WO2005102559A2 - Powdered metal multi-lobular tooling and method of fabrication - Google Patents

Powdered metal multi-lobular tooling and method of fabrication Download PDF

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Publication number
WO2005102559A2
WO2005102559A2 PCT/US2005/007040 US2005007040W WO2005102559A2 WO 2005102559 A2 WO2005102559 A2 WO 2005102559A2 US 2005007040 W US2005007040 W US 2005007040W WO 2005102559 A2 WO2005102559 A2 WO 2005102559A2
Authority
WO
WIPO (PCT)
Prior art keywords
recited
tool
lobular
predetermined length
high speed
Prior art date
Application number
PCT/US2005/007040
Other languages
French (fr)
Other versions
WO2005102559B1 (en
WO2005102559A3 (en
Inventor
Edward Kletecka
Sean Kurtz
Original Assignee
Textron 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 Textron Inc. filed Critical Textron Inc.
Priority to CA002558010A priority Critical patent/CA2558010A1/en
Priority to JP2007508342A priority patent/JP2007532320A/en
Priority to CN2005800119217A priority patent/CN1946511B/en
Priority to EP05724557A priority patent/EP1735117A4/en
Priority to AU2005235543A priority patent/AU2005235543A1/en
Priority to BRPI0509839-4A priority patent/BRPI0509839A/en
Publication of WO2005102559A2 publication Critical patent/WO2005102559A2/en
Publication of WO2005102559A3 publication Critical patent/WO2005102559A3/en
Publication of WO2005102559B1 publication Critical patent/WO2005102559B1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K5/00—Making tools or tool parts, e.g. pliers
    • B21K5/20—Making working faces of dies, either recessed or outstanding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J13/00—Details of machines for forging, pressing, or hammering
    • B21J13/02—Dies or mountings therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/44—Making machine elements bolts, studs, or the like
    • B21K1/46—Making machine elements bolts, studs, or the like with heads
    • B21K1/463—Making machine elements bolts, studs, or the like with heads with recessed heads
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P13/00—Making metal objects by operations essentially involving machining but not covered by a single other subclass
    • B23P13/04—Making metal objects by operations essentially involving machining but not covered by a single other subclass involving slicing of profiled material
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
    • 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
    • B22F2998/10—Processes characterised by the sequence of their steps

Definitions

  • This invention generally relates to multi-lobular tooling for punching a multi-
  • the invention also relates to methods of forming a powdered metal
  • Multi-lobular tools are used to punch a
  • Figure 1 illustrates a
  • the head 12 of the punch pin 10 i.e., having a
  • multi-lobular profile is punched into a workpiece, such as the head of a fastener, to
  • punch pins are formed of standard tool steel such as M42 tool steel.
  • Tool steel by nature, is very nonhomogeneous, and typically contains large, often
  • Figure 2 provides an image of a punch pin formed of M42 tool
  • Figure 3 is similar, but is an image taken along
  • the carbide may cause the lobe to chip prematurely during use, as shown in Figure 4.
  • Figure 4 provides an image of a punch pin formed of M42 tool steel, where the image
  • MIM metal injection molding
  • the binder must be removed (i.e., de-
  • embodiment of the present invention provides a tool made of powdered metal, such as
  • a tool made of powdered metal where the tool has a multi-lobular end profile.
  • method includes steps of: cutting a predetermined length from a rod formed of
  • powdered metal such as a modified T15 HSS (modified in that molybdenum is
  • Figure 1 is a perspective view of a multi-lobular punch pin
  • Figure 2 provides an image of a punch pin formed of M42 tool steel, where the
  • Figure 3 is similar to Figure 2 , but where the image has been taken along a
  • Figure 4 provides an image of a punch pin formed of M42 tool steel, where the
  • Figure 5 provides an image of a punch pin formed of a modified T15 HSS in
  • Figure 6 is similar to Figure 5 , but where the image has been taken along a
  • Figure 7 provides an image of a punch pin formed of a modified T15 HSS in
  • Figure 8 provides a flow chart of a method of fabricating a multi-lobular tool
  • Figures 2-4 relate to a punch pin formed of M42 tool steel.
  • Figures 5-7 provide similar views, but relating to a multi-lobular tool, specifically a
  • molybdenum is added), in accordance with an embodiment of the present invention.
  • the punch pin is very robust and not
  • Figure 5 provides an image of the punch pin, where the image was taken with a
  • Figure 6 is similar to Figure 5, but where the image has been taken along a
  • the carbides are relatively small compared to those
  • the carbides present in a punch pin made of tool steel can be 40 microns or more
  • the punch pin is formed of powdered metal, such a modified T15 HSS
  • the carbides in powdered form, provides that the carbides can be as small as 1-4 microns.
  • Figure 7 provides an image of the punch pin, where the image was taken with a
  • punch pin ( Figure 4) exhibits some chipping at a lobe.
  • lobular tool such as a punch pin
  • multi-lobular tools such as punch pins, are formed of tool
  • the punch pin is more robust and has improved column strength and impact resistance, and will have a longer useful service life.
  • Figure 8 illustrates a method of fabricating a powdered metal multi-lobular
  • the method provides the
  • powdered metal such as a modified T15 HSS (modified in that molybdenum is
  • HIP hot isostatic press
  • the P.M. ingot is then processed like a conventionally poured ingot. While embodiments of the present invention are shown and described, it is

