WO2012058112A1 - Power metal axial and radial retention features for molding applications - Google Patents
Power metal axial and radial retention features for molding applications Download PDFInfo
- Publication number
- WO2012058112A1 WO2012058112A1 PCT/US2011/057275 US2011057275W WO2012058112A1 WO 2012058112 A1 WO2012058112 A1 WO 2012058112A1 US 2011057275 W US2011057275 W US 2011057275W WO 2012058112 A1 WO2012058112 A1 WO 2012058112A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- powder metal
- features
- sintered powder
- metal insert
- die
- Prior art date
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
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
-
- 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
-
- 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
- B22F5/007—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of moulds
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12014—All metal or with adjacent metals having metal particles
Definitions
- This invention relates to sintered powder metal manufacturing and in particular to forming axial and radial locking features in components that will become part of a molded assembly.
- PM parts sintered powder metal (PM) parts has increased in the recent past as a base component or insert that becomes part of a molded product of multi- materials. These materials may be plastic, rubber, aluminum, or another material as required.
- the advantage of the multi-material product is lower cost, increased productivity and greater design flexibility.
- the PM part will have an inner surface that defines features required for consumer use of the product. This may be a straight through hole, keyway, double D hole, or others as required.
- the outer surface engages the other component material. This quite often is achieved by molding the material around the PM part often referred to as overmolding.
- Simple PM parts or inserts might not include any retention features. As such the PM insert may break free and fall out of the component.
- some inserts may include retaining features to provide a more secure connection to the component.
- some PM inserts will have a flange to provide retention in one direction, another may have outer surface features such as ribs, a keyway, a polygonal shape and so forth to provide rotary or radial retention.
- Other designs include knurling, undercuts, or perforations into which the molded material can flow to provide axial retention.
- the present invention provides a PM part that comprises a first or upper end surface and a second or lower end surface.
- the distance between the end surfaces defines an axial or longitudinal direction.
- the PM part further comprises an inner surface that defines a passageway configured as required by consumer use of the product and an outer surface configured to engage a material structure in which the PM part is placed.
- the distance between the inner and outer surfaces defines a radial direction perpendicular to the axial or longitudinal direction.
- the PM part further comprises a first set of retention features that project inwardly from the outer surface and longitudinally from the first end surface.
- a second set of retention features project inwardly from the outer surface and longitudinally from the second end surface.
- This second set of retention features is angularly located midway between the first set of retention features so that they are angularly offset from one another do not intersect.
- Both the first and second sets of retention features have at least a portion of the surface that is perpendicular to the tangential direction. Furthermore these features also have a portion of the feature surface that is perpendicular to the longitudinal direction. Thus they provide retention in both the axial or longitudinal direction to resist punch out of the PM part in the axial direction as well as retention in a radial direction so as to resist rotation of the PM part relative to the material surrounding it.
- the present invention provides a method for forming the part from powder metal.
- This method includes the step of pressing the powder metal in a longitudinal direction. This can be accomplished utilizing a compaction die set including a lower punch, a lower core, a lower die, an upper die, an upper punch, and an upper core.
- the top surface of the PM part will be formed by the upper punch.
- the upper outer surface including the upper retention features will be formed by the upper die cavity.
- the lower outer surface of the part including the lower retention features will be shaped by the lower die cavity.
- the lower end face of the part will be formed by the lower punch.
- the inner surface of the part is shaped with the core.
- This method further includes removal of the part by first raising the upper die and upper punch from the part and final removal by lowering the lower die and core.
- FIG. 1a is a perspective view of a prior art, powder metal part having knurling and circular undercut features for axial and radial retention;
- Fig. 1b is a sectional view of the same powder metal part of Fig. 1a showing the part 51 overmolded with another material 52 as a multi-material product;
- Fig. 2a is a perspective view of a powder metal part redesigned to incorporate the present invention
- Fig. 2b is a sectional view of the same powder metal part of Fig. 2a showing the part 53 overmolded with another material 54 as a multi-material product;
- Figs. 3a - 3f are sectional schematic views of the tooling for forming the powder metal part of Fig. 2a;
- Fig. 4 is a schematic view summarizing which parts of the powder metal part are formed by which parts of the tooling.
- the axial or longitudinal and radial retention features are created during the pressing cycle.
- the PM part further comprises an inner surface 90 that defines a passageway configured as required by consumer use of the product, and an outer surface configured to engage a material structure in which the PM part is placed.
- the distance between the inner and outer surfaces defines a radial direction perpendicular to the axial or longitudinal direction.
- the PM part further comprises a first set of upper retention features 91 that project inwardly from the outer surface and longitudinally from the upper surface 92.
- a second set or lower retention features 93 project inwardly from the outer surface and longitudinally from the lower surface 94.
- This second or lower set if retention features 93 are offset angularly so that they are located on the periphery of the part between the upper retention features 91 so that they do not intersect, were they to be extended into the zone of the other set of retention features.
- Both sets of retention features extend generally parallel to the axial direction of the part and for less in axial length than the length of the part, so that each feature defines a blind end surface 95, which extends radially and circumferentially and is in a plane that is perpendicular to the axial direction.
