WO2017175772A1 - 焼結体の製造方法、および焼結体 - Google Patents

焼結体の製造方法、および焼結体 Download PDF

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Publication number
WO2017175772A1
WO2017175772A1 PCT/JP2017/014145 JP2017014145W WO2017175772A1 WO 2017175772 A1 WO2017175772 A1 WO 2017175772A1 JP 2017014145 W JP2017014145 W JP 2017014145W WO 2017175772 A1 WO2017175772 A1 WO 2017175772A1
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Prior art keywords
sintered body
green compact
compact
sintered
relative density
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PCT/JP2017/014145
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English (en)
French (fr)
Japanese (ja)
Inventor
朝之 伊志嶺
林　哲也
輝和 徳岡
鍛冶　俊彦
Original Assignee
住友電気工業株式会社
住友電工焼結合金株式会社
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Application filed by 住友電気工業株式会社, 住友電工焼結合金株式会社 filed Critical 住友電気工業株式会社
Priority to EP17779150.6A priority Critical patent/EP3441161A1/de
Priority to CN201780002715.2A priority patent/CN107921535B/zh
Priority to US15/750,703 priority patent/US20180236548A1/en
Publication of WO2017175772A1 publication Critical patent/WO2017175772A1/ja
Priority to US17/336,537 priority patent/US20210283685A1/en

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/06—Metallic powder characterised by the shape of the particles
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic 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
    • 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
    • B22F3/10—Sintering only
    • 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
    • B22F5/008—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of engine cylinder parts or of piston parts other than piston rings
    • 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
    • B22F5/06—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of threaded articles, e.g. nuts
    • 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
    • B22F5/08—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of toothed articles, e.g. gear wheels; of cam discs
    • 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
    • B22F5/08—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of toothed articles, e.g. gear wheels; of cam discs
    • B22F5/085—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of toothed articles, e.g. gear wheels; of cam discs with helical contours
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0264—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements the maximum content of each alloying element not exceeding 5%
    • 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
    • B22F2003/026—Mold wall lubrication or article surface lubrication
    • 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
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
    • 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
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0824—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid with a specific atomising fluid
    • B22F2009/0828—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid with a specific atomising fluid with water
    • 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
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • 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

Definitions

  • the present invention relates to a method for manufacturing a sintered body and a sintered body.
  • This application claims priority based on Japanese Patent Application No. 2016-077709 filed on Apr. 7, 2016, and incorporates all the contents described in the aforementioned Japanese application.
  • Patent Document 1 discloses a metal member manufacturing method (sintered body manufacturing method) for calcining a molded body obtained by pressure-molding a metal powder, machining the temporarily calcined calcined body, and then firing the calcined body.
  • the pre-fired body obtained by pre-baking the formed body has higher mechanical strength than the pre-fired formed body, is difficult to be chipped when machined, and is easy to machine. become.
  • the temporarily fired body has a lower hardness than the sintered body after the main firing, and is easy to machine. That is, in the manufacturing method of Patent Document 1, chipping and cracking are less likely to occur during machining by pre-baking the green compact to increase mechanical strength and machining the temporary fired body.
  • the method for producing a sintered body according to the present disclosure includes: Preparing a raw material powder containing iron-based metal powder; A molding step of producing a green compact having an overall average relative density of 93% or more by uniaxially pressing the raw material powder using a mold; A processing step of machining the green compact to produce a processed compact; and A sintering step of sintering the processed molded body to obtain a sintered body; Is provided.
  • the sintered body of the present disclosure is an iron-based sintered body, The average relative density of the entire sintered body is 93% or more.
  • the upper diagram is a schematic diagram showing how a green compact is machined with a cutting tool
  • the lower diagram is a schematic diagram showing how a metal solidified body is machined with a cutting tool.
  • It is a schematic perspective view of the assembly of the planetary carrier and the planetary gear described in the production example. It is a schematic side view of the planetary gear as described in a manufacture example.
  • the upper diagram is a schematic front view of the planetary carrier described in the production example, and the lower diagram is a cross-sectional view taken along the line AA of the upper diagram.
