Cutting Insert Green Compact Pressing for Uniform Powder Density
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Solution Overview
Problem
The existing powder molding press methods for cutting inserts with uneven upper and lower surfaces and varying thicknesses result in density dispersion of raw material powder, leading to strain or deformation during sintering.
Innovation Solution
A method and device that involve a preliminary molding step using a punch with a shape different from the inverted shape of the cutting insert's surface, ensuring the thick portions are filled with more raw material powder than thin portions, followed by final molding to achieve uniform density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the green compact is powder-molding-pressed by a die with punches having shapes matching the uneven surfaces, then the cutting insert can be manufactured with largely uneven upper and lower surfaces and varying thicknesses, but density dispersion occurs in the raw material powder leading to strain or deformation during sintering
Solution Approach 1:
The patent applies preliminary action by performing a preliminary molding step before the final molding. In this preliminary step, the upper punch is designed with a shape that is NOT the inverted shape of the uneven upper surface, allowing raw material powder to be preliminarily formed and then refilled. This preliminary action ensures that thick portions are filled with more raw material powder than thin portions, preventing density dispersion during subsequent final molding and sintering processes.
Solution Approach 2:
The patent segments the molding process into two distinct stages: preliminary molding and final molding. The preliminary molding uses a special upper punch shape that differs from the inverted uneven surface shape, while the final molding uses the conventional punch shape. This segmentation allows the preliminary step to focus on achieving proper density distribution by filling thick portions with more powder, while the final step achieves the target uneven shape.
2Shape
If the upper and lower surfaces of the cutting insert are made largely uneven with varying thicknesses, then the cutting insert can meet modern design requirements, but the green compact requires complex preliminary molding to prevent density dispersion
Solution Approach 1:
The patent uses preliminary action by introducing a preliminary molding step that prepares the raw material powder distribution before final molding. The upper punch for preliminary molding has a specific shape design that enables thick portions to be filled with more raw material powder. This preliminary preparation simplifies the overall process by establishing proper density distribution early, avoiding the need for complex adjustments during final molding or sintering.
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 prevents strain or deformation by ensuring uniform density in the green compact, enabling the production of cutting inserts with high precision and quality, even when the upper and lower surfaces are largely uneven and have partially different thicknesses.
Implementation Method 1
performing a preliminary molding by inserting an upper punch for preliminary molding including a preliminary molding surface having a shape different from a shape obtained by inverting the upper surface of the green compact for a cutting insert in plane symmetry as a lower end surface of the upper punch for preliminary molding into the molding space from above such that a thick portion between the upper and lower surfaces in the direction of the insert center line is filled with more raw material powder than a thin portion therebetween
Data Source
AI summary
A powder molding press method of a green compact for a cutting insert including: filling a molding space with raw material powder in a state where a lower punch is inserted from below into a hole portion of a die; performing preliminary molding by inserting an upper punch for preliminary molding including a preliminary molding surface having a shape different from a shape obtained by inverting the upper surface of the green compact for a cutting insert in a plane symmetry into the molding space from above such that a thick portion between the upper and lower surfaces in the direction of the insert center line is filled with more raw material powder than a thin portion therebetween, relative to a state before the step of performing the preliminary molding; and inserting an upper punch for final molding into the molding space from above to powder-molding-press the raw material powder.