and a movable die, and further to a core die, and mainly refers to a die used for injection molding and blow molding of synthetic resin products. It can also be applied to compression molding, extrusion molding, etc., and can also be applied to metal product manufacturing molds.
Here, PL refers to a contact surface between a fixed mold and a movable mold constituting the molding die, or a contact surface of a non-ferrous metal body constituting the molding die.
Here, the product-related portion refers to, for example, a sliding body and a sliding body receiving portion, a partially molded body, a holding portion that opens toward the cavity, and a PL cavity continuous portion related to the cavity, and the sliding body refers to the cavity. This refers to the projecting pin and slide core that reciprocate toward the sliding body. The sliding body head refers to the exposed portion that projects into the cavity and the fixed range that follows. The sliding body receiving portion refers to the projecting pin insertion hole and the core guide. Say.
Here, the inlet side of the sliding body receiving portion refers to the side facing the cavity, and the sliding body head refers to a range protruding into the cavity and a range following it.

A fifth aspect of the present invention provides the hybrid mold according to the first, second, third, or fourth aspect, wherein the product-related portion is a holding portion of the partially molded body that forms a part of the cavity, and the holding portion opens toward the cavity. Then, at least the inlet side is thinned to a thickness of several mm or less, and an iron-based material is welded to the thin-walled portion using a high energy density heat source to form an iron-based building-up portion, and the surface of the building-up portion It is characterized in that a finished iron material layer is provided, and the holding portion entrance side is protected by the iron material layer.
A sixth aspect of the present invention is the hybrid mold according to one of the first to fifth aspects, wherein the molding mold includes a steel material mold and a nested mold incorporated in the steel material mold, and the nested mold is formed of a non-ferrous metal body. It is characterized by being.
A seventh aspect of the present invention provides the hybrid mold according to the first aspect, wherein the molding mold is a blow molding mold including a left mold and a right mold, and at least the heat exchange range of the left and right molds is a non-ferrous metal body. Each formed, the butt portion of the non-ferrous metal body is thinned to a thickness of a few mm or less, and the steel-based material is welded and welded to the thin-walled portion using a high energy density heat source to form the iron-based built-up portion, An iron material layer that is finished on the surface of the built-up portion is provided, and a burr cut portion is formed by the iron material layer.

Here, the partial molded body refers to an insert body, a gate body, a fine molded body, a core body, and the like, and the holding portion opens toward the cavity, and holds the partial molded body and the core mold firmly. Say the part. However, the insert body separates from the holding part during the mold opening festival.
Here, the steel mold refers to a mold formed of the same material as that of a conventional mold, and the nested mold refers to one member constituting the molding mold, and is usually incorporated in the steel mold.
Here, the left mold and the right mold of the blow mold correspond to, for example, a fixed mold and a movable mold of an injection mold, and the burr cutting portion is a mold release of the blow mold. This refers to the part that cuts burrs (protruding) of products formed on blow molding dies.
Here, the non-ferrous metal body means a copper alloy body, an aluminum alloy body, a nickel alloy body or the like, and specifically, a copper alloy body of HIT75 is used.
Here, the iron-based material means, for example, a steel material or the like, specifically, a wire such as KD1VAX or NAK, or a product name “Starbucks” of a stainless steel material.

Claim 8 is the hybrid mold according to one of claims 1 to 7, wherein the iron material layer is formed by overlaying an iron-based material into a single layer or multiple layers using a heat source having a high energy density, After the build-up portion is formed, the surface is finished and the build-up height is within an average of 2 mm.
A ninth aspect of the present invention is the hybrid mold according to one of the first to eighth aspects, wherein the non-ferrous metal body has a notch portion continuous to the cavity, and a heat source having a high energy density is used for the notch portion. Is built-up welded, provided with an iron-based built-up part for the gate, a gate path is provided on the approximate built-up part, and an iron material layer for the finished gate is provided on the surface of the built-up part, and the notched part is closed with the approximate iron material layer. It is characterized by that.
Claim 10 is the hybrid mold according to one of claims 1 to 9, wherein the ferrous material is a steel wire for welding, and the non-ferrous metal body has a melting temperature lower than that of the ferrous material, It is a good copper alloy body or aluminum alloy body.
The eleventh aspect of the present invention is the hybrid mold according to one of the first to tenth aspects, wherein the high energy density heat source used for overlay welding of the iron-based material is laser welding (YAG laser welding), Pulse welding, electron beam welding, ultrasonic welding, and the like, characterized by overlay welding using at least one of them.

