Tire Vulcanizing Mold Segmentation for Thermal Strain Control
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Solution Overview
Problem
Current methods for producing tire vulcanizing molds face challenges in achieving high precision, durability, and cost-effectiveness, with die-casting being complex and costly, and rapid prototyping prone to deformation and increased costs with mold volume.
Innovation Solution
A method involving the assembly of a pattern molding segment produced by rapid prototyping onto a metal base segment using bolts, where the pattern molding segment is made to correct deformation and the metal base segment is precision-cast, reducing thermal strain and production processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If rapid prototyping is used to produce the pattern molding segment, then production time is reduced and cost is lowered, but the segment is prone to deformation by thermal strain
Solution Approach 1:
The mold is divided into two segments: a pattern molding segment produced by rapid prototyping and a metal base segment. This segmentation allows the rapid prototyping segment to be optimized for quick production while the metal base provides structural stability and resistance to thermal strain, resolving the contradiction between production speed and dimensional stability.
Solution Approach 2:
The mold combines two different materials: a resin-based pattern molding segment from rapid prototyping and a metal base segment. This composite structure leverages the advantages of both materials - the rapid prototyping material enables fast, low-cost production of complex patterns, while the metal base provides thermal stability and structural strength, thereby resolving the contradiction between production efficiency and dimensional precision.
2Manufacturing precision
If die-casting is used to produce the mold, then manufacturing precision and durability are improved, but the number of processes and cost increase
Solution Approach 1:
The mold is segmented into a pattern molding segment and a metal base segment that can be produced by different methods. The pattern molding segment is produced by rapid prototyping while the base is produced by die-casting, allowing each segment to be optimized by the most suitable manufacturing process rather than requiring the entire mold to be produced by the more complex die-casting method.
Solution Approach 2:
The invention merges two different manufacturing approaches - rapid prototyping for the pattern molding segment and die-casting for the metal base segment. This combination allows the mold to achieve the high precision and durability of die-casting while reducing the overall number of processes and cost by using rapid prototyping for the pattern segment, thereby resolving the contradiction between precision and process complexity.
3Loss of time
If rapid prototyping is used for large volume molds, then production time remains short, but cost rises dramatically
Solution Approach 1:
The mold is segmented into a pattern molding segment produced by rapid prototyping and a metal base segment produced by die-casting. This segmentation allows the expensive rapid prototyping process to be applied only to the smaller pattern segment rather than the entire large-volume mold, thereby controlling material costs while maintaining the production time advantages of rapid prototyping.
Solution Approach 2:
The invention applies different manufacturing qualities to different parts of the mold: rapid prototyping is used locally for the pattern molding segment where complex geometry is needed, while die-casting is used for the metal base segment where structural strength and thermal stability are prioritized. This local differentiation allows cost-effective production of large-volume molds while maintaining short production times.
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 results in a tire vulcanizing mold with improved durability, precision, and reduced production costs, while minimizing the number of operational processes compared to traditional methods.
Implementation Method 1
it has a problem of greater likelihood of deformation by thermal strain due to its specificity that each layer is produced by repeating heating and sintering and stacked together
Implementation Method 2
fastening and pressing the pattern molding segment and the metal base segment in a width direction and a circumferential direction by screwing bolts into bolt holes
Data Source
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AI summary
To provide a method for producing a tire vulcanizing mold capable of obtaining a tire vulcanizing mold having excellent durability and high precision at low cost and to provide such a tire vulcanizing mold, the method includes producing a tire vulcanizing mold (sector mold (4)) by assembling a pattern molding segment (pattern mold (30)), produced by rapid prototyping, on a metal base segment (base mold (20)), the method further includes a step of producing the pattern molding segment from a metal based on a shape of a surface layer part (pattern-side mold model (M3)) including a pattern shaping surface in a basic model (mold model (M1)) of the tire vulcanizing mold.