JPH11302708A - Production of composite material part and composite material part - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a complicated three dimensionally shaped composite material parts consisting of a metal or a ceramic and constituted of >=2 kinds of parts different in the component, and to provide its production method. SOLUTION: At least one or more kinds of powdery material selected from ceramic powder and metal powder are mixed with an organic binder to prepare >=2 kinds of molding materials 4 different in the component. A molding composed of >=2 kinds of parts different in the component is molded by injecting each molding material into a metallic mold 1 to carry out injection molding. The molding is dewaxed and sintered. The injection molding is applicable even for the molding of the complicated three dimensional shape. The molding of complicated three dimensional shaped composite material part composed of >=2 kinds of parts different in the component consisting of the ceramic, the metal or the like is easily produced by sintering the molding in this way.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a composite material part comprising two or more kinds of metal or ceramic materials, and a composite material part.

[0002]

2. Description of the Related Art Cutting tools for cutting metals, plastics, ceramic materials, and the like are made of, for example, a base metal made of tool steel such as SK5, a SKH (high speed tool) steel or a cemented carbide alloy. It is manufactured by joining the blade tip. At this time, as a joining method between the base metal and the cutting edge tip, brazing using a silver brazing method has been often used, but since brazing uses flux, maintenance such as cleaning must be performed frequently, There is also a problem that the flux adheres to a jig or the like and the joining accuracy is deteriorated. In addition, in this brazing, since high heat is applied over a considerably wide area near the joint, SK that has been refined by heat treatment is applied.
There is also a problem that hardness and rigidity are reduced due to annealing of a die or a tip manufactured by SKH (high-speed tool) manufactured by SKH 5 or the like.

[0003] Recently, as an alternative joining method by brazing, a joining method of joining a base metal made of an iron-based material and a cutting edge tip made of a cemented carbide with a high energy beam has been developed. ing. However,
In the case of welding an iron-based material and a cemented carbide, the difference in linear expansion coefficient between the two is large, so that thermal stress is generated at the time of joining, and cracks may occur in the joint and cemented carbide due to this thermal stress. is there.

[0004] Therefore, in the case of joining an iron-based material and a cemented carbide, a metal piece such as nickel or copper is inserted between the two joints, and a high-energy beam is irradiated to the vicinity of the insertion surface to obtain an iron-based material. Or by welding a cemented carbide.

[0005] However, the joining method by welding using a metal piece as described above has a disadvantage that the metal piece must be inserted between the joints, and the joining process becomes complicated. In order to solve such a problem, a composite material component in which the cutting edge tip and the metal piece are integrated is required.

Here, as a method of manufacturing a composite part of a metal and a ceramic material, as described in Japanese Patent Application Laid-Open No. Sho 62-30804, each powder material is alternately filled in a mold, and then hot-pressed. There is a method of manufacturing by sintering by a pressing method or an electric heating sintering method.

[0007]

However, according to the above-mentioned method for producing a composite material, a composite material having a simple shape which can be hot-pressed or electrically heated and sintered cannot be produced. It has been difficult to produce complex three-dimensionally shaped composite parts.

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and a method and a composite material for manufacturing a composite material part having a complex three-dimensional shape composed of two or more types of parts composed of different metals or ceramics. The purpose is to provide parts.

[0009]

According to a first aspect of the present invention, there is provided a method for manufacturing a composite material part, comprising kneading at least one powder material selected from ceramic powder and metal powder with an organic binder. Are prepared and injection molding is performed by injecting each molding material 4 into the mold 1 to form a molded body 6 composed of two or more types of components having different components. It is characterized in that the body 6 is degreased and then sintered.

According to a second aspect of the present invention, there is provided a method for manufacturing a composite material part, comprising the steps of:
Is injected into the mold 1 and an injection device 2 having two or more screws 13 for feeding the molding material 4 to the injection nozzle 3 is used to form two or more types of molding materials 4 having different components. Are sent to the injection nozzle 3 by the respective screws 13, and the molding material 4 is injected into the mold 1 from the injection nozzle 3, whereby two or more types of molding materials 4 having different components are injected into the mold 1. It is characterized by the following.

According to a third aspect of the present invention, there is provided a method of manufacturing a composite material part, wherein a molding material
Nozzle 2 for injecting molding material 1 into mold 1 and two or more injection devices 2 each having screw 13 for feeding molding material 4 to injection nozzle 3, using two or more types of molding materials 4 having different components.
Is sent to the injection nozzle 3 by the screw 13 of each injection device 2, and the molding material 4 is injected into the mold 1 from the injection nozzle 3, whereby two or more types of molding materials 4 having different components are injected into the mold 1. Characterized by being injected into

According to a fourth aspect of the present invention, there is provided a method for manufacturing a composite material part, the method comprising the steps of: Forming a preform 6a to be a part, disposing the preform 6a in the main molding die 1b, and injecting the second molding material 4b into the main molding die 1b. In this case, a molded body 6 is obtained by performing the main molding.

According to a fifth aspect of the present invention, there is provided a method of manufacturing a composite material part, comprising, in addition to any one of the first to third aspects, a preformed portion 23a and a main formed portion 23b therein. The molding material 4 can be injected into the mold 1 having a slide mechanism capable of moving a molded part in the mold 1 between the preforming section 23a and the main forming section 23b, and the preforming section 23a. First injection device 2a, main molding unit 2
The second injection device 2b capable of injecting the molding material 4 into the molding material 3b and the molding material 4 is injected into the preforming portion 23a by using the first injection device 2a to perform the preforming, thereby forming the molded body. Forming a pre-formed body 6a to be a part of 6;
The preformed body 6a is moved to the main forming portion 23b by a slide mechanism.
Then, the molding material 6 is obtained by injecting the molding material 4 into the main molding portion 23b using the second injection device 2b to perform the main molding.

According to a sixth aspect of the present invention, there is provided a method of manufacturing a composite material part, wherein in addition to the constitution of any one of the first to fifth aspects, when preparing two or more types of molding materials 4, No. 4 is prepared by using respective powder materials having the same sintering temperature.

According to a seventh aspect of the present invention, there is provided a method of manufacturing a composite material part, wherein in addition to any one of the first to fifth aspects, when two or more types of molding materials 4 are prepared, 4 is prepared using each powder material having a different sintering temperature, and when the compact 6 is sintered, the preliminary sintering is performed at a temperature lower than the lowest sintering temperature among the sintering temperatures of each powder material. After that, the composite material part 8 is obtained by performing the main sintering.

According to a second aspect of the present invention, there is provided a method of manufacturing a composite material part, wherein the powder material used when preparing two or more types of molding materials 4 is added to any one of the first to seventh aspects. At least one of which is a super-hard material,
Another feature is that the material is highly extensible.

According to a ninth aspect of the present invention, there is provided a method of manufacturing a composite material part, wherein an ultra-hard material is used as the first powder material, It is characterized by using nickel or a nickel alloy as the powder material.

A composite material part according to a tenth aspect of the present invention provides a composite material part obtained by kneading a powder material comprising at least one selected from ceramic powder and metal powder, and an organic binder. It is characterized in that a molded body 6 of two or more different molding materials 4 is degreased and then sintered.

According to the eleventh aspect of the present invention, in addition to the constitution of the tenth aspect, a part serving as a blade part 11a having a cutting edge 10 is formed by a molding material 4 containing a super-hard material. Then, the molded body 6 obtained by molding the portion to be the joining portion 11b to be joined to the base metal 24 with the molding material 4 containing the easily weldable material is degreased and sintered to form the cutting edge 12 of the cutting tool. It is characterized by comprising.

[0020]

Embodiments of the present invention will be described below.

In the first aspect of the present invention, two or more types of molding materials 4 having different components are prepared by using a mixture of one or more types selected from ceramic powder and metal powder as the powder material. Injection molding is performed by injecting the material 4 into one mold 1 to form a molded body 6 composed of two or more kinds of components having different components, and the molded body 6 is degreased and then sintered. This is to obtain a composite material part 8 composed of two or more types of parts having different components. The average particle size of the powder material is preferably 1 to 10 μm. At this time, the linear expansion coefficient of each powder material is preferably as close as possible.

Specifically, for example, as the first powder material,
A super-hard material such as a metal material such as SKH57 or SKD11, a ceramic material such as alumina or zirconia, or a cemented carbide such as a tungsten-carbide alloy (WC-Co alloy) is used, and 85 wt% is used as the second powder material. The composite material component 8 can be manufactured by using a nickel-15 wt% tungsten alloy (hereinafter, referred to as a nickel alloy) or the like and using the two kinds of powder materials.

A molding material 4 is obtained by mixing and kneading such a powder material and an organic binder (powder injection molding binder). At this time, it is preferable that the kneading ratio of the powder material and the organic binder is 50:50 by volume in any of the molding materials 4 so that the shrinkage ratios of the respective molding materials 4 after sintering are equal. Here, as the organic binder, those composed of ethylene vinyl acetate copolymer (EVA), polybutyl methacrylate, stearic acid, paraffin wax, and the like can be used. For example, "DC-1235" manufactured by Daiichi Ceramo Co., Ltd. Can be used.

