Vulcanizing Mold Segments Using Milled Rib Skeletons and Additive Inserts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing mold segments for vulcanizing molds are time-consuming, require large installations, and result in warped components due to internal stresses, especially when using additive manufacturing for large-volume parts, necessitating complex and costly post-processing.
Innovation Solution
A hybrid method where a rib skeleton is milled from a base part, and inserts are built up using an additive method to complete the ribs, allowing for precise and cost-effective production of mold segments with minimal material and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If large-volume mold segment parts are produced by additive manufacturing methods, then complex designs with large number of lamellae can be achieved, but production time increases and large installations are required
Solution Approach 1:
The mold segment is divided into two parts: a base part produced by conventional machining and inserts produced by additive manufacturing. The base part contains a rib skeleton milled from solid material, while inserts containing only the complex lamellae structures are additively manufactured and fitted into the base part. This segmentation allows each component to be optimized for its respective manufacturing method, avoiding the need to additively manufacture entire large-volume parts.
2Adaptability or versatility
If large-volume mold segment parts are produced by additive manufacturing methods, then complex designs can be achieved, but large installations with multi-laser systems are required
Solution Approach 1:
The manufacturing process is segmented such that only small insert components are produced by additive manufacturing using standard equipment, while the large base part is produced by conventional machining. This eliminates the need for large-volume additive manufacturing installations and multi-laser systems, as the additive process is applied only to small, localized insert elements.
3Adaptability or versatility
If large-volume mold segment parts are produced by additive manufacturing methods, then complex designs can be achieved, but internal stresses cause warping requiring special manufacturing methods
Solution Approach 1:
The mold segment is segmented into a conventionally machined base part and additively manufactured inserts. By limiting additive manufacturing to small insert components rather than large-volume parts, internal stresses and warping are minimized. The inserts are produced with reduced distortion risk and can be precisely fitted into the machined base part, maintaining overall dimensional stability.
Solution Approach 2:
The base part is pre-machined to include precise recesses and mounting features before the inserts are additively manufactured. This preliminary preparation ensures that when the inserts are produced and fitted, they integrate seamlessly with the base part, maintaining precision without requiring post-manufacturing stress relief or special handling procedures.
4Adaptability or versatility
If complete mold segments are produced by additive manufacturing methods, then complex designs can be achieved, but considerable milling effort is required for post-processing
Solution Approach 1:
The mold segment is segmented into a conventionally machined base part and additively manufactured inserts. The base part is machined to precise tolerances and includes ready-to-receive recesses. The inserts are additively manufactured with their final shapes, requiring minimal post-processing. This division eliminates the need for considerable milling effort that would be required if entire large-volume parts were additively manufactured.
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
The hybrid method reduces production time and costs while maintaining precision, eliminating distortion and internal stresses, enabling modular and efficient production of complex tire tread profiles.
Implementation Method 1
inserts, in particular inserts with frame parts, are built up by means of an additive method, in particular by means of SLM (selective laser melting)
Data Source
AI summary
A method for producing a mold segment of a vulcanizing mold for a pneumatic vehicle tire for forming the profiling of a tread, having a metallic base part (6) with a mold side with ribs (3) which form channels encircling or delimiting profile elements.A rib skeleton (8) consisting of ribs (8′), the arrangement and the profile of which at least partially corresponds to the arrangement and the profile of ribs (3) forming channels, is milled from the base part (6),inserts (7) with peripheral frame parts (7b) are built up by means of an additive method,the inserts (7) being inserted into the rib skeleton (8) and the frame parts (7b) completing the ribs (8′) of the rib skeleton (8) to form the ribs (3) forming the channels.