MANUFACTURING PROCESS OF A COMPONENT WITH COOLING CHANNEL SYSTEM

Description

Technical area

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

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

[0003] This primary forming process is frequently used in plastics processing and enables complex shapes in the resulting product. The cooling required to solidify the material is particularly important in this process, as it has a decisive impact on processing times, among other things.

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

[0005] In general, the manufacture of tools that are exposed to elevated temperatures during use, such as injection molding tools, forming tools, extrusion tools, etc., is complex. In particular, the introduction of cooling channels within the tool is often difficult to accomplish due to the typically very complex geometric shapes of the tools, as the cooling channels can usually only be introduced into the finished tool by drilling.

[0006] For example, the prior art document DE 10 2004 040 929 A1 describes a method in which a tool with a coolant channel is manufactured as a component using an additive material-depositing manufacturing process. A coolant channel is formed within the tool during the additive construction. The method described in DE 10 2004 040 929 A1 utilizes the possibilities of additive manufacturing, which are particularly useful for components with a high degree of customization or components with a complex geometry. It therefore makes it possible to provide recesses, among other things, within the component during the additive construction.

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

[0008] Methods for manufacturing a component with a cooling channel system, comprising the construction of 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, are known from "HYBRID ADDITIVE AND SUBTRACTIVE MANUFACTURING PROCESSES AND SYSTEMS: A REVIEW", Journal of Machine Engineering, Grzesik Wit, Vol. 18, No. 4, November 30, 2018, pages 5-24, Non-Patent Literature Number: XP055845180, ISSN: 1895-7595, DOI: 10.5604 / 01.3001.0012.7629, Found on the Internet: URL: http: / / yadda.icm.edu.pl / baztech / element / bwmetal.element.baztech-a05323d2-13f7-4060-b0a1-5f4ea9652db5 / c / 1_Grzesik_Hybrid_5-24.pdf , "ADDITIVE MANUFACTURING - LASERTEC 65 3D", DMG Mori, September 6, 2016, Video, Non-Patent Literature Number: XP054982287, Found on the Internet, URL: https: / / www.youtube.com / watch?v=L3CkzQQFZXs as well as from DE 197 40 502 A1 and US 2002 / 165634 A1.

[0009] The use of a cover part to cover cooling channels, to which material is subsequently applied by deposition welding, is known from DE 198 34 238 A1. Cooling channel systems with multiple levels or sections, in which cooling channels in one area are connected to cooling channels in another area by connecting channels, are known, for example, from DE 10 2006 017808 A1 and from "AUTOMATIC LAYOUT DESIGN OF PLASTIC INJECTION MOULD COOLING SYSTEM", Li CL et al., Computer-Aided Design, Elsevier Publishers BV, BARKING, GB, Vol. 37, No. 7, June 1, 2005, pages 645-662, Non-Patent Literature Number: XP027649895, ISSN: 0010-4485, the latter also demonstrating the introduction of connecting channels by material-removing machining. Summary of the invention

[0010] An object of the present invention is therefore to provide a method for producing a component with improved heat dissipation.

[0011] To solve this problem, a method for producing a component with a cooling channel system according to claim 1 is proposed.

[0012] Furthermore, a software-supported computer system according to claim 14 is proposed, which is designed for the construction of such a component.

[0013] The respective dependent claims relate to preferred embodiments of the method according to the invention or of the data processing system according to the invention, which can each be provided individually or in combination.

[0014] According to a first aspect of the invention, the method for producing a component with a cooling channel system comprises building up 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 by a cover part, building up a second section of the component by additively applying the build-up material, 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 that removes material at least in some sections to form the cooling channel system, wherein the connecting channel connects the second cavity of the second section to the first cavity of the first section of the component.

[0015] Optionally, the cover part can be securely fixed after insertion, for example, by applying an additive build-up welding track. This may be necessary, for example, if several cover parts are installed on a workpiece to be machined in 5-axis configurations, facing in different directions relative to gravity, to prevent them from falling out. Alternatively, a cover plate can also be secured by spot welding.

[0016] By means of the method according to the invention, components with complex geometric shapes and a cooling channel system running within the component, which is designed to conduct a coolant and also has a complex geometric shape, can be produced in a particularly advantageous manner.

[0017] The cooling channel system running within the component is formed during the build process by additively applying the build material (= additive build) 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 in the component, to be advantageously adapted to the complex final geometry of the component to be manufactured. The cooling channel system runs at least partially adapted to the outer contour surfaces of the component, i.e., at least partially follows them. Sectionally following refers here to an arrangement of the cooling channel system in which the flow direction of the coolant flowing or being conducted through the cooling channel system runs essentially parallel to an outer contour surface of the component.