The molding material 4 thus prepared is
The molding 7 is molded by injecting into one mold 1 and performing injection molding. In this case, as shown in FIG. 1, an injection molding device 9 including a mold 1, a first injection device 2a, and a second injection device 2b can be used.
Here, a sprue bush 5 for injecting the molding material 4 into the mold 1 is formed in the mold 1, and from the first injection device 2 a and the second injection device 2 b via the sprue bush 5. The molding material 4 is injected into the mold 1.

Then, from the first injection device 2a, a first molding material 4a containing an ultra-hard material as a powder material is prepared.
Is injected into the mold 1, and a second molding material 4b containing a nickel alloy as a powder material is injected into the mold 1 from the second injection device 2b to perform injection molding.
A molded body 6 composed of two types of parts having different components, that is, a part 7a formed of a first molding material and a part 7b formed of a second molding material. Here, the injection molding is preferably performed under the conditions of an injection pressure of 1200 kgf / cm ² , a mold pressure of 750 kgf / cm ² , an injection temperature of 180 ° C., and a mold temperature of 15 ° C. Further, here, as shown in FIG. 2 (a), the formed body 6 has a substantially square blade 11a having a cutting edge 10 formed of a portion 7a made of a first forming material in which an ultra-hard material is mixed. Formed and blade part 1
A substantially L-shaped joining portion 11b is formed on the two sides where the cutting edge 10a is not formed by a portion 7b made of a second molding material in which a nickel alloy is blended to form a cutting edge 12b. It can be molded as a body 6.

In the molded body 6 thus produced, the organic binder component in the molded body 6 is removed in the degreasing step. That is, for example, the organic binder component in the molded body 6 is removed by gradually heating to about 500 ° C. in an inert atmosphere.

The molded body 6 from which the organic binder has been removed in this manner is subjected to a pressure reduction of, for example, 0.1 to 1 Torr.
By sintering at 20 ° C., a composite material part 8 as shown in FIG. 2B is obtained. At this time, since the organic binder is lost in the process of degreasing and sintering, the kneading ratio of the powder material and the organic binder in the molding material 4 is 50:50 in volume ratio as described above. And the composite material part 8 is
It shrinks by about 20%. The composite material part 8 obtained in this way is composed of two or more types of parts having different components. In particular, as described above, the compact 6
Is formed as the compact 6 for manufacturing the cutting edge tip 12 as described above, the composite material part 8 is manufactured as the cutting edge tip 12, and a portion made of the first material powder (a portion made of an ultra-hard material) 12a and a portion made of a second powder material (a portion made of a nickel alloy) 12b are composed of two types of portions having different components.

Injection molding is performed by injecting two or more types of molding materials 4 having different components into which the powder material is blended into one mold 1, thereby obtaining two or more types of parts having different components. Since the molded body 6 is formed, the molded body 6 can be easily formed by injection molding even when the molded body 6 is formed into a complicated three-dimensional shape. Therefore, if such a molded body 6 is degreased and then sintered to obtain a composite material part 8, the composite material part 8 having a complicated three-dimensional shape composed of two or more types of parts having different components can be easily manufactured. Is what you can do.

According to a second aspect of the present invention, when molding the molded body 6 by injection molding, one injection nozzle 3 for injecting the molding material 3 into the mold 1 and feeding the molding material 4 to the injection nozzle 3 are provided. The injection device 2 having the screw 13 described above is used. Using such an injection device 2, two or more types of molding materials 4 having different components are sent to the injection nozzle 3 by the respective screws. Injecting the molding material 4 into the mold 1 from the injection nozzle 3 to inject two or more types of molding materials 4 having different components into one mold 1 to form the molded body 6. It was done.

FIG. 3 shows an example of the injection molding apparatus 9 used in the second aspect of the present invention. Here, the mold 1
The one provided with only one sprue bush 5 to which the injection nozzle 3 of the injection device 2 is connected is used. Further, as the injection device 2 for injecting the molding material 4 into the mold 1, a device provided with an injection nozzle 3 at the tip of a cylinder 14 can be used. The inside of the cylinder 14 is divided into two by a partition wall 15 to form a first trough 16a and a second trough 16b.
Screws 13a and 13b are arranged in the tanks a and 16b, and storage tanks 17a and 17b communicating with the troughs 16a and 16b are provided. Here, the screws 13a and 13b are formed by providing a spiral groove 18 on the peripheral surface of the rod material, and are arranged in the troughs 16a and 16b so as to be freely rotatable and slidable in the axial direction. . In the cylinder 14, a material measuring section 19 is provided between the injection nozzle 3 and the screws 13a and 13b so that the weight of the molding material 4 introduced into the material measuring section 19 can be measured.

When molding the molded body 6 using the injection molding apparatus 9 as described above, first, as shown in FIG. 3 (a), the screws 13a, 13b are slid to the side opposite to the injection nozzles 13a, 13b. Then, the first trough 1 of the injection device 2
The first molding material 4a and the second molding material 4b are respectively supplied to the storage tanks 17a and 17b communicating with the inside of the 6a and the second trough 16b, respectively. Each molding material 4a, 4b is supplied. The molding materials 4a and 4b in the troughs 16a and 16b are transported in the axial direction toward the injection nozzle 3 by rotating the screws 13a and 13b.
To supply. After the weights of the molding materials 4a and 4b are measured by the material measuring section 19, the screws 13a and 13b are slid in the axial direction toward the injection nozzle 3 as shown in FIG. The molding materials 4a and 4b are pushed into the mold 1 through the injection nozzle 3 via the sprue bush 5 to push the molding materials 4a and 4b at the tip of the mold. Here, the molding material 4a, 4
Since b is measured by the material measuring unit 19, a predetermined amount of the molding materials 4a and 4b can be injected into the mold 1.

By injecting the first molding material 4a and the second molding material 4b into the mold 1 in this manner, the portion 7a made of the first molding material and the This is for molding a molded body 6 composed of two types of parts having different components, ie, a part 7b composed of two molding materials. It can be molded into Accordingly, if such a molded body 6 is degreased and then sintered to obtain a composite material part 8, it is possible to easily manufacture the complex three-dimensional composite material part 8 composed of two kinds of parts having different components. Can be done.

When a molded body 6 composed of two parts having different components is molded using an injection molding apparatus 9 as shown in FIG. 3, the molding materials 4a and 4b are injected into the mold 1. Then, when the two screws 13a and 13b are simultaneously slid in the axial direction toward the injection nozzle 3 to push the molding materials 4a and 4b at the tips of the screws 13a and 13b, the first molding material 4a and Since both the second molding materials 4b are simultaneously injected from the same sprue bush 5 in the same direction, as shown in FIG. 4, one side is centered on a surface along the injection direction of the molding materials 4a and 4b. The molded body 6 can be obtained in which a portion 7a made of the first molding material is distributed and a portion 7b made of the second molding material is distributed on the other side.

FIG. 5 shows another example of the injection molding apparatus 9 used in the second aspect of the present invention. Here, the mold 1
The one provided with only one sprue bush 5 to which the injection nozzle 3 of the injection device 2 is connected is used. Further, as the injection device 2 for injecting the molding material 4 into the mold 1, a device provided with an injection nozzle 3 at the tip of a main cylinder 21 can be used. A material measuring section 19 is provided inside the main cylinder 21 so that the weight of the molding material 4 introduced into the material measuring section 19 can be measured. A plunger 20 slidable in the axial direction is disposed in the main cylinder 21. The main cylinder 21 is provided with two sub cylinders, a first sub cylinder 22a and a second sub cylinder 22b, connected to each other. Here each sub cylinder 2
Injection nozzles 23a, 2a
3b, each sub-cylinder 22
The injection nozzles 23a and 23b of the main cylinders 22a and 22b are connected to the material measuring device 19 of the main cylinder 22 so that the insides of the sub-cylinders 22a and 22b communicate with the inside of the main cylinder 22. In addition, each sub cylinder 22
a and 22b are inside the troughs 16a and 16b, respectively.
Are formed, and screws 13a and 13 are arranged in each of the troughs 16a and 16b. Here, the screws 13a and 13 are formed by providing a spiral groove 18 on the peripheral surface of the rod material, and are disposed so as to be rotatable in the respective troughs 16a and 16b and slidably move in the axial direction. is there.

When molding the molded body 6 using the injection molding apparatus 9 as described above, first, the plunger 20 in the main cylinder 21 is slid to the side opposite to the injection nozzle 3 as shown in FIG. The first sub-cylinder 2
2a and each trough 16a of the second sub-cylinder 22b,
16b, a first molding material 4a and a second molding material 4b
Are supplied, and the screws 13a, 13b are axially rotated to form the molding materials 4a, 4b in the respective troughs 16a, 16b.
Is transported in the axial direction toward the injection nozzles 23a and 23b, and supplied to the material measuring section 19 of the main cylinder 21 via the injection nozzles 23a and 23b. After the weights of the molding materials 4a and 4b are measured by the material measuring section 19, FIG.
The plunger 20 is slid in the axial direction toward the injection nozzle 3 as shown in FIG.
b is injected from the injection nozzle 3 into the mold 1 via the sprue bush 5. Here, the molding material 4 to be injected into the mold 1
Since a and b are measured by the material measuring unit 19, a predetermined amount of the molding materials 4a and 4b can be injected into the mold 1. By injecting the first molding material 4a and the second molding material 4b into the mold 1 as described above, the first molding material 4a is formed as shown in FIG. A molded body 6 composed of two parts having different components, that is, a part 7a and a part 7b composed of a second molding material is formed.