Here, the build-up height is the same as the formation depth of the thin portion, and the range that can be adopted is 2 mm at the maximum, and the desirable range is 1 mm.
Here, the notch portion is a portion formed deeper than the thin portion, and refers to a portion into which another member is incorporated or fitted.
Here, the high energy density heat source refers to arc welding, laser welding, pulse welding, electron beam welding, and ultrasonic welding, and for example, YAG laser welding or micro YAG laser welding is used as laser welding.
In general, all welding is performed by one means, but first, the iron system is laser welded to form a first overlay layer, and the iron system is pulse-welded on the first overlay layer. It is also possible to do.
Furthermore, if an iron-based first build-up layer is formed by laser welding, it is considered that the iron-base can be welded on the first build-up layer by welding means other than pulse welding.
Here, the gate path means a side gate, a tunnel gate, or a direct gate.

Since the hybrid mold of the present invention is as described above, the following effects can be obtained.
The hybrid mold according to claim 1 is configured such that the heat exchange range of the molding mold is formed of a non-ferrous metal body, the non-ferrous metal body includes a cavity and a product-related portion, and has a high energy density at least in a load concentration range of the cavity product forming surface. Since the iron material is overlay welded using a heat source, and the iron material layer finished on the surface of the overlay is provided, that is, although it is a non-ferrous metal body with excellent thermal conductivity, The strength of the hybrid mold is obtained.
The iron material layer can be formed by overlay welding of iron-based materials accurately (appropriate dimensions) from the beginning, but it requires a high degree of skill to weld to the appropriate dimensions from the beginning, so it is slightly less than the appropriate dimensions. Can be easily machined by conventional techniques if the excess part is welded to a large thickness and the extra part is cut (finished) by post-processing.

In addition to the features of claim 1, the hybrid mold of claim 2 is a non-ferrous metal PL cavity continuous part in addition to the features of claim 1, and this cavity continuous part is a thin part formed with an iron material layer. Therefore, even if the base material is a non-ferrous metal body, damage due to opening and closing of the mold (often due to collision and impact during mold clamping), that is, durability is almost the same as that of conventional steel molds. Become.
In addition to the features of claims 1 and 2, the hybrid mold according to claim 3 includes a sliding body that reciprocates toward the cavity in the molding mold, and a sliding body receiving portion that guides the sliding body slidably. However, since the iron material layer is formed at least on the inlet side of the sliding body receiving portion, even if the base material is a non-ferrous metal body, damage due to sliding of the sliding body, damage due to molten metal, etc. It is almost the same as a steel mold.
In addition to the features of claim 3, the hybrid mold according to claim 4 is provided with an iron material layer at least on the sliding body head. For example, the sliding body is a non-ferrous metal body, and the sliding body head is a cavity. Even if it protrudes inside and touches the high-temperature molten metal, the damage caused by the molten metal is almost the same as that of a conventional steel mold.

In addition to the features of the first, second, third, and fourth aspects, the hybrid mold according to the fifth aspect is configured so that a part of the cavity is formed by a partial molded body. The inlet side is thinned within a few millimeters, an iron layer is provided on the thin part, and the holding part inlet side is protected by the iron layer, so even if the holding part inlet side touches the hot molten metal, damage caused by the molten metal is not This is substantially the same as a conventional steel mold.
The hybrid mold according to claim 6 is characterized in that, in addition to the feature of one of claims 1 to 5, the nested mold to be incorporated into the steel material mold is formed of a non-ferrous metal body. Since the steel material layer is overlaid and welded to the thin-walled portion and the finished iron material layer is provided on the surface of the built-up portion, and is protected by the iron material layer, at least substantially the same effect as in claim 1 can be obtained. .
By making at least 50% of the mold with non-ferrous metal body and covering the non-ferrous metal body where it is easy to wear (the part where high-temperature molten metal touches) with the iron material layer, the amount of expensive non-ferrous metal body used is small Therefore, it can be provided at a low cost.
In other words, it is an extremely practical technology for both the mold making side and the side using the molding die, and it is no exaggeration to say that it is a dream technology with the development and aging of peripheral technologies.

