JP4617404B2 - Method for producing molded product using brazing material - Google Patents

Description

The present invention relates to a method for manufacturing a mold-molded product made of a mold or a machine part using a brazing material manufactured using a mold.

In recent years, for example, with the miniaturization and weight reduction of medical equipment and home appliances, it has become necessary to refine and refine the shape of molds for producing components. In addition, due to the rapid changes in needs for products, the cycle time (use period) of products is also shortening, so the demand for shortening the delivery time of molds has become increasingly severe. For this reason, the necessity to manufacture a highly accurate and fine metal mold with a short delivery time has further increased. This also applies to the mechanical parts that constitute the product.

As a conventionally used mold, for example, Patent Document 1 discloses a mold in which a nested mold processed in a separate process is brazed into a die set as a mother mold. However, since all of the nested molds need to be machined using, for example, a machine tool, there is a limit to shortening the machining time, and it is difficult to shorten the delivery time of the mold.
In Patent Document 2, a master mold having a final product shape in consideration of the shrinkage rate is manufactured, the master mold is inserted into a mold, and a powder obtained by mixing a metal powder and an organic binder is injected into an injection molding machine. A method is disclosed in which a mold is molded by filling in a mold frame using a mold, and then the mold molded product is processed and then degreased and fired to produce a mold. However, since there are a plurality of steps until the mold is manufactured, workability is poor, and further, it is necessary to process the mold product, so that the manufacturing time cannot be further shortened.
In Patent Document 3, the surface of the master mold is subjected to electroless composite plating, and after the surface modification of the plating layer, a low melting point metal is sprayed thereon to form a coating of several mm, A method of manufacturing a mold by releasing a mold after filling a low melting point metal or a thermosetting resin as a reinforcing material is disclosed. However, an apparatus for performing thermal spraying is required and equipment costs are increased. In addition, there are a plurality of mold manufacturing processes, workability is poor, manufacturing time is long, and it is difficult to shorten the delivery time of the mold.

Patent Document 4 discloses a method of manufacturing a cooling medium passage by integral casting with a mold using a collapsible sand core in order to manufacture a mold with improved cooling efficiency. However, every time the mold is manufactured, the collapsible sand core must be formed in the shape of the cooling medium passage, which increases the manufacturing time of the mold and cannot shorten the delivery time of the mold.
Patent Document 5 discloses a method for producing a mold by transferring a master mold. At the time of this transfer, a transfer mold is produced by spraying or electroforming the product surface. However, an apparatus for thermal spraying or electroforming is required, and it is not economical because the equipment cost is high, and it is difficult to sufficiently shorten the mold manufacturing time in order to perform thermal spraying or electroforming on the product surface. .
Further, in Patent Document 6, a product shape model is placed in a casting frame, and a molten metal of a low melting point alloy is poured into the casting frame to solidify it. After casting a pair of molds, only the model is removed and a mold is formed. A method of manufacturing is disclosed. However, since the mold is manufactured by pouring the molten metal, segregation is likely to occur depending on the chemical composition of the molten metal, and there is a risk that a mold composed of a uniform chemical component may not be manufactured, and there are multiple manufacturing processes for the mold. As a result, workability was poor, and the manufacturing time was long, making it difficult to reduce the delivery time of the mold.

Therefore, in order to meet the necessity of manufacturing a highly accurate and fine mold with a short delivery time, the LIGA process shown in FIG. 3 has been proposed. The method will be described below.
First, after forming a photomask layer for obtaining a desired shape on the upper surface of the photoresist layer provided on the substrate, X-rays or ultraviolet rays are directed from the direction in which the photomask layer is arranged toward the photoresist layer. Irradiate light. As a result, a portion of the photoresist layer where the photomask layer is not disposed can remain on the substrate, and a resist microstructure can be obtained. Next, after the molten metal of the metal constituting the mold is cast (electroformed) in the portion where the photoresist layer has been removed and solidified, the photoresist layer remaining on the substrate is removed and the micro mold is removed. Manufacturing.
Thereby, the metal mold | die or mechanical component provided with the fine shape can be manufactured.

