WO2021093046A1 - 一种六角高扭钻柄的制备方法 - Google Patents

一种六角高扭钻柄的制备方法 Download PDF

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Publication number
WO2021093046A1
WO2021093046A1 PCT/CN2019/122599 CN2019122599W WO2021093046A1 WO 2021093046 A1 WO2021093046 A1 WO 2021093046A1 CN 2019122599 W CN2019122599 W CN 2019122599W WO 2021093046 A1 WO2021093046 A1 WO 2021093046A1
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Prior art keywords
hexagonal
drill shank
preparing
module
gas
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PCT/CN2019/122599
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English (en)
French (fr)
Inventor
姜宁
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丹阳市剑庐工具有限公司
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Priority to DE112019004149.5T priority Critical patent/DE112019004149T5/de
Publication of WO2021093046A1 publication Critical patent/WO2021093046A1/zh

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    • 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
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/28—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
    • B23P15/32—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools twist-drills
    • 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
    • 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
    • B22F1/103—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
    • 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
    • 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
    • B22F3/1017—Multiple heating or additional steps
    • B22F3/1021—Removal of binder or filler
    • 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
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
    • 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
    • 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
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/002—Tools other than cutting tools
    • 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

  • the invention belongs to the technical field of electric tool accessories, and in particular relates to a method for preparing a hexagonal high-torsion drill shank.
  • IMPACT gun drills are widely used to make holes or pierce objects in objects. It provides three times the torque of conventional gun drills. Some industries are also called impact gun drills.
  • IMPACT gun drill is a screw and drilling tool powered by AC power supply or DC battery. It is a kind of hand-held power tool. Use the IMPACT gun to drill holes. The diameter of the hole is generally not too large ( ⁇ 6mm), but the drill bit is placed in the drill shank, and the torque is required to be large, and the runout is small. Even the micro drill is required to drill holes quickly. This puts high demands on the internal structure of the drill shank.
  • the high-torque shank is equipped with a drill shank.
  • a drill shank For non-cylindrical cavity, there is a plane on the inner side of the cavity, and a plane on the side of the matching drill shank.
  • the drill shank extends into the drill shank and slowly rotates. When the two planes fit together, the installation is successful (both There is glue between them for bonding). Because the two planes are closely attached, the torque of the drill bit is large when the electric hand drill is rotated, and the drilling accuracy is high.
  • the drill shank requires high strength, toughness, coaxiality, low production cost, and easy processing. Therefore, research and development personnel are required to conduct research on this.
  • the present invention discloses a method for preparing a hexagonal high-twist drill shank, which is convenient to manufacture and low in processing cost, and the processed high-twist drill shank meets the requirements of use.
  • a method for preparing a hexagonal high-twist drill shank includes the following steps:
  • the lower end of the air module extends into the cavity of the mold, the air module is coaxial with the mold cavity, and a high-pressure gas of 150-180 bar is introduced into the air module, and the surface of the air module is provided with a number of air outlets;
  • a non-cylindrical cavity is formed inside the hexagonal drill shank blank (the non-cylindrical cavity is a groove structure similar to a blind hole, and its foundation is still a cylinder, except that a cylinder is provided on the side of the cylinder. Or several planes);
  • the hexagonal high-torsion drill shank is obtained after sintering and densification, and the sintering temperature is 800-1200°C.
  • the air module in step (1) has a hollow tubular structure and has several states, one of which is shown in Figure 3, one side is a plane, and its cross-section is arcuate, and the other types are The cross section is shown in Figure 8.
  • the diameter of the gas module in step (1) is 0.1-0.5 mm smaller than the diameter of the non-cylindrical cavity in step (4).
  • the air outlet in step (1) is trumpet-shaped, with a large outside and a small inside.
  • the diameter of the air module in step (1) is smaller in the upper part and larger in the lower part, and the lower diameter is no more than 0.1 mm larger than the upper diameter.
  • the metal powder in step (2) is a powder of a metal compound or a metal element.
