Near-Net-Shape Spray Forming of Soft Magnetic Components
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Solution Overview
Problem
Existing methods for spray-forming soft-magnetic materials often result in components with tapered edges that require expensive and time-consuming post-machining to achieve the desired geometry, which is inefficient and costly.
Innovation Solution
The method involves using a movable mold mounted on a stage relative to a spray gun, allowing precise control of the deposition of soft magnetic composite materials through a series of scanning motions and varying angles of incidence to fill mold cavities completely, thereby forming components in a near-net shape with minimal post-finishing needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spray-forming is performed without a movable mold, then the process is simpler, but the components have tapered edges requiring extensive post-machining
Solution Approach 1:
The mold is mounted on a movable stage that can be positioned at different locations during the spray-forming process. This dynamic positioning allows the mold to be moved to optimize material deposition angles and control the formation of component edges, eliminating tapered edges and reducing post-machining requirements while maintaining geometric precision.
2Ease of manufacture
If a movable mold on a stage is used, then near-net shape components are achieved, but the device complexity increases
Solution Approach 1:
The mold is positioned on a movable stage that enables motion in multiple dimensions during the spray-forming process. This multi-dimensional control allows precise adjustment of the mold position relative to the spray nozzle, enabling near-net shape fabrication by controlling material deposition from multiple angles and positions, thereby minimizing post-finishing requirements.
3Manufacturing precision
If extensive post-machining is performed, then desired geometry is achieved, but production time and cost increase
Solution Approach 1:
The movable mold system performs preliminary shaping actions during the spray-forming process itself, creating near-net shape components that closely match the final desired geometry. By pre-forming the component with precise geometry control during deposition, the need for extensive post-machining is eliminated, significantly improving production efficiency and reducing manufacturing time.
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 enables the production of components with precise geometry and reduced material removal, eliminating the need for extensive post-machining and allowing for the reuse of molds, thus improving efficiency and reducing costs.
Implementation Method 1
spraying a soft magnetic composite material through a nozzle and into a mold
Implementation Method 2
deposition of the soft magnetic composite material into the mold
Data Source
AI summary
A method for spray-forming a component comprises spraying a soft magnetic composite material through a nozzle and into a mold; and adjusting a position of the mold relative to a position of the nozzle to control a deposition of the soft magnetic composite material into the mold. Adjusting the position of the mold relative to a position of the nozzle is carried out with mounting the mold on a stage such that the mold is movable relative to the nozzle and the spraying of the soft magnetic composite material is controlled to provide the deposition of the soft magnetic composite material to form the component in a near-net shape.