Method for producing a component having a cooling channel system

Abstract

The present invention provides a method for producing a component (100) having a cooling channel system, the method comprising: constructing a first part (10) of the component (100) by applying a building material in an additive and integral manner; and introducing a first cavity (11) having an opening in the first part (10) of the component. The method is characterized in that it also comprises: covering the opening of the first cavity (11) of the first part (10) with a cover (13); constructing a second part (20) of the component (100) by applying a building material in an additive and integral manner, the building material being applied to the first part (10) and the cover (13); introducing a second cavity (21) having an opening in the second part (20) of the component (100); and introducing a connecting channel (90), (90a) in the component (100) by a material removal process to form a cooling channel system, the connecting channel connecting the second cavity (21) of the second part (20) of the component (100) with the first cavity (11) of the first part (10).

Description

Technical Field

[0001] The invention relates to a method for producing a component having a cooling channel system. Background Art

[0002] A frequently used method in industrial production is, for example, injection molding, in which a liquefied material is injected under pressure into a mold insert or an injection molding tool, where it cools and returns to a solid aggregate state.

[0003] This primary forming process is frequently used in the field of plastics processing and enables complex shaping of the products produced therefrom. In this process, the cooling required for the solidifying material is particularly important, since it has a decisive influence on the process time, for example.

[0004] This cooling of the injected material is advantageously carried out via the mold insert or the injection molding tool, as is known. Usually, cooling channels are provided in the mold insert or the injection molding tool for heat dissipation, through which a suitable coolant flows, thereby cooling the mold insert or the injection molding tool and thus the material located therein.

[0005] In principle, the manufacture of tools that are exposed to high temperatures during use, such as injection molding tools, forming tools, extrusion tools, etc., is complex. In particular, since the geometry of the tools is often very complex, the introduction of extended cooling channels in the tool is often not easy to achieve, as cooling channels can usually only be introduced in the finished tool by drilling.

[0006] For example, in the prior art document DE102004040929A1 a method is described, in which a tool with cooling channels produced by an additive deposition manufacturing process is used as a component, the cooling channels being formed inside the tool during the additive manufacturing process. The method shown in the document DE102004040929A1 utilizes the possibilities of additive manufacturing, which is particularly useful for highly individualized components or components with complex geometries, and thus makes it possible to provide recesses, etc. in the component during additive manufacturing.

[0007] However, the possibilities for effective cooling of components produced in this way are limited. Summary of the invention

[0008] It is therefore an object of the present invention to provide a method for producing a component having improved heat dissipation.

[0009] To achieve this object, a method for producing a component having a cooling channel system is proposed according to claim 1 .

[0010] Furthermore, a software-supported computer system is proposed, which is configured to configure such a component.

[0011] The respective dependent claims relate to preferred embodiments of the method according to the invention or of the data processing system according to the invention, which embodiments can be provided individually or in combination.

[0012] According to a first aspect of the present invention, a method for producing a component having a cooling channel system comprises: constructing a first part of the component by applying a building material in an additive and integral manner, and introducing a first cavity having an opening in the first part of the component. The method is characterized in that it also comprises: covering the opening of the first cavity in the first part with a cover, constructing a second part of the component by applying a building material in an additive and integral manner, the building material being applied to the first part and the cover; introducing a second cavity in the second part of the component, and introducing a connecting channel in the component by material removal processing to form a cooling channel system, the connecting channel connecting the second cavity of the second part with the first cavity of the first part of the component.

[0013] Optionally, the cover can be securely fixed after insertion by applying, for example, an additive build-up weld track. This may be necessary, for example, when multiple covers are inserted into a workpiece and five-axis machining is performed in a direction different from gravity to prevent them from falling. Alternatively, the cover can be fixed by spot welding.

[0014] The method according to the invention enables the production of components having complex geometries and of cooling channel systems extending inside the component in a particularly advantageous manner, which cooling channel systems are configured to conduct a coolant and also have complex geometries.

[0015] The formation of the cooling channel system extending inside the component is carried out when the parts of the component are applied with building material in an additive and integral manner (i.e., additive stacking), so that the geometric arrangement of the cooling channel system (which is determined by the position of the cavities and connecting channels in the component) can be advantageously adapted to the complex final geometry of the component to be produced, so that the cooling channel system extends in a manner that at least partially matches the outer contour surface of the component, that is, it at least partially follows the outer contour surface. Here, partially following should be understood as an arrangement of the cooling channel system in which the flow direction of the coolant flowing through or through the cooling channel system is essentially parallel to the outer contour surface of the component.

[0016] In the case of complex component geometries, the introduction of such internal cooling channel systems is often not possible simply by introducing them in the form of holes after the primary forming process.

[0017] Until now, the introduction of holes in conventional methods has been limited due to the geometry of the component and the possibilities of the drilling process, so that only cooling channel systems with extremely simple geometries could be introduced.

[0018] The method according to the invention exploits the synergy of additive, integrally applied build material (ie additive deposition) and subtractive machining, including by introducing connecting channels, to form a cooling channel system extending therein.

[0019] The method according to the invention is therefore a hybrid manufacturing method with an alternating sequence of additive manufacturing steps and subtractive machining steps.

[0020] The method according to the invention makes it possible, in particular, to realize a cooling channel system with a nearly clean profile, as a result of which the heat dissipation by the coolant flowing therein can be significantly improved.

[0021] Furthermore, by introducing a cavity having a larger cross-section than the connecting channel, regions of the component which are subject to particularly thermal stress during use can advantageously be effectively cooled by the coolant flowing through the cavity.