- both the upper and lower retention features have at least a portion of the surface that is perpendicular to the radial direction and also have a portion of the feature surface that is perpendicular to the longitudinal direction. Thus they provide retention in both the axial direction and in the radial direction.
- a PM insert for overmolding can be made according to the invention using a compaction tooling set that includes as tooling members a lower die 501 , an upper die 502, an upper punch 601 , an upper pin 701 , a lower punch 201 , and a lower core pin 101.
- the tooling members are moved by mechanical, hydraulic or other means of power when installed in a powder metal compacting press.
- the starting position is shown in Fig 3a.
- the die 501 is aligned with the lower tooling members 101 and 201 and the lower tooling members all have their upper surfaces level with one another.
- the lower punch 201 is tubular and can be retracted relative to the die 501 and core pin 101 so as to surround the core pin 101 below the cavity into which powder metal is filled.
- the second step is moving the tooling members lower core 101 and die 501 relative to lower punch 201 to form a cavity 582. This may occur by moving the punch 201 down or moving the core 101 and die 501 up.
- the third step is to fill the resulting cavity 582 with powder metal.
- the fourth step, Fig 3d is to bring the tooling members upper die 502, upper pin 701 and upper punch 601 down to the position where the upper die 502 is against lower die 501 , and upper pin 701 is against lower core pin 101.
- the fifth step, Fig 3e, is to continue down with the upper die 502, forcing the lower tooling member die 501 to move downward with the powder being held in a relative position by the lower punch 201.
- the powder cavity 583 is now formed partially by the upper die 502 and partially by the lower die 501.
- the sixth step, Fig 3f is to continue moving the punches toward each other until the powder is compacted between them.
- PM compact 585 is formed with the inside shape formed by the core 101 and on the outside shape formed partially by upper die 502 and partially by lower die 501, with the upper die forming retention features from the top surface and the lower die forming retention features from the bottom surface and the upper die 502 and lower die 501 offset angularly in position with the top to bottom retention features angularly offset so that the features of each set are between the features of the other set, with each set providing both axial and radial retention.
- the alignment of upper die 502 to lower die 501 can be completed with a setting guide tool or additional tooling features can be utilized to facilitate this alignment.
- the final or seventh step, Fig 3g is for the upper die 502 to move upward followed by the upper punch 601 , then the lower die 501 , and lower core 101 moved downward to fully eject the part and return to the starting position.
- the inside surface 90 is formed by the core 101
- the upper surface 92 is formed by the punch 601
- the lower surface 94 is formed by punch 201
- the upper outer section 96 is formed by die 502
- the lower outer section 98 is formed by die 501.
- the part is sintered in a sintering oven to fuse the powder of the compact and solidify it, making it structurally sound while largely maintaining its shape.
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE112011103625T DE112011103625T5 (en) | 2010-10-27 | 2011-10-21 | Axial and radial locking features for powder metal forming applications |
JP2013536684A JP2014500396A (en) | 2010-10-27 | 2011-10-21 | Axial and radial holders for powder metal for molding applications |
US13/821,704 US20130252012A1 (en) | 2010-10-27 | 2011-10-21 | Powder metal axial and radial retention features for molding applications |
CN2011800491722A CN103180070A (en) | 2010-10-27 | 2011-10-21 | Power metal axial and radial retention features for molding applications |
BR112013010504A BR112013010504A8 (en) | 2010-10-27 | 2011-10-21 | axial and radial metal powder retention capabilities for molding applications |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US40729410P | 2010-10-27 | 2010-10-27 | |
US61/407,294 | 2010-10-27 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2012058112A1 true WO2012058112A1 (en) | 2012-05-03 |
Family
ID=45994333
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2011/057275 WO2012058112A1 (en) | 2010-10-27 | 2011-10-21 | Power metal axial and radial retention features for molding applications |
Country Status (6)
Country | Link |
---|---|
US (1) | US20130252012A1 (en) |
JP (1) | JP2014500396A (en) |
CN (1) | CN103180070A (en) |
BR (1) | BR112013010504A8 (en) |
DE (1) | DE112011103625T5 (en) |
WO (1) | WO2012058112A1 (en) |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102014003726A1 (en) * | 2014-03-18 | 2015-09-24 | Gkn Sinter Metals Engineering Gmbh | Press for producing dimensionally stable green compacts and method for manufacturing |
