Manufacturing process for a component with a cooling channel system

Abstract

Method for manufacturing a component (100) with a cooling channel system, comprising: - Construction of a first section (10) of the component (100) by additive, material-bonded application of a build-up material, - Inserting a first cavity (11) with an opening into the first section (10) of the component (100), characterized in that the method further comprises: - partial or complete covering of the opening of the first cavity (11) in the first section (10) by a cover part (13), - Construction of a second section (20) of the component (100) by additively applying the build-up material in a material-bonded manner, wherein the build-up material is applied at least to the cover part (13) and, if necessary, additionally to the first section (10), - Inserting a second cavity (21) into the second section (20) of the component, - Introducing a connecting channel (90; 90a) into the component (100) at least partially by material removal to form the cooling channel system, wherein the connecting channel connects the second cavity (21) of the second section (20) with the first cavity (11) of the first section (10) of the component (100).

Description

Technical field

[0001] The present invention relates to a method for manufacturing a component with a cooling channel system. Background of the invention

[0002] A commonly used method in industrial manufacturing is, for example, injection molding, in which a liquefied material is injected under pressure into a shaping mold insert or injection mold, cools down in it and returns to a solid state.

[0003] This primary forming process is frequently used in plastics processing and enables complex shaping of the resulting product. Cooling, necessary for solidifying the material, is of particular importance in such a process, as it significantly impacts process times.

[0004] It is known that such cooling of the injected material is advantageously achieved via the mold insert or the injection mold. For heat dissipation, cooling channels are typically provided within the mold insert or the injection mold, through which a suitable coolant flows, thus cooling the mold insert or the injection mold and consequently the material contained therein.

[0005] Generally, the production of tools that are exposed to elevated temperatures during use, such as injection molds, forming tools, extrusion dies, etc., is complex. In particular, the integration of cooling channels within the tool is often difficult due to the typically very complex geometric shapes of the tools, as the cooling channels can usually only be created by drilling into the finished tool.

[0006] In the prior art document DE 10 2004 040 929 A1, for example, a method is described in which a tool with a coolant channel is manufactured as a component using an additive manufacturing process, whereby a coolant channel is formed within the tool during the additive build-up. The method shown in document DE 10 2004 040 929 A1 utilizes the possibilities of additive manufacturing, which are particularly applicable to components with a high degree of customization or components with complex geometries, and therefore make it possible to incorporate recesses, among other features, within the component during the additive build-up process.

[0007] However, the possibilities for efficiently cooling a component manufactured in this way are limited.

[0008] Further state of the art is also known from AU 2017 221 880 A1, DE 202 21 730 U1, US 2019 / 0 373 772 A1, US 2002 / 0 165 634 A1, DE 198 34 238 A1 and the following two journal publications: - GRZESIK, Wit: Hybrid additive and subtractive manufacturing processes and systems: a review. In: Journal of machine engineering, Vol. 18, 2018, No. 4, pp. 5-24. - ISSN 1895-7595; - LI, CL ; LI, CG ; MOK, ACK: Automatic layout design of plastic injection mold cooling system. In: Computer-aided design, Vol. 37, 2005, No. 7, pp. 645-662. - ISSN 0010-4485. Summary of the invention

[0009] One object of the present invention is therefore to provide a method for manufacturing a component with improved heat dissipation.

[0010] To solve this problem, a method for manufacturing a component with a cooling channel system according to claim 1 is proposed.

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

[0012] According to a first aspect of the invention, the method for manufacturing a component with a cooling channel system comprises constructing a first section of the component by additively applying a build-up material and introducing a first cavity with an opening into the first section of the component.The method is characterized in that it further comprises covering the opening of the first cavity in the first section with a cover part, building up a second section of the component by additively applying the build-up material in a material-bonded manner, wherein the build-up material is applied to the first section and to the cover part; introducing a second cavity into the second section of the component and introducing a connecting channel into the component by machining, at least partially, to form the cooling channel system, wherein the connecting channel connects the second cavity of the second section with the first cavity of the first section of the component.

[0013] Optionally, the cover plate can be securely fixed after insertion by applying, for example, an additive weld bead. This may be necessary, for instance, if several cover plates are used on a workpiece being machined on a 5-axis system, positioned in different directions relative to gravity, to prevent them from falling out. Alternatively, a cover plate can also be fixed by spot welding.

[0014] The inventive method enables the production of components with complex geometric shapes and a cooling channel system running within the component, which is designed to convey a coolant and also has a complex geometric shape, in a particularly advantageous manner.

[0015] The cooling channel system running within the component is formed during the build process by additively applying the build material (= additive build-up) to the individual sections of the component. This allows the geometric arrangement of the cooling channel system, which is determined by the positions of the cavities and the connecting channel within the component, to be advantageously adapted to the complex final geometry of the component being manufactured. This ensures that the cooling channel system, at least in sections, follows the outer contour surfaces of the component. "Following in sections" here refers to an arrangement of the cooling channel system in which the flow direction of the coolant flowing through the cooling channel system is essentially parallel to an outer contour surface of the component.

[0016] The integration of such an internal cooling channel system is generally not possible in the case of complex component geometries by simply inserting it in the form of bores after the primary forming process.

[0017] Until now, the insertion of the boreholes using conventional methods was limited by the component geometry and the possibilities of the drilling process, meaning that only cooling channel systems with an extremely simple geometric arrangement could be inserted.