Abstract

A tool (10) made of powdered metal, such as a modified T15 HSS in powdered form, and having a multi-lobular end profile (12) for punching multi-lobular recesses into workpieces, such as into the heads of fasteners. The tool (10) is homogenous and contains only carbides which are relatively small, such as in the 1-4 micron range. Also provided is a method of fabricating such a tool. The method requires that a powdered metal bar is cut and then the cut piece is worked to provide the multi-lobular tool. The final part is theoretically 100% dense, as opposed to being only 95-98% dense as in metal injection molded parts. In use, the final part, due to how it is fabricated, has increased column strength and increased impact resistance.

Description

POWDERED METAL MULTI-LOBULAR TOOLING AND METHOD OF FABRICATION
Background
This invention generally relates to multi-lobular tooling for punching a multi-
lobular recess into, for example, the head of a fastener. The invention more
specifically relates to multi-lobular tooling and tooling blank which are formed of
powdered metal. The invention also relates to methods of forming a powdered metal
multi-lobular tool.
Multi-lobular tools, often referred to as "punch pins," are used to punch a
multi-lobular recess into, for example, the head of a fastener. Figure 1 illustrates a
multi-lobular punch pin 10. In use, the head 12 of the punch pin 10, i.e., having a
multi-lobular profile, is punched into a workpiece, such as the head of a fastener, to
form a multi-lobular recess.
Typically, punch pins are formed of standard tool steel such as M42 tool steel.
Tool steel, by nature, is very nonhomogeneous, and typically contains large, often
segregated carbides. Figure 2 provides an image of a punch pin formed of M42 tool
steel, where the image was taken with a microscope at 400x, along a transverse cross-
section (i.e., along line 2 in Figure 1). Figure 3 is similar, but is an image taken along
a longitudinal cross-section (i.e., along line 3 in Figure 1). As shown, carbides (the
lighter areas in the image), many of which are relatively large, can be found along
either cross-section. With regard to size, in a punch pin formed of conventional tool
steel, carbides as large as 10-50 microns or even larger often exist. The presence of a carbide segregation tends to produce a hard, brittle or
weakened plane, wherein the material has a tendency to fracture or splinter. Generally
speaking, it is undesirable for a punch pin to contain large carbides and carbide
segregation, as carbides provide a point of weakness. This is especially true if a fairly
large carbide happens to exist along a lobe of a multi-lobular punch pin. In such case,
the carbide may cause the lobe to chip prematurely during use, as shown in Figure 4.
Figure 4 provides an image of a punch pin formed of M42 tool steel, where the image
was taken with a scanning electron microscope (SEM) at 35x, after the punch pin was
used in a number of cycles to punch multi-lobular recesses into workpieces. Not only
does it present a possible problem when a large carbide exists on a lobe of a punch
pin, but the problem is even more severe the larger the punch pin.
United States Patent No. 6,537,487 discloses a method of molding a powdered
metal part using a metal injection molding ("MIM") process. Such a process is
relatively complicated and uses a binder. The binder must be removed (i.e., de-
binding) during sintering, or prior to sintering. A finished part made with such a
process typically is only 95 to 98% dense, and has diminished column strength and
limited impact resistance.
Objects and Summary
An object of an embodiment of the present invention is provide a multi-lobular
tool and tool blank which are formed of powdered metal, thereby providing that the
tool is very homogenous and contains only carbides of an extremely small nature.
Yet another object of an embodiment of the present invention is provide a
relatively simple method of fabricating a multi-lobular powdered metal tool, where the
method does not require any de-binding steps, either prior to or during sintering.
Briefly, and in accordance with at least one of the foregoing objects, an
embodiment of the present invention provides a tool made of powdered metal, such as
