Intelligent mold part machining method with conformal waterways

Abstract

The application provides a kind of intelligent mold part processing method with conformal waterway, belongs to mold processing technical field.It solves the problem of poor cooling effect of the mold parts made by the existing method.The method includes the following steps:A, select mold steel for processing to form a part body with a mounting cavity, process a conformal half groove one on the inner wall of the mounting cavity;B, process an inner insert using ferrous alloy material, process a conformal half groove two on the outer wall of the inner insert;C, prepare an Al-Si-Sm alloy layer on the inner wall of the mounting cavity and the outer wall of the inner insert, assemble the inner insert into the mounting cavity, and the conformal half groove one and the conformal half groove two enclose a conformal waterway;D, heat treatment in a vacuum environment to tightly bond the inner insert and the part body together, and complete processing.The conformal waterway formed by the method has good flowability, and can process its roughness, increasing the part heat transfer speed and cooling effect.

Description

Technical Field

[0001] This invention belongs to the field of mold processing technology and relates to a method for processing intelligent mold parts with conformal water channels. Background Technology

[0002] Due to limitations in processing technology, traditional molds typically feature straight-through or intersecting cooling water channels. These channels, located on a single plane, result in uneven distances from the center of the water channel to different parts of the mold cavity's contour surface, leading to uneven cooling and impacting the quality of the molded parts. To address this, intelligent molds with conformal cooling channels have become mainstream. These conformal channels follow a trajectory consistent with the shape of the mold cavity, ensuring consistent distances from each point on the channel to the cavity's contour surface. Furthermore, electronic controls allow for precise control of the coolant flow rate and temperature, resulting in uniform cooling.

[0003] For example, Chinese patent application (application number: 201510051427.9) discloses a mold with conformal water channels inside and its manufacturing method. The method includes: firstly, splitting the mold core into three parts at the water channel: upper mold core, lower mold core, and water channel; firstly, manufacturing a water channel model and a lower mold core auxiliary molding fixture; then, using metal powder pressing technology, pressing the lower mold core model with the lower mold core auxiliary molding fixture; then, placing the water channel model on the lower mold core model; then, continuing to fill with metal powder and pressing; finally, forming a mold core model with an embedded water channel model inside in the molding groove; sintering and degreasing the mold core model to remove the resin-made water channel model; and then molding the upper and lower mold core models as a single piece, thus producing a mold core with conformal water channels inside. The conformal water channels are distributed around the cavity in a trajectory consistent with the shape of the cavity, which can uniformly cool the cavity.

[0004] The above method uses high-temperature sintering degreasing to remove the conformal water channel model. High-temperature sintering can easily cause the resin-made conformal water channels to melt, allowing some metal powder to enter the channels and affecting their flow, thus impacting cooling efficiency. Furthermore, the roughness of the inner wall of the sintered conformal water channels is uncontrollable, affecting heat transfer. Additionally, the mold formed by overall sintering results in a porous, unstable prototype structure with internal stress, making it prone to deformation during manufacturing. The mold cavity contour is rough and porous, and its shape is limited by powder particle size and laser spot size, making post-processing difficult. Compared to molds machined from mold steel, the overall mold quality and lifespan are inferior.

[0005] Due to the complex shape of conformal water channels, machining of these channels within the mold steel is impossible. Therefore, to ensure heat transfer efficiency and mold quality, the conventional approach is to manufacture the entire mold in multiple modular pieces. Specifically, mold steel is cut into layers of plates, and conformal water channel segments are machined into each plate. The inner walls of these segments are then ground to increase roughness. Finally, the plates are stacked and welded together to form a complete conformal water channel. However, molds manufactured using this method are prone to leakage at the weld joints, and the overall smoothness of the conformal water channel is poor, affecting the uniformity of cooling. Summary of the Invention

[0006] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a method for processing intelligent mold parts with conformal water channels. The technical problem to be solved by this invention is the poor cooling effect of mold parts produced by existing methods.

[0007] The objective of this invention can be achieved through the following technical solution: a method for processing intelligent mold parts with conformal water channels, characterized by comprising the following steps:

[0008] A. Based on the mold flow analysis results, select mold steel to process and form a part body with a product contour surface. Process an installation cavity on the part body and ensure that the bottom wall of the installation cavity and the wall thickness of the product contour surface are approximately uniform. Process a conformal semi-groove on the inner wall of the installation cavity.

[0009] B. An insert made of iron alloy material is formed to match the inner wall contour of the mounting cavity, and a corresponding conformal semi-groove is formed on the outer wall of the insert.

[0010] C. An Al-Si-Sm alloy layer is formed on both the inner wall of the mounting cavity and the outer wall of the insert. The insert is then assembled into the mounting cavity so that it fits tightly against the inner wall of the mounting cavity. The conformal semi-groove one and conformal semi-groove two together form a conformal water channel.