  • Patent Document 1 Moreover, in the manufacturing method of the metal member of Patent Document 1, pressure molding ⁇ temporary firing ⁇ machining ⁇ main firing is performed, and the number of steps necessary for obtaining the metal member is large. Therefore, the technique of Patent Document 1 has room for improvement in terms of productivity of metal members.
  • This disclosure is intended to provide a method for producing a sintered body that is easy to machine with respect to a green compact before sintering and is excellent in productivity.
  • the manufacturing method of the sintered compact which concerns on embodiment is as follows. Preparing a raw material powder containing iron-based metal powder; A molding step of producing a green compact having an overall average relative density of 93% or more by uniaxially pressing the raw material powder using a mold; A processing step of machining the green compact to produce a processed compact; and A sintering step of sintering the processed molded body to obtain a sintered body; Is provided.
  • a green compact is produced by uniaxial pressing using a mold.
  • uniaxial pressing since the raw material powder can be molded by applying a very high surface pressure to the raw material powder, it is easy to obtain a compacted body having a high relative density and uniform density and no locally fragile portions. Therefore, the green compact obtained by uniaxial pressing is excellent in mechanical strength and is less likely to be chipped or cracked during machining.
  • the compacted body obtained by uniaxial pressing can be used for the processing step without pre-sintering, so that the sintered body can be produced with high productivity according to the above-mentioned method for producing a sintered body. Can do.
  • a uniform green compact having a relative density of 93% or more is produced. Therefore, when a processed green body obtained by processing the green compact is sintered, the dimensions of the processed green body are measured. The way of change is stable. That is, the contraction degree of the processed molded body does not vary locally, and the entire processed molded body contracts almost uniformly. Therefore, it can suppress that the actual dimension of a sintered compact greatly deviates from a design dimension.
  • the relative density is preferably 95% or more.
  • the processing resistance in the processing step is low. Therefore, the machining speed can be made 5 to 10 times faster than the case of machining the metal solidified body, and the tool life used for machining can be extended to 10 to 100 times. Further, since the processing resistance of the green compact is low and the rigidity of the cutting tool or shank is small, a long or thin cutting tool or shank can be used during machining. Thus, since the freedom degree of selection of a cutting tool or a shank is high, there are few restrictions in the design of the shape of a sintered compact, ie, the freedom degree of the said design is high. For example, it becomes possible to produce a sintered body that has been subjected to fine shaping such as hollow processing.
  • the method for producing a sintered body it is possible to reuse the processing waste generated by machining without melting. Because it is compacted by cold molding to produce a compacted body, and since the compacted body is not sintered before machining, the metal powder contained in the processing waste is not altered. It is.
  • the green compact is machined before being sintered, it can be easily formed into a complicated helical gear shape.
  • the uniaxial pressurization pressure may be 600 MPa or more.
  • Cutting can be performed using at least one processing tool such as a milling cutter, a hob, a broach, and a pinion cutter. Since the green compact is excellent in workability, any of the above processing tools can easily perform high-precision cutting.
  • processing tool such as a milling cutter, a hob, a broach, and a pinion cutter. Since the green compact is excellent in workability, any of the above processing tools can easily perform high-precision cutting.
  • the said process process can mention the form performed while giving compressive stress to the said compacting body in the direction which cancels the tensile stress which acts on the said compacting body with a processing tool.
  • the sintered body according to the embodiment is An iron-based sintered body, The average relative density of the entire sintered body is 93% or more.
  • the sintered body according to the embodiment having an average relative density of 93% or more is a novel sintered body that has never existed.
  • the sintered body of the embodiment has an average relative density of 93% or more
  • the sintered body has mechanical strength comparable to a processed product of a metal solidified body.
  • the sintered compact of embodiment is manufactured by the manufacturing method of the sintered compact of embodiment, it is excellent in productivity rather than the processed product of a metal solidification body.
  • the average relative density is preferably 95% or more.
  • the sintered body can be in the form of a helical gear.
  • Sintered helical gears can be used as components for automobile transmissions, for example.
  • the sintered body according to the embodiment since the sintered body according to the embodiment has mechanical strength comparable to that of a processed product of a metal solidified body, it sufficiently functions as a component of an automobile that is subjected to a high load.
  • the helical gear teeth may be inclined at 30 ° or more with respect to the axis of the helical gear.