US9869385B1 (en) | 2016-07-26 | 2018-01-16 | Toyota Motor Engineering & Manufacturing North America, Inc. | Powder metal net shape alignment feature |
US10151383B2 (en) | 2016-07-26 | 2018-12-11 | Toyota Motor Engineering & Manufacturing North America, Inc. | Braze retention feature for a carrier assembly |
US10107384B2 (en) | 2016-07-26 | 2018-10-23 | Toyota Motor Engineering & Manufacturing North America, Inc. | Two-piece sintered metal ravigneaux carrier |
US10428931B2 (en) | 2017-02-27 | 2019-10-01 | Toyota Motor Engineering & Manufacturing North America, Inc. | Braze preform for powder metal sintering |
CN110125391B (en) * | 2019-05-13 | 2022-05-13 | 自贡硬质合金有限责任公司 | Die and method for manufacturing pressed blank with step |
CN110681862A (en) * | 2019-10-28 | 2020-01-14 | 张家港振江粉末冶金制品有限公司 | Forming die for internal gear powder metallurgy |
Citations (5)
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US4666665A (en) * | 1986-01-30 | 1987-05-19 | Federal-Mogul Corporation | Hot-forging small inner diameter powdered metal parts |
US5363714A (en) * | 1992-01-14 | 1994-11-15 | O-Oka Forge Co., Ltd. | Gear product |
US20060236541A1 (en) * | 2003-10-21 | 2006-10-26 | Prucher Stephen L | Over-molded net-shaped gear and manufact uring method |
US20090282939A1 (en) * | 2006-06-28 | 2009-11-19 | Zf Friedrichshafen Ag | Spiral-toothed gear |
US7761995B2 (en) * | 2002-05-17 | 2010-07-27 | Schwaebische Huettenwerke Automotive Gmbh & Co. Kg | Gear wheel with a multiple helical toothing, pressed in one part, and a method and device for manufacturing the same |
Family Cites Families (13)
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US2695230A (en) * | 1949-01-10 | 1954-11-23 | Michigan Powdered Metal Produc | Process of making powdered metal article |
US2999704A (en) * | 1955-09-13 | 1961-09-12 | Haller John | Tolerance ring |
US3962772A (en) * | 1974-09-04 | 1976-06-15 | Michigan Powdered Metal Products, Inc. | Shaft-supported composite high-strength machine element and method of making the same |
US5503795A (en) * | 1995-04-25 | 1996-04-02 | Pennsylvania Pressed Metals, Inc. | Preform compaction powdered metal process |
JP3232500B2 (en) * | 1996-01-12 | 2001-11-26 | エヌオーケー株式会社 | Insert bracket |
WO2003008131A2 (en) * | 2001-07-20 | 2003-01-30 | Hawk Precision Components Group, Inc. | Apparatus and method for high-velocity compaction of multiple-level parts |
JP3786864B2 (en) * | 2001-11-28 | 2006-06-14 | 三菱マテリアルPmg株式会社 | Manufacturing method of sintered products |
US20060275607A1 (en) * | 2005-06-06 | 2006-12-07 | Semih Demir | Composite assemblies including powdered metal components |
US8071016B2 (en) * | 2006-09-22 | 2011-12-06 | Gkn Sinter Metals Llc | Thin walled powder metal component manufacturing |
JP2008121735A (en) * | 2006-11-09 | 2008-05-29 | Citizen Chiba Precision Co Ltd | Planetary gear device |
EP2162651B1 (en) * | 2007-06-13 | 2013-03-06 | Gkn Sinter Metals, Llc | Powder metal component tolerance improvements |
JP2009256723A (en) * | 2008-04-16 | 2009-11-05 | Hitachi Powdered Metals Co Ltd | Molding die of complicated form sintered machine parts |
EP2505330B1 (en) * | 2011-03-28 | 2016-08-31 | Mir Arastirma ve Gelistirme Anonim Sirketi | Fitting elements or piping units having improved adherence to plastic material |
-
2011
- 2011-10-21 US US13/821,704 patent/US20130252012A1/en not_active Abandoned
- 2011-10-21 BR BR112013010504A patent/BR112013010504A8/en not_active Application Discontinuation
- 2011-10-21 WO PCT/US2011/057275 patent/WO2012058112A1/en active Application Filing
- 2011-10-21 JP JP2013536684A patent/JP2014500396A/en active Pending
- 2011-10-21 DE DE112011103625T patent/DE112011103625T5/en not_active Ceased
- 2011-10-21 CN CN2011800491722A patent/CN103180070A/en active Pending
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4666665A (en) * | 1986-01-30 | 1987-05-19 | Federal-Mogul Corporation | Hot-forging small inner diameter powdered metal parts |
US5363714A (en) * | 1992-01-14 | 1994-11-15 | O-Oka Forge Co., Ltd. | Gear product |
US7761995B2 (en) * | 2002-05-17 | 2010-07-27 | Schwaebische Huettenwerke Automotive Gmbh & Co. Kg | Gear wheel with a multiple helical toothing, pressed in one part, and a method and device for manufacturing the same |
US20060236541A1 (en) * | 2003-10-21 | 2006-10-26 | Prucher Stephen L | Over-molded net-shaped gear and manufact uring method |
US20090282939A1 (en) * | 2006-06-28 | 2009-11-19 | Zf Friedrichshafen Ag | Spiral-toothed gear |
Also Published As
Publication number | Publication date |
---|---|
JP2014500396A (en) | 2014-01-09 |
US20130252012A1 (en) | 2013-09-26 |
CN103180070A (en) | 2013-06-26 |
BR112013010504A8 (en) | 2018-07-03 |
BR112013010504A2 (en) | 2016-08-02 |
DE112011103625T5 (en) | 2013-08-14 |
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