[0011] D. Heat treatment in a vacuum environment allows the insert to be tightly bonded to the part body, completing the processing to form an intelligent mold part with conformal water channels.

[0012] A mold is generally composed of multiple mold parts that can be joined together to form a mold cavity. In this application, mold parts refer to components with mold cavity contour surfaces, such as the moving mold and fixed mold in an injection mold. This process differs from conventional techniques by employing machining to manufacture the mold. Specifically, the main body of the component with the mold cavity contour surface is machined from mold steel. Simultaneously, an insert with a contour consistent with the mounting cavity is machined. Furthermore, conformal semi-groove one and conformal semi-groove two are machined on the outer walls of both the mounting cavity and the insert. These conformal semi-groove one and conformal semi-groove two can interlock to form conformal water channels. Simultaneously, Al-Si-Sm alloy layers are formed on the inner wall of the mounting cavity and the outer wall of the insert, respectively. After assembly, the insert and the inner wall of the mounting cavity are first mechanically fitted together, and then heat-treated. As the heat treatment temperature reaches a certain value, Fe, Al, and other atoms diffuse fully. While aluminum atoms diffuse into the interior of the mold steel, iron atoms also enter the diffusion layer and react with Al, Si, Sm, etc. The diffusion reduces the thickness of the original Al layer, and an intermetallic compound (IMC) layer is formed at the interface, whose main components are FeAl and Fe2Al5 phases. At the same time, silicon can lower the melting point of the aluminum alloy, inhibit the growth of Fe2Al5 between iron and aluminum, and make the IMC / Fe matrix interface smoother. It can also reduce the activity coefficient of Al and reduce the thickness of the Fe-Al IMC layer. Sm significantly increases the diffusion barrier energy, inhibits the interdiffusion of Fe and Al atoms, and the SmAl4 phase formed by Sm and Al significantly refines the crystal structure of Fe2Al5 at the interface. The effects of multiple alloying elements on the Fe / Al interface reaction are not simply additive; they interact and couple, jointly influencing the Fe / Al interface reaction. This leads to interdiffusion at the interface between the coating, the part body, and the insert, forming compounds and solid solutions of two or more elements. This alters the composition and microstructure of the surface layer of the part body and the insert, transforming the mechanical bonding into a metallurgical bonding, resulting in a tight bond between the insert and the part body. Molds made using this method do not require sintering and debinding, have good conformal water channel flow, and their roughness can be improved during the machining of conformal half-groove one and conformal half-groove two, increasing the heat transfer rate of the part and improving the cooling and heat transfer effect. Moreover, the resulting conformal water channels are all complete channels without cutting or welding, thus avoiding leakage. Furthermore, the conformal water channels are closer to the mold cavity contour surface and are not limited by the structure and shape of the mold parts. This ensures that the distance from the center of the cross-section of the conformal water channel to the mold cavity contour surface remains consistent, maximizing the rational design and layout of the cooling water channel system, shortening the cooling time in the thermoforming cycle, and enabling the plastic parts to be cooled evenly with higher cooling efficiency.

[0013] In the above-described method for processing intelligent mold parts with conformal water channels, in step A, based on the mold flow analysis results, a three-dimensional modeling design of the intelligent mold part with conformal water channels is first designed using 3D drawing software. Then, mold steel is selected and processed to form the part body with the product contour surface, referring to the three-dimensional modeling design. Performing three-dimensional modeling first allows for structural refinement before manufacturing, minimizing errors.

[0014] In the above-described intelligent mold part processing method with conformal water channels, in step A, the wall thickness of the bottom wall of the mounting cavity and the product contour surface is ensured to be 3-8 mm. Setting the wall thickness within this range ensures that the product contour surface has sufficient strength, preventing deformation and guaranteeing the quality and lifespan of the mold. Simultaneously, this wall thickness also ensures good and uniform cooling spacing, resulting in a better cooling effect.

[0015] In the above-described method for processing intelligent mold parts with conformal water channels, in step B, a gap of 0.1 to 0.75 mm is maintained between the processed insert and the inner wall of the mounting cavity after the insert is installed. This arrangement facilitates installation and also allows for the preparation of an Al-Si-Sm alloy layer by reserving space between the insert and the inner wall of the mounting cavity.

[0016] In the above-described method for processing intelligent mold parts with conformal water channels, in step C, the thickness of the Al-Si-Sm alloy layer is 0.1–0.45 mm. Maintaining the thickness of the Al-Si-Sm alloy layer within this range ensures a good mechanical bond between the insert and the inner wall of the mounting cavity of the part body after installation, guaranteeing proper installation. Furthermore, heat treatment diffusion transforms the mechanical bond into a metallurgical bond.