[0018] In the case of complex component geometries, the introduction of such an internal cooling channel system is generally not possible by simply inserting it in the form of holes following the primary forming process.

[0019] Until now, the creation of holes in conventional processes was limited by the component geometry and the possibilities of the drilling process, so that only cooling channel systems with an extremely simple geometric arrangement could be created.

[0020] The method according to the invention uses the synergy of a build-up by additive material-locking application of the build-up material (=additive build-up) as well as a material-removing machining to form the cooling channel system running therein, among other things by introducing the connecting channel.

[0021] The method according to the invention is thus a hybrid manufacturing method with an alternating sequence of additive build-up steps and material-removing processing steps.

[0022] By means of the method according to the invention, cooling channel systems which are close to the final shape can be realized, whereby the heat dissipation by a coolant flowing therein can be significantly improved.

[0023] In addition, areas of the component that are subject to particularly high thermal stress during use can be efficiently cooled by the coolant flowing through the cavity by introducing a cavity with a cross-section that is larger than the connecting channel.

[0024] Covering the opening of the first cavity in the first section by an advantageously planar and / or flat cover part enables the additive construction of the second section by applying the construction material, wherein the first cavity is completely enclosed in the interior of the component and the first cavity has a simple geometric shape with a planar interface or interface geometry facing the second section.

[0025] Closing the opening of a cavity located entirely within the finished component through purely additive deposition of the build-up material (without a cover part) is only possible if specific, typically non-planar, interface geometries are maintained. The formation of an interface geometry in the form of a planar boundary surface (without a cover part) is not possible due to the process, which is why pyramid- or conical-shaped interface geometries are usually created through additive deposition, e.g., in a roof shape.

[0026] Such non-planar interface geometries of the cavities prove to be disadvantageous in many respects.

[0027] On the one hand, such interface geometries represent undesirable stagnation points for a coolant flowing through the cooling channel system and thus also a deterioration of the resulting heat dissipation.

[0028] On the other hand, such mostly tapered interface geometries (pyramidal or conical) represent potential weak points in the sense of a predetermined breaking point (notch factor), at which excessive stress peaks can occur within the component in the event of mechanical loading of the component, as a result of which the component can fail at the corresponding point (crack, fracture, plastic deformation, etc.).

[0029] By constructing the component in sections in accordance with the invention, the connecting channel can be introduced in a manner that would not be possible following the complete additive construction of the component.

[0030] The connecting channel is advantageously introduced starting from the second cavity in the second section of the component in the direction of 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.

[0031] Access by a tool designed for material removal advantageously occurs through the opening of the second cavity of the second section. The second cavity preferably has a suitable geometry that does not impede the tool from creating the connecting channel, so that, for example, a drill head designed for machining can penetrate the component through the opening of the second cavity without damaging it.

[0032] Advantageously, by introducing the connecting channels based at least partially on material-removing machining, a higher surface quality with smoother surface structures of the surfaces of the component adjacent to the connecting channel can be created in relation to the other surfaces produced by additive construction.

[0033] Surfaces created by additive construction through the cohesive application of the build-up material generally have a surface structure or surface quality with greater roughness values ​​and lower surface quality than is the case with a surface created by material-removing machining, in particular machining.

[0034] The high surface quality of the connecting channel, with its smooth surface structure and lower roughness values, improves the flow of coolant flowing through the connecting channel, as there is lower flow resistance. Rough surfaces of channels or lines through which flow occurs lead to turbulent flow in the surface areas, thus increasing flow resistance, which accordingly impedes flow.

[0035] By introducing the connecting channel based on material removal machining, the flow resistance of a flowing coolant can be significantly reduced compared to a connecting channel manufactured solely by additive construction, which in turn has a positive effect on heat dissipation, since higher flow rates or flow velocities of the flowing coolant can be achieved with lower flow resistance and otherwise identical boundary conditions (pressure difference, channel cross-section).

[0036] In principle, however, it is also possible to insert the connecting channel in sections using an additive process by omitting the corresponding areas during the material application.

[0037] 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, multiple cavities can be introduced into 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. Accordingly, multiple connecting channels can also open into a single cavity to form the cooling channel system.

[0038] For example, it is possible to create two separate cavities in the first section, which, after the second section has been constructed, are connected to a cavity created in the second section by inserting two connecting channels. The two connecting channels both open into the cavity of the second section and connect it to the two cavities in the first section.

[0039] Alternatively, it would also be possible, for example, to introduce a cavity into the first section and to connect it to two cavities introduced in the second section by introducing two connecting channels.

[0040] Improving the heat dissipation of a component includes, among other things, increasing the cooling rates / speeds of the component when the component is used in applications involving thermal stress, e.g., as a tool in a manufacturing process, so that shorter process times or cycle times can be achieved. Heat dissipation occurs through the coolant flowing through the cooling channel system, which absorbs the heat conducted through the component and carries it out or away from it.