When molding a molded body 6 composed of two parts having different components using an injection molding apparatus 9 as shown in FIG. 5, a first molding material 4a and a second molding material 4b are used.
Are simultaneously injected from the same sprue bush 5 in the same direction, so that as shown in FIG.
a, forming a molded body 6 in which a portion 7a made of a first molding material is distributed on one side and a portion 7b made of a second molding material is distributed on the other side around a surface along the injection direction of 4b Can be done.

According to a third aspect of the present invention, when molding the molded body 6 by injection molding, the injection nozzles 3a, 3b for injecting the molding materials 4a, 4b into the mold 1, the injection nozzles 3a,
Screws 13a, 1 for feeding molding materials 4a, 4b to 3b
3b, and two injection devices 2a and 2b having the above-described two injection devices 2a and 2b.
2b, two types of molding materials 4a, 4b having different components are respectively screwed to the injection devices 2a, 2b with screws 13a, 1b,
3b to the injection nozzles 3a and 3b,
a, 3b, the molding materials 4a, 4b are injected into the mold 1 to form two types of molding materials 4a, 4a,
The molded body 6 is formed by injecting b into one mold 1.

FIG. 6 shows an example of the injection molding apparatus 9 used in the third aspect of the present invention. Here, the mold 1
Each of the injection devices 2a and 2b is provided with only one sprue bush 5 to which two injection nozzles 3a and 3b are simultaneously connected. The molding materials 4a, 4a
b, the first injection device 2a
And the second injection device 2b, and each of the injection devices 2a, 2b has a cylinder 14a,
The one provided with injection nozzles 3a and 3b at the tip of 14b is used. Troughs 16a and 16b are formed in the cylinders 14a and 14b, respectively, and screws 13a and 13b are arranged in the troughs 16a and 16b, respectively. Here, the screws 13a and 13b are formed by providing a spiral groove 18 on the peripheral surface of the rod material, and are disposed in the troughs 16a and 16b so as to be rotatable about the axis and slidably move in the axial direction. .

When molding the molded body 6 using the above-described injection molding apparatus, the screws 13a, 13b in the cylinders 14a, 14b of the respective injection apparatuses 2a, 2b are slid to the side opposite to the injection nozzles 3a, 3b. In this state, each trough 16 of the first injection device 2a and the second injection device 2b is
a and 16b are supplied with the first molding material 4a and the second molding material 4b, respectively, and the screws 13a and 13b are rotated axially to form the molding materials 4a and 4b in the troughs 16a and 16b.
b in the axial direction toward the injection nozzles 3a and 3b,
It is supplied to the material measuring section 19. After weighing the molding materials 4a and 4b in the material measuring section 19, the screws 13a,
13b is slid in the axial direction toward the injection nozzles 3a and 3b, and the molding materials 4a and 4b are pushed in at the tips of the screws 13a and 13b. Through the mold 1. Since the molding materials 4a and 4b to be injected into the mold 1 are measured by the material measuring section 19, a predetermined amount of the molding materials 4a and 4b can be injected into the mold 1. Thus, the first molding material 4a is placed in the mold 1.
And the second molding material 4b are injected into one mold 1 so that two parts having different components, that is, a part 7a composed of the first molding material and a part 7b composed of the second molding material are removed. The molded body 6 is formed.

When a molded body 6 composed of two parts having different components is molded by using an injection molding apparatus 9 as shown in FIG. 6, when the molding materials 4a and 4b are injected into the mold 1, , The two screws 13a, 13b are simultaneously slid in the axial direction toward the injection nozzles 3a, 3b to form molding materials 4a, 4b at the tips of the screws 13a, 13b.
, The first molding material 4a and the second molding material 4b are simultaneously injected from the same sprue bush 5 in the same direction, so that the molding materials 4a, 4b Which can obtain a molded body 6 in which a portion 7a made of the first molding material is distributed on one side and a portion 7b made of the second molding material is distributed on the other side around the surface along the injection direction of It is.

FIG. 7 shows another example of the injection molding apparatus 9 used in the third aspect of the present invention. Here, the mold 1
The injection device 2a, 2b is provided with two sprue bushes 5a, 5b to which the injection nozzles 3a, 3b are respectively connected. The molding materials 4a, 4a
As the injection devices 2a and 2b for injecting b, two devices, a first injection device 2a and a second injection device 2b provided with injection nozzles 3a and 3b at the ends of the cylinders 14a and 14b, are used. . As the injection devices 2a and 2b, those similar to those shown in FIG. 6 can be used.

When molding the molded body 6 using the injection molding device 9 as described above, the injection nozzle 3a of the first injection device 2a is connected to one sprue bush 5a of the mold 1, and the other is formed. The injection nozzle 3b of the second injection device 2b is connected to the sprue bush 5b, and each of the injection devices 2a, 2b
Screws 13a, 1 in cylinders 14a, 14b
The first molding material 4a and the second molding material are inserted into the troughs 16a, 16b of the first injection device 2a and the second injection device 2b while the 3b is slid to the side opposite to the injection nozzles 3a, 3b. 4b respectively, and screws 13a,
By rotating the shaft 13b, the molding materials 4a, 4b in the troughs 16a, 16b are transported in the axial direction toward the injection nozzles 3a, 3b, and supplied to the material measuring unit 19. Material measuring section 19
After weighing the molding materials 4a and 4b, the screws 13a and 13b are slid in the axial direction toward the injection nozzles 3a and 3b, and the molding materials 4a and 4b are pushed in at the tips of the screws 13a and 13b. , Molding material 4
a and 4b are injected into the mold 1 from the injection nozzles 3a and 3b via the sprue bushes 5a and 5b. Here, the molding materials 4a and 4b to be injected into the mold 1 are supplied to the material measuring section 19.
, A predetermined amount of molding material 4
a, 4b can be injected. By injecting the first molding material 4a and the second molding material 4b into the mold 1 in this manner, the portion 7a made of the first molding material and the second molding material 4a A molded body 6 composed of two types of parts having different components, that is, a part 7b composed of a material is formed.

When a molded body 6 composed of two parts having different components is molded by using an injection molding apparatus 9 as shown in FIG. 7, when the molding materials 4a and 4b are injected into the mold 1, , The two screws 13a, 13b are simultaneously slid in the axial direction toward the injection nozzles 3a, 3b to form molding materials 4a, 4b at the tips of the screws 13a, 13b.
Is pressed, the first molding material 4a and the second molding material 4b are simultaneously injected from different sprue bushes 5a, 5b in different directions, so that two sprue bushes 5a as shown in FIG. , 5b has a boundary surface at a position substantially equidistant from the arrangement position, and the boundary surface is defined by portions 7a, 12b made of molding materials 4a, 4b.
Can be obtained symmetrically distributed.

In molding the molded body 6 using the injection molding apparatus 9 shown in FIGS. 3, 6, and 7,
When the molding materials 4a and 4b are injected into the mold 1 by sliding the two screws 13a and 13b, the molded body 6 is formed by providing a time difference in the timing of sliding the screws 13a and 13b.
A portion 7a composed of the two types of molding materials 4a and 4b therein;
7b can be controlled.

FIG. 9 shows an example in which a time difference is provided in the timing of sliding the screws 13a and 13b when using the injection molding apparatus 9 shown in FIG. In the example shown in FIG. 9, the first molding material 4 a and the second molding material 4 b are supplied to the material measuring section 19 as shown in FIG. As described above, the screw 13a in the first trough 16a to which the first molding material 4a is supplied is slid in the direction of the injection nozzle 3 to inject the first molding material 4a into the mold 1, and further, FIG. As shown in (c), the second molding material 4b
Screw 1 in the second trough 16b to which
3b is slid in the direction of the injection nozzle 3 to inject the second molding material 4 into the mold 1.

By injecting the two types of molding materials 4a and 4b with a time lag in this way, the molding materials 4a and 4b are respectively provided on the side remote from the position where the sprue bush 5 is disposed and on the side close to the position where the sprue bush 5 is disposed. The molded body 6 in which the portions composed of 4a and 4b are distributed can be molded.

FIG. 10 shows the injection molding apparatus 9 shown in FIG.
This shows an example of a case where a time difference is provided in the timing of sliding the screws 13a and 13b when using. In the example shown in FIG. 10, in a state where the first molding material 4a and the second molding material 4b are supplied to the respective material measuring units 19 of the two injection devices 2a and 2b,
First, as shown in FIG. 10A, a screw 13a in a first injection device 2a to which a first molding material 4a is supplied.
Is slid in the direction of the injection nozzle 3a to inject the first molding material 4a into the mold 1, and as shown in FIG. 10B, the second molding material 4b is supplied. The second molding material 4b is injected into the mold 1 by sliding the screw 13b in the injection device 2b toward the injection nozzle 3a.