[0022] Covering the opening of the first cavity of the first part with a cover (which is advantageously planar and / or flat) allows additive building of the second part by applying a build material, wherein the first cavity is completely enclosed within the part and the first cavity has a simple geometry with a planar interface or interface geometry facing the second part.

[0023] Closing the opening of a cavity that is completely located within the finished component by additive application of build material (without covering) is only possible if certain interface geometries configured for this purpose are met, which are usually non-planar. For process-related reasons, it is not possible to build interface geometries in the form of planar interfaces (without covering), which is why pyramidal or conical interface geometries are often built by additive application, for example in the form of a roof.

[0024] This non-planar interface geometry of the cavity has proven to be disadvantageous in a number of respects.

[0025] On the one hand, the geometry of such interfaces represents undesirable stagnation points for the coolant flowing through the cooling channel system and thus also leads to a deterioration in the heat dissipation resulting therefrom.

[0026] On the other hand, this predominantly pointed interface geometry (pyramid or cone) represents a potential weak point in the sense of a predetermined breaking point (notch factor), at which excessive stress peaks may occur in the component when the component is mechanically loaded, as a result of which the component may fail at the corresponding point (crack, fracture, plastic deformation, etc.).

[0027] Since the component according to the invention is built up in sections, connecting channels can be introduced in a manner that would not be possible after the complete additive build-up of the component.

[0028] Here, the connecting channel is advantageously introduced starting from the second cavity of the second part of the component in the direction of the first cavity of the first part in order to establish a connection with the first cavity arranged in the component after the second part has been built, thus forming a cooling channel system.

[0029] For this purpose, a tool configured for material removal advantageously enters through the opening of the second cavity of the second part. The second cavity preferably has a corresponding geometry that does not hinder the introduction of the tool into the connecting channel, so that, for example, a drill configured for chip removal can enter the component through the opening of the second cavity without damaging it.

[0030] Advantageously, the introduction of the connecting channel, which is at least partially based on material removal, can create a higher surface quality, with the surface of the component adjacent to the connecting channel having a smoother surface structure compared to other surfaces produced by additive deposition.

[0031] Surfaces created by additive deposition by integral application of building material generally have a surface structure or surface quality with greater roughness values ​​and a lower surface quality than surfaces created by material removal machining, in particular chip removal machining.

[0032] A smooth surface structure or a high surface quality with low roughness values ​​in the connecting channel improves the conduction of the coolant through the connecting channel, since the flow resistance is lower here. If the surface of the channel or line for the flow is rough, turbulence occurs in the surface area, which increases the flow resistance and thus impedes the flow.

[0033] Compared with connecting channels produced solely by additive deposition, the introduction of connecting channels based on material removal can significantly reduce the flow resistance of the coolant flowing through, which in turn has a positive effect on heat dissipation, because when the flow resistance is low and other boundary conditions (pressure difference, channel cross section) are the same, the coolant flowing through can achieve a higher flow rate or flow rate.

[0034] In principle, however, it is also possible to use additive methods, in which the connecting channels are introduced in sections by omitting corresponding regions during the application of the material.

[0035] The method according to the invention is by no means limited to only one first cavity in the first part and / or only one second cavity in the second part. Depending on the geometry of the component to be produced, a plurality of cavities can be introduced in individual parts of the component, which cavities can be connected to one another across the parts via a corresponding number of connecting channels to form a cooling channel system; thus, a plurality of connecting channels can also be opened in a single cavity to form a cooling channel system.

[0036] Therefore, for example, two independent chambers can be introduced in the first part, and after the second part has been built, the two independent chambers are connected to each other by introducing two connecting channels with the chamber introduced into the second part. In this case, the two connecting channels all lead to the chamber of the second part and connect it to the two chambers of the first part.

[0037] Alternatively, for example, it is also possible to introduce a cavity into the first part and connect this cavity to two cavities introduced into the second part by introducing two connecting channels.

[0038] Improved heat dissipation of the component means, among other things, that the cooling rate / cooling speed of the component is increased when the component is used under thermal stress, for example as a tool in a manufacturing process, thereby enabling shorter processing times or clock times. The heat is dissipated by a coolant flowing through a cooling channel system, which absorbs the heat conducted through the component and conducts it outwards or remotely.

[0039] In a preferred embodiment of the method, the first and / or further possible cavities are introduced after the corresponding part has been at least partially produced by material removal.

[0040] In a particularly preferred embodiment of the method, the material-removing machining for introduction into the first cavity and / or the second cavity is a chip-removing machining.

[0041] The introduction of cavities by chip removal machining is particularly beneficial, especially compared to surfaces produced entirely by additive application of build material, because the surfaces in the component adjacent to the cavities have a high surface quality, thereby reducing flow resistance within the cooling channel system.

[0042] In a further preferred embodiment of the method, the corresponding regions are omitted during the additive, integral application of the building material, and the first cavity and / or the second cavity are introduced during the deposition of the corresponding parts.

[0043] Due to the omission in applying the building material, the cavity can advantageously already be introduced during the stacking of the respective parts, thereby reducing production costs, production time and saving building material.

[0044] In a particularly preferred embodiment of the method, surfaces of the part which are adjacent to the cavities introduced during the production of the part are re-machined by chip removal machining.

[0045] In particular, chip-free remachining of the surface improves its surface quality compared to a surface created completely by additive application of building material, as a result of which the flow resistance within the cooling channel system can be reduced.

[0046] Compared to introducing only one of the cavities by material removal machining without previously omitting it during the additive deposition process, tool costs can also be reduced since only one surface is machined instead of introducing the entire cavity itself by material removal machining.