  • the helical gear has excellent mechanical strength, even if the helical gear teeth are inclined at an angle of 30 ° or more with respect to the axis, the teeth are hardly damaged during use. As the angle with respect to the tooth axis increases, noise generated when the helical gear meshes with other gears can be reduced.
  • the angle with respect to the tooth axis is preferably 50 ° or more.
  • the method for manufacturing a sintered body includes the following steps.
  • S5. Finishing process A finishing process is performed to bring the actual dimension of the sintered body closer to the design dimension.
  • the metal powder is a main material constituting the sintered body, and examples of the metal powder include iron or iron alloy powder containing iron as a main component. Typically, pure iron powder or iron alloy powder is used as the metal powder.
  • an iron alloy containing iron as a main component means that the element contains iron element in an amount of more than 50% by mass, preferably 80% by mass or more, and further 90% by mass or more.
  • the iron alloy include those containing at least one alloying element selected from Cu, Ni, Sn, Cr, Mo, Mn, and C. The alloying element contributes to improvement of mechanical properties of the iron-based sintered body.
  • the contents of Cu, Ni, Sn, Cr, Mn and Mo are 0.5% by mass or more and 5.0% by mass or less, and further 1.0% by mass or more and 3.0% by mass.
  • the C content may be 0.2% by mass or more and 2.0% by mass or less, and further 0.4% by mass or more and 1.0% by mass or less.
  • iron powder may be used as the metal powder, and the alloying element powder (alloyed powder) may be added thereto.
  • the constituent component of the metal powder is iron in the raw material powder stage, but iron is alloyed by reacting with the alloying element by sintering in the subsequent sintering step.
  • the content of metal powder (including alloyed powder) in the raw material powder is, for example, 90% by mass or more, and further 95% by mass or more.
  • a powder prepared by a water atomizing method, a gas atomizing method, a carbonyl method, a reduction method, or the like can be used.
  • the average particle diameter of the metal powder is, for example, 20 ⁇ m or more and 200 ⁇ m or less, and further 50 ⁇ m or more and 150 ⁇ m or less.
  • the average particle diameter of the metal powder is the average particle diameter of the particles constituting the metal powder.
  • the particle diameter (D50) is such that the cumulative volume in the volume particle size distribution measured by a laser diffraction particle size distribution measuring device is 50%. To do. By using fine metal powder, the surface roughness of the sintered body can be reduced, and the corner edges can be sharpened.
  • the raw material powder in which a metal powder and an internal lubricant are mixed in order to prevent the metal powder from sticking to the mold.
  • the raw material powder does not contain an internal lubricant, or even if it is contained, the raw material powder content is 0.2% by mass or less. This is to suppress a reduction in the ratio of the metal powder in the raw material powder, and to obtain a green compact having a relative density of 93% or more in the molding step described later.
  • the internal lubricant a metal soap such as lithium stearate or zinc stearate can be used.
  • An organic binder may be added to the raw material powder in order to suppress the occurrence of cracking or chipping in the green compact in the processing step described below.
  • the organic binder include polyethylene, polypropylene, polyolefin, polymethyl methacrylate, polystyrene, polyvinyl chloride, polyvinylidene chloride, polyamide, polyester, polyether, polyvinyl alcohol, vinyl acetate, paraffin, and various waxes.
  • the organic binder may be added as necessary, and may not be added. When adding an organic binder, it is necessary to make it the addition amount of the grade which can produce a compacting body with a relative density of 93% or more by a subsequent shaping
  • the green compact is produced by uniaxially pressing the raw material powder using a mold.
  • a die that performs uniaxial pressing includes a die and a pair of punches that are fitted into upper and lower openings thereof, and compresses the raw material powder filled in the die cavity with an upper punch and a lower punch.
  • This is a mold for producing a powder molded body.
  • the green compact that can be molded with this mold has a simple shape. Examples of the simple shape include a columnar shape, a cylindrical shape, a prismatic shape, and a rectangular tube shape.
  • the compacting body which has such a dent and a protrusion is also contained in the compacting body of a simple shape.
  • the pressure (surface pressure) for uniaxial pressurization is 600 MPa or more. By increasing the surface pressure, the relative density of the green compact can be increased.
  • a preferable surface pressure is 1000 MPa or more, and a more preferable surface pressure is 1500 MPa or more. There is no upper limit for the surface pressure.