By injecting the two types of molding materials 4a and 4b with a time lag in this manner, the molding materials 4a and 4b can be respectively placed on the side remote from the sprue bush 5 and on the side near the sprue bush 5 respectively. The molded body 6 in which the portions composed of 4a and 4b are distributed can be molded.

FIG. 11 shows an injection molding apparatus 9 shown in FIG.
This shows an example of a case where a time difference is provided in the timing of sliding the screws 13a and 13b when using. In the example shown in FIG. 11, in a state where the first molding material 4a and the second molding material 4b are supplied to the respective material measuring units 19 of the two injection devices 2a and 2b,
First, as shown in FIG. 11A, a screw 13a in a first injection device 2a to which a first molding material 4a is supplied.
Is slid in the direction of the injection nozzle 3a to inject the first molding material 4a into the mold 1 via the first sprue bush 5a, and further, as shown in FIG. Injecting the second molding material 4b into the mold 1 through the second sprue bush 5b by sliding the screw 13b in the second injection device 2b to which 4b is supplied in the direction of the injection nozzle 3b. It is.

By injecting the two types of molding materials 4a, 4b with a time difference in this way, the second molding material 4a, 4b, which is lately injected, is proximate to the second sprue bush 5b as shown in FIG. It is possible to mold the molded body 6 in which the portion 7b made of the material is distributed and the portion 7a made of the first molding material previously injected is distributed in other portions.

As described above, the two types of molding materials 4
a and 4b are injected with a time lag, as shown in FIG. 23, the hollow first cavity 29a corresponding to the shape of the substantially square blade 11a having the cutting edge 10 as the mold 1 The one provided with a hollow second cavity 29b corresponding to the shape of the substantially L-shaped joint 11b can be used. Here, the second cavity 29b
Are provided at positions where they come into contact with and communicate with the first cavity 29a. In the second cavity 29b, an occupation piece 31 having the same shape as the shape of the second cavity 29b is provided so as to be slidable. This occupation piece 31 occupies the entire inside of the second cavity 29b with the occupation piece 31 as shown in FIG. 23 (a), and the second cavity 29b as shown in FIG. 23 (b).
The occupation piece 31 is slidably movable between a position where the occupation piece 31 and the occupation piece 31 are in contact with each other and the occupation piece 31 is not disposed in the second cavity 29b. Also the first cavity 29
a and the second cavity 29b are both arranged so as to be connected to the sprue bush 5. At this time, the sprue 30, which is a passage for supplying the molding material 4 to each of the cavities 29a and 29b, is shown in FIG. As shown in FIG.
a, 29b. At this time, the first molding material 4a is placed on the first cavity 29a side from the sprue 30.
Is provided on the second cavity 29b side with the second molding material 4b.
Are supplied respectively. here,
The molding material 4 injected into the mold 1 from the injection device 2 via the sprue bush 5 is the first molding material 4 as described above.
a and the second molding material 4b are injected in a separated state. Therefore, by adjusting the arrangement positions of the cavities 29a and 29b, the first molding material is moved from the sprue 30 to the first cavity 29a side. 4a is such that the second molding material 4b can be supplied to the second cavity 29b side, respectively.

Using such a mold 1, the occupied piece 3
1 is arranged at a position where the inside of the second cavity 29b is entirely occupied by the occupation piece 31 as shown in FIG.
First, only the first molding material 4a is injected into the mold 1 by the injection device 2 as shown in FIG.
The first molding material 4a is injected into a. First molding material 4
When a is injected into the first cavity 29a by 80% to 95%, the occupation piece 31 is slid and moved as shown in FIG.
As shown in FIG. 24 (c), the second cavity 29b and the occupied piece 31 are in contact with each other so that the occupied piece 31 is not disposed in the second cavity 29b. 1 is injected with the second molding material 4b so that the second molding material 4b is injected into the second cavity 29b. At this time, if a material having a higher fluidity than the first molding material 4a is used as the second molding material, the first molding material 4a injected into the first cavity 29a and the second cavity 29b are used. It is preferable that the second molding material 4b can be quickly injected into the second cavity 29b before flowing. Thus, the first molding material 4a and the second molding material 4b are transferred to each cavity 29.
a, 29b, finally, as shown in FIG.
As shown in (d), the first cavity 29a is filled with the first molding material 4a, and the second cavity 29b is filled with the second molding material 4b, whereby the molded body 6 can be molded. The molded body 6 formed in this manner is as shown in FIG.
A substantially square blade portion 11a having a cutting edge 10 is formed by a portion 7a made of a first molding material in which an ultra-hard material is blended.
And approximately L on two sides of the blade portion 11a where the cutting edge 10 is not formed.
The joint 11b is formed of a second molding material containing a nickel alloy and a portion 7b made of a second molding material, and is formed as a molded body 6 for manufacturing the blade tip 12. The composite material part 8 can be formed as the cutting edge tip 12 by manufacturing the composite material part 8 by sintering after degreasing 6.

The average particle size, particle size distribution, particle shape, specific gravity of raw materials of the powder material blended with the two or more types of molding materials 4, the type of organic binder blended with each molding material 4, or the molding material By controlling the composition ratio of each of the molding materials 4 to give a difference in the fluidity of each molding material 4, it is possible to control the state of distribution of a portion composed of two or more types of each molding material 4 in the molded body 6. Can be. For example, the first molding material 4
When an ultra-hard material having an average particle diameter of 1 μm is used as the powder material to be mixed into the a and a nickel alloy having an average particle diameter of 10 μm is used as the powder material to be mixed into the second molding material 4b, the average particle diameter is small. The fluidity of the second molding material 4a containing the powder material is higher than the fluidity of the first molding material 4b. In the state where the flowability of each molding material 4 is thus different, the first molding material 4a and the second molding material 4a are formed using the injection molding apparatus 9 shown in FIG. 3, FIG. 5, FIG. 6 or FIG. When the molding material 4b is simultaneously injected into the mold 1, FIG.
As shown in (b), molding in a state where the portion 7a made of the first molding material having higher fluidity is distributed on the surface layer and the portion 7b made of the second molding material having lower fluidity is distributed inside. The body 6 can be obtained.

According to a fourth aspect of the present invention, when the molded body 6 is molded, a preformed product 6a is first formed in advance with the first molding material 4a, and the preformed product 6a is The main molding is performed by disposing the second molding material 4b in the mold 1b and injecting the second molding material 4b into the main molding die 1b.

FIG. 14 shows injection molding devices 9a and 9b used in the invention of claim 4. FIG. 14 (a) shows an injection molding device 9a for preforming, in which a preforming die 1a having a sprue bush 5 and a first molding material 4a are injected into the preforming die 1a. And a first injection device 2a. Here, as the first injection device 2a, the same one as shown in FIGS. 6 and 7 can be used. FIG. 14 (b) shows an injection molding apparatus 9b for main molding, which includes a sprue bush 5 and in which a preform 6a can be disposed, and a main molding die 1b, and a main molding metal. A second injection device 2b for injecting the second molding material 4b into the mold 1b. Here, as the second injection device 2b, the same device as that shown in FIGS. 6 and 7 can be used.

When molding the molded body 6 using the injection molding devices 9a and 9b as described above, first, as shown in FIG. In the state where one molding material 4a is supplied, the first injection device 2
The first molding material 4a is injected into the pre-molding mold 1a by sliding the screw 13a in the direction of the injection nozzle 3a in the direction of the injection nozzle 3a, and the first molding material 4a as shown in FIG. A preform 6a consisting of only a portion 7a made of a molding material is molded. Then, this preformed body 6a is
As shown in FIG. 14 (b), the second molding material 4b is supplied to the material measuring section 19 of the second injection device 2b while being arranged in the main molding die 1b. The screw 13b in the injection device 2b is slid in the direction of the injection nozzle 3b to inject the second molding material 4b into the main molding die 1b, and the first molding material 4b as shown in FIG. A molded body 6 composed of two types of parts having different components, that is, a part 7a composed of a molding material and a part 7b composed of a second molding material, is formed into a complex three-dimensional shape. Even when it is formed, it can be easily formed by injection molding. Therefore, if such a molded body 6 is sintered to obtain a composite material part 8, a composite material part 8 having a complex three-dimensional shape composed of two or more types of parts having different components can be easily manufactured. It is.

According to a fifth aspect of the present invention, when the molded body 6 is molded, a preformed part 23a and a main molded part 23b are provided therein, and a molded product in a mold is formed by the preformed part 23a and the main molded part 23b.
b, and a first injection device 2 capable of injecting the first molding material 4a into the preforming portion 23a while using the mold 1 having a slide mechanism that can be moved between the first molding material 4a and the first molding material 4a.
a, and the second injection device 2b capable of injecting the second molding material 4b into the main molding portion 23b is used, and the first molding material 4a is preformed using the first injection device 2a. The preforming is performed by injecting into the part 23a to form the preformed body 6a, and the preformed body 6a is moved to the main forming part 23b by the slide mechanism, and the second injection device 2b is used for the second forming. By performing the main molding by injecting the molding material 4b into the main molding portion 23b, the molded body 6 is formed.
Is what you get.