In addition to the feature of one of claims 1 to 6, the hybrid mold of claim 7 can be used as a butt portion of the mold even if the heat exchange range of the blow mold is formed of a non-ferrous metal body. It is provided in the thin wall part, and the iron-based material is built-up welded to the thin-walled part, the iron-based built-up part is provided, and the burr cut-out part is formed in the iron material layer, so the burr cut-out part is damaged by the conventional steel material It is almost the same as the mold.
In the hybrid mold according to the eighth aspect, in addition to the feature of one of the first to seventh aspects, if the build-up welding of the iron-based material is a single layer, the formation of the iron material layer is facilitated accordingly.
However, if sufficient durability cannot be obtained with a single layer, sufficient durability can be obtained by overlay welding in multiple layers and setting the overlay height to a maximum of 2 mm.
However, it takes time for overlay welding each time the layers are stacked.

The hybrid mold according to claim 9 is characterized in that, in addition to the feature of one of claims 1 to 8, an iron-based built-up portion for a gate continuous with the cavity is formed, and a gate path is formed in the roughly built-up portion. Since the iron material layer for gate finishing is provided on the surface of the part, it is possible to form the non-ferrous metal body up to the vicinity of the gate part through which the high-temperature molten metal flows.
A hybrid mold according to a tenth aspect is characterized in that, in addition to the feature of one of the first to ninth aspects, a steel wire is used as an iron-based material, a copper alloy body is used as a non-ferrous metal body, and the steel wire is overlay welded. By using laser welding (YAG laser welding) or laser welding and pulse welding as a heat source of energy density, it is possible to stack a nonferrous metal body and an iron material layer for the first time.
In other words, by depositing an iron-based material into a single layer or multiple layers on a thin part of a copper alloy body and finishing the surface of the iron-based overlay part to form an iron material layer, even a copper alloy body has a high-temperature melt. We can protect enough from.
Experiments are also being conducted on other heat sources with a high energy density, and experiments are being conducted on the formation of an iron material layer on a nonferrous metal body other than a copper alloy body, such as an aluminum alloy body.
The hybrid mold according to claim 11 is characterized in that, in addition to the feature of one of claims 1 to 10, laser welding, particularly YAG is used as a high energy density heat source for overlay welding a ferrous material to a non-ferrous metal body. By using laser welding, overlay welding of a ferrous material to a non-ferrous metal body has become possible for the first time.
Furthermore, after forming an iron-based built-up portion of one or two layers by YAG laser welding, if an iron-based built-up portion is formed thereon by pulse welding, build-up welding can be performed efficiently.
As a result, it is possible to manufacture a mold by high-performance composite.

They are sectional drawing (a) of the mold clamping state which shows 1st embodiment of the hybrid metal mold | die by this invention, and sectional drawing (b) of a mold open state. (A) and (B) are cross-sectional views showing examples of the formation range of the iron material layer in the first embodiment. It is principal part sectional drawing of the sliding body used for 2nd embodiment of this invention. It is sectional drawing of the core type | mold built-in part used for 3rd embodiment of this invention. It is principal part sectional drawing which shows the relationship between the partial formation body (insert body) used for 4th embodiment of this invention, and its holding | maintenance part. It is sectional drawing which shows the relationship between the steel material type | mold and nested type in 5th embodiment of this invention. It is sectional drawing (b) in the mold clamping state shown with sectional drawing (a) of the mold opening state of the blow molding die in 6th embodiment of this invention. It is principal part sectional drawing (I) (B) which shows the example of formation of the iron-type built-up part for gates, and principal part sectional drawing (C) (D) which shows formation of a gate path. (A) and (B) are enlarged cross-sectional views showing a lamination example of an iron-based built-up portion. (A), (b), and (c) are cross-sectional views showing examples of forming a gate body. It is principal part sectional drawing of this invention hybrid metal mold | die using a core body. It is a left-right side view, a front view, a bottom view, and a perspective view of a test piece (copper alloy body). They are the front view (I) and the principal part enlarged side view (B) which show the build-up conditions with respect to the welding surface (thin wall part) of a test piece (copper alloy body). It is the front photograph (I) and the side enlarged photograph (B) of the test piece provided with the iron material layer. It is a principal part enlarged photograph which shows the example of formation of the iron material layer in test piece (I) (B). It is a principal part enlarged photograph which shows the example of formation of the iron material layer in test piece (I) (B). It is a principal part enlarged photograph which shows the example of formation of the iron material layer in test piece (I) (B). It is a principal part enlarged photograph which shows the example of formation of the iron material layer in a test piece.

