Ferrite Molding With Integrated Gap Forming to Reduce Breakage
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Solution Overview
Problem
The existing ferrite manufacturing process has a low yield due to breakage during gap forming and microcracks, leading to significant losses in the assembly stage, with a yield of only about 60-65%.
Innovation Solution
A ferrite molding process that integrates a gap forming structure into the molding mold, allowing direct compression and sintering of powder into a blank, followed by molding to form the ferrite without a separate gap forming step, and optionally forming the body and boss structures separately or integrally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a separate gap forming step is performed after sintering, then the ferrite can be manufactured with the required gap structure, but the part becomes extremely fragile and breakage occurs during gap forming and tumble finishing
Solution Approach 1:
The gap structure is pre-formed in the molding mold before sintering. The mold includes gap forming structures that create the gap during the initial compression molding step, so the gap exists in the green blank before sintering. This preliminary formation of the gap structure eliminates the need for subsequent gap forming operations on the sintered part, preventing breakage while maintaining the required geometry.
Solution Approach 2:
The gap forming operation is merged with the compression molding step. The molding mold integrates both the compression function and the gap forming function, so that a single operation simultaneously achieves both the consolidation of the powder and the creation of the gap structure. This eliminates the separate gap forming step that causes breakage.
2Shape
If mechanical cutting is used for gap forming, then the gap can be formed in the sintered part, but the part becomes extremely fragile and yield is reduced to about 60%
Solution Approach 1:
The gap structure is pre-formed in the molding mold before sintering. The mold includes gap forming structures that create the gap during the initial compression molding step, so the gap exists in the green blank before sintering. This preliminary formation of the gap structure eliminates the need for subsequent gap forming operations on the sintered part, preventing breakage while maintaining the required geometry.
Solution Approach 2:
The harmful gap forming operation is extracted from the sintered part processing sequence and transferred to the green blank stage. By removing the gap forming step from post-sintering operations, the source of breakage and low yield is eliminated, while the gap structure is still achieved through the preliminary molding action.
3Manufacturing precision
If tumble finishing is performed on parts with microcracks, then surface finish is improved, but hidden microcracks lead to assembly failures and yield loss of 5% or below
Solution Approach 1:
The gap structure is pre-formed in the molding mold before sintering. The mold includes gap forming structures that create the gap during the initial compression molding step, so the gap exists in the green blank before sintering. This preliminary formation of the gap structure eliminates the need for subsequent gap forming operations on the sintered part, preventing breakage while maintaining the required geometry.
Solution Approach 2:
The structure is strengthened beforehand by avoiding the fragile gap forming step on sintered parts. By forming the gap in the green blank stage and completing sintering with the gap already present, the part maintains structural integrity throughout processing, cushioning against the development of microcracks that would otherwise lead to assembly failures.
4Ease of manufacture
If multiple separate processing steps are used for compression, sintering, gap forming, and finishing, then each step can be optimized independently, but the overall process complexity increases and yield is reduced
Solution Approach 1:
The gap forming operation is merged with the compression molding step. The molding mold integrates both the compression function and the gap forming function, so that a single operation simultaneously achieves both the consolidation of the powder and the creation of the gap structure. This eliminates the separate gap forming step that causes breakage.
Solution Approach 2:
The molding mold is designed with multi-functionality, serving both as the compression tooling and as the gap forming structure. The mold includes integrated gap forming structures that perform the gap creation function during the standard compression molding operation, eliminating the need for dedicated gap forming equipment and reducing overall process complexity.
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 process enhances the structural strength of the sintered blank, reduces breakage, and improves the overall yield of the ferrite manufacturing process to above 70%, while minimizing the need for gap forming equipment.
Implementation Method 1
the blank is sintered in a heating furnace to form a sintered blank
Implementation Method 2
high pressure is applied for compression molding
Data Source
AI summary
Provided are a ferrite molding process, a ferrite molding mold, and a ferrite, which belong to the field of ferrite preparation technologies. The ferrite molding process includes the following steps: adding a powder to a molding mold, where the molding mold is provided with a gap forming structure, and the gap forming structure is used for forming a gap of a ferrite; compressing the powder into a blank; sintering the blank in a heating furnace to form a sintered blank; and performing molding on the sintered blank to obtain a ferrite. The ferrite molding mold includes a main molding mold, and the main molding mold is provided with a molding cavity for molding a blank and a gap forming structure for forming a gap of a ferrite.