FIGS. 16 to 18 show an injection molding apparatus 9 used in the fifth aspect of the present invention. Here, the injection devices 2a and 2b for injecting the molding materials 4a and 4b into the mold 1 include injection nozzles 3 at the tips of the cylinders 14a and 14b.
The first injection device 2a and the second injection device 2b provided with a and 3b are used. As the injection devices 2a and 2b, those similar to those shown in FIG. 6 can be used. The mold 1 includes a pre-molding section 23a and a main molding section 23b therein, and each of the injection nozzles 3 of the first injection device 2a and the second injection device 2b.
The one provided with the first sprue bush 5a and the second sprue bush 5b to which a and 3b are respectively connected is used. Here, the first sprue bush 5a is provided to be connected to the preformed portion 23a, and the second sprue bush 5b is provided to be connected to the main formed portion 23b.
In addition, the preformed body 6a of the formed body 6 is
The hollow second cavity 29b corresponding to the shape excluding the portion corresponding to the above is connected to the second sprue bush 5b and provided. In addition, the mold 1 is provided with a slide body 37 having a first cavity 29a formed hollow in a shape corresponding to the desired shape of the preformed body 6b. The slide body 37 is connected to an air cylinder or the like to be slidably provided.
The first cavity 29a is formed so as to move between the preforming portion 23a and the main forming portion 23b.
Here, the first cavity 29a is
Is formed to be connected to the first sprue bush 5a when it is arranged in the main cavity, and to communicate with the second cavity 29b when it is arranged in the main molding portion 23b.

When molding the molded body 6 using the injection molding device 9 as described above, the first injection device 2a is connected to the first sprue bush 5a connected to the preforming portion 23a of the mold 1. In addition to connecting the injection nozzle 3a, the injection nozzle 3b of the second injection device 2b is connected to the second sprue bush 5b connected to the preforming part 23a, and the inside of the cylinder 14a, 14b of each injection device 2a, 2b is connected. The first molding material 4a and the second molding material 4a are respectively inserted into the troughs 16a, 16b of the first injection device 2a and the second injection device 2b while the screws 13a, 13b are slid to the side opposite to the injection nozzles 3a, 3b. The two molding materials 4b are respectively supplied. Then, the shafts of the screws 13a and 13b are rotated to set the trough 1
The molding materials 4a and 4b in 6a and 16b are transported in the axial direction toward the injection nozzles 3a and 3b, and supplied to the material measuring section 19. After the weights of the molding materials 4a and 4b are measured by the material measuring section 19, first, as shown in FIG. 16, the slide body 37 is placed in a state where the first cavity 29a is arranged at the position where the first cavity 29a is arranged in the preforming section 23a. Then, the screw 13a of the first injection device 2a is slid in the axial direction toward the injection nozzle 3a, and the first molding material 4a is pushed in at the tip of the screw 13a. Is injected into the first cavity 29a through the first sprue bush 5a, and is injected into the first cavity 29a as shown in FIG.
Part 7 made of the first molding material 4a as shown in FIG.
A preform 6a consisting of only a is formed. The preformed body 6a thus formed in the preformed part 23a
17, the slide body 37 is slid by an air cylinder or the like to a position where the first cavity 29a is disposed in the main molding section 23a, thereby moving to the main molding section 23b, and inside the main molding section 23b. Preformed body 6
a, and in this state, as shown in FIG. 18, the screw 13b in the second injection device 2b is slid in the direction of the injection nozzle 3b to move the second molding material 4b through the second sprue bush 5b. Injected into the second cavity 29b, as shown in FIG. 15 (b), two parts having different components, that is, a part 7a made of the first molding material and a part 7b made of the second molding material are used. In this case, even when the molded body 6 is formed into a complicated three-dimensional shape, it can be easily molded by injection molding. Therefore, if such a molded body 6 is sintered to obtain a composite material part 8, a composite material part 8 having a complex three-dimensional shape composed of two or more types of parts having different components can be easily manufactured. It is.

According to a sixth aspect of the present invention, when two or more molding materials 4 are prepared by blending a powder material and an organic binder, powder materials having the same sintering temperature are blended into each molding material 4. It is.

More specifically, for example, the first powder material is made of 92 wt% WC-8 wt% Co having an average particle size of 0.8 μm,
A cemented carbide such as 94 wt% WC-6 wt% Co is used. As a second powder material, nickel having an average particle size of 2.5 μm is 8
5 wt% tungsten with an average particle size of 1.8 μm in 15 w
The sintering temperature of both the first powder material and the second powder material was set to 1420 ° C. using a nickel alloy containing t%, and the first powder material thus prepared was added to butyl methacrylate, methylene- An organic binder ("DC-1235", manufactured by Daiichi Ceramo Co., Ltd.) composed of a vinyl acetate copolymer, paraffin wax, stearic acid, or the like is used, and the weight ratio of the first powder material to the organic binder is 50:50. And the same organic binder is mixed with the second powder material such that the weight ratio of the second powder material to the organic binder is 50:50. Thus, a second molding material 4b is prepared, and injection molding (two-color molding) is performed using an injection molding apparatus as shown in FIG.
The molded body is gradually heated to about 500 ° C. to remove the organic binder, and then heated and sintered at 1420 ° C. for 2 hours under a reduced pressure of 0.1 to 1 Torr to obtain a composite material part 8.

In this way, since the sintering temperatures of the portions made of the two or more molding materials 4 constituting the molded body 6 become equal, the molded body 6 can be heated and sintered in a furnace. It is possible to easily mass-produce a composite material part 8 having a complicated three-dimensional shape composed of two or more kinds of parts having different components. When the composite material component 8 is manufactured using a nickel alloy as the second powder material as described above, when the composite material component 8 is used as, for example, the cutting edge 12 of a cutting tool, it will be described in detail below. And S
A portion made of a nickel alloy of the composite material part 8 is arranged on a joint surface with a base metal 24 made of tool steel such as K5,
By irradiating a high-energy beam or the like to the vicinity of the joint surface between the two, the cutting edge tip 12 and the base metal 24 can be joined by a laser welding method of welding an iron-based material and a cemented carbide, as in the related art. There is no need to insert a metal piece such as a nickel alloy into the joint surface between the blade tip 12 and the base metal 24, and the joining process can be simplified.

According to a seventh aspect of the present invention, when two or more molding materials 4 are prepared by blending a powder material and an organic binder, each molding material 4 is mixed with each powder material having a different sintering temperature. When sintering the compact 6 prepared using the molding material 4 and sintering the compact 6 at a temperature lower than the lowest sintering temperature among the sintering temperatures of the powder materials, Is performed to obtain the composite material part 8. Here, the preferable range of the sintering temperature at the time of performing the preliminary sintering varies depending on the molding material 4 to be used. The temperature is preferably low, and the first powder material may be 92 wt% WC-8 wt% Co or 94 wt% as described below.
When the cemented carbide such as WC-6 wt% Co and the second powder material are made of pure nickel, it is preferable to perform the preliminary sintering at 900 ° C. to 1100 ° C.

For example, 92 wt% WC-
When using a cemented carbide such as 8 wt% Co or 94 wt% WC-6 wt% Co, the second powder material is pure nickel, the sintering temperature of the first powder material is 1420 ° C., and the second powder material is The sintering temperature is 1370 ° C. An organic binder (manufactured by Daiichi Ceramo Co., Ltd.) is added to the first powder material thus prepared.
"DC-1235") is blended to prepare the first molding material 4a, and an organic binder (manufactured by Daiichi Ceramo, "DC-1235") is blended to the second powder material to form the second molding material 4a. The molding material 4b is prepared, and injection molding (two-color molding) is performed by using the injection molding device 9 as shown in FIGS. 3, 5, 6, 7, 14, and 16 to 18 described above. To obtain a molded body 6. The molded body 6 is gradually heated to about 500 ° C. to remove the organic binder, and then heated in vacuum at 1000 ° C., which is lower than the sintering temperature of nickel, to temporarily sinter the molded body 6. Thus, a temporarily sintered body is obtained. The pre-sintered body is fully sintered by spark plasma sintering or the like to obtain the composite material part 8.

Here, the plasma sintering method can be performed using a plasma sintering apparatus as shown in FIG. This plasma sintering apparatus slides freely by inserting pressing dies 33 from both ends into a hollow cylindrical water-cooled vacuum chamber 32 such that the ends of the pressing dies 33 face each other in the water-cooled vacuum chamber 32. It is provided. The ends of the pressing dies 33 are inserted through the ends of a cylindrical sintering die 35 disposed in the water-cooled vacuum chamber 32, respectively. Here, the compact 6 is disposed in the sintering die 35 and is pressed by the pressing force from each pressing die 33. Further, in this plasma sintering apparatus, a vacuum pump (not shown) connected to the water-cooled vacuum chamber 32, a power supply 36 for applying a DC current or a pulse current between the pressing dies 33, and applying a pressure to each pressing die 33. A pressing mechanism 34 is provided, and a pressing die 33 is
Each pressing die 33 is pressed by a current applied between the pressing die 34 and the pressing mechanism 34.
And a control system 38 for controlling the pressing force applied to the motor.