[0047] In a particularly preferred embodiment of the method, it also includes partially or completely covering the opening of the second cavity of the second part with a cover and building the other parts of the component by additively and integrally applying a building material, which is applied to the second part and the cover of the opening of the second cavity.

[0048] The opening of the second cavity is therefore closed with the building material, so that the component has a cooling channel system located completely within it.

[0049] In a particularly preferred embodiment of the method, it further comprises the following steps:

[0050] ZS1: Introduction of at least one further cavity with an opening into one of the previously built parts of the component, the introduction of this further cavity being carried out after the previously built part has been deposited by means of material removal or by omission in the additive, integral application of building material during the depositing of the previously built part.

[0051] ZS2: Introducing one or more connecting channels into the component by material removal machining to further form a cooling channel system, wherein the connecting channels connect the further cavities from step ZS1 with one or more cavities previously introduced into the previously built part of the component.

[0052] ZS3: At least partially covering the opening of the further cavity from step ZS1 with a cover.

[0053] ZS4: Building one or more other parts of the component by additively, integrally applying a build component, the build material being applied to the previously built part or parts and the covering of the previous step ZS3.

[0054] Optionally, after the cover is inserted in step ZS3, it can be firmly fixed by applying, for example, an additive build-up weld track. This may be necessary, for example, when multiple cover parts are inserted on a workpiece to prevent them from falling and five-axis machining is performed in a direction different from gravity. Alternatively, the cover can also be fixed by spot welding.

[0055] In a particularly preferred embodiment of the method, these steps can be repeated multiple times, so that by multiple repetitions of the method step sequence ZS1 to ZS4, a component having multiple parts and a cooling channel system formed in the component are produced, the system comprising multiple cavities and multiple connecting channels for connecting the multiple cavities.

[0056] Thus, components with complex geometries, in particular external geometries, and cooling channel systems extending within the component and advantageously adapted to the complex geometries can be produced.

[0057] Here, the number of cavities per component part is not limited to one, so that a single part can also have a plurality of introduced cavities which contribute to the advantageous formation of the cooling channel system.

[0058] In a particularly preferred embodiment of the method, the material-removing machining for introducing the connecting channel is a chip-removing machining.

[0059] Chip-removing machining can enable surfaces created in the component adjacent to the connecting channels to achieve high surface quality, especially compared to surfaces created entirely by additive, integrally applied build material, thereby reducing flow resistance within the cooling channel system.

[0060] In a particularly preferred embodiment of the method, the additive, integral application of the building material is performed by laser or arc deposition welding.

[0061] In a particularly preferred embodiment of the method, the building material is applied in the form of powder and / or wire by build-up welding during the application process.

[0062] In a particularly preferred embodiment of the method, a concave shoulder is formed by removing material in the surrounding area of ​​the opening of one or more cavities of the corresponding part, which is adapted to the geometry of a cover configured to cover the corresponding opening, so that the corresponding cover for covering the corresponding opening is held in place in a shape-fitting manner.

[0063] This makes the insertion of the cover element to cover the opening and the subsequent additive build-up on the respective cover element easier, since the respective cover element remains in place relative to the component and cannot be moved due to undesired vibrations or the like.

[0064] In a particularly preferred embodiment of the method, the one or more covering elements are circular sheet metal blanks or sheet metal covers.

[0065] In a particularly preferred embodiment of the method, the geometry of the cavity is selected from a set of standard cavities of predetermined geometries.

[0066] Thus, since no arbitrary geometry is selected for the cavity, but rather a selection is made from a set of predetermined standard geometries according to a modular principle, a large-scale standardized production can be achieved. The standardization achieved in this way allows further method steps to be optimized, in particular with regard to the configuration of the covering parts, which, in a particularly preferred embodiment of the process, are likewise selected from a set of prefabricated covering parts, whose geometry is adapted to the standard geometry of the cavity.

[0067] The covering elements can thus be prefabricated in large quantities and, according to the modular principle, can be used directly to cover cavities with standard geometries.

[0068] Since the cover does not have to be produced separately, this leads to a reduction in the production costs; moreover, the method according to the invention can also reduce the production time for producing the component.

[0069] In a particularly preferred embodiment, the normal geometry of the cavity is substantially cylindrical.

[0070] These relatively simple geometries can be introduced quickly and easily by material-removing machining, in particular chip-removing machining, which can further reduce production times.

[0071] In a particularly preferred embodiment of the method according to the present invention, it includes introducing at least one feed channel and at least one discharge channel for a cooling channel system in the component by means of material removal processing, wherein the feed channel and the discharge channel are introduced so that the cooling channel system extends continuously from the feed channel to the discharge channel.

[0072] This provides a continuous cooling channel system through which coolant supplied from outside the component through the feed channel can flow through the cooling channel system inside the component to the discharge channel, thereby providing a cooling circuit for cooling or dissipating heat from the component.

[0073] In a particularly preferred embodiment of the method, it further comprises additively and integrally applying the wear-resistant outer layer to a portion of the outer contoured surface of the component (built from the building material).

[0074] Thus, a wear-resistant surface (preferably made of tool steel) which can also withstand greater mechanical stresses can be formed in a manner suitable for the later use of the component, for example as a tool in other manufacturing and / or production methods.

[0075] In a particularly preferred embodiment of the method, the additive, integral application of the wear-resistant outer layer is performed by laser or arc build-up welding, the material for building the wear-resistant outer layer being provided in the form of powder and / or wire.

[0076] In a particularly preferred embodiment of the method, the building material also has a thermal conductivity that is higher than the thermal conductivity of the wear-resistant outer layer.