  • an external lubricant In uniaxial molding, it is preferable to apply an external lubricant to the inner peripheral surface of the mold (the inner peripheral surface of the die or the pressing surface of the punch) in order to prevent the metal powder from sticking to the mold.
  • an external lubricant for example, a metal soap such as lithium stearate or zinc stearate can be used.
  • fatty acid amides such as lauric acid amide, stearic acid amide, and palmitic acid amide, and higher fatty acid amides such as ethylene bis stearic acid amide can be used as an external lubricant.
  • the overall average relative density of the green compact obtained by uniaxial pressing is 93% or more.
  • the average relative density of the whole of the green compact is preferably 95% or more, more preferably 96% or more, and still more preferably 97% or more.
  • the average relative density of the whole of the green compact is a cross-section (preferably orthogonal) at the position near the center in the pressure axis direction, near one end, and near the other end of the green compact.
  • Can be obtained by taking an image analysis of each cross section. More specifically, first, images of a plurality of observation fields are obtained in each cross section, for example, 10 or more images of an observation field having an area of 500 ⁇ m ⁇ 600 ⁇ m 300000 ⁇ m 2 in each cross section.
  • the acquired image of each observation visual field is binarized to determine the area ratio of the metal particles in the observation visual field, and the area ratio is regarded as the relative density of the observation visual field.
  • required from each observation visual field is averaged, and the average relative density of the whole compacting body is computed.
  • the vicinity of the one end side (near the other end side) is, for example, a position within 3 mm from the surface of the green compact.
  • processing process After the green compact is produced by uniaxial pressing, the green compact is machined without sintering.
  • the machining is typically cutting, and the green compact is processed into a predetermined shape using a cutting tool.
  • the cutting process include a turning process and a turning process, and the turning process includes a drilling process.
  • the cutting tool include drilling, reamer, turning, milling, end mill, turning, cutting tool, and the like, in the case of drilling.
  • cutting may be performed using a hob, broach, pinion cutter, or the like. Machining may be performed using a machining center capable of automatically performing a plurality of types of machining.
  • the image of machining will be described based on the image diagram of FIG.
  • the upper diagram in FIG. 1 schematically shows how the green compact 200 is machined with the cutting tool 100
  • the lower diagram schematically shows how the metal solidified body 300 is machined with the cutting tool 100.
  • machining is performed so that the metal particles 202 are peeled off from the surface of the green compact 200 by the cutting tool 100. Is given. Therefore, the processing waste 201 produced by machining is composed of metal powder formed by separating individual metal particles 202 constituting the green compact 200. The powdered processing waste 201 can be reused without dissolving.
  • the agglomerates may be crushed as necessary.
  • the metal solidified body 300 is machined so that the cutting tool 100 scrapes the surface of the metal solidified body 300. Since the processing waste 301 produced by machining is composed of a series of structures, it cannot be reused unless the processing waste 301 is dissolved.
  • the surface of the compacted body Before being subjected to machining, the surface of the compacted body is prevented from cracking or chipping by applying or immersing a volatile solution or plastic solution in which an organic binder is dissolved on the surface of the compacted body. It doesn't matter.
  • a compressive stress to cancel the tensile stress acting on the green compact For example, when forming a processing hole in a green compact by broaching, a strong tensile stress acts near the exit of the processing hole when the broach penetrates the green compact.
  • a plurality of green compacts can be stacked in multiple stages. It is preferable to dispose a dummy green compact or a plate material under the lowest green compact.
  • a plurality of green compacts are stacked in multiple stages, the lower surface of the green compact on the upper side is pressed against the upper surface of the lower green compact, and compressive stress acts on the lower surface. If broaching is performed from above the multi-stage stacked compacts, cracks and chips near the exit of the processed holes formed on the lower surface of the compact can be effectively prevented. Moreover, when forming a processing groove in a compacting body by milling, strong tensile stress acts in the vicinity of the exit of the processing groove. As a countermeasure, a configuration in which a plurality of powder compacts are arranged in the direction of milling and a compressive stress is applied to a portion serving as an exit of the processing groove can be mentioned.
  • the processed molded body obtained by machining the green compact is sintered.
  • a sintered body in which the metal powder particles are brought into contact with each other and bonded is obtained.