In performing the plasma sintering of the compact 6 using such a plasma sintering apparatus, first, the compact 6
Is placed in a sintering die 35, and while the pressure in the water-cooled vacuum chamber 32 is reduced to 0.1 to 1 Torr by a vacuum pump, the pressing die 33 is pressed by a pressing mechanism 34 to press the molded body 6 from both sides. 200-300kgf by pressing with die 33
/ Cm ² while applying a DC current or a pulse current between the pressing dies 33 by the power source 36.
Is heated to 1300 ° C. In this manner, the molded body 6 is sintered by heating and pressing the molded body 6 for 5 to 20 minutes to obtain the composite material part 8.

In this way, even if it is difficult to sinter in a furnace because the sintering temperatures of the portions made of the two or more molding materials 4 constituting the molded body 6 are different, the molded body 6 is sintered. Thus, it is possible to manufacture a composite material part 8 having a complex three-dimensional shape composed of two or more types of parts having different components.

According to the invention of claim 8, when two or more molding materials 4 are prepared by blending a powder material and an organic binder, an ultra-hard material is used as at least one of the powder materials. A material having high ductility is used as a powder material other than the hard material. As the material having high extensibility, it is preferable to use a sample formed into a bar having a square cross section of 1 × 2 mm and having a sample elongation of 20% or more when a tensile test based on JIS Z2241 is performed. preferable. The higher the extensibility is, the more preferable it is. However, if the upper limit is particularly set, the elongation of the sample when the above tensile test is performed is set to 50%.
%, The desired effect can be sufficiently obtained.

For example, 92 wt% WC-
When using a cemented carbide such as 8 wt% Co or 94 wt% WC-6 wt% Co, the second powder material is JIS Z224.
The elongation of the sample when a tensile test based on No. 1 is performed is 25% nickel alloy or 30% pure nickel.
An organic binder is blended with the first powder material thus prepared to prepare a first molding material 4a, and an organic binder is blended with the second powder material to prepare a second molding material 4b. 3, FIG. 5, FIG. 6, FIG. 7, FIG. 14, FIG.
Injection molding (two-color molding) is performed using an injection molding device 9 as shown in 6 to 6 to obtain a molded body 6. The molded body 6 is degreased and then sintered to obtain a composite material part 8.

In this way, when the compact 6 is heated and sintered, the powder material in the compact 6 at the time of sintering thermally expands, and when the powder material is cooled after the completion of the heating, it shrinks thermally. The occurrence of separation at the interface between the portion made of the super-hard material and the portion other than the super-hard material in the molded body 6 and the breakage of the portion other than the super-hard material are determined by the portion of the molded body 6 other than the super-hard material. It can be prevented by the elastic deformation of the material having high extensibility contained in the composite material, and can easily produce a complex three-dimensional composite material part 8 composed of two or more types of parts having different components. According to a ninth aspect of the present invention, when two types of molding materials 4 are prepared by blending a powder material and an organic binder, an ultra-hard material is used as the first powder material and nickel is used as the second powder material. Or using a nickel alloy Specifically, for example, the first powder material is 92 wt% WC-8 wt% having an average particle diameter of 0.8 μm.
A nickel alloy containing 85 wt% of nickel having an average particle size of 2.5 μm and 15 wt% of tungsten having an average particle size of 1.8 μm. Is used. Then, an organic binder is blended with the first powder material to prepare a first molding material 4a, and an organic binder is blended with the second powder material to prepare a second molding material 4b. FIG.
Injection molding (two-color molding) is performed using an injection molding apparatus as shown in FIG. This molded body 6 is
C. to gradually remove the organic binder by heating to 0.1-1.
The composite material part 8 is obtained by sintering by heating at 1420 ° C. for 2 hours under a reduced pressure of Torr.

As described above, since nickel or a nickel alloy is rich in extensibility as described above, when forming the compact 6 using the two types of molding materials 4a and 4b, nickel or nickel is used as the second powder material. When using the second molding material 4b in which the nickel alloy is blended, when the molded body 6 is heated and sintered, the powder material in the molded body 6 at the time of sintering thermally expands,
Further, in the case of thermal contraction when cooled after completion of heating, peeling occurs at the boundary surface between the portion 7a made of the first molding material and the portion 7b made of the second molding material in the molded body 6, The cracking of the portion 7b made of the second molding material can be prevented by the elastic deformation of nickel or nickel alloy, which is highly extensible and contained in the portion 7b made of the second molding material. A composite material part 8 having a complicated three-dimensional shape composed of two different parts can be easily manufactured. When the composite material component 8 is manufactured using a nickel alloy as the second powder material as described above, when the composite material component 8 is used as, for example, the cutting edge 12 of a cutting tool, it will be described in detail below. A portion made of a nickel alloy of the composite material part 8 is arranged on a joint surface with a base metal 24 made of tool steel such as SK5, and a high-energy beam or the like is irradiated near the joint surface of the two. The cutting edge tip 12 and the base metal 24 can be joined by a laser welding method for welding an iron-based material and a cemented carbide, and a metal such as a nickel alloy is formed on the joining surface between the cutting edge tip 12 and the base metal 24 as in the related art. It is not necessary to insert a piece, and the joining process can be simplified.

According to a tenth aspect of the present invention, a powder material comprising at least one selected from a ceramic powder and a metal powder is kneaded with an organic binder.
Two or more types of molding materials 4 having different components are prepared, and injection molding of the two or more types of molding materials 4 is performed to form a molded body 6 composed of two or more types of components having different components. Is a composite material part 8 obtained by sintering and sintering. This is the composite material part 8 manufactured by the method for manufacturing the composite material part 8 described above.

According to an eleventh aspect of the present invention, when a powder material and an organic binder are blended to prepare two types of molding materials 4a and 4b, an ultra-hard material is used as the first powder material, and the second An easily weldable material is used as a powder material, and a molded body 6 is formed by injection molding using such two types of molding materials 4a and 4b.
1a is molded from a super-hard material, and the joint 11b with the base metal 24 is formed.
Is a composite material part 8 obtained by molding a portion having the following characteristics with an easily weldable material, degreasing and sintering the molded body 6.
Is used as the cutting edge tip 12 of the cutting tool.

The composite material part 8 is manufactured by the above-described method for manufacturing the composite material part 8 in the same manner as in the tenth aspect of the present invention. As shown in FIG. 2 (a), a substantially square blade 11a having a cutting edge 10 is formed by a portion 7a made of a first molding material in which a super-hard material is mixed, and the cutting edge 10a of the blade 11a is formed. L-shaped joints 11b on two sides where no
Is formed by a portion 7b made of a second molding material containing a nickel alloy. The molded body 6 thus formed is degreased and then sintered to form a portion (a portion made of a super-hard material) 12a made of the first material powder as shown in FIG. 2B. A composite material formed as a cutting edge tip 12 which is composed of two parts having different components: a joining part 11b formed by a cutting part 11a and a part (part made of a nickel alloy) 12b made of a second powder material. Parts can be obtained.

FIG. 19 shows a state in which the composite material part 8 according to claim 11 manufactured as the cutting edge tip 12 is joined to the base metal 24. The base metal 24 is formed as a main body of a cutting tool such as a circular saw blade, for example, and is formed by pressing a metal plate such as tool steel such as SK5 or the like and providing a large number of joined portions 25 on the outer periphery. Is what you do. Joined part 25
Is approximately L at the corner of the protruding piece 26 that protrudes from the outer periphery of the base 24.
It is formed in a character shape. Each to-be-joined part 2 of the base metal 24
In joining the cutting edge tip 12 to the base metal 5,
The joined portion 25 of the cutting edge tip 12 is overlapped with the joined portion 25, and a high energy beam is irradiated from both sides in the vicinity of the joined portion 25 of the base metal 24. A laser or an electron beam can be used as the high energy beam. When the high energy beam is irradiated on the vicinity of the joint 25 of the base metal 24 in this manner, the portion of the base metal 24 irradiated with the high energy beam is heated, and the heat is used to form the nickel alloy placed in the vicinity thereof. The joined part 11b to be heated is heated. And a joint 11b made of a nickel alloy
Is melted and nickel is deposited on the base metal 24 and the blade tip 12.
The blade tip 12 can be bonded to the base metal 24 by the molten solidified layer of the nickel alloy of the bonding part 11b and the base metal 24 or the nickel diffusion alloy layer in the blade part 11a. .