[0017] In the above-mentioned intelligent mold part processing method with conformal water channels, in step C, the Al-Si-Sm alloy layer comprises the following components in the following proportions: Sm: 0.1%–1.0%; Si: 5%–12%; the remainder being Al. The brittle intermetallic matrix (IMC) formed at the interface between the coating and the part body is a key factor determining the strength of the connection between the part body and the embedded component. The Al-Si-Sm alloy layer with the above proportions has a low coefficient of thermal expansion, which is close to that of mold steel. During production, the two materials shrink almost synchronously, resulting in very low tensile stress on the IMC at the interface. This avoids the formation of microcracks in this area, ensuring a tight bond between the part, the insert, and the aluminum coating.

[0018] In the above-mentioned intelligent mold part processing method with conformal water channels, in step C, the Al-Si-Sm alloy layer is formed by thermal spraying or hot-dip plating.

[0019] In the above-described method for processing intelligent mold parts with conformal water channels, in step C, the insert is assembled into the mounting cavity and subjected to a pressure of 0.1–0.3 MPa to ensure a tight fit with the inner wall of the mounting cavity. Excessive pressure will cause the molten layer to be squeezed out into the surrounding gaps, resulting in a thin surface metal layer at the joint surface and reduced bonding performance of the molten layer. By controlling the pressure within the aforementioned range, a tight fit of the molten surface alloy layer can be ensured.

[0020] In the above-described processing method for intelligent mold parts with conformal water channels, the specific heat treatment steps in step D are as follows: Under vacuum, the temperature is controlled at 680–790°C and held for 2–10 minutes; then the temperature is controlled at 500–560°C and held for 25–180 minutes. First, at 680–790°C, the chemical composition of the part body and the aluminum alloy layer of the insert is the same, allowing for better fusion. Then, at 500–560°C, atoms diffuse at the aluminum-iron interface, achieving metallurgical bonding in the aluminum-iron bonding zone, thus enabling a tight bond between the part body and the insert.

[0021] In the above-described intelligent mold part processing method with conformal water channels, step D further includes finishing the mold part after processing. After the conformal water channels are formed within the mold part, the mold part is finished to ensure that its dimensions and tolerances meet the technical requirements of the three-dimensional design drawing. Finishing generally includes polishing and grinding.

[0022] Compared with existing technologies, this intelligent mold part processing method with conformal water channels has the following advantages:

[0023] 1. The main body and inserts of the parts are machined, which have sufficient surface hardness, good core toughness, better fatigue resistance, heat resistance and corrosion resistance, and less heat treatment deformation performance compared with sintered mold parts, thus ensuring the quality and life of the mold.

[0024] 2. An Al-Si-Sm alloy layer is formed between the main body of the part and the embedded part. Through heat treatment, the coating and the interface between the main body of the part and the embedded part diffuse to form compounds and solid solutions of two or more elements, changing the composition and structure of the surface layer of the main body of the part and the embedded part. This transforms the mechanical bonding into metallurgical bonding, resulting in a tight bond between the embedded part and the main body of the part. The conformal water channels formed by the processing have good unobstructed flow. Moreover, the roughness of the conformal half-groove one and conformal half-groove two can be processed during the processing, increasing the heat transfer rate of the part and improving the cooling and heat transfer effect.

[0025] 3. The resulting conformal water channels are all complete water channels without cutting or welding, thus avoiding leakage.

[0026] 4. The conformal cooling channel is closer to the mold cavity contour surface and is not limited by the structure and shape of the mold parts. It can ensure that the distance from the center of the cross section of the conformal cooling channel to the mold cavity contour surface is consistent, which maximizes the rational design and layout of the cooling water channel system, shortens the cooling time in the thermoforming cycle, and makes the plastic parts cool evenly and with higher cooling efficiency. Attached Figure Description

[0027] Figure 1 This is a three-dimensional structural diagram of the part body formed in step A.

[0028] Figure 2 This is a cross-sectional structural diagram of the part body formed in step A.

[0029] Figure 3 This is a schematic diagram of the three-dimensional structure of the embedded part formed in step B.

[0030] Figure 4 This is a cross-sectional view of the embedded part formed in step B.

[0031] Figure 5 This is a cross-sectional structural diagram of the part body formed in step C.

[0032] Figure 6 This is a cross-sectional view of the embedded part formed in step C.

[0033] Figure 7 This is a three-dimensional structural diagram of the intelligent mold part after processing in step D.

[0034] Figure 8 This is a cross-sectional view of the intelligent mold part after processing in step D.

[0035] In the figure, 1. Part body; 1a. Product outline surface; 1b. Mounting cavity; 2. Inlay; 3. Al-Si-Sm alloy layer; 4. Conformal water channel; 4a. Conformal half-groove one; 4b. Conformal half-groove two. Detailed Implementation

[0036] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings to further illustrate the technical solutions of the present invention. However, the present invention is not limited to these embodiments.

[0037] Example 1

[0038] This intelligent mold part processing method with conformal water channels includes the following steps:

[0039] A. Based on the mold flow analysis results, firstly, design a three-dimensional modeling drawing of an intelligent mold part with conformal water channels 4 using 3D drawing software, and then select mold steel with reference to the three-dimensional modeling drawing to process and form the part body 1 with the product outline surface 1a.

