Powder Mold Lubricant Circulation System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods face challenges in uniformly applying lubricant to mold assemblies for powder mold products, leading to inconsistent quality and productivity issues, especially when dealing with high-frequency applications where iron loss is significant.
Innovation Solution
A method involving a mold assembly with a supply port and drain port for lubricant circulation, where the lubricant is applied to the inner circumferential face of the die using relative shifting of punches and dies, ensuring uniform application and preventing clogging, thereby enhancing the productivity and quality of powder mold products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spraying or brush application is used to apply lubricant to mold assembly, then friction between mold assembly and powder mold product is reduced, but uniform application of lubricant becomes difficult especially as application area increases
Solution Approach 1:
A lubricant circulation system with supply port and drain port is introduced as an intermediary mechanism between the mold assembly and external lubricant application devices. The lubricant flows through the mold assembly itself, ensuring uniform distribution across the sliding contact face without requiring direct external application to large areas.
Solution Approach 2:
The mold assembly serves its own lubrication function by incorporating supply and drain ports that allow lubricant to circulate through its internal structure. The relative shifting between punch and die automatically distributes lubricant uniformly during the molding process, eliminating the need for separate external application mechanisms.
2Productivity
If successive fabrication of multiple powder mold products is performed, then productivity increases, but the applied state of lubricant tends to vary leading to quality inconsistency
Solution Approach 1:
The circulation system includes a drain port that collects used lubricant and returns it to the supply reservoir. This closed-loop feedback mechanism ensures that lubricant is continuously replenished and redistributed uniformly across the mold assembly during successive molding operations, maintaining consistent product quality.
Solution Approach 2:
The lubricant circulation operates continuously throughout the successive molding process. The lubricant is constantly supplied, distributed, collected, and reused, ensuring that the sliding contact face maintains optimal lubrication state for every molding operation without interruption or degradation.
3Productivity
If high frequency operation is used to increase productivity, then energy loss due to eddy current increases significantly
Solution Approach 1:
The insulating layer is extracted or removed from the coated particles during the molding process. The lubricant circulation system facilitates this by enabling the insulating layer to be stripped off during relative shifting between punch and die, allowing high-frequency operation without excessive eddy-current loss while maintaining acceptable product quality.
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 allows for the consistent production of powder mold products with reduced iron loss, maintaining excellent magnetic characteristics and productivity even at high frequencies, by ensuring uniform lubricant application and preventing accumulation of fine powder.
Implementation Method 1
a lubricant is applied to a mold assembly by spraying or with a brush. Thus, friction between the mold assembly and the powder mold product is reduced
Data Source
AI summary
The present invention relates to a method for molding a powder mold product according to which a powder mold product of uniform quality can be molded with excellent productivity. The present invention includes the steps of: preparing raw material powder 3 (a preparing step); interposing a mold assembly-use lubricant between an outer circumferential face 12s of a first punch (a lower punch 12) and an inner circumferential face 10s of a die 10, the lower punch 12 and the die 10 in this state being relatively shifted to apply the mold assembly-use lubricant to the inner circumferential face 10s of the die 10 (an applying step); and packing the raw material powder 3 into a cavity, a powder mold product 100 being molded by the raw material powder 3 being pressed (a molding step). In the applying step, while the mold assembly-use lubricant is discharged from a supply port 12i provided to the lower punch 12 and the discharged mold assembly-use lubricant is collected from a drain port 12o provided to the lower punch 12, the mold assembly-use lubricant is applied to the inner circumferential face 10s of the die 10.