WO2003008131A2 - Appareil et procede permettant de former des pieces a niveaux multiples par compactage rapide - Google Patents

Appareil et procede permettant de former des pieces a niveaux multiples par compactage rapide Download PDF

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Publication number
WO2003008131A2
WO2003008131A2 PCT/US2002/022499 US0222499W WO03008131A2 WO 2003008131 A2 WO2003008131 A2 WO 2003008131A2 US 0222499 W US0222499 W US 0222499W WO 03008131 A2 WO03008131 A2 WO 03008131A2
Authority
WO
WIPO (PCT)
Prior art keywords
velocity
particulate material
compaction
main ram
cavity
Prior art date
Application number
PCT/US2002/022499
Other languages
English (en)
Other versions
WO2003008131A3 (fr
Inventor
Gerd Hinzmann
Original Assignee
Hawk Precision Components Group, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hawk Precision Components Group, Inc. filed Critical Hawk Precision Components Group, Inc.
Priority to AU2002354920A priority Critical patent/AU2002354920A1/en
Publication of WO2003008131A2 publication Critical patent/WO2003008131A2/fr
Publication of WO2003008131A3 publication Critical patent/WO2003008131A3/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B22F3/087—Compacting only using high energy impulses, e.g. magnetic field impulses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/17—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B11/00—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/02—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a ram exerting pressure on the material in a moulding space
    • B30B11/027—Particular press methods or systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B22F3/03—Press-moulding apparatus therefor
    • B22F2003/033—Press-moulding apparatus therefor with multiple punches working in the same direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy

Definitions

  • the present invention relates to the art of particulate materials. More particularly, the present invention relates to the compaction of particulate materials. Still more particularly, the present invention relates to the high-velocity compaction of multiple-level parts composed of particulate materials, such as metal powder, by utilizing high ram velocities.
  • a different lubrication technique die wall lubrication, allows densities of parts to rise to 93% to 95% of the theoretical density of the material. Still, densities closer to 100% of the theoretical density of the material are desired.
  • High-velocity compaction a recently developed technique, yields parts with further increased densities when used in conjunction with admixed lubricants or die wall lubrication.
  • traditional compaction the top tooling, consisting of one or more punches, is constantly connected to the main ram of a compaction press. Hydraulic cylinders, crank drives or knuckle drives actuate the motion of the ram, resulting in force control or position control of the main ram.
  • the compacting speed reached in traditional compaction is in a range of about 0.02 m/s to about 0.1 m/s.
  • high-velocity compaction reaches speeds substantially greater than 0.1 m/s, in a range of at least 1 m/s and up to about 100 m/s at impact, an average of about two orders of magnitude greater than traditional compaction. This is accomplished through the use of a ram that is not connected to the top tooling.
  • a ram with a discrete mass is accelerated and impacts the top tooling, i.e., the top punch, which is in contact with the powder charge in the die.
  • the mass of the ram and the force of acceleration of the ram which is typically actuated by hydraulic pressure, are kept constant and the acceleration distance is altered to control the kinetic energy of the ram.
  • the main ram is therefore energy controlled rather than force or position controlled.
  • An exemplary high-velocity compaction press using a hydraulic drive is described in U.S. Patent No. 6,202,757, issued to Dahlberg.
  • a high-velocity press using a mechanical drive is described in U.S. Patent No. 4,245,493, issued to Lindell.
  • the compaction ratio i.e., the ratio of the length of a part as filled in the die to the length of that part as finally compacted, is typically greater than two.
  • Such a high compaction ratio and the restricted ability of the powder to flow between sections after pre-compaction dictates a change in the drop height in the tooling during the compaction cycle to achieve a uniform density distribution, minimum part geometry distortion and/or crack prevention in the part. This change of drop height in the tooling is achieved by moving multiple punches relative to one another.
  • this invention is directed to a method and a device to enable the compaction of multiple-level parts using the principle of high-velocity compaction.
  • a method for the high-velocity compaction of a part from particulate material includes the steps of providing a cavity that is at least partially formed by at least one bottom punch, inserting a pre-form that includes at least two levels into the cavity and moving an energy controlled main ram toward the pre-form at a high velocity to increase the density of the pre-form and form the part.
  • a multiple-level part is formed from particulate material by a process including the steps of providing a cavity that is at least partially formed by at least two bottom punches, inserting particulate material into the cavity, moving a main ram in one of force and position control toward the particulate material to compact the particulate material to form a pre-form having at least one step and moving an energy controlled main ram toward the pre-form at a high velocity to increase the density of the pre-form and form the part.
  • a press for high-velocity compaction of a part from particulate material includes an energy controlled, high-velocity mode for a main ram and an alternate operating mode for the main ram.
  • FIG. 1 is a sectional view of a tool set in accordance with an embodiment of the present invention in an open position;
  • FIG. 2 is a sectional view of the tool set of FIG. 1 in a fill position;
  • FIG. 3 is a sectional view of the tool set of FIG. 1 after a first compacting motion in a standard mode
  • FIG. 4 is a sectional view of the tool set of FIG. 1 after a first compacting motion in a standard mode after retracting the bottom punches to a mechanical stop
  • FIG. 5 is a sectional view of the tool set of FIG. 1 after a final compacting motion in an energy controlled, high-velocity mode
  • FIG. 6 is a sectional view of the tool set of FIG. 1 in an ejection position
  • FIG. 7 is a sectional view of a tool set in accordance with another embodiment of the present invention in an insertion position
  • FIG. 8 is a sectional view of the tool set of FIG. 7 after a compacting motion
  • FIG. 9 is a sectional view of the tool set of FIG. 7 in an ejection position
  • FIG. 10 is a sectional view of a tool set in accordance with another embodiment of the present invention in an insertion position
  • FIG. 11 is a sectional view of the tool set of FIG. 10 after a compacting motion
  • FIG. 12 is a sectional view of the tool set of FIG. 10 in an ejection position.