[0077] Thus, a component with improved heat dissipation and high wear resistance can be provided in an efficient manner. Due to the increased thermal conductivity, heat energy entering the component via the outer layer is rapidly conducted from the surface of the outer layer adjacent to the building material to the cooling channel system, thereby achieving improved heat dissipation throughout the component.

[0078] Improved heat dissipation of the component produced by the method according to the invention is intended not only to increase the cooling rate but also to achieve local uniformity of cooling of the component, in particular since, during the method according to the invention, cavities in regions of the component, for example, are subject to particularly severe thermal stresses.

[0079] For example, when the component is used as a tool, undesired deformations caused by locally different cooling rates can be reliably avoided.

[0080] For example, the cooling time of injection-molded parts can be shortened and the cooling of thermoforming tools can be improved to prevent increased local wear.

[0081] According to a further aspect of the invention, a software-supported computer system is proposed, characterized in that the computer system is configured to carry out construction planning of a component to be produced by the method according to the invention and to this end comprises at least one device for defining the component geometry of the component having a cooling channel system.

[0082] In a particularly preferred embodiment, the computer system further includes a device for continuous processing steps, which can be performed by a CNC machine tool and / or a CNC machining center for producing a component; a device for exporting control commands, which are used by the CNC machine tool and / or the CNC machining center to perform the processing steps; and a device for transmitting control commands to the machine tool and / or the machining center, which is configured to perform the processing steps for producing the component.

[0083] In a particularly preferred embodiment, the computer system further comprises a CAD and / or CAM system.

[0084] Further aspects and advantages thereof and more specific exemplary embodiments of the above aspects and features will be described below using the figures shown in the accompanying drawings:

[0085] Figures 1a-1f A component produced stepwise using the method according to the invention and having a cooling channel system is shown in an exemplary cross-sectional view.

[0086] Figure 2 A component with a cooling channel system, which comprises a plurality of cavities and connecting channels, is shown in a perspective perspective view.

[0087] Figure 3a-Figure 3b Shows Figure 2 Enlarged views of different partial areas of a component with a cooling channel system.

[0088] Figure 4 Shows Figure 2 A perspective cross-sectional view of the middle region of the component shown.

[0089] Figure 5 An exemplary embodiment of a method according to the invention for producing a component with a cooling channel system is shown. BRIEF DESCRIPTION OF THE DRAWINGS

[0090] Figure 1a An exemplary component 100 is shown in cross-section after a first portion 10 has been built up during a method according to the invention by additive, integrally applying build material (ie, additive deposition).

[0091] In the given example, additive deposition occurs along a build direction x.

[0092] A first cavity 11 is introduced into the first part 10 in such a way that it has an opening towards the outer surface 15 of the first part 10 .

[0093] The introduction of the first cavity 11 can be implemented through a recess at a relevant point during the additive deposition process of the first part 10, wherein the surface adjacent to the first cavity 11 in the first part is reprocessed by material removal processing, in particular chip removal processing, to improve its surface quality, thereby reducing the flow resistance in the cooling channel system.

[0094] Alternatively, after the additive deposition of the first part 10 , the first cavity 11 can be introduced directly into the solid material by material removal machining, in particular chip removal machining.

[0095] Furthermore, at the opening of the first cavity 11 on the outer surface 15, a shoulder 12 is introduced in the first part 10 by means of a material removal process, said shoulder 12 being used for the subsequent insertion of a cover 13 (see Figure 1b ).

[0096] Figure 1b A cross-sectional view of the components after the step of covering the opening of the first cavity 10 with the cover 13 is shown.

[0097] The cover 13 is advantageously flat and planar and has a small thickness compared to its other dimensions. The cover completely closes the opening of the first cavity.

[0098] Advantageously, the shoulder 12 introduced at the first cavity 10 of the first part 10 and the cover 13 are adapted to each other in shape so that the surface of the flat cover 12 is flush with the outer surface 15 of the first part and preferably forms a flat surface therewith. The cover 13 is preferably fixed by the introduced shoulder 12 in a form-fitting manner.

[0099] Figure 1c The cross-section of the component 100 is shown after the additive deposition of the second portion 20 in a subsequent method step.

[0100] Starting from the outer surface 15 of the first part 10 , the additive deposition of the second part 20 is performed on the first part 10 , and the surface of the cover 13 of the first cavity 11 is flush with the outer surface 15 along the deposition direction x.

[0101] The additive deposition of the second portion 20 can also be performed on the cover 13 by covering the opening of the first cavity 11, which means that it is possible to omit the complete closure of the first cavity 11 by additive application using a complex pyramidal or conical geometry, so that the first cavity 11 has a geometry in which the two surfaces relative to the two sides or the top and bottom are basically parallel.

[0102] like Figure 1c As shown, starting from the entire outer surface 15 of the first part 10 and the surface of the cover 13 flush with the outer surface 15, the exemplary component 100 is subjected to the additive deposition of the second part 20, wherein this should not be understood as a limitation of the method according to the invention. In general, the second part can also be deposited only on part of the outer surface 15 (rather than the entire outer surface) of the first part 10 of the component 100.

[0103] A cavity, namely the second cavity 21 , is also introduced in the second part 20 of the component 100 by means of a material removal machining using one of the methods already described during the introduction of the first cavity 11 (a groove completely introduced after additive deposition and material removal machining or material removal machining).

[0104] although Figure 1c The illustration in shows that the first cavity 11 and the second cavity 21 have the same or similar geometry (same or similar dimensions), but this is generally not necessary in the method according to the invention.

[0105] The second cavity 21 of the second portion 22 is open toward the outer surface 25 of the second portion 20 .