[0040] Then, a mounting cavity 1b is machined on the part body 1, ensuring that the wall thickness of the bottom wall of the mounting cavity 1b is approximately uniform with that of the product contour surface 1a, specifically ensuring that the wall thickness of the bottom wall of the mounting cavity 1b is 3mm. A conformal semi-groove 4a is machined on the inner wall of the mounting cavity 1b, such as... Figure 1 and 2 As shown.

[0041] B. An insert 2, made of ferroalloy material, is formed to conform to the inner contour of the mounting cavity 1b, ensuring a 0.1mm gap between the insert 2 and the inner wall of the mounting cavity 1b after insertion. A corresponding conformal semi-groove 4b is machined on the outer wall of the insert 2, such as... Figure 3 and 4 As shown. The shapes of the conformal semi-groove 4a and conformal semi-groove 4b can be semi-circular, semi-elliptical, or trapezoidal.

[0042] C. An Al-Si-Sm alloy layer 3 is formed on both the inner wall of the mounting cavity 1b and the outer wall of the insert 2. Both Al-Si-Sm alloy layers 3 comprise the following components in the following proportions: Sm: 0.1%; Si: 5%; the remainder being Al. The Al-Si-Sm alloy layers 3 are formed by thermal spraying or hot-dip galvanizing. The thickness of each Al-Si-Sm alloy layer 3 is 0.1 mm. Figure 5 and 6 As shown.

[0043] Then the insert 2 is assembled into the mounting cavity 1b and made to fit tightly with the inner wall of the mounting cavity 1b at 0.1 MPa. The conformal semi-groove 1 4a and conformal semi-groove 2 4b together form the conformal water channel 4.

[0044] D. Under vacuum conditions, the temperature is controlled at 680℃ and held for 10 minutes. The aluminum alloy layers of the main body 1 and the insert 2 have the same chemical composition and can fuse well initially. Then, the temperature is controlled at 500℃ and held for 180 minutes. During this process, Fe and Al atoms diffuse fully. While aluminum atoms diffuse into the interior of the mold steel, iron atoms also enter the diffusion layer and react with Al, Si, Sm, etc. The diffusion reduces the thickness of the original Al layer, and an intermetallic compound (IMC) layer is formed at the interface, whose main components are FeAl and Fe2Al5 phases. At the same time, the silicon element in the alloy layer can lower the melting point of the aluminum alloy, inhibit the growth of Fe2Al5 between iron and aluminum, making the IMC / Fe matrix interface smoother, and also reducing the activity coefficient of Al and reducing the thickness of the Fe-Al IMC layer. Sm significantly increases the diffusion barrier energy, inhibiting the interdiffusion of Fe and Al atoms. The SmAl4 phase formed by Sm and Al significantly refines the crystal structure of Fe2Al5 at the interface. Through the interaction and coupling of various alloying elements, the Fe / Al interface reaction is jointly influenced. This leads to the interdiffusion of compounds and solid solutions of two or more elements at the interface between the coating, the main body 1, and the insert 2. This alters the composition and microstructure of the main body and the surface layer of the insert 2, transforming the mechanical bonding into a metallurgical bonding. This results in a tight bond between the insert 2 and the main body 1, completing the processing to form an intelligent mold part with conformal water channels 4, such as... Figure 7 and 8 As shown.

[0045] In addition, the mold parts after processing are further precision-machined to ensure that their dimensions and tolerances meet the technical requirements of the three-dimensional model design drawings. Precision machining generally includes polishing and grinding.

[0046] This process differs from conventional techniques by employing machining to create the mold. Specifically, the main body 1, with its mold cavity contour surface, is machined from mold steel. Simultaneously, an insert 2 with a contour consistent with the mounting cavity 1b is machined. Irregular semi-grooves 4a and 4b are machined on the outer walls of both the mounting cavity 1b and the insert 2. The insert 2 and the main body 1 are then heat-treated using an Al-Si-Sm alloy layer 3 to achieve a metallurgical bond. The irregular semi-grooves 4a and 4b interlock to form an irregular water channel 4, eliminating the need for sintering and degreasing. The resulting irregular water channel 4 exhibits good flowability. Furthermore, the roughness of the irregular semi-grooves 4a and 4b can be improved during machining, increasing the heat transfer rate and enhancing the cooling effect. Moreover, the formed conformal water channels 4 are all complete water channels without cutting or welding, thus avoiding leakage. Furthermore, the conformal water channels 4 are closer to the mold cavity contour surface and are not limited by the structure and shape of the mold parts. This ensures that the distance from the center of the cross-section of the conformal water channel 4 to the mold cavity contour surface remains consistent, maximizing the rational design and layout of the cooling water channel system, shortening the cooling time in the thermoforming cycle, and enabling the plastic parts to be cooled evenly with higher cooling efficiency.