JP 2000-185336 A Japanese Patent Laid-Open No. 7-268407 JP-A-7-52162 Japanese Unexamined Patent Publication No. 7-47594 JP-A-6-132334 JP-A-2-307633

However, the X-ray exposure apparatus used for the above-described LIGA process is very expensive, and only about 5 units currently exist in the country. Therefore, when this method is used, it is very expensive. In this method, since the mold is manufactured by irradiation with X-rays or ultraviolet light from one direction, the mold that can be manufactured has a two-dimensional shape with the same cross-sectional shape. For this reason, when the target metal mold | die is a three-dimensional shape, it is necessary to perform further conventional machining, and cannot shorten manufacturing time.
In addition, in order to manufacture a mold having a three-dimensional shape with a different cross-sectional shape, there is also a method of manufacturing a mold by producing a target product shape by machining and inverting the shape using high-speed electroforming. .
However, in this method, several hours are required to mold the mold shape, so that it is not possible to shorten the manufacturing time of the mold, and it cannot contribute to shortening the delivery time.

The present invention has been made in view of such circumstances, and is a mold using a brazing material capable of economically producing a product composed of a mold or a machine part having a high precision and a fine shape with a shorter delivery time than before. It aims at providing the manufacturing method of a frame molded product.

The method for manufacturing a mold-molded product comprising a mold or a machine part according to claim 1, wherein the mold or machine part is produced by melting and solidifying a brazing filler metal powder in the mold. A method for producing a molded product, comprising:
The brazing powder has a melting point of 600 ° C. or higher and 1300 ° C. or lower, and is one or more of Ni brazing filler metal, Cu brazing filler metal, Co brazing filler metal, Fe brazing filler metal, and Ag brazing filler metal. Consisting of a mixture, the brazing material powder is heated and melted in a vacuum or an inert gas, and further, the brazing material melted in the mold is cooled and solidified by solidification by pressing,
The mold product is manufactured by repeatedly using the mold.
2. A method of manufacturing a mold-molded product comprising a mold or a machine part according to claim 1, wherein a mold (for example, a plastic injection mold) which is a mold-molded product manufactured from a brazing filler metal powder is used as a mother. It may be a nested mold that is a partial mold used by being fitted in the mold, or may be the entire mold. Examples of mechanical parts include various gears, pulleys, chains, sprockets, bearings, bushings, retaining rings, various joints, various washers, various bolts, and various nuts.
Further, the mold into which the brazing material powder is put is preferably composed of a material having a low coefficient of thermal expansion and hardly reacting with the brazing material. For example, after processing the material using a machining center or an NC machine tool, Depending on the case, it can be manufactured by grinding or polishing which is a finishing process. In addition, as long as the material of a formwork has electroconductivity, it is also possible to manufacture a formwork by electric discharge machining.
By using this method, a mold having a shape corresponding to the product shape, that is, a master die, is produced, so that the surface shape of the master die can be transferred to the molten brazing material.
As the brazing material, one having a melting point of 600 ° C. or higher, preferably 800 ° C. or higher, more preferably 1000 ° C. or higher, and 1300 ° C. or lower, preferably 1200 ° C. or lower can be used. Further, the brazing material has a hardness with a degree of wear resistance that does not cause a problem even when used as a mold, for example, when using Rockwell C scale, H _R C45 or more, preferably H _R C50 As described above, more preferably one having H _R C60 or more can be used. In addition, as a brazing filler metal powder, a powder form or a pellet form can be used.

In this method of manufacturing a mold-molded product made of a mold or a machine part, the Ni-based brazing material contains Ni, for example, one or more elements of Cr, B, Si, Fe, C, and W. The Cu-based brazing material is Cu containing, for example, one or more elements of Sn, Fe, Ni, Mn, Ag, P, Si, and Zn. The brazing filler metal contains Co, for example, one or more elements of Cr, W, Si, B, Ni, Mo, and Fe. The Fe brazing filler metal is Fe, For example, one or more elements of Cr, B, Si, C, Co, and Mo are contained, and the Ag-based brazing material is Ag, for example, Cu, Zn, Cd, Ni, Sn , Li, and Si contain one or more elements.
Moreover, in the manufacturing method of the mold molding product which consists of this metal mold | die or machine parts, a vacuum is in any state from a low vacuum (10 < ² > Pa or more) to a very high vacuum (10 < ^-10 > Pa or less) , for example. Although there may be, it is so preferable that a vacuum degree is high. Moreover, it is preferable to use argon gas as an inert gas.
In this method of manufacturing a molded product comprising a mold or a machine part, pressing does not apply a large load to the molten brazing material, for example, there is no gap formed between the brazing material powders. And when the molten brazing material is solidified and contracted, a load is applied to such an extent that there is no gap generated between the molten brazing material and the inner surface of the mold.