[0041] In a preferred embodiment of the method, the first and / or possibly further cavities are introduced following the construction of the respective sections, at least in sections, by material-removing machining.

[0042] In a particularly preferred embodiment of the method, the material-removing machining for creating the first and / or the second cavity is a machining operation.

[0043] The introduction of the cavities by means of machining is particularly positive, as this results in surfaces of the component adjacent to the cavities having a high surface quality, especially in relation to surfaces created by a purely additive application of the build-up material, which can reduce the flow resistance within the cooling channel system.

[0044] In a further preferred embodiment of the method, the first and / or the second cavity is introduced during the construction of the respective sections by omitting the corresponding areas during the additive, cohesive application of the construction material.

[0045] By omitting the build-up material during application, the cavities can advantageously be introduced during the build-up of the respective sections, which leads to a reduction in production costs, production time and savings in build-up material.

[0046] In a particularly preferred embodiment of the method, the surfaces of the sections adjacent to the cavities introduced during the construction of the sections are reworked by machining.

[0047] 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, whereby the flow resistance within the cooling channel system can be reduced.

[0048] In contrast to the introduction of one of the cavities by only material removal machining without prior omission during additive construction, tool costs can also be reduced because only one surface is machined and not the entire cavity itself is introduced by material removal machining.

[0049] 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, wherein the build-up material is applied to the second section and to the cover part of the opening of the second cavity.

[0050] This closes the opening of the second cavity with build-up material so that the component has a cooling channel system located entirely within it.

[0051] In a particularly preferred embodiment of the method, this further comprises the steps: ZS1: Introduction of at least one further cavity with an opening into one of the previously constructed sections of the component, wherein the introduction of the further cavity takes place following the construction of the previously constructed section by material-removing machining or during the construction of the previously constructed section by omissions during the additive, material-to-material application of the construction material. ZS2: Introduction of one or more connecting channels into the component by material-removing machining to further form the cooling channel system, wherein the connecting channel(s) connect the further cavity from step ZS1 with the previously introduced cavities in the previously constructed sections of the component. ZS3: At least partial covering of the opening of the further cavity from step ZS1 with a cover part.ZS4: Construction of one or more further sections of the component by additive material-to-material application of the build-up material, whereby the build-up material is applied to one or more of the previously constructed sections and to the cover part of the preceding step ZS3.

[0052] Optionally, the cover part can be securely fixed after insertion in step ZS3, for example, by applying an additive build-up welding track. This may be necessary, for example, if several cover parts are installed on a workpiece to be machined in 5-axis configurations, facing 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.

[0053] In a particularly preferred embodiment of the method, these steps can be repeated several times, so that by several repetitions of the method step sequence ZS1 to ZS4, a component with a plurality of sections and a cooling channel system formed within the component, which is formed from a plurality of cavities and a plurality of connecting channels for connecting the plurality of cavities, is produced.

[0054] This makes it possible to produce components with complex geometries, particularly external geometries, and a cooling channel system running within the component that is advantageously adapted to the complex geometry.

[0055] The number of cavities per section of the component is not limited to one, so that individual sections can also have several cavities, which contribute to the advantageous formation of the cooling channel system.

[0056] In a particularly preferred embodiment of the method, the material-removing machining for introducing the connecting channel(s) is a machining operation.

[0057] Through machining, a high surface quality of the created surfaces of the component that border the connecting channels can be achieved, especially in relation to surfaces that are created by a purely additive application of the build-up material, whereby the flow resistance within the cooling channel system can be reduced.

[0058] In a particularly preferred embodiment of the method, the additive material-bonded application of the build-up material is carried out by deposition welding with a laser or arc.

[0059] In a particularly preferred embodiment of the method, the build-up material is supplied during deposition by build-up welding in the form of powder and / or wire.

[0060] In a particularly preferred embodiment of the method, in an area around the opening(s) of one or more of the cavities in the respective sections, recessed shoulders adapted to geometries of the cover parts designed to cover the respective openings are formed by material-removing machining in such a way that the respective cover parts are held in position in a form-fitting manner to cover the respective openings.

[0061] This can simplify the insertion of the cover part(s) for covering the opening(s) as well as the subsequent additive assembly on the respective cover part, since the respective cover part is held in position relative to the component and does not shift due to undesired vibrations or the like.

[0062] In a particularly preferred embodiment of the method, one or more of the cover parts are sheet metal blanks or sheet metal covers.

[0063] In a particularly preferred embodiment of the method, geometries of the cavities are selected from a set of predetermined standard geometries of the cavities.