  • metal powders start to pre-compact, i.e., mechanically bond, at a density of about 58% to 66% of the theoretical density of the material.
  • Pre-compaction occurs in both traditional compaction and high- velocity compaction.
  • the adverse effects of pre-compaction include substantial part distortion and, to a lesser extent, inhomogeneous density distribution.
  • the present invention involves multiple punches that are pre-lifted and then retract to compact a pre-form by force or position control, similar to traditional compaction.
  • the pre-lifted punches may be stationary during a high-velocity impact or impacts. The retraction of a punch below the shape of the pre-form prior to a subsequent high-velocity impact may facilitate material flow during the subsequent impact.
  • the speed profile of the high-velocity compaction may not allow for adequate timing of the punch motion.
  • the present invention overcomes such difficulties by compacting a part at high velocity only after a pre-form is made.
  • the first ram compacting motion that forms a pre-form may be force controlled or position controlled rather than energy controlled.
  • FIGS. 1-6 show an exemplary embodiment of the present invention utilizing multiple punches at various steps of a compaction method.
  • FIG. 1 depicts a tool set in an open position.
  • the set includes a top punch 10 that defines a central orifice 12, a die 14, a bottom inner punch 16, a bottom outer punch 18 and a core rod 20 that is disposed in an inner circumference of the bottom inner punch 16.
  • the die 14, bottom inner punch 16, bottom outer punch 18 and core rod 20 cooperate to define a cavity 22.
  • the lower limit of the movement of the bottom punch 16 is defined by a first mechanical stop 24, while the bottom outer punch 18 has a lower limit defined by a second mechanical stop 26.
  • particulate material 28 also known as a powder charge, is inserted into the cavity 22.
  • the powder charge may be pre- weighed.
  • a representative height of a first level of the particulate material 28 is used to illustrate the stages of compaction and is shown at a fill height of the first level A.
  • the bottom inner punch 16 is pre-lifted as known in the art in the fill position and is then at least partially retracted upon the first compacting motion.
  • a main ram (not shown) of a compaction press (not shown) is activated and moved to cause the top punch 10 to move and compact the particulate material 28.
  • FIG. 3 the tool position after a first compacting motion is shown. This tool position is arrived at by force or position control of the main ram, where the compacting speed is in a range of about 0.02 m/s to about 0.1 m/s.
  • the particulate material 28 after this first compacting motion has become a pre-form 32.
  • the representative height of the first level has decreased to a distance B in the pre-form 32 that is significantly lower than the height A of the first level in the fill stage (referring back to FIG. 2).
  • a gap 38 may be present between the inner punch 16 and the pre-form 32.
  • the gap 38 is created by the retraction of the inner punch 16 below the pre-form 32 onto its mechanical stop 24 after the first compacting motion to maintain an equal compaction ratio for both levels during a subsequent high-velocity impact.
  • the bottom inner punch 16 may reach its mechanical stop 24 at the end of the first compaction motion.
  • the fill heights of the particulate material and the pre-lift travel of the bottom inner punch 16 are set to allow the density of the section of the pre-form 32 above the bottom inner punch 16 to be lower than the remainder of the pre-form 32. This in turn allows a uniform density distribution in the pre-form 32 after the subsequent high velocity compaction impact or impacts.
  • the main ram is operated at high velocity with energy control.
  • the energy control of the main ram is typically through the use of a ram with a given mass and a constant acceleration force, such as hydraulic pressure.
  • the acceleration distance of the ram is altered to achieve different ram energies.
  • the acceleration distance may be constant and the acceleration force may be altered to change and control the energy of the main ram.
  • the pre-form 32 is further densified through one or more impacts at high velocity, i.e., a main ram velocity that is substantially greater than 0.1 m/s at impact.
  • the main ram velocity is in a range of at least 1 m/s and up to about 100 m/s at impact. More preferably, the main ram velocity is in a range of from about 10 m/s to about 30 m/s at impact.
  • the pre-form has become a part 40.
  • the representative height of the first level has decreased from its previous height B (referring back to FIG. 3) to a final, smaller height C of the first level.
  • the high-velocity impact or impacts increase the density and homogenize the density distribution in the multiple-level part 40 beyond levels accomplished through traditional compaction.
  • the part 40 is ejected, as shown in FIG. 6.
  • the top punch 10 is raised to allow access to the part 40 and the core rod 20 is retracted or lowered to allow the part to be pushed out of the cavity 22 by the bottom outer punch 18 with minimal resistance.
  • an existing pre-form may be inserted into the tool.
  • an energy control mode allowing for high-velocity compaction may be the sole mode that is used.