[0018] The inventive method utilizes the synergy of a build-up by additive material-bonding application of the build-up material (=additive build-up) and a material-removing machining process to form the cooling channel system running therein, among other things by introducing the connecting channel.

[0019] The method according to the invention is therefore a hybrid manufacturing process with an alternating sequence of additive build-up steps and material-removing machining steps.

[0020] The method according to the invention makes it possible in particular to realize near-net-shape cooling channel systems, which significantly improves heat dissipation through a coolant flowing therein.

[0021] Furthermore, areas of the component that are subject to particularly high thermal stress during application can be advantageously cooled efficiently by introducing a cavity with a cross-section larger than that of the connecting channel, using the coolant flowing through the cavity.

[0022] Covering the opening of the first cavity in the first section with an advantageously flat and / or planar cover enables the additive construction of the second section by applying the build-up material, wherein the first cavity is completely enclosed within the component and the first cavity has a simple geometric shape with a planar interface or interface geometry facing the second section.

[0023] Closing the opening of a cavity located entirely within the finished component by purely additively applying the build-up material (without a cover) is only possible by adhering to specific, typically non-planar, interface geometries. Creating an interface geometry in the form of a flat surface (without a cover) is not possible due to the nature of the process; therefore, pyramidal or conical interface geometries are usually built up through additive application; for example, in a roof shape.

[0024] Such non-planar interface geometries of the cavities prove to be disadvantageous in many respects.

[0025] Firstly, such interface geometries represent undesirable stagnation points for coolant flowing through the cooling channel system, and thus also a deterioration of the heat dissipation that occurs as a result.

[0026] On the other hand, such often pointed interface geometries (pyramidal or conical) represent potential weak points in the sense of a predetermined breaking point (notch factor), where, in the event of mechanical stress on the component, excessive stress peaks can occur within the component, as a result of which the component can fail at the corresponding point (crack, fracture, plastic deformation, etc.).

[0027] By constructing the component in sections according to the invention, the connecting channel can be introduced in a way that would not be possible after the complete additive manufacturing of the component.

[0028] The connecting channel is advantageously introduced from the second cavity in the second section of the component towards the first cavity in the first section, in order to establish a connection to the first cavity arranged within the component after the construction of the second section, and thus to form the cooling channel system.

[0029] The access of a tool designed for material removal is advantageously achieved via the opening of the second cavity of the second section. Preferably, the second cavity has a suitable geometry that does not impede the insertion of the connecting channel by the tool, so that, for example, a drill head designed for machining can penetrate the component through the opening of the second cavity without damaging it.

[0030] Advantageously, by introducing the connection channels, at least partially based on material removal, a higher surface quality with smoother surface structures of the surfaces of the component adjacent to the connection channel can be created in relation to the other surfaces produced by additive manufacturing.

[0031] Surfaces created through additive manufacturing by the material-bonding application of the building material generally exhibit a surface structure or surface finish with higher roughness values ​​and lower surface quality than surfaces created by material removal, especially machining.

[0032] The high surface quality of the connecting channel, with its smooth surface structure and lower roughness values, improves the flow of coolant through the channel, as it results in less flow resistance. In channels or pipes with rough surfaces, turbulent flow occurs in the surface areas, leading to an increase in flow resistance and consequently impeding flow.

[0033] By introducing the connecting channel based on material removal, the flow resistance of a flowing coolant can be significantly reduced compared to a connecting channel manufactured solely through additive manufacturing, which in turn has a positive effect on heat dissipation, since higher flow rates or flow velocities of the flowing coolant are achieved with lower flow resistance and otherwise identical boundary conditions (pressure difference, channel cross-section).

[0034] However, it is also possible, in principle, to introduce the connecting channel section by section using an additive process, by omitting corresponding areas during material application.

[0035] The method according to the invention is in no way limited to a single first cavity in the first section and / or a single second cavity in the second section. Depending on the geometry of the component to be manufactured, several cavities can be provided in the individual sections of the component, which can be interconnected across sections via a corresponding number of connecting channels to form the cooling channel system; thus, several connecting channels can also open into a single cavity to form the cooling channel system.

[0036] For example, it is possible to create two separate cavities in the first section, which, after the construction of the second section, are connected to a cavity created in the second section by the introduction of two connecting channels. These two connecting channels both open into the cavity of the second section and connect it to the two cavities in the first section.

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

[0038] Improving the heat dissipation of a component includes, among other things, increasing its cooling rates / speeds when used under thermal stress, for example, as a tool in a manufacturing process, thus enabling shorter cycle times. Heat dissipation is achieved through the coolant flowing through the cooling channel system, which absorbs the heat conducted through the component and carries it away.

[0039] In a preferred embodiment of the method, the introduction of the first and / or possibly further cavities is carried out at least section by material removal following the construction of the respective sections.

[0040] In a particularly preferred embodiment of the method, the material removal process for creating the first and / or second cavity is a machining process.

[0041] The creation of the cavities by machining is particularly advantageous because it results in a high surface quality on the surfaces of the component adjacent to the cavities, especially in relation to surfaces created by purely additive application of the build-up material, thereby reducing the flow resistance within the cooling channel system.

[0042] In a further preferred embodiment of the method, the introduction of the first and / or the second cavity during the construction of the respective sections is achieved by omitting the corresponding areas during the additive, material-bonded application of the build-up material.

[0043] By omitting the cavities during the application of the build-up material, they can be advantageously incorporated during the build-up of the respective sections, leading to a reduction in manufacturing costs, manufacturing time and savings in build-up material.