[0106] Furthermore, in a manner similar to the process in the case of the first cavity 11 , a shoulder 22 is introduced at the opening of the outer surface 25 of the second cavity 21 by means of a material removal process.

[0107] Figure 1d The component 100 is shown in a cross-sectional view after the subsequent method step of introducing the connecting channel 90 .

[0108] The connecting channel 90 is introduced into the component 100 by means of material removal processing, so that the first cavity 11 of the first part 10 is connected to the second cavity 21 of the second part 20 .

[0109] When the two cavities 11 , 21 are connected via the connecting channel 90 to form a cooling channel system, material must also be removed from the cover 13 enclosed in the component during the additive deposition process, since otherwise no connection between the cavities 11 and 21 can be established.

[0110] The material-removing machining for introducing the connecting channel 90 can be performed by laser machining or chip-removing machining, for example using a milling cutter or a drill, with chip-removing machining being preferred due to the high surface quality introduced in this way.

[0111] The material removal process (e.g. inserting a drill bit) is performed starting from the second cavity 22, wherein, since the cross-section of the second cavity 21 is larger than the cross-section of the connecting channel 90, the exemplary drill bit can be easily guided through the component 100 to the first cavity 11 without damaging the component 100 in an undesirable manner, such as colliding with the second part 20 in the area around the second cavity 21.

[0112] Furthermore, the relatively large second cavity 22 allows the example drill to be introduced into the component at an angle from the perpendicular direction of the outer surface 25. The possibility of introducing the connecting channel 90 at an oblique angle corresponding to the perpendicular direction of the outer surface 25 (without damaging the second part 20 in an undesirable manner) leads to greater flexibility in forming the cooling channel system in the component 100.

[0113] Therefore, the connecting channel 90 can be advantageously introduced both at a steeper and a shallower inclination angle relative to the vertical direction of the outer surface 25 .

[0114] Therefore, the connecting channel 90 can be Figure 1d , in a partial region of the component 100, the cooling channel system is routed parallel (or almost parallel) to the other outer surface 26 of the component 100. The result of this is that in such a cross section, points on different surfaces of the other outer surface 26 are at the same (or almost the same) distance from the connecting channel 90. This distance should advantageously be selected to be as small as possible so that the cooling channel system can be routed close to the outer contour, so that, for example, the heat entering the component 100 through the other outer surface 26 can be dissipated by means of the cooling channel system through which the coolant flows. By introducing the connecting channel 90 as part of the cooling channel system in this way, the material between the other outer surface 26 of the component 100 and the connecting channel 90 in this partial region has a substantially constant thickness, which also means that locally uniform heat dissipation can also be achieved in the relevant partial region.

[0115] Figure 1e The component 100 is shown in cross-section after additive build-up of another (third) portion 30 that is used to complete the exemplary component 100 .

[0116] According to the method of the invention, the opening of the second cavity 21 on the outer surface 25 of the second part 20 is covered and closed by a cover 23 matched with the shoulder 22 , wherein a surface of the cover also ends flush with the outer surface 25 .

[0117] Starting from the outer surface 25 of the second part 20 , the additive deposition of the third part 30 is performed on the second part 20 , and the surface of the cover 23 of the second cavity 21 extends flush with the outer surface 25 in the building direction x.

[0118] Figure 1f The component 100 is shown in cross section after the cooling channel system has been completed by introducing the feed channel 91 and the discharge channel 92 .

[0119] The introduction of the feed channel 91 and the outlet channel 92 is carried out through material removal processing, and it is possible to introduce the feed channel 91 and the outlet channel 92 in the component 100 in such a way that the coolant starts from the inlet Z and then passes through the cooling channel system composed of the cavity 21, the cavity 22, the connecting channel 90, the feed channel 91 and the outlet channel 92 until the outlet A.

[0120] The positions of the coolant inlet Z and outlet A are usually not fixed, but can be interchanged at will, so that the flow direction of the coolant flowing through the cooling channel system is consistent with that of the cooling channel system. Figure 1f The flow directions shown are opposite.

[0121] The feed channel 91 and the discharge channel 92 may also pass through the component 100 so that they follow the outer surface of the component 100 at least in a portion to improve heat dissipation.

[0122] The feed channel 91 and the discharge channel 92 are advantageously introduced in such a way that the inlet Z and the outlet A of the coolant in the cooling channel system of the component 100 are located on one or both outer surfaces (A and Z are not necessarily arranged on the same surface or side of the component).

[0123] Figure 1f The component 100 shown in the figure with the finished cooling channel system clearly shows that a cooling channel system with such a complex geometry can never be produced by material removal processing (for example by drilling) after the component 100 (here having three parts 10, 20, 30) has been completely stacked, but is only possible by the method according to the invention.

[0124] Furthermore, surfaces adjacent to the internal cooling channel system in the component 100 are advantageously introduced or at least reworked by material removal, in particular by chip removal. In this way, a high surface quality of the surface can be achieved with a low roughness, in particular in comparison with surfaces that are completely produced by additive deposition. In this way, the flow resistance of the coolant through such a cooling channel system can be significantly reduced, so that higher flow speeds or higher flow rates can be achieved, in particular in comparison with cooling channel systems that are produced completely by additive deposition (i.e. without material removal / rework), which themselves have a lower surface quality and therefore a greater flow resistance for the coolant.

[0125] Figure 2 A further component with a cooling channel system is shown in a perspective view, which component is produced completely by the method according to the invention and which has a plurality of cavities and a plurality of channels.