  • the tool set includes an upper punch 44 that may include a step 46 to complement the multiple-level configuration of a pre-form.
  • the tool set also includes a die 48, a bottom inner punch 50, a bottom outer punch 52 and a core rod 54 that is disposed on an inner circumference of the bottom inner punch 50.
  • the bottom inner punch 50 has a lower limit defined by a first mechanical stop 56 and the bottom outer punch 18 has a lower limit defined by a second mechanical stop 58.
  • the die 48, bottom inner punch 50, bottom outer punch 52 and core rod 54 cooperate to define a cavity 60.
  • a pre-form 62 is inserted into the cavity 60.
  • the pre-form can be made by any means known in the art, such as by forming in a traditional compaction press.
  • the pre-form may be pre-sintered to burn off lubricant or fully sintered.
  • the pre-sintering or full sintering of the pre-form constitutes a sizing or coining operation rather than a compacting operation, but also serves the objective to form a high-density powder metal part.
  • a representative height of a central level of the pre-form 62 is at a distance D.
  • a gap 66 is shown between the bottom inner punch 50 and the pre-form 62. The gap 66 allows an equal compaction ratio for all levels to be maintained after one or more high-velocity impacts.
  • the main ram is moved at high velocity by energy control to increase the density of the pre-form 62 through one or more impacts.
  • the pre-form has become a part 68.
  • the representative height has decreased from its previous height D (referring back to FIG. 7) to a final, smaller height E of the central level.
  • the use of high-velocity impact or impacts has increased the density and homogenized the density distribution in the multiple-level part 68 beyond levels accomplished through traditional compaction.
  • the part 68 is ejected, as illustrated in FIG. 9.
  • the top punch 44 is raised to allow access to the part 68 and the core rod 54 is retracted or lowered to allow the part to be pushed out of the cavity 60 by the bottom outer punch 52 with minimal resistance. It is to be noted that more than two bottom punches may be included in a tool set in accordance with the present invention.
  • the tool set includes the die 48 and the upper punch 44 that may include a step 46.
  • a single bottom punch 70 includes a step 72 with an appropriate draft angle 74 between the step 72 and the lower level 76 of the punch 70 to allow removal of a finished part.
  • the core rod 54 is disposed in an inner circumference of the bottom punch 70.
  • the bottom punch 70 has a lower limit defined by a mechanical stop 78.
  • the die 48, bottom punch 70 and core rod 54 cooperate as in the above embodiment to define the cavity 60.
  • the pre-form 62 with the representative height D of the central level is inserted into the cavity 60.
  • the gap 66 between the bottom punch 70 and the pre-form 62 may again be present to allow an equal compaction ratio to be maintained for all levels after one or more high-velocity impacts.
  • the main ram is moved at high velocity by energy control to increase the density of the pre-form 62 through one or more impacts.
  • FIG. 11 after the final compacting impact, the pre-form has become a part 68.
  • the representative height has decreased from its previous height D (referring back to FIG. 10) to a final, smaller height E of the central level.
  • the part 68 is ejected, as illustrated in FIG. 12.
  • the top punch 44 is raised to allow access to the part 68 and the core rod 54 and the die 48 are lowered to allow the part 68 to be removed from the top of the bottom punch 70.
  • the part 68 may also be removed by raising the bottom punch 70, as described above.
  • the press includes a ram drive that is energy controlled and capable of high velocity, also known in the art as a high-velocity compaction press, and an alternate ram drive mode that may be position controlled or force controlled.
  • the press may perform at least one compacting motion in a force controlled or position controlled mode and then perform subsequent high-velocity compaction in an energy controlled mode.
  • a method for the high-velocity compaction of a part from particulate material, such as powder metal is also disclosed.
  • the method comprises the production of parts in accordance with the steps that are presented in the process detailed in FIGS. 1- 12 above.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un procédé de compactage rapide de matières particulaires afin de former une pièce. Ce procédé comporte les étapes consistant à : fournir une cavité au moins partiellement formée par au moins un poinçon inférieur ; insérer dans cette cavité une préforme comprenant au moins deux niveaux ; et à déplacer rapidement un piston principal commandé énergétiquement en direction de la préforme pour accroître la densité de la préforme et former ladite pièce. L'invention se rapporte en outre à une pièce à niveaux multiples constituée de matière particulaire ainsi qu'à une presse de compactage.
PCT/US2002/022499 2001-07-20 2002-07-16 Appareil et procede permettant de former des pieces a niveaux multiples par compactage rapide WO2003008131A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2002354920A AU2002354920A1 (en) 2001-07-20 2002-07-16 Apparatus and method for high-velocity compaction of multiple-level parts