[0047] Example 2

[0048] This intelligent mold part processing method with conformal water channels includes the following steps:

[0049] A. Based on the mold flow analysis results, firstly, design a three-dimensional modeling drawing of an intelligent mold part with conformal water channels 4 using 3D drawing software, and then select mold steel with reference to the three-dimensional modeling drawing to process and form the part body 1 with the product outline surface 1a.

[0050] Then, a mounting cavity 1b is machined on the part body 1, ensuring that the wall thickness of the bottom wall of the mounting cavity 1b is approximately uniform with that of the product contour surface 1a, specifically ensuring that the wall thickness of the bottom wall of the mounting cavity 1b is 5mm. A conformal semi-groove 4a is machined on the inner wall of the mounting cavity 1b, such as... Figure 1 and 2 As shown.

[0051] B. An insert 2, made of ferroalloy material, is formed to conform to the inner contour of the mounting cavity 1b, ensuring a 0.4mm gap between the insert 2 and the inner wall of the mounting cavity 1b after insertion. A corresponding conformal semi-groove 4b is machined on the outer wall of the insert 2, such as... Figure 3 and 4 As shown. The shapes of the conformal semi-groove 4a and conformal semi-groove 4b can be semi-circular, semi-elliptical, or trapezoidal.

[0052] C. An Al-Si-Sm alloy layer 3 is formed on both the inner wall of the mounting cavity 1b and the outer wall of the insert 2. Both Al-Si-Sm alloy layers 3 have the following composition ratio: Sm: 0.55%; Si: 9%; the remainder is Al. The Al-Si-Sm alloy layers 3 are formed by thermal spraying or hot-dip plating, and the thickness of each Al-Si-Sm alloy layer 3 is 0.25 mm. Figure 5 and 6 As shown.

[0053] Then the insert 2 is assembled into the mounting cavity 1b and made to fit tightly with the inner wall of the mounting cavity 1b at 0.2 MPa. The conformal semi-groove 4a and conformal semi-groove 4b together form the conformal water channel 4.

[0054] D. Under vacuum conditions, the temperature is controlled at 735℃ and held for 6 minutes. The aluminum alloy layers of the main body 1 and the insert 2 have the same chemical composition and can fuse well initially. Then, the temperature is controlled at 530℃ and held for 102 minutes. During this process, Fe and Al atoms diffuse fully. While aluminum atoms diffuse into the interior of the mold steel, iron atoms also enter the diffusion layer and react with Al, Si, Sm, etc. The diffusion reduces the thickness of the original Al layer, and an intermetallic compound (IMC) layer is formed at the interface, whose main components are FeAl and Fe2Al5 phases. At the same time, the silicon element in the alloy layer can lower the melting point of the aluminum alloy, inhibit the growth of Fe2Al5 between iron and aluminum, making the IMC / Fe matrix interface smoother, and also reducing the activity coefficient of Al and reducing the thickness of the Fe-Al IMC layer. Sm significantly increases the diffusion barrier energy, inhibiting the interdiffusion of Fe and Al atoms. The SmAl4 phase formed by Sm and Al significantly refines the crystal structure of Fe2Al5 at the interface. Through the interaction and coupling of various alloying elements, the Fe / Al interface reaction is jointly influenced. This leads to the interdiffusion of compounds and solid solutions of two or more elements at the interface between the coating, the main body 1, and the insert 2. This alters the composition and microstructure of the main body and the surface layer of the insert 2, transforming the mechanical bonding into a metallurgical bonding. This results in a tight bond between the insert 2 and the main body 1, completing the processing to form an intelligent mold part with conformal water channels 4, such as... Figure 7 and 8 As shown.

[0055] In addition, the mold parts after processing are further precision-machined to ensure that their dimensions and tolerances meet the technical requirements of the three-dimensional model design drawings. Precision machining generally includes polishing and grinding.

[0056] This process differs from conventional techniques by employing machining to create the mold. Specifically, the main body 1, with its mold cavity contour surface, is machined from mold steel. Simultaneously, an insert 2 with a contour consistent with the mounting cavity 1b is machined. Irregular semi-grooves 4a and 4b are machined on the outer walls of both the mounting cavity 1b and the insert 2. The insert 2 and the main body 1 are then heat-treated using an Al-Si-Sm alloy layer 3 to achieve a metallurgical bond. The irregular semi-grooves 4a and 4b interlock to form an irregular water channel 4, eliminating the need for sintering and degreasing. The resulting irregular water channel 4 exhibits good flowability. Furthermore, the roughness of the irregular semi-grooves 4a and 4b can be improved during machining, increasing the heat transfer rate and enhancing the cooling effect. Moreover, the formed conformal water channels 4 are all complete water channels without cutting or welding, thus avoiding leakage. Furthermore, the conformal water channels 4 are closer to the mold cavity contour surface and are not limited by the structure and shape of the mold parts. This ensures that the distance from the center of the cross-section of the conformal water channel 4 to the mold cavity contour surface remains consistent, maximizing the rational design and layout of the cooling water channel system, shortening the cooling time in the thermoforming cycle, and enabling the plastic parts to be cooled evenly with higher cooling efficiency.