[0126] and Figures 1a to 1f Compared to the example in Figure 2 The component 100 shown has a more complex exterior geometry and a more complex geometry of the cooling channel system extending within the interior of the component 100 .

[0127] The component 100 is produced using the method according to the invention, wherein, due to the hybrid nature of the method comprising alternating additive deposition steps and subtractive machining steps, a cooling channel system can be formed within the component 100, whereby the component (with coolant flow) has improved heat dissipation properties.

[0128] The component is built by additively, integrally applying a build material onto a body 101 of the component 101 .

[0129] During the process according to the invention, the first cavity 11, the second cavity 21 and two further cavities (i.e. the third cavity 31 and the fourth cavity 41) are advantageously introduced into the component, each cavity being introduced by chip removal machining. In addition, the surfaces adjacent to the cavities 11, 21, 31, 41 can be re-machined, for example by further material removal machining, to improve the surface quality.

[0130] The geometry of the cavity is advantageously selected from a set of standard geometries, which preferably include simple cylindrical and / or substantially cylindrical geometries with the greatest dimensional variation. Substantially cylindrical geometries are understood to be formed by extruding a base surface of any shape (such as a circle, ellipse, polygon, etc.) along an extrusion axis.

[0131] The second cavity 21 , the third cavity 31 , and the fourth cavity 41 have a cylindrical shape with a circular cross section, and the dimensions of the cylindrical shape of each cavity differ in terms of the diameter of the circular cross section and the height of the cylinder.

[0132] On the other hand, the first cavity 11 has a generally cylindrical shape, and its cross section is non-circular.

[0133] During the production of the component using the method according to the invention, the cavities 11, 21, 31, 41 are connected to one another via connecting channels 90a, 90b, 90c to form a cooling channel system, which are introduced into the component 100 by material removal machining, in particular by chip removal machining.

[0134] The connecting channel 90 a connects the first chamber 11 with the second chamber 21 , the connecting channel 90 b connects the first chamber 11 with the third chamber 31 , and the connecting channel 90 c connects the third chamber 31 with the fourth chamber 41 .

[0135] Therefore, the flow direction of the coolant flowing through the cooling channel system will be in the following order:

[0136] Second chamber 21 -> connecting channel 90a -> first chamber 11 -> connecting channel 90b -> third chamber 31 -> connecting channel 90c -> fourth chamber 41

[0137] Or proceed in the corresponding reverse order.

[0138] Starting from the body 101 of the component 100 , a feed channel 91 and a discharge channel 92 for the coolant are also introduced into the component 101 by means of a material removal process, so as to finally complete the cooling channel system.

[0139] The determination of the feed channel 91 and the discharge channel 92 and the flow direction from the feed channel 91 to the discharge channel 92 is not to be understood as being mandatory, since the coolant can also flow through the cooling channel system in the opposite flow direction.

[0140] Figure 3a A cross-sectional perspective view is shown. Figure 2 The component in the middle area.

[0141] The sectional view shows that connecting channels 90a, 90b for connecting cavities 11, 21, 31 are introduced into component 100 in such a way that they at least partially follow the outer contour or outer contour surface of component 100; ie extend parallel or approximately parallel to these contours and are thus formed as a nearly net contour.

[0142] Figure 3b Shown in side view Figure 3a As shown in Figure 2 A cross section of a component in the middle area.

[0143] The side view shows that, in addition to the connecting channels 90a, 90b for connecting the cavities 11, 21, 31, the discharge channel 92 of the cooling channel system is also introduced into the component 100 in such a way that it at least partially follows the outer contour or outer contour surface of the component 100; that is, it extends parallel or approximately parallel thereto.

[0144] exist Figure 3b In the illustration shown, the discharge channel 92 of the cooling channel system opens into the body 101 , from which the cooling channel system is connected to a coolant supply unit configured to supply the cooling channel system.

[0145] Figure 3cIt is shown that after an intermediate step of the method according to the invention for producing a component, Figure 2 A perspective cross-sectional view of a component in the upper region.

[0146] In the illustration shown, after the fourth cavity 41 is introduced, a cover 43 (not shown here, see Figure 3d ) covers the opening of the fourth cavity 41 on the outer surface 45, and adds material to the outer surface 45 Figure 2 The method steps of the last part of the component 100 are shown as not yet being carried out.

[0147] Here, the outer surface 45 is merely the outer surface formed during a preceding method step and not, in the present case, the outer surface of the finished component.

[0148] Here, the component is additively deposited up to the outer surface 45 .

[0149] Furthermore, at the opening of the fourth cavity 41 on the outer surface 45 , a shoulder 42 configured to receive a cover 43 (not shown here) is introduced by material removal machining, in particular by chip removal machining.

[0150] The geometry of the shoulder 42 is adapted to the cylindrical shape of the fourth cavity and is configured such that a cover 43 placed thereon during a subsequent method step is held in place in a form-fitting manner.

[0151] Figure 3d It is shown that after a further intermediate step of the method according to the invention for producing a component, Figure 2 A perspective cross-sectional view of a component in the upper region.

[0152] In the process of the manufacturing method according to the present invention, Figure 3c In the illustrated state of the components, the opening of the fourth cavity 41 on the outer surface 45 has been covered by a cover 43 which is adapted to the shoulder 42 .

[0153] The cover 43 is configured (matched to the shoulder 42) such that it can be inserted into the shoulder 42 to cover the fourth cavity and positioned therein in a form-fitting manner, with one surface of the cover 42 being slightly recessed relative to the outer surface 45 of the component.

[0154] Thus, a defined terminal is formed, at which the subsequent method steps can be carried out. Figure 2 Additive buildup of the final portion of the component shown.