[0044] In a particularly preferred embodiment of the method, the surfaces of the sections adjacent to the cavities introduced during the assembly of the sections are post-processed by machining.

[0045] The machining of said surfaces improves their surface quality, especially in relation to surfaces created by a purely additive application of the build-up material, thereby reducing the flow resistance within the cooling channel system.

[0046] In contrast to the additive manufacturing process, where one of the cavities is created by simply removing material without prior omission, tooling costs can also be reduced, since only one surface is machined and not the entire cavity itself is created by removing material.

[0047] In a particularly preferred embodiment of the method, this further comprises partially or completely covering an opening of the second cavity of the second section by a cover part and building up a further section of the component by additively applying the build-up material in a material-bonded manner, wherein the build-up material is applied to the second section and to the cover part of the opening of the second cavity.

[0048] This seals the opening of the second cavity with build-up material, so that the component has a cooling channel system that lies completely inside it.

[0049] In a particularly preferred embodiment of the method, this further comprises the following steps: ZS1: Introducing at least one additional cavity with an opening into one of the previously constructed sections of the component, wherein the introduction of the additional cavity is carried out following the construction of the previously constructed section by material removal or during the construction of the previously constructed section by omissions during the additive, material-bonded application of the build-up material. ZS2: Introducing one or more connecting channels into the component by material removal for further development of the cooling channel system, wherein the connecting channel(s) connect the at least one further cavity from step ZS1 with the previously introduced cavity(ies) in the previously constructed sections of the component. ZS3: At least partial covering of the opening of the further cavity from step ZS1 by a cover part. ZS4: Construction of one or more further sections of the component by additive, material-bonded application of the construction material, wherein the construction material is applied to one or more of the previously constructed sections and to the cover part of the preceding step ZS3.

[0050] Optionally, the cover part can be securely fixed after insertion in step ZS3 by applying, for example, an additive weld bead. This may be necessary, for instance, if several cover parts are used on a workpiece being machined on a 5-axis system, positioned in different directions relative to gravity, to prevent them from falling out. Alternatively, a cover plate used for this purpose can also be fixed by spot welding.

[0051] In a particularly preferred embodiment of the method, these steps can be repeated multiple times, so that by several repetitions of the process step sequence ZS1 to ZS4 a component with a plurality of sections and a cooling channel system formed within the component, which consists of a plurality of cavities and a plurality of connecting channels for connecting the plurality of cavities, is produced.

[0052] This allows components with complex geometries, especially external geometries, and a cooling channel system running inside the component that is advantageously adapted to the complex geometry to be manufactured.

[0053] The number of cavities per section of the component is not limited to one, so that individual sections can also have several incorporated cavities, which contribute to the advantageous design of the cooling channel system.

[0054] In a particularly preferred embodiment of the method, the material removal process for introducing the connecting channel(s) is a machining process.

[0055] Through machining, a high surface quality can be achieved on the surfaces of the component adjacent to the connecting channels, especially in relation to surfaces created by purely additive application of the build-up material, thereby reducing the flow resistance within the cooling channel system.

[0056] In a particularly preferred embodiment of the method, the additive, material-bonded application of the build-up material is carried out by cladding welding with laser or arc.

[0057] In a particularly preferred embodiment of the method, the supply of the build-up material during application by cladding welding is in the form of powder and / or wire.

[0058] In a particularly preferred embodiment of the method, recessed shoulders adapted to the geometries of the cover parts designed to cover the respective openings are formed in an area around the opening(s) of one or more of the cavities in the respective sections by material removal machining, such that the respective cover parts are held in position in a form-fitting manner to cover the respective openings.

[0059] This simplifies the insertion of the cover part(s) to cover the opening(s) and the subsequent additive assembly on the respective cover part, as the respective cover part is held in position relative to the component and does not shift due to unwanted vibrations or the like.

[0060] In a particularly preferred embodiment of the method, one or more of the cover parts are sheet metal discs or sheet metal covers.

[0061] In a particularly preferred embodiment of the method, geometries of the cavities are selected from a set of predetermined standard geometries of the cavities.

[0062] This enables largely standardized manufacturing, since not just any geometries are selected for the cavities, but rather a selection is made from a set of predetermined standard geometries according to a modular principle. The resulting standardization allows for the optimization of further process steps, particularly with regard to the design of the cover parts, which, in a particularly preferred embodiment of the method, are similarly selected from a set of prefabricated cover parts geometrically adapted to the standard geometries of the cavities.

[0063] The cover parts can therefore be prefabricated in large quantities and can be used directly to cover cavities with standard geometry according to the modular principle.

[0064] This leads to a reduction in manufacturing costs, as individual production of the cover parts is eliminated and, in addition, manufacturing times for the production of components can be reduced by the inventive method.

[0065] In a particularly preferred embodiment, the standard geometries of the cavities generally have cylindrical shapes.

[0066] These relatively simple geometries can be introduced quickly and easily through material removal processes, especially machining, so that manufacturing times can be further reduced.

[0067] In a particularly preferred embodiment of the method according to the invention, this comprises introducing at least one supply channel and at least one discharge channel for the cooling channel system into the component by material removal machining, wherein the supply channel and the discharge channel are introduced in such a way that the cooling channel system runs continuously from the supply channel to the discharge channel.