[0057] Example 3

[0058] This intelligent mold part processing method with conformal water channels includes the following steps:

[0059] A. Based on the mold flow analysis results, firstly, design a three-dimensional modeling drawing of an intelligent mold part with conformal water channels 4 using 3D drawing software, and then select mold steel with reference to the three-dimensional modeling drawing to process and form the part body 1 with the product outline surface 1a.

[0060] Then, a mounting cavity 1b is machined on the part body 1, ensuring that the wall thickness of the bottom wall of the mounting cavity 1b is approximately uniform with that of the product contour surface 1a, specifically ensuring that the wall thickness of the bottom wall of the mounting cavity 1b is 8mm. A conformal semi-groove 4a is machined on the inner wall of the mounting cavity 1b, such as... Figure 1 and 2 As shown.

[0061] B. An insert 2, made of ferroalloy material, is formed to conform to the inner wall contour of the mounting cavity 1b, ensuring a 0.75mm gap between the insert 2 and the inner wall of the mounting cavity 1b after insertion. A corresponding conformal semi-groove 4b is machined on the outer wall of the insert 2, such as... Figure 3 and 4 As shown. The shapes of the conformal semi-groove 4a and conformal semi-groove 4b can be semi-circular, semi-elliptical, or trapezoidal.

[0062] C. An Al-Si-Sm alloy layer 3 is formed on both the inner wall of the mounting cavity 1b and the outer wall of the insert 2. Both Al-Si-Sm alloy layers 3 have the following composition ratio: Sm: 1.0%; Si: 12%; the remainder is Al. The Al-Si-Sm alloy layers 3 are formed by thermal spraying or hot-dip galvanizing. The thickness of each Al-Si-Sm alloy layer 3 is 0.45 mm. Figure 5 and 6 As shown.

[0063] Then the insert 2 is assembled into the mounting cavity 1b and made to fit tightly with the inner wall of the mounting cavity 1b at 0.3 MPa. The conformal semi-groove 1 4a and conformal semi-groove 2 4b together form the conformal water channel 4.

[0064] D. Under vacuum conditions, the temperature is controlled at 790℃ and held for 2 minutes. The aluminum alloy layers of the main body 1 and the insert 2 have the same chemical composition and can fuse well initially. Then, the temperature is controlled at 560℃ and held for 25 minutes. During this process, Fe and Al atoms diffuse fully. While aluminum atoms diffuse into the interior of the mold steel, iron atoms also enter the diffusion layer and react with Al, Si, Sm, etc. The diffusion reduces the thickness of the original Al layer, and an intermetallic compound (IMC) layer is formed at the interface, whose main components are FeAl and Fe2Al5 phases. At the same time, the silicon element in the alloy layer can lower the melting point of the aluminum alloy, inhibit the growth of Fe2Al5 between iron and aluminum, making the IMC / Fe matrix interface smoother, and also reducing the activity coefficient of Al and reducing the thickness of the Fe-Al IMC layer. Sm significantly increases the diffusion barrier energy, inhibiting the interdiffusion of Fe and Al atoms. The SmAl4 phase formed by Sm and Al significantly refines the crystal structure of Fe2Al5 at the interface. Through the interaction and coupling of various alloying elements, the Fe / Al interface reaction is jointly influenced. This leads to the interdiffusion of compounds and solid solutions of two or more elements at the interface between the coating, the main body 1, and the insert 2. This alters the composition and microstructure of the main body and the surface layer of the insert 2, transforming the mechanical bonding into a metallurgical bonding. This results in a tight bond between the insert 2 and the main body 1, completing the processing to form an intelligent mold part with conformal water channels 4, such as... Figure 7 and 8 As shown.

[0065] In addition, the mold parts after processing are further precision-machined to ensure that their dimensions and tolerances meet the technical requirements of the three-dimensional model design drawings. Precision machining generally includes polishing and grinding.