[0155] The covering element used during the method according to the invention, here the covering element 43, is preferably selected from a group of prefabricated covering elements, the geometry of which is adapted to the standard geometry of the cavity.

[0156] Corresponding to the cylindrical geometry of the fourth chamber 41 , the cover 43 has a circular planar geometry adapted thereto and is preferably designed as a thin, flat metal blank.

[0157] Figure 4 Shows Figure 2 A perspective cross-sectional view of the middle region of the component shown.

[0158] The figure shows different material structures of a component 100 having a cooling channel system.

[0159] The component produced during the method according to the invention has a core 102 made of a building material, in which a cooling channel system is formed.

[0160] In addition, other materials are applied by additive integration to form a wear-resistant outer layer 103 on the outer contour surface of the core 102. The other materials have higher wear resistance than the construction material forming the core 102.

[0161] On the other hand, the construction material forming the core 102 preferably has a higher thermal conductivity than the other materials forming the wear-resistant outer layer 103 .

[0162] The resulting combination advantageously combines the improved thermal conductivity of the core 102 forming the cooling channel system with the high wear resistance of the wear-resistant outer layer 103 .

[0163] In a possible embodiment, the thermally conductive construction material is copper or a copper alloy, and the wear-resistant outer layer is formed of tool steel.

[0164] Since the cooling channel system is introduced into the core 102 by means of material removal processing in the method process according to the present invention, and since the core 102 with stronger thermal conductivity (such as copper alloy) is usually lower in strength than other materials of the wear-resistant outer layer 103 (such as tool steel), the processing workload and processing cost can also be reduced, thereby simplifying the material removal processing of the core.

[0165] Figure 5 An exemplary embodiment of a method according to the invention for producing a component having a cooling channel system is schematically shown in FIG.

[0166] In step S1 , a first portion of a component is built up by additive, integrally applying a build material.

[0167] In step S2 , a first cavity having an opening is introduced in a first part of the component.

[0168] In step S3 , the opening of the first cavity of the first part is partially or completely covered by a cover.

[0169] In step S4 , a second portion of the component is built up by additive, integral application of build material, which is applied to the first portion and at least part of the cover and, if appropriate, also to the first portion.

[0170] In step S5, a second cavity is introduced in a second portion of the component.

[0171] In step S6 , a connecting channel is introduced into at least a partial section of the component by material removal processing to form a cooling channel system, wherein the connecting channel connects the second cavity of the second part of the component with the first cavity of the first part.

[0172] In this exemplary embodiment, the two cavities are introduced by omitting corresponding regions during the application of the material.

[0173] A connecting channel connecting the two cavities is introduced by chip removal machining.

[0174] In a particular embodiment of the exemplary embodiment shown, the method further comprises a step S7, wherein the opening formed in the second cavity of the second part is also partially or completely covered by the cover by omitting the corresponding area.

[0175] In step S8, another portion of the component is built up by additively and integrally applying a building material at least to the cover of the second cavity opening and also to the second portion to achieve a better integral connection and ensure termination of the opening.

[0176] As described above, these steps can be further repeated in order to continuously build further parts with cavities in this way, which are then connected by introducing connecting channels. According to the invention, the connecting channels are at least partially produced by material removal, while according to the invention, within the scope of the invention, the cavities are at least partially built by additive, integral application of building material.

[0177] The exemplary embodiments of the present invention and their advantages have been described in detail above with reference to the accompanying drawings.

[0178] However, the present invention is by no means limited to the above-described exemplary embodiments and their implementing features, but also includes modifications of the exemplary embodiments, in particular modifications resulting from modifications and / or combinations of one or more features of the exemplary embodiments within the scope of the independent claims.

[0179] List of reference numbers

[0180] 10 Part 1

[0181] 11 First cavity

[0182] 12 shoulder at the opening of the first cavity

[0183] 13. Covering member for covering the first cavity

[0184] 15 Outer surface of the first part

[0185] 20 Part 2

[0186] 21 Second cavity

[0187] 22 shoulder at the opening of the second cavity

[0188] 23 Covering member for covering the second cavity

[0189] 25 The outer surface of the second part

[0190] 26 Another outer surface of the second part

[0191] 31 The third cavity

[0192] 41 Fourth cavity

[0193] 42 Shoulder at the opening of the fourth cavity

[0194] 43 Covering member for covering the fourth cavity

[0195] 45 Outer surface

[0196] 90, 90a, 90b, 90c connecting channels

[0197] 91 Feed channel

[0198] 92 discharge channel

[0199] 100 parts

[0200] 101 Component Body

[0201] 102 component core

[0202] 103 wear-resistant outer layer

[0203] Z Entrance

[0204] Exit A

[0205] X Build Direction

Claims

1. A method for producing a component (100) having a cooling channel system, comprising: - constructing the first portion (10) of the component (100) by additive, integral application of construction material, - introducing a first cavity (11) having an opening in said first portion (10) of said component (100), Characterized in that the method further comprises: - partially or completely covering the opening of the first cavity (11) of the first part (10) with a cover (13), - building up the second portion (20) of the component (100) by additive, integral application of the building material, the building material being applied at least to the cover (13) or also to the cover (13) and the first portion (10), - introducing a second cavity (21) into said second portion (20) of said component, - introducing a connecting channel (90, 90a) in at least a partial section of the component (100) by material removal processing to form the cooling channel system, wherein the connecting channel connects the second cavity (21) of the second part (20) of the component (100) with the first cavity (11) of the first part (10).