  • known conditions corresponding to the composition of the metal powder can be applied.
  • the sintering temperature is, for example, 1100 ° C. or higher and 1400 ° C. or lower, and 1200 ° C. or higher and 1300 ° C. or lower.
  • the sintering time include 15 minutes to 150 minutes, and further, 20 minutes to 60 minutes.
  • the processing degree in the processing step may be adjusted based on the difference between the actual size and the design size of the sintered body.
  • finishing process the surface roughness of the sintered body is reduced by polishing the surface of the sintered body, and the dimensions of the sintered body are adjusted to the design dimensions.
  • a sintered body having an overall average relative density of 93% or more can be obtained.
  • the overall average relative density of the sintered body is approximately equal to the overall average relative density of the green compact before sintering.
  • the average relative density of the entire sintered body is preferably 95% or more, more preferably 96% or more, and further preferably 97% or more. The higher the average relative density, the higher the strength of the sintered body.
  • the acquired image of each observation visual field is binarized to determine the area ratio of the metal particles in the observation visual field, and the area ratio is regarded as the relative density of the observation visual field.
  • required from each observation visual field is averaged, and the average relative density of the whole sintered compact is computed.
  • the pressing axis direction of the sintered body is uniaxially pressed in the production process of the sintered body, it can be easily grasped by observing the deformation state of the metal powder in the cross section of the sintered body. .
  • the vicinity of the one end side is, for example, a position within 3 mm from the surface of the sintered body.
  • the assembly 1 of the planetary gear 2 and the planetary carrier 3 shown in FIG. 2 was produced by the manufacturing method of the sintered body of the embodiment or the conventional manufacturing method of the sintered body.
  • the planetary gear 2 is a helical gear in which the teeth 20 are cut obliquely with respect to the axis (see the alternate long and short dash line).
  • the planetary carrier 3 includes a disk-shaped first component 31 and a second component 32 in which three bridge portions 32 b are formed on a disc portion 32 s. .
  • the raw material powder was press-molded by uniaxial pressing to produce the following three compacts.
  • the molding pressure was 1200 MPa for all.
  • -A cylindrical compact for planetary gear 2 ...
  • Diameter 50mm x Height 20mm -Disc shaped compact for the first part 31 ...
  • Diameter 130mm x Height 35mm -Columnar compact for the second part 32 ...
  • the average relative density of the green compact is the above ⁇ S2.
  • a cross section is taken near the center and near both ends in the direction of the pressing axis, and 10 or more observation fields having an area of 300000 ⁇ m 2 or more in each cross section are obtained by image analysis. It was.
  • the average relative density of the specific green compact was about 96.2%.
  • the average bulk density of the green compact was 7.5 g / cm 3 .
  • each of the produced green compacts was machined to produce a processed compact with a desired shape.
  • teeth 20 inclined by 50 ° with respect to the axis were formed.
  • a boss portion 31b is formed by machining, a hole is formed in the center of the boss portion 31b, and an internal part is formed inside the hole. Lugia teeth were formed.
  • the bridge portion 32b is formed by cutting, and, as shown in the lower part of FIG. 4, the base portion of the bridge portion 32b is connected to the disc portion 32s.
  • the inner peripheral surface portion (see the portion indicated by the black arrow) was formed in an R shape.
  • strength of the bridge part 32b can be improved.
  • the processing waste generated by machining was a metal powder formed by separating individual particles constituting the green compact.
  • the processed molded body was sintered, and the planetary gear 2 and the planetary carrier 3 composed of the sintered body were produced. During the sintering, no cracks or chips occurred in the sintered body. Finally, the dimensions of the planetary gear 2 and the planetary carrier 3 were brought close to the design dimensions by polishing or the like, and the surface roughness was reduced.
  • the average relative density of the planetary gear 2 and the planetary carrier 3 is as follows. It calculated
  • the observation visual field acquired from the cross section includes the portion of the teeth 20 of the planetary gear 2, and even if the relative density of the portion alone is obtained, the relative density of the portion is 96.2%. It was confirmed that
  • the planetary gear 2 and the planetary carrier 3 of the sample A had a mechanical strength comparable to that of a planetary gear and a planetary carrier made of a solidified metal produced by a melting method. Therefore, it has been found that the planetary gear 2 and the planetary carrier 3 of the sample A can be sufficiently used as automobile components.