a modified (in that molybdenum is added) T15 high speed steel (HSS) in powdered
form, and having a multi-lobular end profile for punching multi-lobular recesses into
workpieces, such as into the heads of fasteners.
Another embodiment of the present invention provides a method of fabricating
a tool made of powdered metal, where the tool has a multi-lobular end profile. The
method includes steps of: cutting a predetermined length from a rod formed of
powdered metal, such as a modified T15 HSS (modified in that molybdenum is
added); applying a 47 45° chamfer to both ends; grinding the outside diameter to a
predetermined size; applying oil and extruding a multi-lobular configuration on one
end of the cutoff in the extrusion die that is secured in a punch press; stress relieving
the part in a heat treat furnace; coining a trademark (if desired) onto the part; grinding
the outside diameter to a predetermined size; facing to predetermined length; shaving a
nose angle; heat treating to a predetermined hardness; grinding the nose angle to achieve a desired finish and length; grinding the outside diameter step to a
predetermined size and length; and polishing the nose angle to desired finish.
Brief Description of the Drawings
The organization and manner of the structure and operation of the invention,
together with further objects and advantages thereof, may best be understood by
reference to the following description, taken in connection with the accompanying
drawings, wherein like reference numerals identify like elements in which:
Figure 1 is a perspective view of a multi-lobular punch pin;
Figure 2 provides an image of a punch pin formed of M42 tool steel, where the
image was taken with a microscope at 400x, along a transverse cross-section (i.e.,
along line 2 in Figure 1);
Figure 3 is similar to Figure 2 , but where the image has been taken along a
longitudinal cross-section (i.e., along line 3 in Figure 1);
Figure 4 provides an image of a punch pin formed of M42 tool steel, where the
image was taken with a scanning electron microscope (SEM) at 35x, after the punch
pin was used in a number of cycles to punch multi-lobular recesses into workpieces;
Figure 5 provides an image of a punch pin formed of a modified T15 HSS in
powdered form, in accordance with an embodiment of the present invention, where the
image was taken with a microscope at 400x, along a transverse cross-section (i.e.,
along line 2 in Figure 1);
Figure 6 is similar to Figure 5 , but where the image has been taken along a
longitudinal cross-section (i.e., along line 3 in Figure 1); Figure 7 provides an image of a punch pin formed of a modified T15 HSS in
powdered form, where the image was taken with a SEM at 5 Ox, after the punch pin
was used in a number of cycles to punch multi-lobular recesses into workpieces; and
Figure 8 provides a flow chart of a method of fabricating a multi-lobular tool,
such as a punch pin, where the method is in accordance with an embodiment of the
present invention.
Description
While the present invention may be susceptible to embodiment in different
forms, there are shown in the drawings, and herein will be described in detail,
embodiments thereof with the understanding that the present description is to be
considered an exemplification of the principles of the invention and is not intended to
limit the invention to that as illustrated and described herein.
As discussed above, Figures 2-4 relate to a punch pin formed of M42 tool steel.
Figures 5-7 provide similar views, but relating to a multi-lobular tool, specifically a
punch pin, formed of a modified Tl 5 HSS in powdered form (modified in that
molybdenum is added), in accordance with an embodiment of the present invention.
As a result of being formed of powdered metal, the punch pin is much more
homogenous and contains only carbides (the lighter areas in the images shown in
Figures 5 and 6) which are relatively small, compared to carbides which are typically
contained in a punch pin formed of tool steel. As a result of being more homogenous
and containing only relatively small carbides, the punch pin is very robust and not
prone to chipping or otherwise failing during use (i.e., while being used to, for
example, punch recesses in the heads of fasteners).
Figure 5 provides an image of the punch pin, where the image was taken with a