[0066] This process differs from conventional techniques by employing machining to create the mold. Specifically, the main body 1, with its mold cavity contour surface, is machined from mold steel. Simultaneously, an insert 2 with a contour consistent with the mounting cavity 1b is machined. Irregular semi-grooves 4a and 4b are machined on the outer walls of both the mounting cavity 1b and the insert 2. The insert 2 and the main body 1 are then heat-treated using an Al-Si-Sm alloy layer 3 to achieve a metallurgical bond. The irregular semi-grooves 4a and 4b interlock to form an irregular water channel 4, eliminating the need for sintering and degreasing. The resulting irregular water channel 4 exhibits good flowability. Furthermore, the roughness of the irregular semi-grooves 4a and 4b can be improved during machining, increasing the heat transfer rate and enhancing the cooling effect. Moreover, the formed conformal water channels 4 are all complete water channels without cutting or welding, thus avoiding leakage. Furthermore, the conformal water channels 4 are closer to the mold cavity contour surface and are not limited by the structure and shape of the mold parts. This ensures that the distance from the center of the cross-section of the conformal water channel 4 to the mold cavity contour surface remains consistent, maximizing the rational design and layout of the cooling water channel system, shortening the cooling time in the thermoforming cycle, and enabling the plastic parts to be cooled evenly with higher cooling efficiency.

[0067] Example 4

[0068] This intelligent mold part processing method with conformal water channels includes the following steps:

[0069] A. Based on the mold flow analysis results, firstly, design a three-dimensional modeling drawing of an intelligent mold part with conformal water channels 4 using 3D drawing software, and then select mold steel with reference to the three-dimensional modeling drawing to process and form the part body 1 with the product outline surface 1a.

[0070] Then, a mounting cavity 1b is machined on the part body 1, ensuring that the wall thickness of the bottom wall of the mounting cavity 1b is approximately uniform with that of the product contour surface 1a, specifically ensuring that the wall thickness of the bottom wall of the mounting cavity 1b is 7mm. A conformal semi-groove 4a is machined on the inner wall of the mounting cavity 1b, such as... Figure 1 and 2 As shown.

[0071] B. An insert 2, made of ferroalloy material, is formed to conform to the inner contour of the mounting cavity 1b, ensuring a 0.6mm gap between the insert 2 and the inner wall of the mounting cavity 1b after insertion. A corresponding conformal semi-groove 4b is machined on the outer wall of the insert 2, such as... Figure 3 and 4 As shown. The shapes of the conformal semi-groove 4a and conformal semi-groove 4b can be semi-circular, semi-elliptical, or trapezoidal.

[0072] C. An Al-Si-Sm alloy layer 3 is formed on both the inner wall of the mounting cavity 1b and the outer wall of the insert 2. Both Al-Si-Sm alloy layers 3 have the following composition ratio: Sm: 0.85%; Si: 11%; the remainder is Al. The Al-Si-Sm alloy layers 3 are formed by thermal spraying or hot-dip plating, and the thickness of each Al-Si-Sm alloy layer 3 is 0.4 mm. Figure 5 and 6 As shown.

[0073] Then the insert 2 is assembled into the mounting cavity 1b and made to fit tightly with the inner wall of the mounting cavity 1b at 0.25 MPa. The conformal semi-groove 1 4a and conformal semi-groove 2 4b together form the conformal water channel 4.

[0074] D. Under vacuum conditions, the temperature is controlled at 745℃ and held for 5 minutes. The aluminum alloy layers of the main body 1 and the insert 2 have the same chemical composition and can fuse well initially. Then, the temperature is controlled at 500℃ and held for 130 minutes. During this process, Fe and Al atoms diffuse fully. While aluminum atoms diffuse into the interior of the mold steel, iron atoms also enter the diffusion layer and react with Al, Si, Sm, etc. The diffusion reduces the thickness of the original Al layer, and an intermetallic compound (IMC) layer is formed at the interface, whose main components are FeAl and Fe2Al5 phases. At the same time, the silicon element in the alloy layer can lower the melting point of the aluminum alloy, inhibit the growth of Fe2Al5 between iron and aluminum, making the IMC / Fe matrix interface smoother, and also reducing the activity coefficient of Al and the thickness of the Fe-Al IMC layer. Sm significantly increases the diffusion barrier energy, inhibiting the interdiffusion of Fe and Al atoms. The SmAl4 phase formed by Sm and Al significantly refines the crystal structure of Fe2Al5 at the interface. Through the interaction and coupling of various alloying elements, the Fe / Al interface reaction is jointly influenced. This leads to the interdiffusion of compounds and solid solutions of two or more elements at the interface between the coating, the main body 1, and the insert 2. This alters the composition and microstructure of the main body and the surface layer of the insert 2, transforming the mechanical bonding into a metallurgical bonding. This results in a tight bond between the insert 2 and the main body 1, completing the processing to form an intelligent mold part with conformal water channels 4, such as... Figure 7 and 8 As shown.

[0075] In addition, the mold parts after processing are further precision-machined to ensure that their dimensions and tolerances meet the technical requirements of the three-dimensional model design drawings. Precision machining generally includes polishing and grinding.