  The first embodiment of the hybrid mold according to the present invention will be described with reference to an injection mold for synthetic resin. As shown in FIG. 1, the mold 1 is formed of a nonferrous metal body 3 having good heat conduction. The molding die 1 is provided with a cavity E and a product related part 7, and at least in the load concentration range of the cavity E and the product related part 7, for example, in the cavity E, on the product forming surface e and the product related part 7. Is a thin part of the continuous part 3a of the parting line (hereinafter referred to as PL) having a thickness of several millimeters or less, and a high energy density heat source is used for the thin part 13 and the iron system has higher durability than the nonferrous metal body 3. Overlay welding of the material F, forming the iron-based built-up portion 4, and providing a finished iron material layer 4A on the surface of the built-up portion 4a, the cavity E of the appropriate dimension that protects the load concentration range with the iron material layer 4A Protected with iron material layer 4A Forming a L cavity continuous portion 3a.

In the first embodiment, a copper alloy body 3A is used as the non-ferrous metal body 3, a steel wire W is used as the iron-based material F, and laser welding, particularly YAG laser welding is used as a heat source with high energy density. The alloy body 3A constitutes a fixed mold 1A and a movable mold 1B of the molding die 1, and a cavity E is provided inside the molding die 1, and the thin portion 13 is provided in the load concentration range where the cavity E is easily worn. The steel wire W is YAG laser welded to the thin-walled portion 13 to form an iron material layer 4A composed of the iron-based built-up portion 4, and the thin-walled portion 13 of the copper alloy body 3A is covered with the iron material layer 4A. The slowly changing portion remains the copper alloy body 3A, and the cavity E is formed by the copper alloy body 3A and the iron material layer 4A.
As the load concentration range in which the cavity E is likely to be worn, for example, a corner portion or a shape-changing portion as shown in FIG.
The iron material layer 4 </ b> A is formed by welding a single layer or multiple layers with a built-up height t of the steel material wire W within an average of 2 mm and finishing (cutting, polishing with a grinder or file).

  A second embodiment of a hybrid mold according to the present invention will be described with reference to FIGS. 1 and 3. As a product-related portion 7, a projecting pin 51 of a sliding body 5 that reciprocates toward a cavity E and a sliding body receiving portion 6. And at least the inlet side 6a of the sliding body receiving portion 6, that is, the inlet side 61a of the protruding pin insertion hole 61 is thinned to a thickness of several millimeters or less, and the YAG laser is formed in the thin portion 13. Welding steel wire W into a single layer or multiple layers using welding to form an iron-based built-up portion 4 having an average thickness of 2 mm or less, and providing an iron material layer 4A finished on the built-up surface 4a The iron layer 4A protects the inlet side 61a of the protruding pin insertion hole 61.

If the third embodiment of the hybrid mold according to the present invention is described in terms of differences from the second embodiment, the hybrid mold of the third embodiment is a molding mold using a core mold 1C as shown in FIG. The core mold 1C includes a slide core 52 of a sliding body 5 that reciprocates toward a cavity E, and a core guide 62 of a sliding body receiving portion 6 that guides the sliding body 5 in a slidable manner. In order to incorporate the core mold 1C, the holding part 9 that opens toward the cavity E as the product-related part 7 in the copper alloy body 3A of the non-ferrous metal body 3 constituting the molding mold 1, specifically, the core mold A mold holding unit 92 is provided.
Therefore, at least the inlet side 9a of the holding part 9, and in the third embodiment, the inlet side 92a (cavity side) of the core mold holding part 92 is thinned to a thickness of several mm or less, and the thin part 13 is The steel wire W is build-up welded using laser welding to form an iron-based build-up portion 4, and a finished iron material layer 4A is provided on the build-up portion surface 4a. Protect side 92a.
When the core guide 62 of the core mold 1C is formed of the copper alloy body 3A of the non-ferrous metal body 3, the guide head 62a of the core guide 62 is thinned to a thickness within a few millimeters, and the YAG label is formed on the thin portion 13. The steel wire W is build-up welded using the welding to form the iron-based build-up portion 4, and a finished iron material layer 4A is provided on the build-up surface 4a, and the guide head 62a is formed by the iron material layer 4A. Protect.