microscope at 400x, along a transverse cross-section (i.e., along line 2 in Figure 1).
Figure 6 is similar to Figure 5, but where the image has been taken along a
longitudinal cross-section (i.e., along line 3 in Figure 1). As shown in Figures 5 and 6,
the carbides (the lighter areas in the images) are relatively small compared to those
present in the tool steel punch pin, as shown in Figures 2 and 3. Specifically, while
the carbides present in a punch pin made of tool steel can be 40 microns or more,
providing that the punch pin is formed of powdered metal, such a modified T15 HSS
in powdered form, provides that the carbides can be as small as 1-4 microns.
Figure 7 provides an image of the punch pin, where the image was taken with a
SEM at 50x, after the punch pin was used in a number of cycles to punch multi-lobular
recesses into workpieces. Comparing Figure 7 to Figure 4, the powdered metal punch
pin (Figure 7) exhibits merely acceptable wear with no chipping, while the tool steel
punch pin (Figure 4) exhibits some chipping at a lobe.
Because large carbides provide a point of weakness, and the lobes of a multi-
lobular tool, such as a punch pin, receive a lot of the stress during impact, it is
important to provide or insure that large carbides do not exist at a lobe of a multi-
lobular tool. Typically, multi-lobular tools, such as punch pins, are formed of tool
steel which is very non-homogenous. Providing that the multi-lobular tool is instead
made of powdered metal, such as a modified T15 HSS in powdered form, provides
that the grain structure of the part is much more homogenous. As such, there is less of
a likelihood or even no likelihood, that large carbides will exist in the area of, or on one of the lobes. As a result, the punch pin is more robust and has improved column strength and impact resistance, and will have a longer useful service life.
Figure 8 illustrates a method of fabricating a powdered metal multi-lobular
tool, such as a punch pin as shown in Figures 5-7, where the method is in accordance
with an embodiment of the present invention. As shown, the method provides the
following steps: cutting a predetermined length from a rod from bar stock formed of
powdered metal, such as a modified T15 HSS (modified in that molybdenum is
added); applying a 47 45° chamfer to both ends; grinding the outside diameter to a
predetermined size; applying oil and extruding a multi-lobular configuration on one
end of the cutoff in the extrusion die that is secured in a punch press; stress relieving
the part in a heat treat furnace; coining a trademark (if desired) onto the part; grinding
the outside diameter to a predetermined size; facing to predetermined length; shaving a
nose angle; heat treating to a predetermined hardness; grinding the nose angle to
achieve a desired finish and length; grinding the outside diameter step to a
predetermined size and length; and polishing the nose angle to desired finish. The
process is relatively simple, and does not require any de-binding steps, as opposed to a
metal injection molding process, where a binder must be removed during sintering, or
prior to sintering. A finished part made with such an injection metal molding process
typically is only 95 to 98% dense. In contrast, a finished part fabricated with the
above-described method is theoretically 100% dense, and has improved column
strength, impact resistance, and tool life. To provide the powdered steel bar, before perfoπning the fabricating steps
described above, the following process may be used:
1. Molten metal, of the proper composition, is atomized in an inert
atmosphere.
2. The resulting powered metal is sealed in a large steel "can" which
is a steel pipe 5 to 6 feet long and 10 to 12 inches in diameter.
3. The sealed can is placed in a hot isostatic press ( HIP ) which
exerts a pressure of 1000 atmospheres at a temperature 2100F.
4. After the HIP process, the steel can is machined off of the now
solid and 100% dense P.M. ingot.
5. The P.M. ingot is then processed like a conventionally poured ingot. While embodiments of the present invention are shown and described, it is
envisioned that those skilled in the art may devise various modifications of the present
invention without departing from the spirit and scope of the disclosure.