[0068] This provides a continuous cooling channel system through which a coolant supplied from outside the component via the supply channel can flow through the cooling channel system inside the component to the discharge channel, thus providing a cooling circuit for cooling or heat dissipation from the component.

[0069] In a particularly preferred embodiment of the method, this further comprises the additive, material-bonded application of a wear-resistant outer layer to a part of an outer contour surface of the component built up from the build-up material.

[0070] Adapted to the later use of the component, e.g. as a tool in other manufacturing and / or production processes, a wear-resistant surface (preferably made of tool steel) can be formed that can withstand even greater mechanical stresses.

[0071] In a particularly preferred embodiment of the method, the additive, material-bonded application of the wear-resistant outer layer is carried out by laser or arc welding, wherein a material used to build up the wear-resistant outer layer is supplied in the form of powder and / or wire.

[0072] In a particularly preferred embodiment of the method, the build-up material further exhibits a thermal conductivity that is greater than the thermal conductivity of the wear-resistant outer layer.

[0073] This allows for the efficient production of a component with improved heat dissipation properties and high wear resistance. The increased thermal conductivity ensures that thermal energy entering the component through the outer layer is quickly transferred from the surface of the outer layer adjacent to the core material to the cooling channel system, resulting in improved heat dissipation throughout the entire component.

[0074] An improved heat dissipation of a component produced by the inventive method aims not only at increasing the cooling rates but also at achieving a local uniformity in the cooling of the component, in particular through the cavities placed in the course of the inventive method in, for example, thermally stressed areas of the component.

[0075] For example, when using the component as a tool, unwanted deformations caused by locally varying cooling rates can be reliably avoided.

[0076] For example, cooling times can be reduced for injection-molded parts and cooling can be improved for hot forming tools to prevent increased local wear.

[0077] Furthermore, an exemplary software-based computer system is proposed, which is characterized in that the computer system is set up for the design planning of a component to be produced by the method according to the invention and includes at least one means for defining a component geometry of the component with cooling channel system.

[0078] In a particularly preferred embodiment, the computer system further comprises a means for determining successive machining steps that can be performed by a numerically controlled machine tool and / or a numerically controlled machining center for the production of the component, a means for deriving control commands to be used by the numerically controlled machine tool and / or the numerically controlled machining center for carrying out the machining steps, and a means for transmitting the control commands to the machine tool and / or the machining center that are set up to carry out the machining steps for the production of the component.

[0079] In a particularly preferred embodiment, the computer system further comprises a CAD and / or a CAM system.

[0080] Further aspects and their advantages, as well as more specific examples of the aforementioned aspects and features, are described below with the aid of the drawings shown in the accompanying figures: Fig. 1a - Fig. Figure 1f shows exemplary cross-sections illustrating the step-by-step production of a component with a cooling channel system using the method according to the invention. Fig. Figure 2 shows a component with a cooling channel system, consisting of several cavities and connecting channels in a perspective transparent view. Fig. 3a - Fig. Figure 3b shows enlarged views of various sub-areas of the component with cooling channel system. Fig. 2. Fig. 4 shows a middle section of the Fig. 2 of the component shown in a perspective cross-sectional view. Fig. Figure 5 shows an embodiment of a method according to the invention for manufacturing a component with a cooling channel system. Detailed character description

[0081] Fig. Figure 1a shows an exemplary component 100 after a first section 10 was built up in the course of the inventive method by additive material bonding of a build-up material (=additive build-up) in a cross-section.

[0082] In the given example, the additive build-up takes place along a build-up direction x.

[0083] A first cavity 11 is placed in the first section 10 in such a way that it has an opening towards an outer surface 15 of the first section 10.

[0084] The introduction of the first cavity 11 can be carried out during the additive manufacturing of the first section 10 by means of recesses at the relevant locations, whereby a post-processing of the surfaces of the first section adjacent to the first cavity 11 is carried out by a material-removing machining operation, in particular a machining operation, in order to improve the surface quality and thus reduce the flow resistance in the cooling channel system.

[0085] Alternatively, the first cavity 11 can be directly introduced into the solid material following the additive build-up of the first section 10 by material removal, in particular machining.

[0086] Furthermore, a step 12 is introduced into the first section 10 at the opening of the first cavity 11 on the outer surface 15 by material removal, which serves for the subsequent insertion of a cover part 13 (see Fig. 1b)

[0087] Fig. Figure 1b shows the component in cross-section after a step of covering the opening of the first cavity 10 by a cover part 13.

[0088] The cover part 13 is advantageously flat and even and has a small thickness in relation to its other dimensions. The cover part completely closes the opening of the first cavity.

[0089] Advantageously, the shoulder 12 incorporated into the first section 10 at the first cavity 10 and the cover part 13 are shaped to fit each other such that a surface of the flat cover part 12 is flush with the outer surface 15 of the first section and preferably forms a flat surface with it. The cover part 13 is preferably held precisely in position by the shoulder 12 in a form-fitting manner.

[0090] Fig. Figure 1c shows the component 100 in cross-section after a subsequent process step for the additive construction of a second section 20.

[0091] The additive build-up of the second section 20 takes place on the first section 10 starting from the outer surface 15 of the first section 10 and the surface of the cover part 13 of the first cavity 11, which is flush with the outer surface 15, along the build-up direction x.

[0092] By covering the opening of the first cavity 11, the additive construction of the second section 20 can also take place on the cover part 13, thus eliminating the need to close the first cavity 11 purely by additive application, using complex pyramidal or cone-shaped geometries, and the first cavity 11 therefore has a geometric shape with essentially parallel opposing side surfaces or top and bottom surfaces.