The method of manufacturing a mold-molded product comprising a mold or a machine part according to claim 2 is the method of manufacturing a mold-molded product comprising a mold or a machine part according to claim 1 , wherein the mold is made of a boron nitride material. , Graphite material, and ceramic material.
3. The method for producing a molded product comprising a mold or a machine part according to claim 2, wherein the boron nitride material is, for example, hBN that can be machined, cBN that is a hard material, or pcBN (polycrystalline cubic nitriding). Boron) or wBN (wurtzite boron nitride) can be used. As the boron nitride material, for example, a material having conductivity in which conductive metal powder is dispersed inside, or, for example, CaO, B ₂ O ₃ , Al ₂ O ₃ , SiO ₂ , AlN, and Si It is also possible to use one containing ₃ N ₄ or more.
Further, as the ceramic material, for example, one or more of Al ₂ O ₃ , Si ₃ N ₄ , AlN, and ZrO ₂ can be used.

Method for producing a mold shaped articles consisting of a mold or machine component according to claim 3, wherein, in the method for manufacturing a mold shaped articles consisting of a mold or machine component according to claim 1 and 2, wherein cooling in the mold in 1 or 2 or more of pipes, heaters, and thermocouples are disposed, and after the brazing filler metal powder is put in the mold and melted, or the brazing filler metal powder is put in the mold After melting and arranging one or more of cooling pipes, heaters, and thermocouples in the molten brazing material, the molten brazing material is solidified.
In the manufacturing method of the mold-molded product which consists of a metal mold | die or a machine part of Claim 3 , cooling piping flows the water which is a cooling medium inside, for example, in order to remove heat of the product which became high temperature. There can be used a material having a melting point higher than that of the brazing material, for example, steel. In addition, the shape of the cooling pipe is configured by one or both of a straight line and a curve, for example, depending on the installation position of the cooling pipe.
Here, the heater is installed at a target position in a state where the surface side is protected, and the thermocouple is installed in the protective tube.

The method for producing a molded product comprising a mold or a machine part according to any one of claims 1 to 3 is manufactured by melting and solidifying a brazing filler metal powder in a mold, so that conventional machining is unnecessary. Thus, a product having a high precision and a fine shape can be economically manufactured with a shorter delivery time than before.
In addition, for example, even when a large number of products are required, the products can be manufactured easily and in a short time by repeatedly using the above-mentioned formwork, and the effect of shortening the manufacturing time is more remarkable. Obtainable.
In addition, since melting | fusing point can be lowered | hung compared with a pure metal by using brazing material, the heat energy cost at the time of manufacture of a mold-molded product can be reduced and it is economical, for example. Further, by using a brazing material, for example, hardness can be increased as compared with other alloys and the like, so that it is suitable for manufacturing a mold-molded product made of a mold or a machine part in which wear resistance is a problem. .

Then, by defining the brazing material to use, it can produce a product with a quality capable of withstanding long-term use.
Also, by using a mold that has been subjected to grinding or polishing work on the surface, the surface state of this mold is transferred to the brazing material, so there is no need for final finishing. Can produce products.
And since the brazing filler metal is in the form of powder, the chemical components of each powder are substantially uniform, and the segregation of the chemical components during melting of the brazing filler metal occurs when the molten state is made shorter. It is difficult to produce a product having chemical components that are substantially uniform throughout the product.

In particular, the method for manufacturing a molded product comprising a mold or a machine part according to claim 2 can manufacture a mold having a quality that can withstand long-term use by setting the constituent material of the mold. A plurality of products can be repeatedly manufactured from one mold, and the manufacturing cost of the products can be reduced.

In the method for producing a molded product comprising a mold or a machine part according to any one of claims 1 to 3 , the brazing filler metal powder is heated and melted in a vacuum or in an inert gas, so that oxidation of the brazing filler metal can be suppressed. In addition, the amount of voids remaining in the brazing filler metal can be reduced by melting the brazing filler metal powder in vacuum compared to the case where the brazing filler metal is melted in air, thereby suppressing and further preventing the presence of voids. Can provide good quality products.

In the method for producing a molded product comprising a mold or a machine part according to claims 1 to 3 , since the molten brazing material is cooled and solidified by being pressed, the amount of voids remaining in the brazing material is further reduced. Can be reduced.