  • the particle size of the metal powder in step (2) is 2-15 microns.
  • the component weight ratio of the organic binder in step (2) is: sodium carboxymethyl cellulose: 60-80%, enhancer: 9-20%, tackifier: 10 -20%, preservative: 0.5-5%.
  • the temperature in the plasticized state in step (3) is less than 150°C.
  • the thermal decomposition temperature in step (5) is 180-200°C.
  • Figure 1 is a schematic diagram of the structure of the present invention.
  • Fig. 2 is a top view of the gas module according to the present invention extending into the mold cavity.
  • Fig. 3 is a schematic diagram of the gas module according to the present invention.
  • Fig. 4 is a schematic diagram of the vent hole according to the present invention.
  • Figure 5 is a schematic diagram of the advantages and disadvantages of the six drill shanks described in the background art of the present invention.
  • Figure 6 is a comparison diagram of six drill shank torque tests.
  • Figure 7 is a comparison diagram of six drill shank diameter jump tests.
  • Figure 8 is a cross-sectional view of several gas modules.
  • Figure 9 is an assembly drawing of the drill shank and the drill bit.
  • the method for preparing a hexagonal high-twist drill shank according to the present invention is based on a powder injection molding method and adopts a method of inserting an air module into the mold cavity for ventilation.
  • the internal pressure is greater than the injection pressure, so that the air module is outside A stable space is formed, and a shaped non-cylindrical cavity is formed in the drill shank blank.
  • the method is novel and the process is few.
  • the air module 3 is a hollow tubular structure, the lower end of the air module 3 extends into the cavity 2 of the mold, the air module 3 is coaxial with the cavity 2, and the air module 3 is open when in use Into the high pressure gas of 150-180 bar, the surface of the gas module 3 is provided with a number of gas outlet holes 4, as shown in FIG. 3.
  • Metal powder can use metal compounds or simple metal substances as raw materials, both of which can be powders; if it is a metal compound, it can be obtained by electrolysis, thermal decomposition or thermal reduction decomposition, etc.; if it is a simple metal substance, it can be obtained by After being melted at a high temperature, the metal powder is obtained by high-pressure spraying and rapid cooling.
  • the metal powder of traditional powder injection molding uses powder larger than 40 ⁇ m, and the particle size of the metal powder of the present invention is controlled within 0.5-20 ⁇ m; the finer the particles, the larger the specific surface area, which is easier for molding and sintering.
  • the function of the organic adhesive is to bond metal powder particles, so that the mixture is heated in the barrel of the injection machine, and has rheology and lubricity.
  • the existence of the adhesive ensures the uniform distribution of the powder and can eliminate the unevenness in the microstructure of the blank. In turn, the density of the sintered product can reach the theoretical density of its material. Therefore, the choice of adhesive is the key to the entire powder injection molding.
  • the requirements for organic adhesives are: using less adhesive can make the metal powder produce better rheology; in the process of removing the adhesive, it is different from the metal powder.
  • the weight ratio of the organic binder used in the present invention is: sodium carboxymethyl cellulose: 60-80%, reinforcing agent: 9-20% , Tackifier: 10-20%, preservative: 0.5-5%, which can meet the requirements.
  • the hexagonal drill shank blank of the present invention has a hexagonal shape on the outside and a non-cylindrical cavity inside.
  • the outside width is 5-10mm. It is matched with the chuck of the existing electric hand drill.
  • the inner hole diameter does not exceed 6mm.
  • the side of the non-cylindrical cavity has 1-4 planes 8, used for assembly and torque transmission.
  • the gas module 3 of the present invention is filled with a high-pressure gas of 150 bar inside and a powder mixture of 140 bar outside.
  • the high-pressure gas sprayed from the gas outlet 4 forms a space of 0.1 mm outside the gas module 3. If the inside of the gas module 3 With 180 bar of high-pressure gas, the high-pressure gas ejected from the air outlet 4 forms a space of 0.5mm outside the gas module 3. That is to say, the high-pressure gas pressure inside the gas module 3 and the gas module 3 determine the inside of the drill shank
  • the pore size is shown in Figures 1 and 2.
