3D-Printed Hot Press Die Projections for Hard Convex Forming
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Solution Overview
Problem
Conventional hot press forming dies face challenges in forming convex portions with sufficient hardness and height, leading to increased wear resistance issues, lengthy repair times, and high manual labor costs due to the need for electrochemical machining, chemical etching, or plating methods, which hinder efficient cooling medium flow and risk clogging of ejection holes.
Innovation Solution
A hot press forming die with a die main body made of alloy tool steel, featuring forming projections formed by a 3D printer using steel-based materials with higher hardness than the die main body, where the projections are designed as projecting strips to enhance wear resistance and cooling efficiency, allowing for improved forming surface contact and refrigerant passage flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If forming projections are formed by electrochemical machining, chemical etching, electric discharge machining, or plating method, then the forming projections can be created on the die, but the process becomes complex and time-consuming, and the die must be dipped in liquid tanks
Solution Approach 1:
The patent replaces complex chemical and electrochemical processes with a simple mechanical pressing method. The forming projections are created by pressing a forming mold against the die surface, eliminating the need for electrochemical machining, chemical etching, or plating operations. This mechanical approach is much simpler and does not require liquid tanks or complex equipment.
2Reliability
If forming projections are made with sufficient height and hardness, then wear resistance improves, but conventional methods cannot easily achieve both sufficient height and high hardness simultaneously
Solution Approach 1:
The patent uses a composite structure where the forming projections are made of a material with different properties than the die body. Specifically, the forming projections are made of a hard material (such as cemented carbide or hardened steel) that is pressed onto the die surface. This composite approach allows the projections to have high hardness and wear resistance while being easily manufactured through the pressing process.
3Ease of repair
If forming projections are repaired by manual build-up welding, then the worn projections can be restored, but the work time and cost increase significantly
Solution Approach 1:
The patent replaces the complex manual welding repair process with a simple mechanical pressing operation. When forming projections wear down, they can be quickly restored by pressing a new forming mold against the die surface, which is much faster and simpler than manual build-up welding. This eliminates the need for heating, welding, and extensive finishing operations.
4Ease of manufacture
If forming projections are made by conventional methods, then they can be created on the die, but the ejection holes and suction holes for cooling medium may be closed by build-up welding material
Solution Approach 1:
The patent replaces the welding process with a mechanical pressing process that does not involve molten material. Since the forming projections are created by pressing a mold against the die surface rather than by welding, there is no risk of build-up welding material clogging the ejection holes and suction holes. The cooling holes remain clear and functional.
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 3D-printed forming projections with higher hardness and increased surface area improve pressure resistance, prevent slipping of metal plates, enhance cooling efficiency, and reduce the risk of clogging, resulting in a more efficient and cost-effective forming process with reduced manual labor requirements.
Implementation Method 1
the forming projection provided on the third forming portion is formed by a 3D printer
Implementation Method 2
a cooling device configured to quickly cool the metal plate material by applying a cooling medium to the metal plate material at the time of forming
Data Source
AI summary
A hot press forming die includes a die main body (2) made of alloy tool steel, and a number of forming projections (3) projecting on the die main body and configured to form a forming surface (5) that comes into contact with a heated metal plate material that is an object to be formed and form a refrigerant passage through which a cooling medium flows. The die main body includes a first forming portion (14) in which the forming surface is formed to extend in a direction intersecting a forming direction of the metal plate material, a second forming portion (15) in which the forming surface is formed to extend in the forming direction, and a third forming portion (16) configured to connect the first forming portion and the second forming portion such that the forming surface becomes a convex surface. The forming projection provided on the third forming portion is formed to be a projecting strip extending between the first forming portion and the second forming portion.It is possible to provide a hot press forming die for which forming convex portions with a high hardness can easily be formed.