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US30682601P 2001-07-20 2001-07-20
US60/306,826 2001-07-20

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Publication Number Publication Date
WO2003008131A2 true WO2003008131A2 (fr) 2003-01-30
WO2003008131A3 WO2003008131A3 (fr) 2003-11-27

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WO (1) WO2003008131A2 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010080064A1 (fr) 2009-01-12 2010-07-15 Metec Powder Metal Ab Pièces à multiples niveaux obtenues à partir d'une poudre métallique sphérique agglomérée
JP2014500396A (ja) * 2010-10-27 2014-01-09 ジーケーエヌ シンター メタルズ、エル・エル・シー 成形アプリケーション用の粉末金属の軸方向及び径方向の保持部
CN109153075A (zh) * 2016-08-18 2019-01-04 大冶美有限公司 成型模具及成型方法

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3664785A (en) * 1968-12-13 1972-05-23 Birmingham Small Arms Co Ltd Presses for production of complex components
US3767351A (en) * 1970-10-22 1973-10-23 Von Roll Ag Vibratory granulate compacting apparatus for block manufacture
GB1395180A (en) * 1971-08-10 1975-05-21 Schwelmer Eisenwerk Mueller Co Method of and press for compacting materials in powder form to produce pieces to be sintered
US6049983A (en) * 1996-08-02 2000-04-18 Hitachi Powdered Metal Co. Ltd. Method for producing a sintered porous bearing and the sintered porous bearing
US6139975A (en) * 1997-06-12 2000-10-31 Hitachi Powered Metals Co., Ltd. Sheet metal member, method of manufacturing same, and heat radiation plate
WO2002038315A1 (fr) * 2000-11-09 2002-05-16 Höganäs Ab Produits extremement denses et leur procede de preparation
EP1228856A2 (fr) * 2001-02-06 2002-08-07 Aktiebolaget SKF Outil pour le compactage de poudre

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3664785A (en) * 1968-12-13 1972-05-23 Birmingham Small Arms Co Ltd Presses for production of complex components
US3767351A (en) * 1970-10-22 1973-10-23 Von Roll Ag Vibratory granulate compacting apparatus for block manufacture
GB1395180A (en) * 1971-08-10 1975-05-21 Schwelmer Eisenwerk Mueller Co Method of and press for compacting materials in powder form to produce pieces to be sintered
US6049983A (en) * 1996-08-02 2000-04-18 Hitachi Powdered Metal Co. Ltd. Method for producing a sintered porous bearing and the sintered porous bearing
US6139975A (en) * 1997-06-12 2000-10-31 Hitachi Powered Metals Co., Ltd. Sheet metal member, method of manufacturing same, and heat radiation plate
WO2002038315A1 (fr) * 2000-11-09 2002-05-16 Höganäs Ab Produits extremement denses et leur procede de preparation
EP1228856A2 (fr) * 2001-02-06 2002-08-07 Aktiebolaget SKF Outil pour le compactage de poudre

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010080064A1 (fr) 2009-01-12 2010-07-15 Metec Powder Metal Ab Pièces à multiples niveaux obtenues à partir d'une poudre métallique sphérique agglomérée
US9101982B2 (en) 2009-01-12 2015-08-11 Metec Powder Metal Ab Multilevel parts from agglomerated spherical metal powder
EP2376247A4 (fr) * 2009-01-12 2017-08-23 Metec Powder Metal AB Pièces à multiples niveaux obtenues à partir d'une poudre métallique sphérique agglomérée
US10035190B2 (en) 2009-01-12 2018-07-31 Metec Powder Metal Ab Multilevel parts from agglomerated spherical metal powder
JP2014500396A (ja) * 2010-10-27 2014-01-09 ジーケーエヌ シンター メタルズ、エル・エル・シー 成形アプリケーション用の粉末金属の軸方向及び径方向の保持部
CN109153075A (zh) * 2016-08-18 2019-01-04 大冶美有限公司 成型模具及成型方法
EP3501693A4 (fr) * 2016-08-18 2020-01-01 Diamet Corporation Matrice de moulage et procédé de moulage
CN109153075B (zh) * 2016-08-18 2021-07-09 大冶美有限公司 成型模具及成型方法
US11446737B2 (en) 2016-08-18 2022-09-20 Diamet Corporation Molding die and molding method

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WO2003008131A3 (fr) 2003-11-27
AU2002354920A1 (en) 2003-03-03

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