  • the present invention designs the air outlet to be horn-shaped with a large outer diameter and a small inner diameter, as shown in FIG. 4, to ensure an even pressure of the air curtain.
  • the present invention designs the air module 3 to have a small diameter.
  • the lower part is larger, and the lower diameter is a little larger, no more than 0.1mm. It is used to compensate for the pressure change caused by the pressure weakening, to ensure that the high-pressure gas ejected from the air outlet 4 forms a space of the same size outside the air module 3 to ensure accuracy.
  • the present invention uses a thermal decomposition method to remove the binder in the hexagonal drill shank blank; thermal decomposition The temperature is 180-200°C.
  • the manufactured hexagonal drill shank, the inner non-cylindrical cavity can be used to clamp the arc-shaped drill shank (a flat surface), two-sided milling or three-sided milling drill shank, and the plane of the two-sided milling drill shank can be symmetrical or asymmetrical, such as Shown in Figure 8.
  • the present invention adds a method of inserting air modules into the mold cavity to ventilate.
  • the internal pressure is greater than the injection pressure, a standard non-cylindrical cavity is formed in the drill shank blank, and high density and high precision are quickly manufactured through sintering.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Powder Metallurgy (AREA)

Abstract

一种六角高扭钻柄的制备方法，包括以下步骤：先制作气模块（3），气模块（3）下端伸入模具（1）的模腔（2）内，气模块（3）内部通入高压气体，气模块（3）表面设有若干出气孔（4）；将金属粉末与有机粘结剂均匀混和；经制粒后在加热塑化状态下，用注射成形机注入模腔（2）内进行固化为六角钻柄毛坯（5），在气模块（3）作用下，六角钻柄毛坯（5）内部形成非圆柱体腔，然后用热分解的方法将六角钻柄毛坯（5）中的粘结剂脱除；最后经烧结致密化得到六角高扭钻柄。该制备方法在金属粉末注射成型的基础上，增加在模腔（2）内插入气模块（3）通气的方法，通过烧结快速制造高密度、高精度、三维复杂形状的六角高扭钻柄，切削量少，材质均匀，在保证强度的同时兼具韧性，耐冲击，机械性能好，工序少，加工成本低。

