Split-Die Press Tool Geometry for Powder Leakage Restraint
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Solution Overview
Problem
Conventional split-die press tools experience powder leakage during the filling process, which can affect operator health, damage the tool, and cause shape deviations in the green body of double-sided and double positive cutting inserts.
Innovation Solution
The split-die press tool design includes inclined side surface portions that extend from the pressing level to the expansion level, with a second side surface portion positioned to narrow the horizontal gap and prevent powder leakage by aligning vertically with the first side surface portion and extending to a restraining level where the horizontal distance to the punch unit is reduced, thereby containing escaping powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the press tool uses a conventional design with horizontal die sections and vertical punches for forming green bodies, then the tool can produce double-sided and double positive cutting inserts with the required geometry, but powder leaks between the lower punch and die sections during filling, causing health hazards, tool damage, and shape deviations
Solution Approach 1:
The invention introduces a new dimensional approach by inclining the lower die section surface at an angle β (≥α) relative to the horizontal plane, rather than using a conventional horizontal surface. This angular orientation creates a self-contained geometry that directs powder away from the leakage path between the punch and die section, effectively preventing powder escape in the vertical dimension while maintaining forming precision
Solution Approach 2:
The inclined lower die section surface acts as an intermediary element between the punch and the powder material. By introducing this angled surface as a mediating structure, the invention creates a controlled interface that prevents direct contact and leakage pathways, thereby eliminating the harmful powder leakage effect while maintaining the necessary forming function
2Manufacturing precision
If the lower punch is positioned at the upper most position inside the press tunnel during compression, then the green body can be formed with the correct dimensions, but powder leaks out between the lower punch and side surface of die sections during filling
Solution Approach 1:
The invention changes the orientation of the lower die section surface from horizontal to inclined at angle β (≥α). This angular configuration creates a geometric barrier that prevents powder from reaching the space between the punch and die section during filling, thereby eliminating health hazards and tool damage while preserving compression accuracy
Solution Approach 2:
The inclined die section surface is designed to preemptively counteract the powder leakage tendency by creating a self-contained geometry during the filling operation. The angular surface prevents powder from accumulating or escaping toward the punch-die interface before leakage can occur, thereby preventing health and safety issues in advance
3Manufacturing precision
If the press tunnel surface extends below the front end surface of the lower punch to allow green body expansion, then the green body can expand downward without damaging the bottom edge, but the horizontal gap between the lower punch and die section allows powder to leak out
Solution Approach 1:
By inclining the lower die section surface at angle β (≥α), the invention creates a three-dimensional containment geometry that prevents powder from accessing the expansion space. The angular surface acts as a barrier that maintains edge integrity while preventing the horizontal gap from becoming a leakage pathway, thereby eliminating powder loss
Solution Approach 2:
The invention applies a localized geometric modification to the lower die section surface, creating an inclined region with specific angular properties (β ≥α) at the critical interface area. This localized angular configuration provides powder containment exactly where needed, preventing loss while maintaining the expansion space functionality
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 effectively reduces powder leakage during the filling and decompression processes, ensuring the green body expands without damaging the bottom edge and allowing for precise formation of double-sided and double positive cutting inserts with improved accuracy and safety.
Implementation Method 1
the green body expands downward when decompressing without risking to damage the bottom edge at the lower end of the inclined side surface
Implementation Method 2
a second side surface portion which is vertically aligned with the first side surface portion and extends from the expansion level to a restraining level, wherein a horizontal distance from the second side surface portion to the adjacent punch unit at the restraining level is less than at the expansion level
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A split-die press tool for forming, by compressing a powder, a green body (8) for a double-sided and double positive cutting insert for metal cutting comprising a die with at least two die sections (1, 2), wherein the die sections (1, 2) form between them a punch tunnel (18) extending along a vertical pressing axis (6), and an upper punch unit (3) and a lower punch unit (4), wherein, when the lower punch unit (4) is in a distal position in form of a decompression position, a front end periphery (20) of the lower punch unit (4) is at a first expansion level (24) corresponding to a maximal downward vertical decompression expansion of the green body (8) to be formed. The punch tunnel (18) comprises a first side surface portion (22) located on at least one of the die sections (1), which first side surface portion (22) has a vertical extension downward from the first pressing level (23) to the first expansion level (24) and is inclined downward and away from the pressing axis (6) by an angle β of at least the angle α of an adjacent inclined lower surface (13) of the green body (8) to be formed. The punch tunnel (18) comprises a second side surface portion (25) located on the at least one of the die sections (1), which second side surface portion (25) is vertically aligned with the first side surface portion (22) and has a vertical extension downward from the first expansion level (24) to a first restraining level (27), and at which first restraining level (27) a horizontal distance to the adjacent front end periphery of the lower punch unit (4) is less than at the first expansion level (24).