Additive Press Quenching Tool With 3D Fluid Channels
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Solution Overview
Problem
The existing methods for manufacturing tools for press quenching and tempering methods, such as gear wheels, are costly due to the complexity and limitations of traditional machining techniques, which restrict the precision and efficiency of fluid distribution channels, leading to suboptimal temperature control and mechanical properties.
Innovation Solution
The tool is partially or completely manufactured using additive methods, allowing for the creation of complex fluid pipes with customized dimensions and geometries that can optimize fluid flow and temperature control, enabling better adjustment to specific areas of the tool and workpiece, and potentially combining different materials for enhanced thermal and mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional machining methods by stock removal are used to manufacture tools, then the manufacturing process is well-established and reliable, but the manufacturing costs are very high and the complexity of fluid distribution channels is limited
Solution Approach 1:
The patent applies additive manufacturing technology to fundamentally change the manufacturing method from traditional stock removal to layer-by-layer material deposition. This enables the creation of complex three-dimensional fluid distribution channels with varying cross-sections, curves, and spatial arrangements that cannot be achieved by conventional machining, while simultaneously reducing manufacturing costs for complex geometries
Solution Approach 2:
The invention transitions from two-dimensional surface channels or simple bored holes to three-dimensional spatial fluid distribution networks. The additive manufacturing process allows pipes and channels to extend through the volume of the tool in complex paths, enabling optimized fluid distribution that adapts to the specific thermal and mechanical requirements of different tool regions
2Manufacturing precision
If complex fluid distribution channels are created to optimize temperature control, then temperature control precision improves, but manufacturing costs increase significantly
Solution Approach 1:
By changing the manufacturing process to additive manufacturing, the patent enables the economical production of complex channel geometries. The layer-by-layer deposition process naturally accommodates complex three-dimensional paths without requiring multiple machining operations or expensive tooling, thus achieving both high temperature control precision and cost-effectiveness
Solution Approach 2:
The additive manufacturing approach allows for local optimization of fluid channel characteristics. Different regions of the tool can have channels with different diameters, wall thicknesses, and spatial orientations tailored to the specific thermal requirements of each area, enabling precise temperature control without uniformly increasing complexity throughout the entire tool
3Ease of manufacture
If pipes with constant cross-sectional area are used, then manufacturing is simpler, but fluid distribution efficiency and temperature control are suboptimal
Solution Approach 1:
The patent implements pipes with variable cross-sectional areas that adapt to local requirements. Channels can be narrower in regions requiring lower fluid flow and wider in regions needing enhanced cooling or heating, optimizing temperature control precision while the additive manufacturing process maintains reasonable manufacturing simplicity
Solution Approach 2:
The invention employs curved and spatially varying channel paths rather than straight constant-cross-section pipes. The additive manufacturing process naturally accommodates these curved geometries, enabling fluid to follow optimized paths that better distribute thermal energy throughout the tool volume, improving temperature control without significantly complicating manufacturing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing costs, improves temperature control and mechanical properties, allows for more complex and efficient fluid flow patterns, and enhances the flexibility in handling workpieces with complex geometries, while minimizing contamination and environmental hazards.
Implementation Method 1
for the distribution of the fluid respectively the heat transfer fluid which can also be a gas... for controlling the temperature of the workpiece
Implementation Method 2
the tool is at least in part manufactured as an additive... in an additively manufactured area of the tool
Data Source
AI summary
The invention relates to a tool for realising a press quenching and tempering method for a rotational symmetric tool, in particular for a gear wheel, wherein the tool is at least in part manufactured as an additive and wherein, in an additively manufactured area of the tool, is formed at least one pipe for guiding a fluid.