Description

一种六角高扭钻柄的制备方法 技术领域
本发明属于电动工具辅件技术领域，具体涉及一种六角高扭钻柄的制备方法。
背景技术
在建筑、装修、泛家具等行业，IMPACT枪钻被广泛用于在物件上开孔或洞穿物体，它提供的扭力是常规枪钻的3倍，有的行业之也称为冲击枪钻。IMPACT枪钻是以交流电源或直流电池为动力的旋螺钉和钻孔工具，是手持式电动工具的一种。用IMPACT枪钻打孔，打孔的直径一般不会太大(≤6mm)，但是钻头放入钻柄内，要求扭矩要大，跳动要小，即使是微型钻头打孔，也要求快速打通，这就对钻柄内部结构提出了很高的要求。
现有的钻柄有6种，分别为冲压柄、销钉柄、锌合金柄、锥度柄、高扭柄以及整体柄，如图5所示，其中冲压柄中3mm以下钻头的扭力、IMPACT强度、径跳不达标，销钉柄钻头的扭力、IMPACT强度不达标，锌合金柄柄部变形以及IMPACT强度不达标，锥度柄钻头的扭力、IMPACT强度不达标，只有高扭柄和整体柄性能达标，但是整体柄制作工序多(13-14道)，成本高，同轴度难保证等原因不被厂商考虑，所以现在高扭柄成为市场的热点，所述高扭柄是在钻柄内部设有一个非圆柱体腔，腔内侧面设有平面，在与之配套的钻头柄部侧面也设有平面，钻头柄部伸入钻柄后慢慢旋转，当两个平面贴合时代表安装成 功(二者之间有胶进行粘合)，由于两个平面紧密贴合，手电钻旋转时钻头扭矩大，打孔的精度高。
要做到这一点，也就是说对钻柄要求很高，既要有强度、韧性、同轴度，又要制作成本低，加工方便，因此需要研发人员对此进行研究。
发明内容
为解决上述问题，本发明公开了一种六角高扭钻柄的制备方法，制造方便、加工成本低，加工出来的高扭钻柄达到使用要求。
为达到上述目的，本发明的技术方案如下：
一种六角高扭钻柄的制备方法，包括以下步骤：
(1)制作气模块，所述气模块下端伸入模具的模腔内，气模块与模腔同轴，气模块内部通入150-180巴的高压气体，气模块表面设有若干出气孔；
(2)将金属粉末与有机粘结剂均匀混和；
(3)经制粒后在加热塑化状态下，用注射成形机注入模腔内进行固化为六角钻柄毛坯，注射压力为140巴；
(4)在气模块作用下，六角钻柄毛坯内部形成非圆柱体腔(非圆柱体腔是一个类似于盲孔的凹槽结构，其基础还是圆柱体，只不过是在圆柱体的侧面设有一个或几个平面)；
(5)然后用热分解的方法将六角钻柄毛坯中的粘结剂脱除；
(6)表面加工，去毛刺；
(7)最后经烧结致密化得到六角高扭钻柄，烧结温度800-1200℃。
作为本发明的一种改进，步骤(1)所述气模块为空心管状结构，有几种状态，其中一种如图3所示，一个侧面为平面，其横截面为弓形，其他几种的横截面如图8所示。
作为本发明的一种改进，步骤(1)所述气模块直径比步骤(4)的非圆柱体腔直径小0.1-0.5mm。
作为本发明的一种改进，步骤(1)所述出气孔为喇叭形，外大里小。
作为本发明的一种改进，步骤(1)所述气模块直径上小下大，下方直径比上方直径大不超过0.1mm。
作为本发明的一种改进，步骤(2)所述金属粉末为金属化合物或金属单质的粉末。
作为本发明的一种改进，步骤(2)所述金属粉末粒径在2-15微米。
作为本发明的一种改进，步骤(2)所述有机粘结剂的组分重量比为：羧甲基纤维素钠：60-80％，增强剂：9-20％，增粘剂：10-20％，防腐剂：0.5-5％。
作为本发明的一种改进，步骤(3)所述塑化状态温度小于150℃。
作为本发明的一种改进，步骤(5)所述热分解的温度为180-200℃。
本发明的有益效果是：
(1)采用在模腔内插入气模块通气的方法，内部压力大于注射压力，在钻柄毛坯内形成成型的非圆柱体腔，方法新颖；