According to the method for manufacturing a molded product comprising a mold or a machine part according to claim 3, before the brazing material is solidified, any one or more of a cooling pipe, a heater, and a thermocouple are provided inside the brazing material. For example, when manufacturing a mold, it is possible to form not only a linear refrigerant passage as in the prior art but also a bent refrigerant passage that cannot be formed in the past. is there. In addition, also about the installation position of a heater and a thermocouple, the freedom degree can be given to the installation position rather than before.
Accordingly, one or more of cooling pipes, heaters, and thermocouples can be installed at a position following the surface shape of the mold to be manufactured, that is, at a substantially constant distance from the mold surface. Therefore, the temperature control of the mold can be surely performed, and a molded article having good quality can be manufactured.
In addition, for mechanical parts, for example, a product capable of performing temperature management can be provided by installing one or more of cooling pipes, heaters, and thermocouples.

Next, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention.
Here, FIG. 1 is an explanatory view of a method for producing a molded product using the brazing material according to the first embodiment of the present invention, and FIG. 2 shows the brazing material according to the second embodiment of the present invention. It is explanatory drawing of the manufacturing method of the used formwork molded product.

As shown in FIG. 1, a mold-molded product (hereinafter also simply referred to as a product) 10 using a brazing filler metal according to a first embodiment of the present invention is partially used by being fitted into a mother mold. It is a mold or a machine part that is a mold, and is manufactured by putting the brazing filler metal powder 11 into a mold 12 and melting and solidifying it. This will be described in detail below.

The brazing filler metal powder is composed of one or a mixture of two or more of a Ni brazing filler metal, a Cu brazing filler metal, a Co brazing filler metal, an Fe brazing filler metal, and an Ag brazing filler metal, depending on the application. The melting point thereof is, for example, 600 ° C. or higher, preferably 800 ° C. or higher, more preferably 1000 ° C. or higher, and 1300 ° C. or lower, preferably 1300 ° C. or lower. The hardness of the solidified brazing filler metal is, for example, H _R C45 or higher, preferably H _R C50 or higher, more preferably H _R C60 or higher when using Rockwell C scale.
As the powder, for example, a powdery powder having a size of 0.1 mm or more and 5 mm or less, preferably 0.1 mm or more and 2 mm or less can be used, but a pellet can also be used. . In addition, in order to raise the true density of the product to manufacture, the one where the magnitude | size is fine is preferable.

Next, a method for manufacturing a molded product using the brazing filler metal according to the first embodiment of the present invention will be described with reference to FIG.
First, the brazing filler metal powder 11 is charged into the mold 12.
The mold 12 is composed of one or more of boron nitride material, graphite material, and ceramic material. Depending on the shape of the product 10 to be manufactured, for example, a machining center is used on the inside thereof. It has been processed.

The mold 12 is placed in a high-frequency induction heating furnace (not shown), and a current is passed through the heating coil 13 disposed around the mold 12 so that the mold 12 is heated at a temperature, for example, about 50 ° C. higher than the melting point of the brazing powder. The material powder 11 is melted by high frequency induction heating.
The melting of the brazing filler metal powder 11 is preferably performed, for example, by using a vacuum pump (not shown) connected to the inside of a high-frequency induction heating furnace and evacuating the furnace atmosphere. It is also possible to carry out by filling a gas (for example, argon gas).

When almost the entire brazing filler metal powder 11 is melted, a pressing material 14 corresponding to the shape of the inner upper part of the mold 12 is used, and the molten brazing material is cooled while being pressed from above. The pressure is such that there is no gap formed between the brazing filler metal powder 11 and that there is no gap generated between the molten brazing material and the inner surface of the mold 12 when the molten brazing material is solidified and contracted. This is done by applying a load. As a result, it is possible to manufacture the product 10 in which the molten brazing material can be spread to the details of the complex shape, and the generation of voids is suppressed and further prevented.
And by this cooling, the product 10 can be manufactured by solidifying the molten brazing material while solidifying it. When the product 10 is a nested type, it is attached to a mold apparatus (not shown) and used for manufacturing a molded product, and when the product 10 is a mechanical part, the product 10 can be used as it is.

Next, a method for manufacturing a molded product using the brazing filler metal according to the second embodiment of the present invention will be described. The form-molded product manufactured here is a telescopic mold 15.
First, a rectangular parallelepiped material made of a boron nitride material is processed using a tool 17 attached to a spindle 16 of a machining center, and further subjected to, for example, grinding or polishing to manufacture a mold body 18. To do.
Next, after the mold body 18 is attached to the fixed mold 19 serving as a mother mold to form the mold 20, the surface of the mold body 18 and the preset gap are formed so that a predetermined gap is formed. The cooling pipe 21 deformed into a shape following the surface shape is installed on the fixed mold 19 and its position is fixed. Then, the brazing filler metal powder 22 is charged into the mold 20.