As described above, when the composite material part 8 of the eleventh aspect formed as the cutting edge tip 12 is joined to the base metal 24, the joining can be performed by welding with a high energy beam. When the composite material part 8 as the cutting edge tip 12 is joined to the base metal 24 by welding with the high energy beam in this manner, the high energy beam irradiates the base metal 24, so that the cutting edge tip 12 is rapidly heated by the high energy beam. Therefore, even if the blade portion 11a of the cutting edge tip 12 is formed of a super-hard material having low toughness, it is possible to prevent the cutting edge tip 12 from cracking due to thermal shock. Alternatively, the joint portion 11b made of a nickel alloy and the blade portion 11a made of a super-hard material are integrated to form the blade tip 1
2 is formed, there is no need to insert a metal piece into the joint surface between the cutting edge tip 12 and the base metal 24 when the cutting edge tip 12 is joined to the base metal 24 by welding with a high energy beam. In addition, the joining process can be simplified. When the composite material part 8 as the cutting edge tip 12 is manufactured, when the compact 6 is formed from the powder material as described above, the first molding material in which the super hard material is blended as the first powder material is used. 4a and a second molding material 4b containing an easily weldable material as a second powder material, two molding materials 4a and 4b having different components are injected into one mold 1 by injection. By performing the molding, the portion 7a made of the first molding material including the super-hard material is formed.
And a portion 7 made of a second molding material containing an easily weldable material
b, a molded body 6 composed of two or more types of parts having different components can be molded. In this case, even when the molded body 6 is formed into a complicated three-dimensional shape, it is easily molded by injection molding. Is what you can do. Therefore, a composite material part 8 obtained by sintering such a molded body 6
Can be easily manufactured as a complex three-dimensional composite material part 8 composed of two parts having different components, namely, a blade part 11a made of a super-hard material and a joint part 11b made of an easily weldable material. Thus, the composite material part 8 can be easily formed as the cutting edge tip 12 having various shapes.

FIG. 20 shows another example of the composite material part 8 according to the eleventh aspect. The composite material component 8 shown in FIG. 20 is formed as a cutting edge tip 12 provided with cutting edges 10a and 10b protruding on both sides of the tip of the cutting edge portion 11a of the cutting edge tip 12, respectively. In the present invention, the composite material component 8 having such a complicated three-dimensional shape can be easily manufactured. Such a tip 8
Using a cutting tool manufactured by joining the
When cutting wood with a cutting tool, it is possible to perform clean cutting without leaving uncut portions such as fluff.

That is, FIG. 21 shows a state in which the wood 27 is cut by a cutting tool formed by joining the blade tip 12 provided with only one cutting edge 10 to the base metal 24, and FIG. ), (B), (c), and (d), the cutting proceeds in this order, but with the single cutting edge 10, the cutting edge such as the fluff 28 tends to be left as shown in FIG. The cutting direction is indicated by an arrow). On the other hand, FIG.
FIGS. 22 (a) and 22 (b) show cutting of the wood 27 by a cutting tool formed by joining the cutting edge tip 12 having two a and 10b on both sides of the tip to the base metal 24. The cutting proceeds in this order, but no uncut portion such as the fluff 28 occurs (the cutting direction is indicated by an arrow).

[0079]

As described above, the method for producing a composite material component according to the first aspect of the present invention comprises mixing and kneading at least one powder material selected from ceramic powder and metal powder with an organic binder. Preparing two or more different molding materials of different, injection molding by injecting each molding material into a mold to form a molded body composed of two or more different components with different components,
Since the molded body is degreased and sintered, it can be easily molded by injection molding even when the molded body is formed into a complex three-dimensional shape.By sintering such a molded body, It is possible to easily manufacture a complex three-dimensionally shaped composite material part composed of two or more types of parts having different components composed of ceramics, metal, and the like.

The method for manufacturing a composite material part according to the second aspect of the present invention includes one injection nozzle for injecting the molding material into the mold, and two or more screws for feeding the molding material to the injection nozzle. By using an injection device, two or more types of molding materials having different components are sent to an injection nozzle by respective screws, and the molding material is injected into a mold from the injection nozzle, thereby forming two or more types of molding materials having different components. To
Since it is injected into a mold, it can be easily formed by injection molding even when a molded article is formed into a complicated three-dimensional shape. By sintering such a molded article, ceramics, metals, etc. Thus, it is possible to easily manufacture a composite material part having a complicated three-dimensional shape composed of two or more kinds of parts having different components.

According to a third aspect of the present invention, there is provided a method for manufacturing a composite material component, comprising: an injection nozzle for injecting a molding material into a mold; and a screw for feeding the molding material to the injection nozzle. By using two or more types of molding materials having different components, each is sent to an injection nozzle by a screw of each injection device, and the molding material is injected into the mold from the injection nozzle, thereby forming two or more types of molding materials having different components. Can be easily molded by injection molding even when the molded body is formed into a complex three-dimensional shape, by sintering such a molded body. A composite material part having a complicated three-dimensional shape composed of two or more types of parts having different components made of metal or the like can be easily manufactured.

According to a fourth aspect of the present invention, there is provided a method for manufacturing a composite material part, wherein a preform which is to be a part of a preform is previously formed by injection molding of a first molding material, and the preform is formed. In order to obtain a molded body by performing the main molding by arranging the molded body in the main molding die and injecting the second molding material into the main molding die, the molded body is formed into a complex three-dimensional shape. Even if it is formed, it can be easily molded by injection molding, and by sintering such a molded body, a complex three-dimensional shape composed of two or more types of components composed of ceramics, metals, etc. Can be easily manufactured.

According to a fifth aspect of the present invention, there is provided a method for manufacturing a composite material part, comprising a preformed part and a main formed part therein, and moving the formed part between the preformed part and the main formed part. A mold having a slide mechanism capable of injecting a molding material into a pre-molding section, and a second injection apparatus capable of injecting a molding material into a main molding section. The preforming is performed by injecting the molding material into the preforming part using the first injection device to form a preformed body which becomes a part of the formed body, and the preformed body is used as a main body by a slide mechanism. A preformed part and a main forming part are provided inside the main part, which is moved to a forming part, and a main body is obtained by performing main forming by injecting a molding material into the main forming part using a second injection device. Is moved between the preforming section and the main forming section. Using a mold having a slide mechanism capable of performing injection, a first injection device capable of injecting a molding material into a pre-molding portion, and a second injection device capable of injecting a molding material into a main molding portion. The preforming is performed by injecting the molding material into the preforming section by using the first injection device to form a preformed body that becomes a part of the formed body, and the preformed body is fully formed by the slide mechanism. To the department,
In order to obtain a molded body by performing the main molding by injecting the molding material into the main molding part using the second injection device, even if the molded body is formed into a complicated three-dimensional shape, it is easily molded by injection molding. By sintering such a compact, ceramics,
A composite material part having a complicated three-dimensional shape composed of two or more kinds of parts having different components made of metal or the like can be easily manufactured.

In the method for manufacturing a composite material part according to claim 6 of the present invention, in preparing two or more types of molding materials, each molding material is prepared using powder materials having the same sintering temperature. Therefore, it is possible to equalize the sintering temperature of the portion composed of two or more molding materials constituting the molded body, and to sinter the molded body by heating it in a furnace, thereby obtaining ceramics, metals, etc. Thus, it is possible to easily mass-produce a composite material component having a complex three-dimensional shape composed of two or more types of parts having different components.

In the method for manufacturing a composite material part according to claim 7 of the present invention, in preparing two or more types of molding materials, each molding material is prepared by using each powder material having a different sintering temperature. Then, when sintering the molded body, in order to obtain a composite material component by performing preliminary sintering at a temperature lower than the lowest sintering temperature of the sintering temperature of each powder material, and then performing the main sintering Even if it is difficult to sinter in a furnace because the sintering temperature of the part consisting of two or more molding materials constituting the molded body is different, the molded body can be sintered, and components composed of ceramics, metal, etc. It is possible to easily manufacture a composite material part having a complicated three-dimensional shape composed of two or more kinds of different parts.

In the method of manufacturing a composite material part according to claim 8 of the present invention, at least one of the powder materials is a super-hard material, and the other is a material having high ductility. When the compact is heated and sintered, the powder material in the compact at the time of sintering thermally expands, and when it is thermally contracted when cooled after the end of heating, it is made of the super hard material in the compact. Separation occurs at the interface between the part and the other part, and that the part other than the super hard material is cracked,
It can be prevented by the elastic deformation of the highly extensible material contained in the part other than the super-hard material of the molded body, and it is a complex three-dimensional shape composed of two or more parts with different components consisting of ceramics, metals, etc. Can be easily manufactured.

In the method of manufacturing a composite material part according to the ninth aspect of the present invention, a super-hard material is used as the first powder material and nickel or a nickel alloy is used as the second powder material. When heating and sintering, when the powder material in the compact at the time of sintering expands thermally and contracts when cooled after the end of heating, the portion made of the super-hard material in the compact and Exfoliation occurs at the interface with other parts, or that parts other than the super-hard material are cracked, due to the elastic deformation of nickel or nickel alloy, which is highly extensible and contained in the parts other than the super-hard material of the molded body. Thus, it is possible to easily manufacture a complex three-dimensional composite material part composed of two types of parts having different components composed of ceramics, metal, and the like.

The composite material part according to claim 10 of the present invention is characterized in that a component material obtained by kneading a powder material comprising at least one selected from ceramic powder and metal powder and an organic binder is provided. Degreasing and sintering molded bodies of two or more different molding materials, so that even if the molded body is formed into a complex three-dimensional shape, the molded body can be easily formed into a complex three-dimensional shape by injection molding. By sintering such a molded body, a complex three-dimensional composite material part composed of two or more parts having different components composed of ceramics, metal, and the like can be easily manufactured. .