(2)采用超细金属粉末注射成型的方法，通过烧结快速制造高密度、高精度、三维复杂形状的六角高扭钻柄，少切削，材质均匀，在保证强度的同时兼具韧性，耐冲击，机械性能好；
(3)采用羧甲基纤维素钠为粘结剂，用较少的粘接剂能使金属粉末产生较好的流变性；在去除粘接剂的过程中与金属粉末不起任何化学反应；而且易去除，在制品内不残留碳；
(4)制造方便，只需要7道工序，加工成本低。
附图说明
图1为本发明的结构示意图。
图2为本发明所述的气模块伸入模腔内的俯视图。
图3为本发明所述的气模块示意图。
图4为本发明所述的出气孔示意图。
图5为本发明背景技术所述的6种钻柄的优缺点示意图。
图6为6种钻柄扭力测试对比图。
图7为6种钻柄径跳测试对比图。
图8为几种气模块的截面图。
图9为钻柄与钻头的装配图。
附图标记列表：
1、模具，2、模腔，3、气模块，4、出气孔，5、钻柄毛坯，6、通气管，7、注射口，8、平面。
具体实施方式
下面结合附图和具体实施方式，进一步阐明本发明，应理解下述具体实施方式仅用于说明本发明而不用于限制本发明的范围。需要说明的是，下面描述中使用的词语“前”、“后”、“左”、“右”、“上”和“下”指的是附图中的方向，词语“内”和“外”分别指的是朝向或远离特定部件几何中心的方向。
如图所示，本发明所述的一种六角高扭钻柄的制备方法，以粉末注塑方法为基础，采用在模腔内插入气模块通气的方法，内部压力大于注射压力，使得气模块外形成一个稳定的空间，在钻柄毛坯内形成成型的非圆柱体腔，方法新颖，工序少。
具体包括以下步骤：
(1)制作气模块，所述气模块3为空心管状结构，所述气模块3下端伸入模具的模腔2内，气模块3与模腔2同轴，使用时往气模块3内部通入150-180巴的高压气体，气模块3表面设有若干出气孔4，如图3所示。
(2)将金属粉末与有机粘结剂均匀混和；
金属粉末可以利用金属化合物或是金属单质为原料，它们都可以是粉末；如果是金属化合物，则可以通过电解或热分解或热还原分解等方法来得到金属粉末；如果是金属单质，则可以通过高温熔融后再高压喷出并快速冷却的方法来得到金属粉末。
传统粉末注塑的金属粉末采用大于40μm的粉末，本发明所述金属粉末颗粒尺寸控制在0.5～20μm；颗粒越细，比表面积也越大，易 于成型和烧结。
有机胶粘剂作用是粘接金属粉末颗粒，使混合料在注射机料筒中加热，具有流变性和润滑性，粘接剂的存在保障了粉末的均匀排布从而可消除毛坯微观组织上的不均匀，进而使烧结制品密度可达到其材料的理论密度。因此，胶粘剂选择是整个粉末注射成型的关键，对有机粘接剂要求是：用较少的粘接剂能使金属粉末产生较好的流变性；在去除粘接剂的过程中与金属粉末不起任何化学反应；而且易去除，在制品内不残留碳；本发明采用的有机粘结剂的组分重量比为：羧甲基纤维素钠：60-80％，增强剂：9-20％，增粘剂：10-20％，防腐剂：0.5-5％，可以达到要求。
(3)经制粒后在加热塑化状态下(小于150℃)，用注射成形机注入模腔内进行固化为六角钻柄毛坯，注射压力为140巴(注射压力小于气模块3内部的高压气体压力)，140巴＝14000000帕斯卡。
(4)在注射金属粉末与有机粘结剂混合物的同时，通过通气管6往气模块3内部注入高压气体，高压气体从若干个出气孔4喷出(出气孔4设置在气模块3外侧以及底面)，使钻柄毛坯内部形成一个非圆柱体腔，非圆柱体腔与气模块3旋转相同，大小不一样，所述非圆柱体腔尺寸比气模块3大0.1-0.5mm。
本发明所述的六角钻柄毛坯，外侧为六角形，内部有非圆柱体腔，外侧宽度为5-10mm，与现有手电钻的夹头相配套，内部孔径不超过6mm，非圆柱体腔侧面有1-4个平面8，用于装配以及传递扭矩。
本发明所述的气模块3内部通入150巴的高压气体，外部有140 巴的粉末混合物，从出气孔4喷出的高压气体在气模块3外形成0.1mm的空间，如果气模块3内部通入180巴的高压气体，那么从出气孔4喷出的高压气体在气模块3外形成0.5mm的空间，也就是说，气模块3内部的高压气体压力与气模块3决定了钻柄内部的孔径，如图1和2所示。