The mold 20 is placed in a high-frequency induction heating furnace (not shown) and the atmosphere in the furnace is evacuated, and the brazing filler metal powder 22 is high-frequency induction at a temperature, for example, about 50 ° C. higher than the melting point of the brazing filler metal powder 22. Heat to melt. Here, it is also possible to put the brazing filler metal powder 22 in the mold 20 and melt it, and further dispose the cooling pipe 21 in the molten brazing filler metal.
When almost the whole brazing filler metal powder 22 is melted, a press member 23 provided above the mold 20 so as to be movable up and down is used, and the molten brazing filler metal is cooled while being pressed.

By this cooling, the molten brazing material is solidified while being solidified, and an insert mold 15 in which a cooling pipe 21 is arranged can be manufactured. The insert mold 15 is attached to a mold apparatus (not shown) to form a metal mold. Used for the production of molded products.
In this way, since the cooling pipe can be arranged in advance in the melting process of the brazing filler metal powder, it is complicated in accordance with the shape of the mold product manufactured using the insert mold inside the insert mold. It becomes possible to arrange complicated cooling pipes. Here, it is also possible to install a heater instead of the cooling pipe.
The same applies to the thermocouple, and the thermocouple can be reliably arranged at a position where temperature measurement is required.

As described above, the present invention has been described with reference to the embodiment. However, the present invention is not limited to the configuration described in the above embodiment, and the matters described in the scope of claims. Other embodiments and modifications conceivable within the scope are also included. For example, a case where a method for manufacturing a molded product using the brazing material of the present invention is configured by combining some or all of the above-described embodiments and modifications is also included in the scope of the present invention.
Moreover, in the said embodiment, although the case where a telescopic mold was manufactured as a metal mold | die which is a mold forming product was demonstrated, with the metal mold | die which became a structure separable like a base mold and a telescopic mold In addition, the present invention can be applied to the case of manufacturing a mold in which a mother mold and a nested mold are integrated.
In order to further increase the hardness of the brazing material, for example, one or more treatments of formation of intermetallic compounds, adjustment of crystal grain size, and dispersion of high hardness material (for example, titanium nitride or ceramic powder) are performed. It is also possible to apply.

It is explanatory drawing of the manufacturing method of the formwork molded product using the brazing material which concerns on the 1st Embodiment of this invention. It is explanatory drawing of the manufacturing method of the formwork molded product using the brazing material which concerns on the 2nd Embodiment of this invention. It is explanatory drawing of the manufacturing method of the micro metal mold | die which concerns on a prior art example.

10 :: Molded product using brazing material, 11: brazing powder, 12: mold, 13: heating coil, 14: pressed material, 15: insert mold, 16: main shaft, 17: tool, 18: Mold body, 19: fixed mold, 20: mold, 21: cooling pipe, 22: brazing powder, 23: press material

Claims (3)

A method for producing a molded product comprising a mold or a machine part that is produced by melting and solidifying a brazing filler metal powder in a mold ,
The brazing powder has a melting point of 600 ° C. or higher and 1300 ° C. or lower, and is one or more of Ni brazing filler metal, Cu brazing filler metal, Co brazing filler metal, Fe brazing filler metal, and Ag brazing filler metal. Consisting of a mixture, the brazing material powder is heated and melted in a vacuum or an inert gas, and further, the brazing material melted in the mold is cooled and solidified by solidification by pressing,
A method for producing a mold-molded product using a brazing material, wherein the mold-molded product is produced by repeatedly using the mold. The method for manufacturing a molded product according to claim 1 , wherein the mold is made of one or more of boron nitride material, graphite material, and ceramic material . method of manufacturing a mold molded products had. The method for manufacturing a molded product according to claim 1 or 2 , wherein any one or more of a cooling pipe, a heater, and a thermocouple are disposed in the mold, and the brazing material is further disposed in the mold. After the powder is put and melted, or the brazing material powder is put in the mold and melted, and one or more of cooling pipes, heaters, and thermocouples are placed in the melted brazing material. A method for producing a molded product using a brazing material, characterized by solidifying the melted brazing material after the placement.

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