[0093] The additive construction of the second section 20 is carried out according to the representation in Fig. 1c for the exemplary component 100, starting from the entire outer surface 15 of the first section 10 and from the surface of the cover part 13 which is flush with the outer surface 15, whereby this is not to be understood as a limitation of the method according to the invention. The construction of the second section can generally also take place only on a part of the outer surface 15 (and not the entire outer surface) of the first section 10 of the component 100.

[0094] A cavity, a second cavity 21, is also introduced into the second section 20 of component 100 by material removal machining using one of the methods already described in the course of introducing the first cavity 11 (recesses in additive manufacturing and material removal post-processing or complete introduction by material removal machining).

[0095] Even if the presentation in Fig. While 1c suggests that the first cavity 11 and the second cavity 21 have the same or similar geometric shape with the same or similar dimensions, this need not generally be the case in the method according to the invention.

[0096] The second cavity 21 in the second section 22 is open towards an outer surface 25 of the second section 20.

[0097] Furthermore, in an analogous manner to the procedure used for the first cavity 11, a step 22 was introduced at the opening of the second cavity 21 on the outer surface 25 by material removal.

[0098] Fig. Figure 1d shows the component 100 in cross-section after a subsequent process step for the insertion of a connecting channel 90.

[0099] The connecting channel 90 is introduced into the component 100 by material removal machining in such a way that it connects the first cavity 11 of the first section 10 with the second cavity 21 of the second section 20.

[0100] When connecting the two cavities 11 and 21 through the connecting channel 90 to form a cooling channel system, material is inevitably removed from the cover part 13 enclosed in the component during the additive manufacturing process, as otherwise no connection between the cavities 11 and 21 could be established.

[0101] The material removal process for the introduction of the connecting channel 90 can be carried out, among other things, by laser processing or machining, e.g. using a milling tool or a drill head, whereby machining is preferable due to the high surface quality of the surfaces thus introduced.

[0102] The material removal process, e.g., the insertion of a drill head, is carried out starting from the second cavity 22, whereby, due to the cross-section of the second cavity 21 being larger in relation to the cross-section of the connecting channel 90, the exemplary drill head can be guided through the component 100 to the first cavity 11 without damaging the component 100 in an undesirable way, e.g., by collision with the second section 20 in an area around the second cavity 21.

[0103] Furthermore, the relatively large second cavity 22 allows the exemplary drill head to be inserted obliquely into the component, starting from a perpendicular to the outer surface 25. The ability to insert the connecting channel 90 at a corresponding angle to the perpendicular of the outer surface 25 (without undesirably damaging the second section 20) results in greater flexibility in the design of a cooling channel system within the component 100.

[0104] The connecting channel 90 can therefore be advantageously installed at both steep and shallow angles of inclination with respect to the vertical of the outer surface 25.

[0105] Thus, connection channel 90 can be used according to the representation in Fig. The cooling channel 90 is routed in a partial area of ​​component 100 parallel (or nearly parallel) to another outer surface 26 of component 100. This results in various surface points of the other outer surface 26 having the same (or nearly the same) distance to the connecting channel 90 in such a partial area. This distance should advantageously be chosen to be as small as possible in order to allow the cooling channel system to be routed close to the outer contour and thus improve the dissipation of heat entering component 100, for example through the other outer surface 26, via the cooling channel system through which a coolant flows.When the connecting channel 90 is incorporated in this way as part of the cooling channel system, the component 100 has a largely constant material thickness in this sub-area between the further outer surface 26 and the connecting channel 90, which also allows for a locally uniform heat dissipation in the relevant sub-area.

[0106] Fig. Figure 1e shows the component 100 after an additive build-up of a further (third) part 30 to finalize the exemplary component 100 in cross-section.

[0107] According to the inventive method, the opening of the second cavity 21 on the outer surface 25 in the second section 20 is covered and closed by a cover part 23 adapted to the shoulder 22, wherein here too a surface of the cover part is flush with the outer surface 25.

[0108] The additive construction of the third section 30 takes place on the second section 20 starting from the outer surface 25 of the second section 20 and the surface of the cover part 23 of the second cavity 21, which is flush with the outer surface 25, along the construction direction x.

[0109] Fig. Figure 1f shows the component 100 in cross-section after the cooling channel system has been finalized by the insertion of an inlet channel 91 and an outlet channel 92.

[0110] The inlet and outlet channels 91 and 92 are introduced by material removal machining, whereby the inlet and outlet channels 91 and 92 are introduced into the component 100 in such a way that a subsequent flow of coolant from an inlet Z via the cooling channel system formed by the cavities 21,22, the connecting channel 90 and the inlet and outlet channels 91 and 92 to an outlet A is possible.

[0111] The positions of the inlet Z and outlet A for the coolant are generally not fixed but can optionally be swapped, so that one of the configurations shown in Fig. The flow direction shown in 1f is the reverse flow direction of the coolant flowing through the cooling channel system.

[0112] The inlet and outlet channels 91 and 92 can also be routed through the component 100 in such a way that they at least partially follow an outer surface of the component 100 in order to improve heat dissipation.

[0113] The inlet and outlet channels 91 and 92 are advantageously arranged such that the inlet Z and the outlet A for the coolant into the cooling channel system of the component 100 are located on an outer surface or surfaces that are less relevant for the later use of the component 100, e.g. as an injection mold (A and Z are not necessarily on the same surface or side of the component).