[0064] This enables largely standardized production, since no random geometries are selected for the cavities, but rather a selection is taken from a set of predetermined standard geometries according to a modular principle. The standardization thus achieved allows further process steps to be optimized, particularly with regard to the design of the cover parts, which, in a particularly preferred embodiment of the process, are similarly selected from a set of prefabricated cover parts geometrically adapted to the standard geometries of the cavities.

[0065] The cover parts can thus be prefabricated in large quantities and can be used directly to cover the cavities with standard geometry according to the modular principle.

[0066] This leads to a reduction in manufacturing costs, since individual production of the cover parts is no longer necessary and, in addition, production times for manufacturing components can be reduced by the method according to the invention.

[0067] In a particularly preferred embodiment, the standard geometries of the cavities generally have cylindrical shapes.

[0068] These relatively simple geometries can be quickly and easily produced by material removal, particularly machining, so that production times can be further reduced.

[0069] 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-removing 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.

[0070] This provides a continuous cooling channel system through which a coolant supplied from outside the component through the supply channel can flow through the cooling channel system inside the component to the discharge channel and thus a cooling circuit for cooling or heat dissipation from the component can be provided.

[0071] In a particularly preferred embodiment of the method, this further comprises additive material-to-material application of a wear-resistant outer layer to a part of an outer contour surface of the component constructed from the construction material.

[0072] 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.

[0073] In a particularly preferred embodiment of the method, the additive material-to-material application of the wear-resistant outer layer is carried out by deposition welding with a laser or arc, wherein a material used to build up the wear-resistant outer layer is supplied in the form of powder and / or wire.

[0074] In a particularly preferred embodiment of the method, the construction material further has a thermal conductivity that is greater than a thermal conductivity of the wear-resistant outer layer.

[0075] Thus, a component with improved heat dissipation properties and high wear resistance can be provided efficiently. Due to the increased thermal conductivity, thermal energy entering the component via the outer layer is quickly conducted from the surface of the outer layer adjacent to the build material to the cooling channel system, so that improved heat dissipation can be achieved within the entire component. Improved heat dissipation of a component produced by the method according to the invention aims not only at increasing the cooling rates but also at ensuring localized uniformity of cooling of the component, in particular through the cavities placed during the method according to the invention, for example in areas of the component subject to particularly high thermal stress.

[0076] For example, when the component is used, e.g. as a tool, undesirable deformations caused by locally different cooling rates can be reliably avoided.

[0077] For example, cooling times can be reduced for injection-molded parts and cooling can be improved for hot-forming tools in order to prevent increased local wear.

[0078] According to a further aspect of the invention, a software-based computer system is proposed, which is defined in claim 14.

[0079] In a particularly preferred embodiment, the computer system further comprises a means for deriving control commands to be used by the numerically controlled machine tool and / or the numerically controlled machining center to carry out the machining steps, as well as a means for transmitting the control commands to the machine tool and / or to the machining center, which are configured to carry out the machining steps for producing the component.

[0080] In a particularly preferred embodiment, the computer system further comprises a CAD and / or a CAM system.

[0081] Further aspects and their advantages as well as more specific embodiments of the aforementioned aspects and features are described below with the aid of the drawings shown in the attached figures: Fig. 1a - Fig. 1f show exemplary cross-sections of the step-by-step production of a component with a cooling channel system using the method according to the invention. Fig. 2 shows a component with a cooling channel system, consisting of several cavities and connecting channels, in a perspective transparent view. Fig. 3a - Fig. 3b show enlarged views of various sections of the component with a cooling channel system. Fig. 2 . Fig. 4 shows a central section of the Fig. 2 shown component in a perspective cross-sectional view. Fig. 5 shows an embodiment of a method according to the invention for producing a component with a cooling channel system. Detailed character description

[0082] Fig. 1ashows an exemplary component 100 after a construction of a first section 10 carried out in the course of the method according to the invention by additive material-locking application of a construction material (=additive construction) in a cross-section.

[0083] In the given example, the additive build-up takes place along a build-up direction x.

[0084] A first cavity 11 is introduced into the first section 10 such that it has an opening towards an outer surface 15 of the first section 10.

[0085] The introduction of the first cavity 11 can be carried out during the additive construction of the first section 10 by means of recesses at the relevant locations, wherein a post-processing of the surfaces of the first section adjacent to the first cavity 11 is carried out by means of a material-removing processing, in particular a machining process, in order to improve the surface quality and thus reduce the flow resistance in the cooling channel system.

[0086] Alternatively, the first cavity 11 can be introduced directly into the solid material following the additive construction of the first section 10 by material-removing machining, in particular machining.

[0087] Furthermore, at the opening of the first cavity 11 on the outer surface 15, a shoulder 12 is introduced into the first section 10 by material-removing machining, which serves for the subsequent insertion of a cover part 13 (see Fig. 1b )

[0088] Fig. 1b shows the component after a step of covering the opening of the first cavity 10 by a cover part 13 in cross section.