2. The method according to claim 1, characterized in that The introduction of the first cavity (11) and / or the second cavity (21) and / or the introduction of the connecting channel is carried out by removing material at least in part after the corresponding parts (10, 20) are constructed.

3. The method according to claim 2, characterized in that The material removal processing for introducing into the first cavity (11) and / or the second cavity (21) and / or the connecting channel is chip removal processing.

4. The method according to claim 1, characterized in that The introduction of the first cavity (11) and / or the second cavity (21) and / or the introduction of the connecting channel is omitted in at least some sections during the construction of the corresponding parts (10, 20) when the construction material is applied in an additive, integral manner.

5. The method according to claim 4, characterized in that Surfaces of the part (10, 20) adjacent to the first and second cavities (11, 21) introduced during the construction of the part (10, 20) are re-machined by chip removal machining.

6. The method according to any one of claims 1 to 5, characterized in that The method further comprises: - partially or completely covering the opening of the second cavity (21) of the second part (20) with a cover (23), and - Building the other parts (30, 40) of the component (100) by additively and integrally applying the building material, the building material being applied at least to the cover (23) of the opening of the second cavity (21), or it is also applied to the cover (23) and the second part (20).

7. The method according to claim 6, characterized in that The method further comprises the following steps: ZS1: Introducing a further cavity (31, 41) having the opening into one of the previously constructed first and second parts (10, 20) of the component (100), wherein the introduction of the further cavity (31, 41) is performed by material removal after the construction of the previously constructed first and second parts (10, 20) or is omitted during the additive, integral application of the construction material during the construction of the previously constructed first and second parts (10, 20), ZS2: introducing one or more connecting channels (90, 90a, 90b, 90c) in the component (100) by means of material removal processing to further form the cooling channel system, wherein the connecting channels (90, 90a, 90b, 90c) connect the further cavities (31, 41) of step ZS1 with one or more previously introduced first and second cavities (11, 21) in the previously constructed first and second parts (10, 20) of the component (100), ZS3: partially or completely covering the opening of the other cavity or cavities (31, 41) from step ZS1 with a cover (43), ZS4: Building one or more other parts of the component (100) by additively and integrally applying the building material, which is applied to one or more of the previously built first and second parts (10, 20) and the cover (43) of the previous step ZS3.

8. The method according to claim 7, characterized in that The method further comprises: - Repeating the method step sequence ZS1 to ZS4 multiple times to produce a component (100) having a plurality of parts (10, 20) and a cooling channel system formed in the component (100), the cooling channel system comprising a plurality of cavities (11, 21, 31, 41) and a plurality of connecting channels (90, 90a, 90b, 90c, 90d) for connecting the plurality of cavities.

9. The method according to any one of claims 1 to 8, characterized in that The material removal process for introducing the connecting channel (90, 90a, 90b, 90c) is a chip removal process.

10. The method according to any one of claims 1 to 9, characterized in that The additive, integral application of the building material is performed by laser or arc deposition welding.

11. The method according to claim 10, characterized in that The building material is provided in powder and / or wire form.

12. The method according to any one of claims 1 to 11, characterized in that In the surrounding area of ​​the opening of one or more cavities (11, 21, 31, 41) of the corresponding part, a concave shoulder (12, 22, 42) is formed by material removal, which is adapted to the geometric shape of the cover (13, 23, 43) configured to cover the corresponding opening, so that the corresponding cover (13, 23, 43) for covering the corresponding opening is held in place in a form-fitting manner.

13. The method according to claim 12, characterized in that One or more of the covers (13, 23, 43) are circular sheet metal blanks or sheet metal covers.

14. The method according to any one of claims 1 to 13, characterized in that The geometry of the cavity (11, 21, 31, 41) is selected from a set of predetermined standard geometries of cavities.

15. The method according to claim 14, characterized in that The standard geometry of the cavity is generally cylindrical.

16. The method according to any one of claims 14 or 15, characterized in that The cover (13, 23, 43) is selected from a group of prefabricated covers, the geometry of which is adapted to the standard geometry of the cavity.

17. The method according to any one of claims 1 to 16, characterized in that The method further comprises: - introducing at least one feed channel (91) and at least one discharge channel (92) for the cooling channel system into the component (100) by means of a material removal process, wherein the feed channel (91) and the discharge channel (92) are introduced in such a way that the cooling channel system extends continuously from the feed channel (91) to the discharge channel (92).

18. The method according to any one of claims 1 to 17, characterized in that The method further comprises: - Additive, integral application of a different material having a different wear resistance than the building material of the built component (100).

19. The method according to claim 18, characterized in that The thermal conductivity of the construction material surrounding the cooling channel is greater than the thermal conductivity of the wear resistant outer layer (103).

20. A computer system supported by software, characterized in that The computer system is configured to carry out construction planning of a component (100) to be produced by a method according to one of claims 1 to 19 and to this end comprises at least: - means for defining the geometry of said component (100) having a cooling channel system.

21. The software-supported computer system according to claim 20, characterized in that: The means for defining the geometry of the component (100) having the cooling channel system comprises selecting the geometry of the cooling channel portion from a set of predefined geometric cavities.

22. The software-supported computer system according to claim 20, characterized in that: The computer system further comprises: - means for determining successive machining steps executable by a CNC machine and / or a CNC machining centre for producing said component (100); - means for deriving control commands for said CNC machine tool and / or CNC machining centre for carrying out said machining steps; - means for transmitting said control commands to said machine tool and / or machining centre, said machine tool and / or machining centre being configured to carry out said machining steps for producing said component (100).

23. A software-supported computer system according to any one of claims 20 to 22, It is characterized in that The computer system comprises a CAD and / or CAM system.

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