Claims

What is claimed is:
1. A tool (10) having a body and a multi-lobular end profile (12) for punching multi-lobular recesses into workpieces, said tool (10) characterized by said body being made of powdered metal.
2. A tool (10) as recited in claim 1, characterized in that said tool (10) is made of high speed steel in powdered form.
3. A tool (10) as recited in claim 2, characterized in that the high speed steel comprises T15 high speed steel.
4. A tool (10) as recited in claim 2, characterized in that the high speed steel includes molybdenum.
5. A tool (10) as recited in claim 3, characterized in that the T15 high speed steel includes molybdenum.
6. A tool (10) as recited in claim 1, characterized in that said tool (10) is configured to punch multi-lobular recesses into the heads of fasteners.
7. A method of fabricating a tool (10) made of powdered metal, where the tool (10) has a multi-lobular end profile (12) for punching multi-lobular recesses into workpieces, said method characterized by: providing a rod formed of powdered metal; cutting a predetermined length from the rod, said predetermined length defining a part; applying a chamfer to at least one end of the part; grinding an outside diameter of the part to a predetermined size; extruding a multi-lobular configuration on one end (12) of the part; grinding an outside diameter of the part to a predetermined size; and forming the part to a predetermined length.
8. A method as recited in claim 7, further characterized by stress relieving the part in a heat treat furnace.
9. A method as recited in claim 7, further characterized by coining a trademark onto the part.
10. A method as recited in claim 7, further characterized by facing the part to a predetermined final length.
11. A method as recited in claim 7, further characterized by shaving a nose angle on the part.
12. A method as recited in claim 7, further characterized by heat treating the part to a predetermined hardness.
13. A method as recited in claim 11 , further characterized by polishing the nose angle to desired finish.
14. A method as recited in claim 7, characterized in that the step of cutting a predetermined length from the rod comprises cutting a predetermined length from a rod formed of high speed steel.
15. A method as recited in claim 7, characterized in that the step of cutting a predetermined length from the rod comprises cutting a predetermined length from a rod formed of T15 high speed steel.
16. A method as recited in claim 7, characterized in that the step of cutting a predetermined length from the rod comprises cutting a predetermined length from a rod formed of high speed steel which includes molybdenum.
17. A method as recited in claim 7, characterized in that the step of cutting a predetermined length from the rod comprises cutting a predetermined length from a rod formed of T15 high speed steel which includes molybdenum.
18. A method as recited in claim 7, characterized in that the step of applying a chamfer to at least one end of the part comprises applying a 47745° chamfer to both ends of the part.
19. A method as recited in claim 7, characterized in that the step of extruding a multi-lobular configuration on one end of the part further comprises applying oil to the part and extruding the multi-lobular configuration in an extrusion die that is secured in a punch press.
PCT/US2005/007040 2004-04-13 2005-03-03 Powdered metal multi-lobular tooling and method of fabrication WO2005102559A2 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
CA002558010A CA2558010A1 (en) 2004-04-13 2005-03-03 Powdered metal multi-lobular tooling and method of fabrication
JP2007508342A JP2007532320A (en) 2004-04-13 2005-03-03 Powdered metal multilobe tool and method of making
CN2005800119217A CN1946511B (en) 2004-04-13 2005-03-03 Powdered metal multi-lobular tooling and method of fabrication
EP05724557A EP1735117A4 (en) 2004-04-13 2005-03-03 Powdered metal multi-lobular tooling and method of fabrication
AU2005235543A AU2005235543A1 (en) 2004-04-13 2005-03-03 Powdered metal multi-lobular tooling and method of fabrication
BRPI0509839-4A BRPI0509839A (en) 2004-04-13 2005-03-03 Multilobular pulverized metal tool and manufacturing method

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US56172804P 2004-04-13 2004-04-13
US60/561,728 2004-04-13
US11/052,438 2005-02-07
US11/052,438 US20050227772A1 (en) 2004-04-13 2005-02-07 Powdered metal multi-lobular tooling and method of fabrication

Publications (3)

Publication Number Publication Date
WO2005102559A2 true WO2005102559A2 (en) 2005-11-03
WO2005102559A3 WO2005102559A3 (en) 2005-12-22
WO2005102559B1 WO2005102559B1 (en) 2006-02-02

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US (2) US20050227772A1 (en)
EP (1) EP1735117A4 (en)
JP (1) JP2007532320A (en)
KR (2) KR100824175B1 (en)
AR (1) AR048680A1 (en)
AU (1) AU2005235543A1 (en)
BR (1) BRPI0509839A (en)
CA (1) CA2558010A1 (en)
RU (1) RU2366528C2 (en)
TW (1) TWI321502B (en)
WO (1) WO2005102559A2 (en)

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EP1735117A2 (en) 2006-12-27
KR20070005667A (en) 2007-01-10
US20050227772A1 (en) 2005-10-13
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TWI321502B (en) 2010-03-11
RU2366528C2 (en) 2009-09-10
BRPI0509839A (en) 2007-10-23
CA2558010A1 (en) 2005-11-03
US20080236341A1 (en) 2008-10-02
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KR20070118198A (en) 2007-12-13
WO2005102559A3 (en) 2005-12-22
AR048680A1 (en) 2006-05-17
RU2006138688A (en) 2008-05-27
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TW200602138A (en) 2006-01-16
JP2007532320A (en) 2007-11-15

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