The fourth embodiment of the hybrid mold according to the present invention will be described with respect to differences from the first to third embodiments. The hybrid mold according to the fourth embodiment projects toward the cavity E as the product-related portion 7. When the holding part 9 is formed in the copper alloy body 3A, the at least the inlet side 9a of the general holding part 9 has a thickness within several millimeters. Then, the steel material wire W is build-up welded to the thin-wall portion 13 by using YAG laser welding to form an iron-based build-up portion 4, and the iron material layer 4 </ b> A finished to the build-up portion surface 4 a is formed. The holding portion inlet side 9a is protected by the iron material layer 4A.
When the partial molded body 8 is, for example, an insert material 81 or a fine molded body 83 as shown in FIG. 5, a partial formed body holding portion 91 for the insert material 81 or the fine molded body 83 is provided on the copper alloy body 3A. The iron material layer 4A is provided at least on the inlet side 91a of 91, and the holding portion inlet side 91a is protected by the iron material layer 4A.

The fifth embodiment of the hybrid mold according to the present invention will be described with respect to differences from the first to fourth embodiments. The hybrid mold according to the fifth embodiment is the same as the mold 1 shown in FIG. 10 and a nested mold 20 incorporated in the steel material mold 10, the nested mold 20 is a copper alloy body 3A of a non-ferrous metal body 3, and a cavity E is formed in the nested mold 20 composed of this copper alloy body 3A. As in the embodiment, the thin wall portion 13 is provided in the load concentration range of the cavity E and the cavity continuous portion 3a of the PL, and the steel wire W is overlay welded to the thin wall portion 13 using YAG laser welding. 4 is provided, and the nested mold 20 made of the copper alloy body 3A is protected by the iron material layer 4A.
Further, as shown in the second embodiment, the insert pin 51 of the slide body 5 and the slide body receiving portion 6 may be provided with the protruded pin insertion hole 61 in the insert mold 20 made of the copper alloy body 3A.
Furthermore, as in the third embodiment, the molding die 1 can be configured using the core die 1C, or the holding portion 9 of the partial molded body 8 can be formed as in the fourth embodiment.

  The sixth embodiment of the hybrid mold according to the present invention will be described in terms of differences from the first to fifth embodiments. The hybrid mold of the sixth embodiment is such that the molding mold 1 is a left mold as shown in FIG. A blow mold 11 comprising a mold 11A and a right mold 11B, wherein at least the heat exchange ranges of the left and right molds 11A and 11B are formed by the non-ferrous metal bodies 3 and 3, respectively, and at least the non-ferrous metal bodies 3 and 3 are butted The part is thinned to a thickness of several millimeters or less, and the steel wire W is build-up welded to the thin-wall part 13 using YAG laser welding to form an iron-based build-up part 4, and the build-up part surface 4 a The finished iron material layer 4A is provided, and the burr cutting portions 24, 24 are formed by the iron material layer 4A so that the burr of the product can be cut at the time of release.

Experimental Example 1 (Verifying the welding state of a non-ferrous metal body)
Experimental conditions Copper alloy body 3A: As shown in FIG. 12, a test piece is an HIT75 having a vertical d = 10 mm, a horizontal w = 10 mm, and a height h = 10 mm (a dice type having a side of 10 mm).
Steel wire W: Stainless steel wire W having a trade name “Starbucks” of 0.3 mmφ and 0.6 mmφ is used. In addition, when laser welding the 0.3φ steel wire W, it is possible to build up a thickness of about 0.2 mm by one welding, and when 0.6φ steel wire W is pulse-welded, Can build up to 0.4 mm.
-Build-up conditions A 0.5 mm thin portion 13 (welded surface) is provided on a half width of 5 mm on one side of the test piece.
YAG laser welding: 100W and 200W laser welding machines made in Germany are used.
After welding the steel wire W at a constant pitch using a YAG laser on the welding surface and providing the iron-based built-up portion 4 in a slightly higher range than the welding surface, The test piece provided with the raised portion 4 is finished (polished) to form an iron material layer 4A having a build-up height t of 0.5 mm.

In order to verify the formation state of the iron material layer 4A, particularly the bonding state of the iron material layer 4A, an experiment was performed by changing the YAG laser welding conditions and the like.
Observation result In visual observation, the iron material layer 4A and the copper alloy body 3A are in a laminated state as shown in FIG. 14, and a boundary line is visible between the iron material layer 4A and the copper alloy body 3A.
In the 300 times magnified photograph taken with a microscope, depending on the conditions of YAG laser welding, cracks or pores were formed in the iron material layer 4A as shown in FIGS. 15 to 18, and the boundary line with the copper alloy body 3A was disturbed. The detailed relationship between the YAG laser welding conditions and the sample will be added later.
The linear trace in FIG. 15 is generated by polishing.
The very surface of the copper alloy body 3A is melted by the energy of the YAG laser, and the steel wire W melted by the energy of the YAG laser flows into the melted part, solidifies and solidifies on the surface of the copper alloy body 3A. 4 appears to be formed, but a trace of the melting of the surface of the copper alloy body 3A could not be found by a microscope.
However, the iron material layer 4 </ b> A and the copper alloy body 3 </ b> A are strongly attached so that the heel is also attached with glue or an adhesive.

