Press-Tool With Movable Die Members For Barrel-Shaped Inserts
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Solution Overview
Problem
The manufacturing of cross-hole cutting inserts with non-parallel core arrangements leads to uneven density distribution in the green body, causing deformation during sintering and necessitating costly post-machining, as existing press-tools are either too complex or unsuitable for producing barrel-shaped green bodies.
Innovation Solution
A press-tool design featuring movable die members and integrated core portions that follow the movement of the die members, reducing the need for auxiliary drives and allowing for the formation of a through-hole without damaging the cutting insert green body, resulting in a simpler and more robust manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a non-splitable die cavity is used, then the press-tool structure is simple, but it is impossible to eject barrel-shaped cutting insert green bodies without damage
Solution Approach 1:
The die cavity is divided into two separate die members (first die member and second die member) that can move relative to each other along a second axis B. This segmentation allows the die members to open and eject barrel-shaped green bodies without damage, while maintaining structural simplicity compared to fully complex multi-axis systems.
Solution Approach 2:
The die members are made movable along the second axis B, transforming the static non-splitable die cavity into a dynamic system. This dynamic capability enables the die members to open and close, allowing ejection of barrel-shaped green bodies while maintaining press-tool simplicity.
2Device complexity
If movable die members with integrated core portions are used, then the press-tool complexity is reduced, but the capability to form through-holes in barrel-shaped green bodies must be maintained
Solution Approach 1:
The core portions are integrated into the die members, merging the core formation function with the die member structure. This eliminates the need for separate auxiliary drives for core portions, reducing press-tool complexity while maintaining the capability to form through-holes in barrel-shaped green bodies.
Solution Approach 2:
The core portions are moved together with the die members along the second axis B, making the core portions self-servicing through the die member movement. This eliminates the need for independent auxiliary drive mechanisms, reducing overall system complexity while preserving through-hole formation capability.
3Ease of operation
If conventional pressing methods are used, then the press-tool operation is simple, but uneven density distribution causes green body deformation during sintering
Solution Approach 1:
The die members are designed to move along a second axis B that is non-parallel to the pressing axis A, creating an asymmetric movement pattern. This asymmetric movement, combined with the barrel-shaped cavity design, enables uniform density distribution in the green body while maintaining simple pressing operation.
Solution Approach 2:
The pressing operation utilizes movement along a non-parallel second axis B, changing the geometric parameters of the pressing process. This parameter change enables the formation of barrel-shaped green bodies with uniform density distribution, preventing deformation during sintering while keeping the operation simple.
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 design enables the efficient and reliable production of cutting inserts with a through-hole, reducing the complexity and cost of the press-tool while minimizing deformation issues, allowing for faster and more accurate manufacturing of near-net shape cutting inserts.
Implementation Method 1
The powder is compacted into a cutting insert green body by opposing first and second punches in a die cavity
Implementation Method 2
After compaction, the cutting insert green body is removed from the die cavity and sintered into a solid cutting insert
Data Source
AI summary
A press-tool for manufacturing a cutting insert green body includes a first and a second punch movable along a first pressing axis. A first and a second die member are movable towards an end position. The first and the second die members are configured to form, in the end position, a die cavity. A core extends between and through the die cavity when the first and the second die member are in the end position. At least a first core portion is arranged to form the core, wherein the at least first core portion is arranged in the first or the second die member such that the at least first core portion is moved together with the first or the second die member.