[0114] The in Fig. The component 100 shown in Figure 1f with a finalized cooling channel system illustrates that a cooling channel system with such a complex geometric structure cannot be achieved by material removal machining, e.g. by drilling, following the complete assembly of the component 100, here with the three sections 10, 20 and 30, but is only accessible through the method according to the invention.

[0115] Furthermore, the surfaces of component 100 adjacent to the internal cooling channel system are advantageously finished or at least post-processed by material removal, in particular by machining. This allows for a high surface quality with lower roughness, especially compared to a surface created by purely additive manufacturing. In this way, the flow resistance of a coolant flowing through such a cooling channel system can be significantly reduced, enabling higher flow velocities or higher flow rates, particularly compared to a cooling channel system manufactured by purely additive manufacturing (i.e., without material removal / post-processing), which would inherently have a lower surface quality and thus higher flow resistance for the coolant.

[0116] Fig. Figure 2 shows another component produced by the inventive method with a cooling channel system, which has several cavities and several connecting channels, in a perspective transparent view.

[0117] In contrast to the depictions in the Fig. 1a to 1f shows Fig. 2 a component 100 with a more complex outer geometry and complex geometry of the cooling channel system running inside the component 100.

[0118] The component 100 is manufactured using the method according to the invention, whereby, due to the hybrid nature of the process consisting of alternating additive build-up steps and material-removing machining steps, a cooling channel system can be formed within the component 100, as a result of which the component has improved heat dissipation properties (with a coolant flow).

[0119] The component is built up by additively applying a build-up material to a base body 101 of the component 101 in a material-bonded manner.

[0120] In the process according to the invention, a first cavity 11 and a second cavity 21, as well as two further cavities, a third cavity 31 and a fourth cavity 41, are advantageously provided in the component, each by machining. Additionally, the surfaces adjacent to the cavities 11, 21, 31 and 41 can be post-processed, e.g. by further material removal, to improve the surface finish.

[0121] Advantageously, the cavity geometries are selected from a set of standard geometries, preferably comprising simple cylindrical and / or general cylindrical geometries of various dimensions. General cylindrical geometries are understood to be geometries formed by extruding an arbitrarily shaped base (e.g., circle, ellipse, polygon, etc.) along an extrusion axis.

[0122] The second, third and fourth cavities 21, 31 and 41 have cylindrical shapes with a circular cross-section, with the dimensions of the cylindrical shapes of the individual cavities differing both in diameter of the circular cross-sections and in height of the cylinders.

[0123] In contrast, the first cavity 11 has a generally cylindrical shape with a non-circular cross-section.

[0124] In the course of manufacturing the component by the inventive method, the cavities 11, 21, 31 and 41 are connected to each other to form the cooling channel system by connecting channels 90a, 90b and 90c, which are introduced into the component 100 by material removal, in particular by machining.

[0125] The connecting channel 90a connects the first cavity 11 with the second cavity 21, the connecting channel 90b connects the first cavity 11 with the third cavity 31 and the connecting channel 90c connects the third cavity 31 with the fourth cavity 41.

[0126] One flow direction of a coolant flowing through the cooling channel system would therefore be either in the sequence second cavity 21 -> connecting channel 90a -> first cavity 11 -> connecting channel 90b -> third cavity 31 -> connecting channel 90c -> fourth cavity 41 or in the corresponding reverse sequence possible.

[0127] Starting from the base body 101 of component 100, a supply channel 91 and a discharge channel 92 for the coolant are also incorporated into component 101 by material removal machining to finalize the cooling channel system.

[0128] The determination of the supply channel 91 and the discharge channel 92, and thus a flow direction from the supply channel 91 to the discharge channel 92, is not to be understood as conclusive in this case, since the coolant can also flow through the cooling channel system in a flow direction opposite to this one.

[0129] Fig. Figure 3a shows a perspective section of the component. Fig. 2 in a middle sub-area.

[0130] The section shows that the connecting channels 90a and 90b for connecting the cavities 11, 21 and 31 are incorporated into the component 100 in such a way that they at least partially follow the outer contours or outer contour surfaces of the component 100; that is, they run parallel or approximately parallel to these, and are thus formed close to the final contour.

[0131] Fig. 3b shows the one in Fig. 3a shown section of the component from Fig. 2 in a central sub-area in a side view.

[0132] The side view shows that, in addition to the connecting channels 90a and 90b for connecting the cavities 11, 21 and 31, the drainage channel 92 of the cooling channel system is also incorporated into the component 100 in such a way that it follows at least section by section an outer contour or an outer contour surface of the component 100; i.e., it runs parallel or approximately parallel to it.

[0133] The discharge channel 92 of the cooling channel system empties into the Fig. 3b shown in the representation into the base body 101, from which a connection of the cooling channel system to a coolant supply unit set up for supplying the cooling channel system is made.

[0134] Fig. Figure 3c shows a perspective view of the component. Fig. 2 after an intermediate step of the inventive method for manufacturing the component in an upper sub-area.

[0135] In the illustration shown, the process steps following the insertion of the fourth cavity 41 are the covering of the opening of the fourth cavity 41 on an outer surface 45 by means of a cover part 43 (not shown here, see figure). Fig. 3d) as well as an additive assembly of a final section of the in on the outer surface 45 Fig. The second component shown, 100, has not yet been completed.