Experimental example 2 (consideration on build-up height t)
Experimental conditions Non-ferrous metal body 3: The same copper alloy body 3A as in Experimental Example 1 is used.
Steel wire W: 0.3 mmφ stainless steel wire W is used.
Sample 1 = overlay height t = 0 · 0.1 mm
Sample 2 = overlay height t = 0.3 mm
Sample 3 = overlay height t = 0.5 mm
Sample 4 = overlay height t = 1.0 mm
The thin-walled portion 13 of each sample is thinned according to the build-up height t, and after welding the steel wire W to the thin-walled portion 13 using a YAG laser, the surface of the iron-based built-up portion 4 is adjusted to an appropriate dimension. Finished until it was.

Experimental example 3 (consideration by welding means)
Experimental conditions: Same as Experimental Example 1.
Sample 5 = The iron-based built-up portion 4 is formed only by YAG laser welding.
Sample 6 = The first layer is formed by YAG laser welding, and the rest is built up by pulse welding.
Sample 7 = The iron-based built-up portion 4 is formed only by pulse welding.
Comparison of Samples 5 to 7 The time required for overlay welding is in the relationship of Sample 7 <Sample 6 <Sample 5.
Adhesion status of the iron-based built-up portion 4: In the observation with a microscope, the sample 5 and the sample 6 were substantially the same.
Sample 7 was somewhat disturbed.

-Inspection target Review the quality of each sample and determine the appropriate thickness.
Welding technology and joint strength and reliability evaluation related to the above.
Evaluation of physical properties of the joint surface of the steel layer 4A that has undergone overlay welding.
Investigate surface hardness. (Micro Vickers hardness measurement)
Investigation of the soundness of the joint interface (whether pinholes and interface phases are formed, weld cracks, etc.) due to changes in welding conditions, (light microscope observation of cross-sectional structure, EPMA analysis)
Confirmation of heat treatment effect of iron material layer 4A (micro Vickers hardness measurement)
Investigation of material in heat affected zone (presence of phase transformation, change in crystal grain size and change in physical properties)
Consideration of system for mold production, repair and modification using this technology.

・ Experimental results Qualitative analysis and situation observation of the copper alloy body 3A and the steel layer 4A overlay welded to it In the observation and analysis (SEM) under the microscope, almost no defects due to welding were observed, and a quality of practical level was obtained. Is very likely.

-Attempts by welding methods other than YAG laser In TIG and precision spot welding, many defects such as "pinholes" and "cracks" are observed, and some of the build-up parts fall off, which is not practical.
The above-mentioned experiment is only a very limited preliminary observation, and intensive research and development will be conducted for full-scale technological development. In particular, a high energy density heat source other than a YAG laser is currently being tested.

When the sliding body 5 is formed of the copper alloy body 3A of the non-ferrous metal body 3, at least the head portion 5a is thinned to a thickness within several millimeters as shown in FIG. 9, and the thin-walled portion 13 is subjected to YAG laser welding. The steel material wire W is build-up welded to form the iron-based built-up portion 4, and the finished iron material layer 4A is provided on the build-up surface 4a, and the sliding body head 5a is protected by the iron material layer 4A.
For example, when the slide core 52 of the sliding body 5 is formed of the copper alloy body 3A, the core core 52a (exposed portion exposed in the cavity and an appropriate range following the core) 52a at least in the range where the slide core 52 is likely to be worn is several. The steel wire W was overlay welded to the thin portion 13 using YAG laser welding to form an iron-based overlay portion 4, and the overlay portion surface 4a was finished. The iron material layer 4A is provided, and the core head portion 52a is protected by the iron material layer 4A.
When the protruding pin 51 of the sliding body 5 is formed of the copper alloy body 3A, an iron material layer 4A is provided on the pin head 51a in the same manner as the slide core 52 made of the copper alloy body 3A. Protect 51a.

