Cutting Insert Green Body Compression Die Segmentation
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Solution Overview
Problem
The existing methods for manufacturing cutting insert green bodies result in residual edges and porosity due to powder leakage during the compression process, leading to increased production costs and potential deformation of the upper edge.
Innovation Solution
The method involves subdividing the die into an upper and lower die, with the upper die being removable, reducing the need for a large release portion and minimizing the gap between the punch edge and the die, thereby minimizing powder leakage and residual edges. The lower die has an inclined inner peripheral surface to facilitate ejection and maintain the shape of the green body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a large release portion is provided in the die cavity to enable green body expansion upon ejection, then the green body can be successfully ejected without damage, but powder leakage increases forming residual edges and porosity
Solution Approach 1:
The die is divided into two separate parts: a first die for compression and a second die for ejection. This segmentation allows the first die to be removed after compression, eliminating the need for a large release portion in the compression cavity, thereby preventing powder leakage and residual edge formation while still enabling successful ejection through the second die
2Productivity
If the upper punch is forwarded close to the inner peripheral surface of the die to minimize gap, then compression efficiency improves, but contact between punch edge and die causes damage
Solution Approach 1:
By separating the die into two parts, the first die can be positioned very close to the punch edge during compression without risk of damage, as the first die is removed before ejection. This eliminates the need for a large safety gap while maintaining system reliability
3Manufacturing precision
If a small release portion is used to minimize powder leakage, then residual edges are reduced, but the green body cannot expand sufficiently upon ejection
Solution Approach 1:
The first die provides a small release portion to minimize powder leakage during compression, while the second die provides the necessary expansion space for successful ejection. This segmentation allows both requirements to be satisfied simultaneously without compromise
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 the formation of residual edges and porosity, minimizing material loss and ensuring a more accurate shape of the cutting insert green body, thus enhancing the sintering process and reducing production costs.
Implementation Method 1
the lower die has an inclined inner peripheral surface to facilitate ejection
Implementation Method 2
a method for manufacturing a cutting insert green body by compressing a powder
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
A method and device for manufacturing a cutting insert green body by compressing a powder, the method comprising the steps of providing a compression tool comprising an upper die (1) and a lower die (2), an upper punch (3) and a lower punch (4), wherein the upper die (1) defines a punch tunnel (7) in which the upper punch (3) is able to slide, and the lower die (2) defines a punch tunnel (8) in which the lower punch (4) is able to slide, and wherein the dies (1, 2), when joined, together define a die cavity (9) provided to accommodate a powder to be compressed by action of the respective punches for the forming of said green body, compressing a powder in said die cavity (9) by forwarding the upper punch (3) through the punch tunnel of the upper die (1), wherein the upper punch (3) is forwarded a predetermined distance L through said opening of the lower die (2) and into the lower die (2); displacing the upper die (1) relative the opening (15) of the lower die (2); and removing the upper punch (3) from the lower die (2), and moving the green body out of the lower die (2) through said opening (15) of the lower die (2).