[0136] The outer surface 45 is merely an external surface formed in the course of the previous process steps and is not an outer surface of the finished component.

[0137] The additive manufacturing of the component has been carried out up to the outer surface 45.

[0138] Furthermore, a shoulder 42 designed to receive the cover part 43 (not shown here) is formed at the opening of the fourth cavity 41 on the outer surface 45 by material removal, in particular by machining.

[0139] The geometric shape of the shoulder 42 is adapted to the cylindrical shape of the fourth cavity and is designed in such a way that the cover part 43 placed in the course of the subsequent process steps is held in position in a form-fitting manner.

[0140] Fig. 3D shows a perspective section of the component. Fig. 2 after a further intermediate step of the inventive method for manufacturing the component in an upper sub-area.

[0141] Following the in Fig. In the state of the component shown in 3c during the manufacturing process according to the invention, the opening of the fourth cavity 41 on the outer surface 45 has been covered by the cover part 43 adapted to the shoulder 42.

[0142] The cover part 43 is designed such that (matching the recess 42) it can be inserted into the recess 42 to cover the fourth cavity and is positioned there in a form-fitting manner, with one surface of the cover part 42 being slightly recessed relative to the outer surface 45 of the component.

[0143] This creates a defined closure, upon which the final section of the process is additively built in the subsequent process steps. Fig. 2 of the component shown can be done.

[0144] The cover parts used in the process according to the invention, here cover part 43, are preferably selected from a set of prefabricated cover parts geometrically adapted to the standard geometries of the cavities.

[0145] In accordance with the cylindrical geometry of the fourth cavity 41, the cover part 43 has a circular flat geometry adapted to it and is preferably designed as a thin flat sheet metal disc.

[0146] Fig. 4 shows a middle section of the Fig. 2 of the component shown in a perspective cross-sectional view.

[0147] The illustration shows the different material structure of component 100 with cooling channel system.

[0148] The component produced in accordance with the inventive method has a core body 102 made from the assembly material, in which the cooling channel system is formed.

[0149] Furthermore, a wear-resistant outer layer 103 is formed on an outer contour surface of the core body 102 by additive, metallurgical application of another material. This additional material exhibits a higher wear resistance than the base material from which the core body 102 is formed.

[0150] On the other hand, the structural material from which the core body 102 is formed preferably has a higher thermal conductivity than the further material from which the wear-resistant outer layer 103 is formed.

[0151] The combination thus formed advantageously combines the better heat conduction properties of the core body 102, in which the cooling channel system is formed, with the high wear resistance of the wear-resistant outer layer 103.

[0152] In one possible embodiment, the thermally conductive material is copper or a copper alloy, and the wear-resistant outer layer is made of tool steel.

[0153] Since the cooling channel system is introduced into the core body 102 by material removal in the process according to the invention, the machining effort and machining costs can also be reduced, since the more thermally conductive core body 102, e.g. copper alloy, typically has a lower strength than the other material of the wear-resistant outer layer 103, e.g. tool steel, and thus material removal on the core body is simplified.

[0154] An embodiment of a method according to the invention for manufacturing a component with a cooling channel system is described in Fig. 5 schematically represented: In step S1, the first section of the component is built up by additively applying a build-up material in a material-bonded manner. In step S2, a first cavity with an opening is introduced into the first section of the component. In step S3, the opening of the first cavity in the first section is partially or completely covered by a cover part. In step S4, a second section of the component is built up by additively applying the build-up material in a material-bonded manner, whereby the build-up material is applied to the first section and at least to the cover part and, if necessary, additionally to the first section. In step S5, a second cavity is introduced into the second section of the component. In step S6, a connecting channel is introduced into the component, at least partially, by material removal to form the cooling channel system, whereby the connecting channel connects the second cavity of the second section with the first cavity of the first section of the component.

[0155] In this embodiment, the two cavities are created by omitting the corresponding areas during the material application.

[0156] The connecting channel for linking the two cavities is created by machining.

[0157] In a particular embodiment of the illustrated exemplary embodiment, the method additionally includes step S7, in which an opening of the second cavity of the second section, created by omitting the corresponding area, is also partially or completely covered by a cover part.

[0158] In step S8, a further section of the component is then built up by additively applying a build-up material, whereby the build-up material is applied at least to the cover part of the opening of the second cavity and possibly also to the second section in order to ensure a better, material-bonded connection and a closure of the opening.

[0159] As described above, these steps can be repeated to successively build up further sections with cavities, which are then subsequently connected by introducing the connecting channels. According to the invention, the connecting channels are produced at least partially by material removal, while the construction of the cavity is carried out at least partially by additive, material-bonded application of the build-up material within the scope of the present invention.

[0160] Above, exemplary embodiments of the present invention and their advantages have been described in detail with reference to the accompanying figures.