  • Sample B conventional method of manufacturing a sintered body
  • the same raw material powder as that of Sample A was prepared, and a green compact having a shape close to the planetary gear 2 and a green compact having a shape close to the planetary carrier 3 were prepared by near net shape molding.
  • the planetary gear 2 is a helical gear
  • a rotary press machine was used for forming the near-net shape of the planetary gear 2.
  • the inclination of the teeth 20 with respect to the axis cannot be 45 ° or more.
  • the molding pressure using a rotary press machine could only be much lower than 600 MPa.
  • the planetary gear 2 and the planetary carrier 3 according to the sample B were produced by sintering a compact molded body of a near net shape and performing a finishing process.
  • the relative density of the observation field of the cross section was obtained by the same method as that of the sample A.
  • the relative density of each observation field varied.
  • the average relative density of the teeth 20 portion of the planetary gear 2 is about 88.5% (average bulk density is 6.9 g / cm 3 )
  • the average relative density of portions other than the teeth 20 is about 89.7. % (Average bulk density was 7.0 g / cm 3 ).
  • the average relative density of the entire sample B is about 89%.
  • the mechanical strength of the planetary gear 2 and the planetary carrier 3 of this sample B was significantly inferior to that of the planetary gear and the planetary carrier made of a solidified metal produced by a melting method.
  • the planetary gear 2 and the planetary carrier 3 of the sample B are considered to be inappropriate as components of an automobile.
  • the method for manufacturing a sintered body according to the embodiment can be suitably used for manufacturing a sintered part having a complicated shape that is difficult to be formed only by pressure molding using a mold.
  • the method of manufacturing a sintered body according to the embodiment may be used for manufacturing sprockets, rotors, gears, rings, flanges, pulleys, vanes, bearings and the like used in machines such as automobiles.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Nanotechnology (AREA)
  • Powder Metallurgy (AREA)
PCT/JP2017/014145 2016-04-07 2017-04-04 焼結体の製造方法、および焼結体 WO2017175772A1 (ja)

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EP17779150.6A EP3441161A1 (de) 2016-04-07 2017-04-04 Verfahren zur herstellung eines sinterkörpers und sinterkörper
CN201780002715.2A CN107921535B (zh) 2016-04-07 2017-04-04 制作烧结体的方法及烧结体
US15/750,703 US20180236548A1 (en) 2016-04-07 2017-04-04 Method for manufacturing sintered body and sintered body
US17/336,537 US20210283685A1 (en) 2016-04-07 2021-06-02 Method for collecting iron-based powder and method for manufacturing sintered body

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JP2016-077069 2016-04-07
JP2016077069A JP6509771B2 (ja) 2016-04-07 2016-04-07 焼結体の製造方法

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US17/336,537 Continuation-In-Part US20210283685A1 (en) 2016-04-07 2021-06-02 Method for collecting iron-based powder and method for manufacturing sintered body

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WO2019181453A1 (ja) * 2018-03-22 2019-09-26 日本電産株式会社 原料粉末、焼結ギアの製造方法および焼結ギア
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WO2020226111A1 (ja) * 2019-05-08 2020-11-12 住友電気工業株式会社 焼結歯車の製造方法
WO2021038878A1 (ja) * 2019-08-30 2021-03-04 住友電気工業株式会社 焼結材、及び焼結材の製造方法
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US11919081B2 (en) * 2019-03-05 2024-03-05 Sumitomo Electric Industries, Ltd. Method of making sintered part
CN113646113A (zh) * 2019-04-24 2021-11-12 住友电气工业株式会社 烧结体的制造方法及压粉成型体
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CN113098163B (zh) * 2021-04-19 2023-03-24 云南铜业压铸科技有限公司 一种高转速电动机用铸铜转子的制备方法
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WO2019181453A1 (ja) * 2018-03-22 2019-09-26 日本電産株式会社 原料粉末、焼結ギアの製造方法および焼結ギア
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JP6509771B2 (ja) 2019-05-08
US20180236548A1 (en) 2018-08-23
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CN107921535A (zh) 2018-04-17
EP3441161A1 (de) 2019-02-13
JP2017186625A (ja) 2017-10-12

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