Ceramic Ball Molding Using Elastic Rubber Mold to Eliminate Burrs
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Solution Overview
Problem
The production of ceramic balls for bearings is hindered by the formation of significant burrs during the molding process, which increases labor and costs, and can lead to defects during polishing, reducing production yield.
Innovation Solution
A method involving the creation of a ceramic slurry by mixing ceramic powder, resin, and curing agent, injecting it into an elastic container, curing to form a molded body, and then demolding to minimize burrs, followed by drying, degreasing, and firing to produce a sintered body with reduced processing needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal mold or rubber mold divided into two or more pieces is used to form a spherical molded body, then the molding process can be completed, but burrs inevitably form at the mold joining portion
Solution Approach 1:
The patent uses a flexible rubber mold instead of rigid metal molds divided into pieces. The rubber mold can be continuously deformed and opened, allowing the molded body to be removed without requiring mold joints, thereby eliminating burr formation at joining portions while maintaining ease of manufacture
Solution Approach 2:
The invention segments the mold removal process by using a rubber mold that can be cut into multiple pieces after molding. This allows the mold to be separated for demolding without creating burrs during the molding process itself, as the flexible material conforms to the cavity without requiring rigid joints
2Productivity
If significant burrs are formed during molding, then the molded body can be produced, but labor and production costs increase due to extensive burr removal
Solution Approach 1:
The patent converts the potential harm of burr formation into a benefit by using a flexible rubber mold that naturally prevents burr formation at all. This eliminates the need for subsequent burr removal processes, directly improving productivity while reducing processing complexity and costs
3Productivity
If burrs are present on the molded body, then the molding process is complete, but defects occur during polishing reducing production yield
Solution Approach 1:
The patent applies preliminary anti-action by preventing burr formation in the first place through the use of a flexible rubber mold. This preliminary prevention eliminates the need for corrective actions during polishing and ensures high product quality without reducing production yield
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 results in ceramic articles with fewer burrs, reduced processing requirements, lower production costs, and enhanced yield by achieving a sintered body with desired shape and properties.
Implementation Method 1
curing the resin in the raw material slurry injected into the elastic container to form a molded body having a desired shape
Implementation Method 2
firing the degreased molded body
Data Source
AI summary
A method for molding a ceramic material includes: mixing a ceramic powder, a resin, a curing agent and a solvent to obtain a raw material slurry for a ceramic material; injecting the raw material slurry into an elastic container; curing the resin in the raw material slurry injected into the elastic container to form a molded body having a desired shape; and demolding the molded body from the elastic container.