Sintered Cemented Carbide Thread Rolling Die
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Solution Overview
Problem
Conventional thread rolling dies made from high speed steels and tool steels lack sufficient compressive strength, stiffness, and wear resistance, leading to premature failure and limited service life when processing high-strength workpiece materials.
Innovation Solution
The use of sintered cemented carbide materials with specific properties such as compressive yield strength of at least 400,000 psi, Young's modulus between 50 x 10^6 psi to 80 x 10^6 psi, and abrasion wear volume of 5 mm^3 to 30 mm^3, along with optional non-cemented carbide pieces for enhanced durability and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional high speed steels and tool steels are used for thread rolling dies, then the dies are easier to manufacture and machine, but they lack sufficient compressive strength, stiffness, and wear resistance leading to premature failure
Solution Approach 1:
The patent applies composite materials by using sintered cemented carbide (a composite of carbide particles and metal binder) instead of conventional homogeneous steel materials. This composite structure provides superior compressive strength (exceeding 300,000 psi) and wear resistance while maintaining manufacturability through powder metallurgy processes.
Solution Approach 2:
The patent changes the material parameters by transitioning from traditional steel alloys to sintered cemented carbide with specific compositional parameters (carbide content, binder type and amount). This parameter change enables achieving compressive strength >300,000 psi and improved stiffness while controlling wear resistance through material composition optimization.
2Ease of repair
If conventional tool steels are used for thread rolling dies, then the manufacturing process is simpler, but the stiffness and service life are insufficient for processing high-strength workpiece materials
Solution Approach 1:
The sintered cemented carbide composite material provides enhanced stiffness and service life for processing high-strength workpieces. The composite structure of hard carbide particles in a metal binder matrix delivers the required mechanical properties while the sintering process maintains reasonable manufacturing complexity.
Solution Approach 2:
The patent extends die service life significantly through material selection, making the dies durable enough for high-volume production. The improved stiffness and wear resistance of sintered cemented carbide allow dies to withstand processing of high-strength workpiece materials without premature failure, effectively reducing replacement frequency.
3Productivity
If thread cutting methods are used, then the thread geometry can be precisely machined, but material waste is produced and the process is slow and costly
Solution Approach 1:
The patent replaces the mechanical cutting system with a forming system using sintered cemented carbide dies. Instead of removing material through cutting, the hardened dies cold-form the thread geometry by plastic deformation, eliminating chip waste and enabling high-speed threading operations that improve productivity.
Solution Approach 2:
The patent changes the threading process parameters from cutting (material removal) to cold forming (material displacement). This parameter change eliminates material waste (23) while achieving high threading speeds (39) through the use of durable sintered cemented carbide forming dies that can withstand the high pressures of cold forming.
4Strength
If high strength workpiece materials are processed with conventional dies, then the workpiece strength is achieved, but the dies suffer from excessive plastic deformation and premature failure
Solution Approach 1:
The sintered cemented carbide composite material provides the necessary compressive strength (exceeding 300,000 psi) to process high-strength workpiece materials while maintaining die reliability. The composite structure resists plastic deformation and wear, preventing premature die failure even when forming threads in high-strength alloys.
Solution Approach 2:
The patent changes the die material parameters to achieve compressive strength >300,000 psi, which exceeds the strength of conventional tool steels. This parameter change enables the dies to reliably process high-strength workpiece materials without suffering from excessive plastic deformation or premature failure, thereby improving die reliability (27).
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
The sintered cemented carbide thread rolling dies exhibit improved compressive strength, stiffness, and wear resistance, enabling longer service life and the ability to process high-strength workpiece materials with increased precision and reduced material waste.
Implementation Method 1
The thread rolling region includes a sintered cemented carbide material
Implementation Method 2
Thread rolling results in a significant increase in the hardness and yield strength of the material in the thread region of the workpiece due to work hardening caused by the compressive forces exerted during the thread rolling operation
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A thread rolling die (10) includes a thread rolling region (12) comprising a working surface (14) including a thread form (16). The thread rolling region (12) of the thread rolling die (10) comprises a sintered cemented carbide material having a hardness in the range of 78 HRA to 89 HRA. In certain embodiments, the thread rolling die (10) may further include at least one non-cemented carbide piece (18) metallurgically bonded to the thread rolling region (12) in an area of the thread rolling region that does not prevent a workpiece from contacting the working surface, and wherein the non-cemented carbide piece (18) comprises at least one of a metallic region and a metal matrix composite region.