The composite material part according to the eleventh aspect of the present invention is obtained by molding a portion to be a cutting part having a cutting edge with a molding material containing a super hard material, and using a molding material containing an easily weldable material. A high-energy beam is used when joining a composite material part to a base metal, because the molded part that forms the joint part to be bonded to the base metal is degreased and then sintered to form the cutting edge of the cutting tool. Can be joined by welding, and the cutting edge tip will not be rapidly heated by the high energy beam,
Even if the blade portion of the cutting edge tip is formed of a super-hard material having low toughness, it is possible to prevent cracking of the cutting edge tip due to thermal shock. Further, at the time of this joining, there is no need to insert a metal piece into the joining surface between the cutting edge tip and the base metal, so that the joining process can be simplified. In the case of manufacturing this cutting edge tip, injection molding is performed to obtain two parts having different components, that is, a part composed of a first molding material containing a super-hard material and a part composed of a second molding material containing a weldable material. It is possible to mold a molded body composed of more than one kind of parts, and at this time, even when this molded body is formed into a complicated three-dimensional shape, it can be easily molded by injection molding, A composite material part obtained by sintering such a molded body is a complex three-dimensional composite material composed of two types of parts having different components, a cutting part made of a super hard material and a joint part made of a weldable material. The composite material component can be easily manufactured as a component, and the composite material component can be formed as a cutting edge tip having various shapes.

[Brief description of the drawings]

FIG. 1 is a partially broken plan view showing an example of an injection molding apparatus used in the present invention.

FIG. 2A is a perspective view showing an example of a molded article molded in the present invention, and FIG. 2B is a perspective view showing a composite material part produced from the molded article in FIG.

FIGS. 3 (a) and 3 (b) are partially broken plan views showing the operation of another example of the injection molding apparatus used in the present invention.

FIG. 4 is a perspective view showing another example of a molded article molded in the present invention.

FIGS. 5A and 5B are partially cutaway plan views showing the operation of still another example of the injection molding apparatus used in the present invention.

FIG. 6 is a partially broken plan view showing still another example of the injection molding apparatus used in the present invention.

FIG. 7 is a partially broken plan view showing still another example of the injection molding apparatus used in the present invention.

FIG. 8 is a perspective view showing still another example of a molded article molded in the present invention.

9 (a) to 9 (c) are partially broken plan views showing another operation of the injection molding apparatus shown in FIG.

FIGS. 10A and 10B are partially cutaway plan views showing another operation of the injection molding apparatus shown in FIG. 6;

11 (a) and 11 (b) are partially broken plan views showing another operation of the injection molding apparatus shown in FIG. 7.

FIG. 12 is a perspective view showing still another example of a molded article molded in the present invention.

FIG. 13A is a perspective view showing still another example of a molded article molded in the present invention, and FIG. 13B is a cross-sectional view of FIG.

FIGS. 14A and 14B show still another example of the injection molding apparatus used in the present invention, wherein FIG. 14A is a partially cutaway plan view showing an injection molding apparatus for preliminary molding, and FIG. FIG. 2 is a partially broken plan view showing the injection molding apparatus of FIG.

FIG. 15A is a perspective view showing an example of a preformed body formed in the present invention, and FIG. 15B is a perspective view showing a formed body formed by fully forming the preformed body of FIG. It is.

FIG. 16 is a partially broken plan view showing a first stage operation of still another example of the injection molding apparatus used in the present invention.

FIG. 17 is a partially broken plan view showing a second stage operation of still another example of the injection molding apparatus used in the present invention.

FIG. 18 is a partially broken plan view showing a third stage operation of still another example of the injection molding apparatus used in the present invention.

FIG. 19 is a perspective view showing a state in which a composite material component formed as a cutting edge tip of the present invention is joined to a base metal.

FIG. 20 is a perspective view showing another example of a composite material part formed as a cutting edge tip of the present invention.

FIGS. 21 (a) to (d) are views showing a state in which wood is cut by a cutting tool having a single cutting edge.

FIGS. 22 (a) and (b) are views showing a state in which wood is cut by a cutting tool having two cutting edges.

FIGS. 23A and 23B are perspective views showing a first cavity and a second cavity.

24 (a) to (d) are schematic views showing a process of injecting molding material into the first cavity and the second cavity of FIG. 23.

FIG. 25 is a partially broken perspective view showing an example of a plasma device.

[Explanation of symbols]

 Reference Signs List 1 mold 1b mold for main molding 2 injection device 2a first injection device 2b second injection device 3 injection nozzle 4 molding material 4a first molding material 4b second molding material 6 molded body 6b preformed body Reference Signs List 8 composite material part 10 cutting edge 11a blade part 11b joining part 12 blade tip 13 screw 23a preforming part 23b main forming part 24 base metal

────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] June 22, 1998

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0002

[Correction method] Change

[Correction contents]

[0002]

BACKGROUND ART Metal and plastic, blades for cutting a ceramic based material, for example a base metal made of tool steel such as SK5, the cutting edge made with SKH (high speed tool) steel or cemented carbide It is made by joining chips. The bonding method of this time base metal and cutting tip, although brazed with cormorants silver filtration have been used well, brazing for using flux, without requiring frequent maintenance such as cleaning, There is also a problem that the flux adheres to a jig or the like and the joining accuracy is deteriorated. In addition, in this brazing, high heat is applied over a fairly wide range near the joint, so that a metal die made of SK5 or the like tempered by heat treatment or a cutting edge tip made of SKH (high-speed tool) or the like is used. There is also a problem that hardness and rigidity are reduced by annealing.

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0022

[Correction method] Change

[Correction contents]

Specifically, for example, as the first powder material,
WC-Co cemented carbide is used.
7, SKD11 and other metal materials, alumina, zirconia, etc.
May be used. Also, a composite material part 8 can be manufactured by using an 85 wt% nickel-15 wt% tungsten alloy (hereinafter, referred to as a nickel alloy) or the like as the second powder material and using these two powder materials.

Continued on the front page (72) Inventor Masahiro Ikegami 1048 Kadoma Kadoma, Osaka Prefecture Matsushita Electric Works, Ltd.

Claims (11)

[Claims] At least one powder material selected from ceramic powder and metal powder and an organic binder are kneaded to prepare two or more molding materials having different components, and each molding material is injected into a mold. A method of manufacturing a composite material part, comprising: performing injection molding to form a molded body composed of two or more types of components having different components, and sintering the molded body after degreasing the molded body. 2. An injection device having one injection nozzle for injecting a molding material into a mold and two or more screws for feeding the molding material to the injection nozzle, using two or more molding materials having different components. 2. Each of the screws is sent to an injection nozzle by each screw, and the molding material is injected into the mold from the injection nozzle, whereby two or more types of molding materials having different components are injected into the mold. 3. The method for producing a composite material part according to item 1. 3. Using two or more injection devices each having an injection nozzle for injecting the molding material into a mold and a screw for feeding the molding material to the injection nozzle, two or more types of molding materials having different components are respectively used. By sending to the injection nozzle by the screw of the injection device and injecting the molding material into the mold from the injection nozzle, two or more types of molding materials having different components,
The method for producing a composite material part according to claim 1, wherein the composite material part is injected into a mold. 4. A preform which is to be a part of a preform by injection molding of a first molding material, and the preform is placed in a mold for main molding, and a second molding material is formed. 2. A molded body is obtained by performing main molding by injecting this into a mold for main molding.
4. The method of manufacturing a composite material part according to any one of claims 1 to 3. 5. A preforming part and a main forming part are provided inside,
A mold having a slide mechanism capable of moving a molded part between the preforming part and the main molding part, and a first injection device capable of injecting a molding material into the preforming part,
Using a second injection device capable of injecting the molding material into the main molding portion, performing a pre-molding by injecting the molding material into the pre-molding portion using the first injection device, and forming a part of the molded body. By molding a preform to be formed, moving the preform to the main molding section by a slide mechanism, and injecting a molding material into the main molding section using a second injection device to perform the main molding. The method for producing a composite material part according to any one of claims 1 to 3, wherein a molded body is obtained. 6. The method according to claim 1, wherein when preparing two or more types of molding materials, each molding material is prepared by using a powder material having the same sintering temperature.
The method for producing a composite material part according to any one of the above. 7. When preparing two or more types of molding materials, each molding material is prepared by using each powder material having a different sintering temperature, and when sintering a compact, sintering of each powder material is performed. The composite material according to any one of claims 1 to 5, wherein preliminary sintering is performed at a temperature lower than the lowest sintering temperature among the temperatures, and thereafter, main sintering is performed to obtain a composite material component. The method of manufacturing the part. 8. The method according to claim 1, wherein at least one of the powder materials used in preparing the two or more molding materials is a super-hard material, and the other is a material having high ductility. 8. The method of manufacturing a composite material part according to any one of 1 to 7. 9. The composite material part according to claim 1, wherein an ultra-hard material is used as the first powder material, and nickel or a nickel alloy is used as the second powder material. Manufacturing method. 10. A molded body of two or more types of molding materials having different components obtained by kneading a powder material comprising at least one selected from ceramic powder and metal powder and an organic binder. A composite material component characterized by being post-sintered. 11. A cutting part having a cutting edge is formed of a molding material containing an ultra-hard material, and a joining part to be joined to a base is formed of a molding material containing an easily weldable material. The composite material part according to claim 10, wherein the formed body is degreased and then sintered to form a cutting edge of a cutting tool.