[0089] The cover part 13 is advantageously designed to be flat and level and has a small thickness relative to the other dimensions. The cover part completely closes the opening of the first cavity.

[0090] Advantageously, the shoulder 12 introduced into the first section 10 at the first cavity 10 and the cover part 13 are adapted to one another in such a way that a surface of the flat cover part 12 is flush with the outer surface 15 of the first section and, together with it, preferably forms a flat surface. The cover part 13 is preferably held precisely in position by the introduced shoulder 12 in a form-fitting manner.

[0091] Fig. 1cshows the component 100 after a subsequent process step for the additive construction of a second section 20 in cross section.

[0092] The additive construction 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 construction direction x.

[0093] 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, whereby a purely additive closing of the first cavity 11 by complex pyramidal or conical geometries is eliminated and the first cavity 11 thus has a geometric shape with essentially parallel opposite side surfaces or ceiling and bottom surfaces.

[0094] The additive structure of the second section 20 is as shown 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 that 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 be carried out only on a part of the outer surface 15 (and not the entire outer surface) of the first section 10 of the component 100.

[0095] A cavity, a second cavity 21, is also introduced into the second section 20 of the component 100 by material-removing machining using one of the methods already described in the course of introducing the first cavity 11 (recesses during additive construction and material-removing post-processing or complete introduction by material-removing machining).

[0096] Even if the representation in Fig. 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 does not generally have to be the case with the method according to the invention.

[0097] The second cavity 21 in the second section 22 is open towards an outer surface 25 of the second section 20.

[0098] Furthermore, in a manner analogous to the procedure for the first cavity 11, a shoulder 22 is introduced at the opening of the second cavity 21 on the outer surface 25 by material-removing machining.

[0099] Fig. 1d shows the component 100 after a subsequent process step for introducing a connecting channel 90 in cross section.

[0100] The connecting channel 90 is introduced into the component 100 by material-removing 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.

[0101] When connecting the two cavities 11 and 21 by 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 construction, since otherwise no connection could be established between the cavities 11 and 21.

[0102] The material-removing processing for introducing the connecting channel 90 can be carried out, among other things, by laser processing or machining, e.g. by means of a milling tool or a drill head, whereby machining is preferable due to the high surface quality of the surfaces thus introduced.

[0103] The material-removing machining, e.g. the insertion of a drill head, takes place starting from the second cavity 22, wherein 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 easily guided through the component 100 up to the first cavity 11 without damaging the component 100 in an undesirable manner, e.g. by collision with the second section 20 in an area around the second cavity 21.

[0104] Furthermore, the relatively large second cavity 22 allows the exemplary drill head to be inserted into the component at an angle starting from a perpendicular to the outer surface 25. The possibility of inserting the connecting channel 90 at a corresponding angle of inclination to the perpendicular to the outer surface 25 (without undesirably damaging the second section 20) results in greater flexibility in the formation of a cooling channel system within the component 100.

[0105] The connecting channel 90 can thus advantageously be introduced at both steep and flat angles of inclination with respect to the vertical of the outer surface 25.

[0106] Thus, the connecting channel 90 can be arranged as shown in Fig. 1din a partial area of ​​the component 100 parallel (or almost parallel) to a further outer surface 26 of the component 100. This results in different surface points of the further outer surface 26 being at the same (or almost the same) distance from the connecting channel 90 in such a section-wise area. This distance should advantageously be chosen to be as small as possible in order to enable the cooling channel system to be guided close to the outer contour and thus to improve the dissipation of heat entering the component 100, for example through the further outer surface 26, through the cooling channel system through which a coolant flows.With such an introduction of the connecting channel 90 as part of the cooling channel system, the component 100 has a largely uniform material thickness between the further outer surface 26 and the connecting channel 90 in this partial area, whereby a locally uniform heat dissipation can also be achieved in the relevant partial area.

[0107] Fig. 1e shows the component 100 after an additive construction of a further (third) part 30 to finalize the exemplary component 100 in cross section.

[0108] According to the method according to the invention, 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.

[0109] 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.

[0110] Fig. 1f shows the component 100 after finalization of the cooling channel system by introducing a supply channel 91 and a discharge channel 92 in cross section.

[0111] The introduction of the supply and discharge channels 91 and 92 is carried out by material-removing machining, wherein the supply and discharge channels 91 and 92 are introduced into the component 100 in such a way that a subsequent passage of a coolant starting from an inlet Z via the cooling channel system formed by the cavities 21, 22, the connecting channel 90 and the supply and discharge channels 91 and 92 to an outlet A is possible.