[0161] However, the present invention is in no way limited to the embodiments and features described above and further includes modifications of the aforementioned embodiments, in particular those resulting from modifications and / or combinations of individual or multiple features of the described embodiments within the scope of protection of the independent claims. List of reference symbols 10 first section 11 first cavity 12th paragraph on opening of the first cavity 13 Cover part for covering the first cavity 15 Outer surface of the first section 20 second section 21 second cavity 22 paragraph on opening of the second cavity 23 Cover part for covering the second cavity 25 Outer surface of the second section 26 additional outdoor areas of the second section 31 third cavity 41 fourth cavity 42 paragraph on opening of the fourth cavity 43 Cover part for covering the fourth cavity 45 outdoor area 90, 90a, 90b, 90c connection channel 91 Supply channel 92 Drainage channel 100 components 101 Basic body of the component 102 Core body of the component 103 wear-resistant outer layer Z Inlet A process x Construction direction

Claims

A method for manufacturing a component (100) with a cooling channel system, comprising: - building up a first section (10) of the component (100) by additively applying a build-up material in a material-bonded manner, - introducing a first cavity (11) with an opening into the first section (10) of the component (100), characterized in that the method further comprises: - partially or completely covering the opening of the first cavity (11) in the first section (10) by a cover part (13), - building up a second section (20) of the component (100) by additively applying the build-up material in a material-bonded manner, wherein the build-up material is applied at least to the cover part (13) and optionally to the second section (20).additionally applied to the first section (10),- introduction of a second cavity (21) into the second section (20) of the component,- introduction of a connecting channel (90; 90a) into the component (100) at least partially by material removal to form the cooling channel system, wherein the connecting channel connects the second cavity (21) of the second section (20) with the first cavity (11) of the first section (10) of the component (100). Method according to claim 1, characterized in that the introduction of the first (11) and / or the second cavity (21) and / or the introduction of the connecting channel following the construction of the respective sections (10; 20) is carried out at least partially by material removal. Method according to claim 2, characterized in that the material removal process for introducing the first (11) and / or the second cavity (21) and / or the connecting channel is a machining process. Method according to claim 1, characterized in that the introduction of the first (11) and / or the second cavity (21) and / or the introduction of the connecting channel is carried out at least section by section during the construction of the respective sections (10, 20) by means of omissions during the additive material-bonding application of the build-up material. Method according to claim 4, characterized in that the surfaces of the sections (10; 20) adjacent to the cavities (11; 21) introduced in the course of the construction of the sections (10; 20) are machined by machining. A method according to one of the preceding claims, characterized in that the method further comprises: - partial or complete covering of an opening of the second cavity (21) of the second section (20) by a cover part (23), and - construction of a further section (30; 40) of the component (100) by additively applying the build-up material in a material-bonded manner, wherein the build-up material is applied at least to the cover part (23) of the opening of the second cavity (21) and optionally also to the second section (20). The method according to claim 6, characterized in that the method further comprises the steps: ZS1: introducing further cavities (31; 41) with an opening into one of the previously constructed sections (10; 20) of the component (100), wherein the introduction of the further cavities (31; 41) is carried out following the construction of the respective previously constructed section (10; 20) by material removal or during the construction of the previously constructed section (10; 20) by creating gaps during the additive, material-bonded application of the build-up material; ZS2: introducing one or more connecting channels (90; 90a; 90b; 90c) into the component (100) by material removal for the further development of the cooling channel system, wherein the connecting channel(s) (90; 90a; 90b; 90c) connect further cavities (31; 41) from step ZS1 with one or more of the previously introduced cavities (11; 21) in the previously constructed sections (10;20) of the component (100) connects, ZS3: partial or complete covering of the opening of the further cavity(s) (31; 41) from step ZS1 by a cover part (43), ZS4: construction of one or more further sections of the component (100) by additive material-bonded application of the build-up material, wherein the build-up material is applied to one or more of the previously constructed sections and to the cover part (43) of the preceding step ZS3.; The method according to claim 7, characterized in that the method further comprises: - Several repetitions of the process step sequence ZS1 to ZS4 for producing the component (100) with a plurality of sections (10, 20) and a cooling channel system formed within the component (100), which is formed from 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. Method according to one of the preceding claims, characterized in that the material removal process for introducing the connecting channel(s) (90; 90a; 90b; 90c) is a machining process. Method according to one of the preceding claims, characterized in that the additive, material-bonded application of the build-up material is carried out by cladding welding with laser or arc. Method according to claim 10, characterized in that the supply of the build-up material is in the form of powder and / or wire. Method according to one of the preceding claims, characterized in that in an area around the opening(s) of one or more of the cavities (11; 21; 31; 41) in the respective sections, recessed shoulders (12; 22; 42) adapted to the geometries of the cover parts (13; 23; 43) designed to cover the respective openings are formed by material removal machining such that the respective cover parts (13; 23; 43) are held in position in a form-fitting manner to cover the respective openings. Method according to claim 12, characterized in that one or more of the cover parts (13; 23; 43) are sheet metal discs or sheet metal covers. Method according to one of the preceding claims, characterized in that geometries of the cavities (11; 21; 31; 41) are selected from a set of predetermined standard geometries of the cavities. Method according to claim 14, characterized in that the standard geometries of the cavities generally have cylindrical shapes. Method according to one of claims 14 or 15, characterized in that the cover parts (13; 23; 43) are selected from a set of prefabricated cover parts geometrically adapted to the standard geometries of the cavities. Method according to one of the preceding claims, characterized in that the method further comprises: - introducing at least one supply channel (91) and at least one discharge channel (92) for the cooling channel system into the component (100) by material removal machining, wherein the supply channel (91) and the discharge channel (92) are introduced in such a way that the cooling channel system runs continuously from the supply channel (91) to the discharge channel (92). Method according to one of the preceding claims, characterized in that the method further comprises: - additive material-bonding application of different materials, each with a different wear resistance than the base material of the constructed component (100). Method according to claim 18, characterized in that the assembly material around the cooling channel has a thermal conductivity that is greater than the thermal conductivity of the wear-resistant outer layer (103).

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