As shown in FIG. 8, the nonferrous metal body 3 is provided with a notch 19 continuous to the cavity E, and the steel wire W is overlay welded to the notch 19 using YAG laser welding. It is also possible to process the gate path 2 in the roughly built-up portion 14 and provide the gate iron material layer 14A finished on the built-up portion surface 4a so as to close the notch 19 with the roughly iron material layer 14A. .
As the gate path 2, a side gate 2a, a tunnel gate 2b, and a direct gate 2c can be provided.

  The molding die 1, the sliding body 5, the component forming body 8, etc. having the iron material layer 4 </ b> A in the load concentration range where the nonferrous metal body 3 is likely to be worn are placed in a heating furnace and kept for a certain time at a temperature lower than the melting point of the copper alloy If heated, distortion (such as internal stress generated by welding) generated when the iron material layer 4A is built up by heating is removed. As a result, damage and breakage due to distortion are significantly reduced.

In the embodiment, YAG laser and pulse welding are used for overlay welding with the steel wire W, but laser welding other than YAG laser welding, electron beam welding, ultrasonic welding, etc. may be used. . In addition, the first layer is formed by YAG laser welding, and the second and subsequent layers are formed by pulse welding to form the iron-based built-up portion 4, and then finished to the built-up portion surface 4 a to form the iron material layer 4 </ b> A. It is preferable to do.
The embodiment has exemplified the injection mold for synthetic resin and the blow mold, but is not limited to both molds. For example, the present invention can be applied to a compression mold and an extrusion mold. For example, it can be applied to die casting molds, rubber molding molds, and glass molds other than resin molds.
Further, when the partially molded body 8 is a core body 84 made of the copper alloy body 3A as shown in FIG. 11 and the core body holding portion 94 is also provided on the copper alloy body 3A, the iron material layer 4A is provided on the entire surface of the core body 84. Preferably, the core body holding portion 94 is also covered with the iron material layer 4A.
When the partial molded body 8 is a gate body 82 made of steel as shown in FIG. 10, it is possible to provide the copper body 3 </ b> A with the gate body holding portion 93 and incorporate the gate body 82 into the general holding portion 93.
Even if the molding die 1 or the non-ferrous metal body 3 constituting the molding die 1 is a copper alloy body 3A having good heat conduction, it is preferable to provide a cooling water channel as in the case of a conventional steel mold. .

DESCRIPTION OF SYMBOLS 1 Molding die, 1A Fixed die, 1B Movable die, 1C Core die 11 Blow molding die, 11A Left die, 11B Right die 10 Steel material type, 20 Nesting die 2 Gate path 2a Side gate, 2b Tunnel Gate, 2c Direct gate 3 Non-ferrous metal body, 3A Copper alloy body (test piece), 13 Thin part (welded surface)
3a Parting line (PL) cavity continuous part 4 Iron-based built-up part, 4A Iron material layer, 4a Overlaid part surface 14 Iron-based built-up part for gate, 14A Gate iron-made part, 24 Burr cut-off part 5 Sliding body, 5a Head (exposed part + α)
51 Extruding Pin, 52 Slide Core 51a Pin Head, 52a Core Head 6 Sliding Body Receiving Part, 6a Receiving Port Entrance Side 61 Pin Inserting Hole, 62 Core Guide 61a Inserting Hole Inlet Side, 62a Guide Head 7 Product Related Parts 8 Partial molded body, 81 Insert body (in-mold), 82 Gate body 83 Fine molded body, 84 Core body 9 Holding part, 19 Notch part 91 Partial molded body holding part, 92 Core mold holding part, 93 Gate body holding part 94 Core body holding part, 9a, 91a, 92a Holding part inlet side F Iron-based material, W Steel wire E Product forming part (cavity), e Product forming surface R laser, R1 YAG laser (precision micro YAG laser)
t Overlay height

Claims (11)