[0112] The positions of the inlet Z and the outlet A for the coolant are generally not fixed but can optionally be swapped, so that a Fig. 1f The flow direction shown is the reverse of the flow direction of the coolant flowing through the cooling channel system.

[0113] The supply and discharge channels 91 and 92 can also be guided through the component 100 in such a way that they follow an outer surface of the component 100 at least in sections in order to improve heat dissipation.

[0114] Supply and discharge channels 91 and 92 are advantageously introduced in such a way that the inlet Z and the outlet A for the coolant in the cooling channel system of the component 100 are arranged on an outer surface or outer surfaces (A and Z not necessarily on the same surface or side of the component) that are less relevant for the later use of the component 100, e.g. as an injection molding tool.

[0115] The Fig. 1f The component 100 shown with the finalized cooling channel system illustrates that a cooling channel system with such a complex geometric structure can in no way be produced by material-removing machining, e.g. by drilling, following the complete construction of the component 100, here with the three sections 10, 20 and 30, but is only accessible through the method according to the invention.

[0116] Furthermore, the surfaces of the component 100 adjacent to the internal cooling channel system have advantageously been created or at least reworked by material-removing machining, in particular by machining. This allows a high surface quality of said surfaces with lower roughness to be achieved, particularly compared to a surface created by a purely additive construction. In this way, the flow resistance of a coolant flowing through such a cooling channel system can be significantly reduced, so that higher flow velocities or higher flow rates can be achieved, particularly compared to a cooling channel system manufactured by a purely additive construction (i.e., without material-removing machining / rework), which would inherently have a lower surface quality and thus a higher flow resistance for the coolant.

[0117] Fig. 2shows another component manufactured by the method according to the invention with a cooling channel system, which has several cavities and several connecting channels, in a perspective transparent view.

[0118] In contrast to the representations in the Fig. 1a to 1f shows Fig. 2 a component 100 with a more complex external geometry and a complex geometry of the cooling channel system running within the component 100.

[0119] The component 100 is manufactured using the method according to the invention, whereby, due to the hybrid nature of the method consisting of alternating additive build-up steps and material-removing processing steps, a cooling channel system can be formed within the component 100, as a result of which the component (with a coolant flow) has improved heat dissipation properties.

[0120] The component is constructed by additively applying a build-up material to a base body 101 of the component 101.

[0121] In the course of the method 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 introduced into the component, each of which is created by machining. In addition, the surfaces adjacent to the cavities 11, 21, 31, and 41 can be reworked to improve the surface quality, e.g., by further material-removing machining.

[0122] Advantageously, the geometries of the cavities are selected from a set of standard geometries, preferably comprising simple cylindrical and / or generally cylindrical geometries of various dimensions. Generally cylindrical geometries are geometries formed by extruding a base surface of any shape (e.g., circle, ellipse, polygon, etc.) along an extrusion axis.

[0123] The second, third and fourth cavities 21, 31 and 41 have cylindrical shapes with a circular cross-section, whereby the dimensions of the cylindrical shapes of the individual cavities differ both in the diameter of the circular cross-sections and in the heights of the cylinders.

[0124] The first cavity 11, on the other hand, has a generally cylindrical shape with a non-circular cross-section.

[0125] In the course of manufacturing the component by the method according to the invention, the cavities 11, 21, 31 and 41 are connected to one another by connecting channels 90a, 90b and 90c to form the cooling channel system, which connecting channels are introduced into the component 100 by material-removing machining, in particular by machining.

[0126] 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.

[0127] A flow direction of a coolant flowing through the cooling channel system would thus be possible 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 correspondingly reversed sequence.

[0128] Starting from the base body 101 of the component 100, a supply channel 91 and a discharge channel 92 for the coolant are also introduced into the component 101 by material-removing machining to finalize the cooling channel system.

[0129] The definition 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 final in the present case, since the coolant can also flow through the cooling channel system in a flow direction opposite to this.

[0130] Fig. 3a shows a perspective section of the component from Fig. 2 in a middle sub-area.

[0131] The section shows that the connecting channels 90a and 90b for connecting the cavities 11, 21 and 31 are introduced into the component 100 in such a way that they follow at least partially outer contours or outer contour surfaces of the component 100; thus, they run parallel or approximately parallel to these, and are thus formed close to the final shape.

[0132] Fig. 3b shows the Fig. 3a shown section of the component from Fig. 2 in a middle section in a side view.

[0133] The side view shows that, in addition to the connecting channels 90a and 90b for connecting the cavities 11, 21 and 31, the discharge channel 92 of the cooling channel system is also introduced into the component 100 in such a way that it follows, at least in sections, an outer contour or an outer contour surface of the component 100; thus, it runs parallel or approximately parallel to it.