[0076] This process differs from conventional techniques by employing machining to create the mold. Specifically, the main body 1, with its mold cavity contour surface, is machined from mold steel. Simultaneously, an insert 2 with a contour consistent with the mounting cavity 1b is machined. Irregular semi-grooves 4a and 4b are machined on the outer walls of both the mounting cavity 1b and the insert 2. The insert 2 and the main body 1 are then heat-treated using an Al-Si-Sm alloy layer 3 to achieve a metallurgical bond. The irregular semi-grooves 4a and 4b interlock to form an irregular water channel 4, eliminating the need for sintering and degreasing. The resulting irregular water channel 4 exhibits good flowability. Furthermore, the roughness of the irregular semi-grooves 4a and 4b can be improved during machining, increasing the heat transfer rate and enhancing the cooling effect. Moreover, the formed conformal water channels 4 are all complete water channels without cutting or welding, thus avoiding leakage. Furthermore, the conformal water channels 4 are closer to the mold cavity contour surface and are not limited by the structure and shape of the mold parts. This ensures that the distance from the center of the cross-section of the conformal water channel 4 to the mold cavity contour surface remains consistent, maximizing the rational design and layout of the cooling water channel system, shortening the cooling time in the thermoforming cycle, and enabling the plastic parts to be cooled evenly with higher cooling efficiency.

[0077] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

[0078] Although this document frequently uses terms such as part body 1, product contour surface 1a, mounting cavity 1b, insert 2, Al-Si-Sm alloy layer 3, conformal water channel 4, conformal semi-groove 1 4a, and conformal semi-groove 2 4b, the possibility of using other terms is not excluded. These terms are used merely for the convenience of describing and explaining the essence of the invention; interpreting them as any additional limitation would contradict the spirit of the invention.

Claims

1. A method for processing intelligent mold parts with conformal water channels, characterized in that, Includes the following steps: A. Based on the mold flow analysis results, select mold steel to process and form a part body (1) with a product contour surface (1a). Process a mounting cavity (1b) on the part body (1) and ensure that the bottom wall of the mounting cavity (1b) and the wall thickness of the product contour surface (1a) are uniform. Process a conformal semi-groove (4a) on the inner wall of the mounting cavity (1b). B. An insert (2) made of iron alloy material is formed to have the same inner wall contour as the mounting cavity (1b), and a corresponding conformal semi-groove (4b) is formed on the outer wall of the insert (2). C. An Al-Si-Sm alloy layer (3) is formed on the inner wall of the mounting cavity (1b) and the outer wall of the insert (2). The insert (2) is assembled into the mounting cavity (1b) so that it fits tightly with the inner wall of the mounting cavity (1b). The conformal semi-groove one (4a) and conformal semi-groove two (4b) together form a conformal water channel (4). D. Heat treatment in a vacuum environment makes the insert (2) and the part body (1) tightly bonded together, and completes the processing to form an intelligent mold part with conformal water channels (4).

2. The method for processing intelligent mold parts with conformal water channels according to claim 1, characterized in that, In step A, based on the mold flow analysis results, a three-dimensional modeling design drawing of an intelligent mold part with conformal water channels (4) is first designed using 3D drawing software. Then, mold steel is selected and processed to form a part body (1) with a product outline surface (1a) by referring to the three-dimensional modeling design drawing.

3. The method for processing intelligent mold parts with conformal water channels according to claim 1 or 2, characterized in that, In step A, ensure that the wall thickness of the bottom wall of the mounting cavity (1b) and the product contour surface (1a) is 3 to 8 mm.

4. The method for processing intelligent mold parts with conformal water channels according to claim 1 or 2, characterized in that, In step B, it is ensured that the processed insert (2) has a gap of 0.1 to 0.75 mm between it and the inner wall of the mounting cavity (1b) after being inserted into the mounting cavity (1b).

5. The method for processing intelligent mold parts with conformal water channels according to claim 4, characterized in that, In step C, the thickness of the Al-Si-Sm alloy layer (3) is 0.1 to 0.45 mm.

6. The method for processing intelligent mold parts with conformal water channels according to claim 5, characterized in that, In step C, the Al-Si-Sm alloy layer (3) comprises the following components in the following proportions: Sm: 0.1% to 1.0%; Si: 5% to 12%; the remainder is Al.

7. The method for processing intelligent mold parts with conformal water channels according to claim 6, characterized in that, In step C, the Al-Si-Sm alloy layer (3) is formed by thermal spraying or hot-dip plating.

8. The method for processing intelligent mold parts with conformal water channels according to claim 7, characterized in that, In step C, the insert (2) is assembled into the mounting cavity (1b) and subjected to a pressure of 0.1 to 0.3 MPa to ensure a tight fit with the inner wall of the mounting cavity (1b).

9. The method for processing intelligent mold parts with conformal water channels according to claim 1 or 2, characterized in that, In step D, the specific steps of the heat treatment are as follows: under vacuum, the temperature is controlled at 680-790℃ and held for 2-10 minutes; then the temperature is controlled at 500-560℃ and held for 25-180 minutes.

10. The method for processing intelligent mold parts with conformal water channels according to claim 1 or 2, characterized in that, In step D, the mold parts that have been processed are also subjected to finishing treatment.

Images