Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
  • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
  • B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
• • 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

Definitions

• the invention object of this application consists in the method of production (as well as the elements produced) by closed forging of molds, dies or any single piece or small series (always metal parts or compounds with metal base) using a mold of form constructed of concrete or mortar (especially concretes and mortars made of high-strength cements and / or refractories based on porcelain, aluminous, silicate, ... and with aggregates of basalt, silicon oxide, or other aggregate of those usually used in construction, or aggregates based on alumina or other refractory materials).
• the main interest of the invention is focused on the drastic reduction of costs and time involved in being able to form metal parts of difficult geometry by closed forging.
• the present invention obtaining molds, dies and small series pieces
• the production cost of the shape mold is not excessively high.
• Another point of interest is the possibility of forming materials, metal based, very difficult to machine, or non-mechanizable, but on the other hand they have enough hot creep to be shaped by forging.
• Plastic parts and metal parts are often obtained industrially through the use of molds and dies. This is usually the case when the number of pieces to produce is high since the construction of a mold or matrix is almost always very expensive, being able to justify this high cost, only when it can be distributed among many units produced.
• Mold or matrix is considered to be any element shaped to form metal, polymer, ceramic, or composite parts.
• the shape of the mold or matrix can be the negative of the piece to be obtained, as is the case of injection molds, pressing, drawing dies, bending, stamping or any other form of forming, they can also simply be a contoured profile as in the case of some cutting matrices).
• the mold or matrix can be used to obtain a single piece or more commonly to obtain hundreds to millions of pieces per repeated action, and often also, obtaining more than one piece at each stage of forming.
• denomination "form mold” is used to designate any container capable of shaping a metal part in a closed forging operation (Also commonly referred to as: forging stamps, forging molds, dies of forging or forging tools).
• a metal block is used (usually a forged block, or cut from a forged or laminated bar, but molten blocks are also used), obtaining the desired geometry by mechanically removing the excess material .
• the toughness is much higher than that of the same alloy obtained by casting which often translates into a longer life of the tool (NOTE: in this document the term useful is used to simultaneously designate molds and matrices). This option is generally used for the manufacture of long series where the profile of the piece to be obtained does not have very large differences in dimensions.
• machining by chip removal is an expensive process and the greater the emptying, the more material becomes a chip and more hours are spent on it.
• the increase in toughness achieved by the process of forging or rolling is smaller the farther from the surface of the material with which the tool is constructed, thus in a deep emptying the part of the cavity of the finished die or mold, which is the part that works, has structure and properties practically of molten material. So that rarely is this method used for tools with differences in dimensions greater than 400mm with most mold and die building materials. It is the preferred method for long series, since the tools manufactured with this method are customary. to have greater durability.
• this method is in principle rocambolesque, since the molten material instead of sneaking directly to a geometry close to the desired one, sneaks into ingots, which are subsequently forged to turn them into billets that are again forged or rolled to obtain Forged blocks or bars, in the latter case the bars must be cut to the desired block size, and in both cases (forged block or bar cut) the block must be machined by chip removal or electro-erosion conferring the desired geometry .
• the subsequent processes of tempering, finishing machining, ... are common for both production methods.
• the forge has been used for many years as a means of obtaining shaped pieces, a process that is generally called a "closed forge", since a mold of a shape or cavity must be used so that the piece to be obtained acquires the desired shape by the creep of the material filling and copying the shape of the cavity or shape mold.
• molds of metallic or technological ceramics are used to obtain several pieces with the same mold, to amortize the cost of said mold.
• the molds and dies are generally unique, and very exceptionally there are more than ten cavities or segments with the same geometry, the Mold cost has to be amortized in one or very few pieces.
• the product produced, mold or matrix has to have a cost clearly higher than the shape mold. This is also the case in obtaining molds and dies by casting in a sand-shaped mold.
• molds and dies are obtained as economically and as simply as is currently achieved with the foundry, but at the same time with durability qualities as good or even superior to those of the molds and dies obtained by the machining of forged or laminated blocks (often blocks cut from forged and / or laminated bars).
• the method allows the use of materials of difficult mechanization (even those considered “non-mechanizable") that greatly increase the hours of service and / or productivity of the tools or parts manufactured with these materials.
• the present invention consists in providing a method of producing matrices, molds and single or short series pieces by forging in a mold form.
• the method consists in the construction of a mold so that it can withstand the temperature and mechanical stresses required for forging in a closed system of the material to be used for the construction of the mold or matrix (it is not important if the shape mold is destroyed during the forging process if it is possible to deform the material of the mold, matrix or piece), the mold being sufficiently economical so that its amount does not exceed the cost reduction with respect to the machining process.
• Mortars and concrete are especially indicated: with cements high strength (based on porcelain, silica, ...), with refractory cements (based on alumina, aluminosilicates, ...), with basaltic aggregate, sand (SiO 2 ), other refractory aggregates (based on alumina ,), or other aggregates commonly used in construction.
• Other mortars can also be used (based on: MgO, SiC, ZnO, Cr 2 O 3 , ZrO 2 , B 2 O 3 , Al 2 SiO 5 , CeO 2 , C 2 Si 3 , CaF 2 , Silica, graphite, magnesite, silicates, linosulfonates, phosphates (boron, aluminum, ...))).
• Some of the aggregates mentioned above can also be used with a binder (for example aluminum phosphate).
• part of the invention in the production of die molds or castings is also a great advantage, since if molds of mortar or concrete form are used, the dimensional tolerances that can be achieved as well as the quality of the surface finish, They look remarkably increased.
• the present invention also has a great advantage for obtaining finished parts or preforms (especially if it is a single piece or few units), especially if the material used to obtain the piece has a high cost or is difficult to mechanize . Some geometries are not possible to obtain economically in any other way in the case of very difficult machining materials such as metal or polymer matrix compounds with ceramic charge.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Forging (AREA)
• Mounting, Exchange, And Manufacturing Of Dies (AREA)

Priority Applications (2)

Applications Claiming Priority (1)

Publications (1)

Family

ID=36498327

Family Applications (1)

Country Status (2)

Cited By (1)

• 2004
  • 2004-11-16 EP EP04798237A patent/EP1892049A1/fr not_active Withdrawn
  • 2004-11-16 WO PCT/ES2004/000510 patent/WO2006056621A2/fr active Application Filing

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