[0134] The discharge channel 92 of the cooling channel system flows into the Fig. 3b shown representation into the base body 101, from which a connection of the cooling channel system to a coolant supply unit set up to supply the cooling channel system takes place.

[0135] Fig. 3c shows a perspective section of the component from Fig. 2 after an intermediate step of the method according to the invention for producing the component in an upper partial region.

[0136] In the illustration shown, the method steps following the introduction of the fourth cavity 41 of covering the opening of the fourth cavity 41 on an outer surface 45 by means of a covering part 43 (not shown here, see Fig. 3d ) and an additive construction on the outer surface 45 of a final section of the Fig. 2 shown component 100, has not yet taken place.

[0137] The outer surface 45 is merely an external surface formed during the previous process steps and in this case not an outer surface of the finished component.

[0138] The additive construction of the component has been completed up to the outer surface 45.

[0139] Furthermore, at the opening of the fourth cavity 41 on the outer surface 45, a shoulder 42 designed to receive the cover part 43 (not shown here) is introduced by material-removing machining, in particular by machining.

[0140] 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 during the subsequent process steps is held in position in a form-fitting manner.

[0141] Fig. 3d shows a perspective section of the component from Fig. 2after a further intermediate step of the method according to the invention for producing the component in an upper partial region.

[0142] Following the Fig. 3c In the state of the component shown in the course of 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.

[0143] The cover part 43 is designed in such a way that (matching the shoulder 42) can be inserted into the shoulder 42 to cover the fourth cavity and is positioned there in a form-fitting manner, wherein a surface of the cover part 42 is slightly recessed relative to the outer surface 45 of the component.

[0144] In this way, a defined conclusion is formed, to which an additive construction of the last section of the Fig. 2 shown component can be done.

[0145] The cover parts used in the course of the method 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.

[0146] Corresponding to the cylindrical geometry of the fourth cavity 41, the cover part 43 has a circular flat geometry adapted thereto and is preferably designed as a thin flat sheet metal disc.

[0147] Fig. 4 shows a central part of the Fig. 2 shown component in a perspective cross-sectional view.

[0148] The illustration shows the different material structure of component 100 with cooling channel system.

[0149] The component produced in the course of the method according to the invention has a core body 102 made of the construction material, in which the cooling channel system is formed.

[0150] Furthermore, a wear-resistant outer layer 103 is formed on an outer contour surface of the core body 102 by additively applying a further material. This further material exhibits a higher wear resistance than the construction material from which the core body 102 is formed.

[0151] On the other hand, the construction 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.

[0152] The resulting combination 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.

[0153] In one possible embodiment, the thermally conductive construction material is copper or a copper alloy and the wear-resistant outer layer is made of tool steel.

[0154] Since the cooling channel system is introduced into the core body 102 by material-removing machining in the course of the method according to the invention, the machining effort and the machining costs can also be reduced, since the more thermally conductive core body 102, e.g. copper alloy, usually has a lower strength than the other material of the wear-resistant outer layer 103, e.g. tool steel, and thus material-removing machining on the core body is simplified.

[0155] An embodiment of a method according to the invention for producing a component with a cooling channel system is described in Figure 5 shown schematically: In step S1, a first section of the component is built up by additively applying a build material. 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 material, whereby the build 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 in part, by material-removing machining 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.

[0156] In this embodiment, the two cavities are created by omitting the corresponding areas during the material application.

[0157] The connecting channel for connecting the two cavities is created by machining.

[0158] In a particular embodiment of the illustrated embodiment, the method additionally comprises step S7, in which an opening of the second cavity of the second section created by omitting the corresponding region is also partially or completely covered by a cover part.

[0159] In step S8, a further section of the component is then built up by additively applying a build-up material, wherein the build-up material is applied at least to the cover part of the opening of the second cavity and, if necessary, also to the second section in order to ensure a better, cohesive connection and a closure of the opening.

[0160] As described above, these steps can be repeated further 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-removing machining, while the cavity is constructed at least partially by additive, cohesive application of the build-up material within the scope of the present invention.

[0161] Embodiments of the present invention and their advantages have been described in detail above with reference to the accompanying figures. List of reference symbols

[0162] 10First section 11First cavity 12Step at the opening of the first cavity 13Cover part for covering the first cavity 15Outer surface of the first section 20Second section 21Second cavity 22Step at the opening of the second cavity 23Cover part for covering the second cavity 25Outer surface of the second section 26Further outer surface of the second section 31third cavity 41fourth cavity 42step at the opening of the fourth cavity 43cover part for covering the fourth cavity 45outer surface 90, 90a, 90b, 90cConnecting channel 91Supply channel 92Discharge channel 100Component 101Base body of the component 102Core body of the component 103Wear-resistant outer layer ZInlet AOutlet xInstallation direction

Claims

1. Method for producing a component (100) with a cooling channel system, comprising: - building up a first section (10) of the component (100) by additive material-bonding application of a build-up material, - 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 additive material-bonding application of the build-up material, wherein the build-up material is applied at least to the cover part (13) and optionally additionally to the first section (10), - introducing 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 in sections by material-removing machining to form the cooling channel system, wherein the connecting channel connects the second cavity (21) of the second section (20) to the first cavity (11) of the first section (10) of the component (100).