为了保证出气孔4喷出的高压气体能够覆盖整个气模块3外侧，保证压力平均，本发明将出气孔设计为喇叭形，外大里小，如图4所示，确保气幕压力平均。
在喷气过程中，由于气模块3有一定长度，虽然长度很短，但是气流在气模块3内通行时压力会减弱，为了防止气流压力衰竭，本发明将所述气模块3直径设计为上小下大，下方直径大一点点，不超过0.1mm，用于补偿压力减弱带来的气压变化，确保出气孔4喷出的高压气体在气模块3外形成尺寸相同的空间，确保精度。
(5)钻柄毛坯在烧结前必须去除毛坯内所含有的有机粘接剂，而且不能降低毛坯的强度，本发明采用热分解的方法将六角钻柄毛坯中的粘结剂脱除；热分解的温度为180-200℃。
(6)表面加工，去毛刺；
(7)最后经烧结致密化得到六角高扭钻柄，如图9所示。
制作出来的六角钻柄，其内部非圆柱体腔可以装夹弓形面的钻柄(一个平面)、两面铣或者三面铣的钻柄，其中两面铣的钻柄的平面可以对称也可以非对称，如图8所示。
本发明在金属粉末注射成型的基础上，增加在模腔内插入气模块 通气的方法，内部压力大于注射压力，在钻柄毛坯内形成标准的非圆柱体腔，通过烧结快速制造高密度、高精度、三维复杂形状的六角高扭钻柄，切削量少，材质均匀，在保证强度的同时兼具韧性，耐冲击，机械性能好，工序少，加工成本低；如图6和7所示，其扭力与径跳的检测数据与其他几种相比，兼顾了机械性能与成本，方法新颖；制造方便，值得推广。
本发明方案所公开的技术手段不仅限于上述实施方式所公开的技术手段，还包括由以上技术特征任意组合所组成的技术方案。

Claims (10)

  1. 一种六角高扭钻柄的制备方法，其特征在于：包括以下步骤：
    (1)制作气模块，所述气模块下端伸入模具的模腔内，气模块与模腔同轴，气模块内部通入150-180巴的高压气体，气模块表面设有若干出气孔；
    (2)将金属粉末与有机粘结剂均匀混和；
    (3)经制粒后在加热塑化状态下，用注射成形机注入模腔内进行固化为六角钻柄毛坯，注射压力为140巴；
    (4)在气模块作用下，六角钻柄毛坯内部形成非圆柱体腔，非圆柱体腔的侧面设有平面；
    (5)然后用热分解的方法将六角钻柄毛坯中的粘结剂脱除；
    (6)表面加工，去毛刺；
    (7)最后经烧结致密化得到六角高扭钻柄。
  2. 根据权利要求1所述的一种六角高扭钻柄的制备方法，其特征在于：步骤(1)所述气模块与非圆柱体腔内部相配套。
  3. 根据权利要求1所述的一种六角高扭钻柄的制备方法，其特征在于：步骤(1)所述气模块直径比步骤(4)的非圆柱体腔直径小0.1-0.5mm。
  4. 根据权利要求1所述的一种六角高扭钻柄的制备方法，其特征在于：步骤(1)所述出气孔为喇叭形，外大里小。
  5. 根据权利要求1所述的一种六角高扭钻柄的制备方法，其特征在于：步骤(1)所述气模块直径上小下大，下方直径比上方直径大不 超过0.1mm。
  6. 根据权利要求1所述的一种六角高扭钻柄的制备方法，其特征在于：步骤(2)所述金属粉末为金属化合物或金属单质的粉末。
  7. 根据权利要求1所述的一种六角高扭钻柄的制备方法，其特征在于：步骤(2)所述金属粉末粒径在2-15微米。
  8. 根据权利要求1所述的一种六角高扭钻柄的制备方法，其特征在于：步骤(2)所述有机粘结剂的组分重量比为：羧甲基纤维素钠：60-80％，增强剂：9-20％，增粘剂：10-20％，防腐剂：0.5-5％。
  9. 根据权利要求1所述的一种六角高扭钻柄的制备方法，其特征在于：步骤(3)所述塑化状态温度小于150℃。
  10. 根据权利要求1所述的一种六角高扭钻柄的制备方法，其特征在于：步骤(5)所述热分解的温度为180-200℃。
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