Composite Mold Element Layers for Low-Force Metal Forming
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Solution Overview
Problem
Conventional metal machining tools formed entirely from metal require high holding-down forces and can cause deformation, warping, or surface flaws during metal forming processes due to their uniform material properties and coefficients of friction, limiting process windows and efficiency.
Innovation Solution
A metal machining tool is produced using a first mold element made of plastics material with strategically applied layers of different plastics materials, enhancing the coefficient of friction and load-bearing capabilities, and a second mold element with complementary geometry, allowing for reduced holding-down forces and improved dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal machining tools are formed entirely from metal, then structural strength is ensured, but high holding-down forces are required causing deformation and surface flaws
Solution Approach 1:
The mold element is constructed as a composite structure with a metal base body providing structural strength and plastic material layers applied on the contact surfaces. This combination allows the metal substrate to bear mechanical loads while the plastic layers reduce friction and holding-down forces, preventing deformation and surface flaws of the workpiece.
Solution Approach 2:
Different materials are applied to different regions of the mold element. The metal base body provides overall structural support, while plastic material layers are selectively applied on specific contact surfaces where friction reduction is needed. This local differentiation optimizes both structural integrity and surface interaction properties.
2Ease of manufacture
If uniform material properties are used in metal tools, then manufacturing simplicity is maintained, but process windows are limited and efficiency is reduced
Solution Approach 1:
The mold element features non-uniform material distribution with different plastic material layers applied on different contact surfaces. Each layer can have different friction coefficients and mechanical properties optimized for specific forming operations, expanding the process window and improving machining efficiency while maintaining a relatively simple manufacturing approach.
3Stability of the object's composition
If high holding-down forces are applied, then material stability is maintained, but tensile forces increase causing warping and deformation
Solution Approach 1:
The plastic material layers on the contact surfaces have lower friction coefficients compared to metal-on-metal contact. This reduces the holding-down forces required to maintain material stability during forming, thereby decreasing tensile forces that would otherwise cause warping and deformation of the workpiece.
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 tool reduces deformation and warping risks, diminishes tensile forces, and allows for higher machining speeds and flexibility in load distribution, enabling the production of structural parts with consistent thickness and reduced material removal time.
Implementation Method 1
Plastics material is filled into the at least one cavity and cured, wherein the plastics material is connected to the surface of the main body at the at least one region and is applied thereto, forming the layer
Data Source
AI summary
A method for producing a first mold element for a metal machining tool, wherein the first mold element is configured as a holding-down mechanism, for producing the first mold element, a main body made of plastics material is provided, wherein a surface of the main body is subdivided into a plurality of regions, on at least one region of the surface of the main body, at least one casting mold is arranged, wherein the at least one casting mold and the at least one region of the surface enclose at least one cavity, which forms a negative mold for a layer of plastics material to be applied, wherein plastics material is filled into the at least one cavity and cured, wherein the plastics material in the at least one region is connected to the surface of the main body and applied to it, forming the layer.