2. 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 partially in sections by material-removing machining following the build-up of the respective sections (10; 20).

3. Method according to claim 2, characterized in that the material-removing machining for introducing the first (11) and / or the second cavity (21) and / or the connecting channel is machining.

4. 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 partially in the course of the build-up of the respective sections (10, 20) by omissions during the additive material-bonding application of the build-up material.

5. Method according to claim 4, characterized in that the surfaces of the sections (10; 20) adjoining the cavities (11; 21) introduced in the course of the build-up of the sections (10; 20) are reworked by machining.

6. Method according to one of the preceding claims, characterized in that the method further comprises the steps of: - partially or completely covering an opening of the second cavity (21) of the second section (20) by a cover part (23), - building up a further section (30; 40) of the component (100) by additive material-bonding application of the build-up material, 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), and ZS1: introducing further cavities (31; 41) with an opening into one of the previously already built-up sections (10; 20) of the component (100), wherein the introduction of the further cavity (31; 41) is carried out following the build-up of the respective previously already built-up section (10; 20) by material-removing machining or in the course of the build-up of the previously already built-up section (10; 20) by omissions during the additive material-bonding application of the build-up material, ZS2: introducing one or more connecting channels (90; 90a; 90b; 90c) into the component (100) by material-removing machining, which is in particular machining, for further forming the cooling channel system, wherein the connecting channel or channels (90; 90a; 90b; 90c) connect further cavity (31; 41) from step ZS1 to one or more of the previously introduced cavities (11; 21) in the previously built-up sections (10; 20) of the component (100), ZS3: partially or completely covering the opening of the further cavity or cavities (31; 41) from step ZS1 by a cover part (43), ZS4: building up one or more further sections of the component (100) by additive material-bonding application of the build-up material, wherein the build-up material is applied to one or more of the previously built-up sections and to the cover part (43) of the preceding step ZS3.

7. Method according to claim 6, characterized in that the method further comprises: - a plurality of repetitions of the method step sequence ZS1 to ZS4 for producing the component (100) with a multiplicity of sections (10, 20) and a cooling channel system which is formed within the component (100) and which is formed from a multiplicity of cavities (11; 21; 31; 41) and a multiplicity of connecting channels (90; 90a; 90b; 90c; 90d) for connecting the multiplicity of cavities.

8. Method according to one of the preceding claims, characterized in that the additive material-bonding application of the build-up material is carried out by deposition welding with a laser or electric arc and the supply of the build-up material is carried out in the form of powder and / or wire.

9. Method according to one of the preceding claims, characterized in that, in a region around the opening or openings of one or more of the cavities (11; 21; 31; 41) in the respective sections, recessed shoulders (12; 22; 42) which are adapted to geometries of the cover parts (13; 23; 43) which are designed to cover the respective openings and which are in particular circular sheet metal blanks or sheet metal covers are formed by material-removing machining in such a way that the respective cover parts (13; 23; 43) are held in position in a form-fitting manner for covering the respective openings.

10. 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 which in particular have generally cylindrical shapes, and the cover parts (13; 23; 43) are selected from a set of prefabricated cover parts which are geometrically adapted to the standard geometries of the cavities.

11. 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-removing 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).

12. Method according to one of the preceding claims, characterized in that the method further comprises: - additive material-bonding application of different materials with different wear resistance as the build-up material of the component (100).

13. Method according to claim 12, characterized in that the build-up material around the cooling channel has a thermal conductivity which is greater than a thermal conductivity of a wear-resistant outer layer (103).

14. Software-supported computer system, characterized in that the computer system is configured for design planning of a component (100) to be produced by the method according to one of claims 1 to 13 and for this purpose at least comprises: - means for defining a component geometry of the component (100) with a cooling channel system, in particular by selecting a geometry of a cooling channel section from a group of predetermined, geometrically predetermined cavities, - means for determining machining steps which can be carried out in succession by a numerically controlled machine tool and / or a numerically controlled machining centre for producing the component (100) by means of the steps according to one of claims 1 to 13.

15. Software-supported computer system according to claim 14, characterized in that the computer system further comprises: - means for deriving control commands to be used by the numerically controlled machine tool and / or the numerically controlled machining centre for carrying out the machining steps, - means for transmitting the control commands to the machine tool and / or the machining centre, which are configured for carrying out the machining steps for producing the component (100).