Forming at least the heat exchange range of the molding die (1) with a non-ferrous metal body (3);
A non-ferrous metal body (3) is provided with a cavity (E) and a product-related part (7),
Forming a thin-walled portion (13) in which at least the product concentration surface (e) of the cavity (E) that is easily damaged is made thinner than a predetermined finish thickness;
Using a heat source with a high energy density for the thin-walled portion (13), the iron-based material (F) having a melting temperature higher than that of the non-ferrous metal body (3) is welded to form an iron-based built-up portion (4), Provide the finished iron layer (4A) on the surface of the overlay (4a)
A hybrid mold characterized in that an iron material layer (4A) protects a load concentration range where product formation surface (e) is easily damaged.   The product related part (7) is the cavity continuous part (3a) of the parting line (PL) of the non-ferrous metal body (3), and the thin part (13) is formed in the substantially continuous part (3a). 13) Using a heat source with a high energy density, the iron-based material (F) is build-up welded to form an iron-based built-up portion (4), and the surface of the built-up portion (4a) is finished with an iron material layer ( The hybrid mold according to claim 1, wherein 4A) is provided and a PL cavity continuous part (3a) is formed in the iron material layer (4A). The product-related part (7) is a sliding body (5) that reciprocates toward the cavity (E), and a sliding body receiving part (6) that guides the sliding body (5) slidably,
The sliding body receiving portion (6) has the thin portion (13) formed at least on the inlet side (6a), and the iron-based material (F) is welded to the thin portion (13) using a high energy density heat source. Then, an iron-based built-up part (4) is formed, and the surface of the built-up part (4a) is provided with a finished iron material layer (4A), and the iron material layer (4A) is provided at the inlet side of the sliding body receiving part (6) ( The hybrid mold according to claim 1 or 2, wherein 6a) is protected. The sliding body (5) is formed of a non-ferrous metal body (3),
Forming the thin-walled portion (13) on at least the head (5a);
The steel-based material (F) was build-up welded to the thin-walled portion (13) using a heat source with a high energy density to form the iron-based built-up portion (4), and the surface of the built-up portion (4a) was finished. The hybrid mold according to claim 3, wherein an iron material layer (4A) is provided, and the sliding body head (5a) is protected by the iron material layer (4A).   The product-related part (7) is a holding part (9) of the partially molded body (8) forming a part of the cavity (E), and the holding part (9) opens toward the cavity (E), at least of which The thin-walled portion (13) is formed on the inlet side (9a), and the iron-based material (F) is build-up welded to the thin-walled portion (13) using a heat source having a high energy density, and the iron-based built-up portion (4) And an iron material layer (4A) finished on the surface of the built-up portion (4a) is provided, and the holding portion inlet side (9a) is protected by the iron material layer (4A). The hybrid metal mold | die as described in any one of -4. The molding die (1) consists of a steel material die (10) and a nested die (20) incorporated in the steel material die (10).
The hybrid mold according to any one of claims 1 to 5, wherein the nesting mold (20) is formed of a non-ferrous metal body (3). The molding die (1) is a blow molding die (11) comprising a left die (11A) and a right die (11B), and at least the heat exchange range of the left and right dies (11A, 11B) is a non-ferrous metal body ( 3, 3)
Forming the thin-walled portion (13) at the butted portion of the non-ferrous metal body (3, 3);
The steel-based material (F) was build-up welded to the thin-walled portion (13) using a heat source with a high energy density to form the iron-based built-up portion (4), and the surface of the built-up portion (4a) was finished. The hybrid metal mold according to claim 1, wherein an iron material layer (4A) is provided, and the burr cut-off portions (24, 24) are formed by the iron material layer (4A).   The iron material layer (4A) is formed by depositing the iron-based material (F) into a single layer or multiple layers using a heat source with a high energy density to form the iron-based cladding portion (4), and then the surface (4a). The hybrid mold according to any one of claims 1 to 7, wherein the hybrid mold is finished to have an average height (t) of 2 mm or less.   The non-ferrous metal body (3) is provided with a notch (19) continuous to the cavity (E), and an iron-based material (F) is welded to the notch (19) using a high energy density heat source, and the gate An iron-based built-up part (14) is provided, a gate path (2) is provided on the approximate built-up part (14), and an iron material layer (14A) for finishing the built-up part surface (4a) is provided. The hybrid mold according to any one of claims 1 to 8, wherein the notch (19) is closed with a layer (14A).   The iron-based material (F) is a steel wire (W) for welding, and the non-ferrous metal body (3) has a lower melting temperature than the iron-based material (F), and has good heat conduction, such as a copper alloy body (3A) or aluminum. It is an alloy body etc., The hybrid metal mold | die as described in any one of Claims 1-9 characterized by the above-mentioned.   The high energy density heat source used for overlay welding of iron-based material (F) uses at least one means during laser welding (YAG laser welding), pulse welding, electron beam welding, and ultrasonic welding. The hybrid mold according to claim 1, wherein overlay welding is performed.