Method for making tool for forming

FIELD: plastic working of materials, preferably metals, possibly in machine engineering for making tools for forming processes.

SUBSTANCE: method comprises steps of preliminarily making of easy-to-work material model of one member of tool in scale 1:1; making concrete form for producing reinforced concrete at using said model as bottom of form; applying layer of liquid material containing filler onto model; placing reinforcement in concrete form; then filling form with concrete; after curing of concrete, removing form and applying liquid material onto working surface of formed member of tool; using formed first member of tool and additional concrete form for making second member of tool from concrete kind no less than 500 and using as filler quartz sand, basalts or gneisses.

EFFECT: simplified low-cost process of manufacturing forming tool.

8 cl, 3 ex

 

The invention relates to the field of materials processing pressure, preferably of metal, in particular to the manufacture of tooling for stamping processes, preferably hot, and can be used in machine building, aircraft building, automotive industry and in the manufacture of products for everyday use.

There is a method of manufacturing dies (SU authorship 1692709 21 D 37/20, 1978). According to a known method creates a layer of synthetic resin on the surface of the master model with the formation of a clamping surface and a reinforced concrete base matrix, punch and clamp placing concrete into formwork, and a synthetic resin layer to establish a wear-resistant insert, the clamping surface of the matrix is made from a sheet, the inside of which forms a matrix, punch and clamp mount three-dimensional reinforcing bars that bring together the layer of synthetic resin, the wear resistant insert and the casing and then the casing of the matrix, punch and clamp connected between a technological straps, make a bookmark of concrete in the formwork of the matrix to withstand concrete setting, turn and make a bookmark concrete formwork punch and clamp, after curing of the concrete bearing surface elements of the stamp handle the parallelism of planes.

<> The disadvantage of this method should recognize its high complexity, and the need to employ highly skilled workers.

There is also known a method of manufacturing a stamp (RU, patent 2060080 21 D 37/20, 1998). According to a known method made formative element of the stamp with the simultaneous creation using the master model polymer layer, and forming a cavity between the molding element of the stamp and the master model by setting the master model on formative element of the stamp with a gap, the formation of the polymer layer is performed by the injection of the polymer in the liquid state (epoxypolyester) formed in the cavity with subsequent polymerization, and the obtained molding element coated with a polymeric wear layer used for the formation of the response parts of the stamp.

The disadvantage of this method should recognize the low durability of the obtained stamp because of the low mechanical strength of the polymer layer.

There is a method of manufacturing dies for sheet metal forming (SU authorship 1766561 21 D 37/20, 1992). When implementing the method produces a model of one of the deforming tools, on the surface that after installing the proper, made of metal frame is rigidly connected with either the armature put several layers of epoxy compound with a metal powder to the connection ends of the armature. As the master model for other products of the deforming tool use the cured layer of the first deforming element, covered by a deforming layer, whose thickness is equal to the thickness manufactured using manufactured of stamped parts. The frame set of the second frame with fittings and similarly put several layers of epoxy compound powder across the surface of the separation layer before joining ends of the armature. After hardening compound is rigidly connected to one another both frame, carry out a cascade of concrete pouring and curing for each of the frames. Curing of concrete is carried out by heating the Assembly, before pouring the concrete to fully cure the epoxy compound with the metal powder in it enter reinforcing elements on the part of their height, transition pillows are made of epoxy compound cold-curing, after curing which the outer surfaces of pillows mechanically treated prior to mounting base plates. The separation of the frames is carried out before carrying out finishing work. The Assembly is heated to 80°C and maintained at this temperature for 6 to 8 hours.

The disadvantage of this method should recognize its high complexity and the need of IP is the use of skilled workers in the manufacturing elements of the stamp.

The technical problem to be solved by the proposed method consists in the simplification and cheapening of the method of manufacturing a snap.

The resulting implementation of the method the technical result consists in reducing the cost of tooling.

To achieve the technical result of the proposed use of the method of manufacturing tooling for stamping according to which pre-of free-cutting material form the layout of one of the elements tooling (punch or matrix), create formwork for manufacturing reinforced concrete, using the specified layout as the bottom of the casing, cover it with a layer of liquid material, which is in a liquid form high affinity to concrete, installed in the casing of the valve, fill the formwork with concrete after hardening of the concrete mixture to remove the formwork, re-cover the working surface of the snap-mentioned liquid material and using additional casing is formed from concrete and reinforcement of the second casing element, this use concrete grade not lower than 500. Usually the specified layout made from wood binding materials (clay, alabaster or gypsum) or from a polymeric material (polystyrene, polyvinyl chloride, etc.). For the formation of bodies of elements snap-in can use impact-resistant reinforced concrete, polimerbetone fiber-reinforced concrete (concrete as filler, used in which the metal and polymer). As specified liquid material is usually used acrylic liquid polymers with filler, and can be used graphite grease and oligoneuriidae with filler. Mainly as filler use silica sand or crushed to a size of 2-3 mm basalt, Garbo or gneiss. When this is specified, the specified layer of liquid material is usually applied with a thickness of 10 to 100 μm. Using the specified liquid layer provides a smooth impact-resistant working surface of the punch and die.

Made in a similar manner the punch and the matrix can be used for hot and cold forging, because the coefficient of thermal expansion of concrete is practically zero, which leads to an invariance of the geometric dimensions of these elements snap.

In the future the method will be presented using examples of its implementation.

When the tooling for forming the hoods of trucks originally made of wood was made team model engine in 1:1 scale. Then was formed the formwork for the manufacture of punch, and the model was used as the bottom. Model engine smeared with a layer of acrylic liquid polymer with what ispolnitelem - quartz sand when the content of the last 54% wt. the thickness of 80-90 μm. Then in the formwork was installed steel reinforcement and fill the formwork with concrete, installing on the surface of the tool attachment of the punch press. After hardening of the concrete monolith separated from the model of the engine. His strength was 340-360 kg/cm2. The resulting monolith was placed in a box formwork working surface up, covered the surface of the same layer, set the valves and fill the formwork with concrete, installing on the surface of the tool mounting matrix in the press. After hardening of the concrete monolith representing a matrix tooling, separated from the punch. Tooling for stamping hoods truck ready. The use of these layers of the liquid material is allowed to obtain a smooth working surface of the punch and die. Production amounted to 0,046% from the traditional way with complete exclusion from the process of alloy steel commonly used for the production of tools. Production costs amounted to 5.4% from the traditional way. In the future, the cost is further diminished because of the presence of the finished model of the engine, which again is used for the production of tools.

When the tooling for forming the tailgate Legkov the th car original plaster model was made of the trunk in 1:1 scale. Then was formed the formwork for the production of matrix, and the model was used as the bottom. The model of the trunk smeared with a layer of graphite lubricant filled with basalt sand when the content of the last 61% wt. the thickness of 50-70 microns. Then in the formwork was installed steel rebar and filled the casing with the mixture of the polymer with the surface of the tool mounting matrix in the press. After solidification of the polymer monolith was separated from the trunk. His strength was 380 kg/cm2. The resulting monolith was placed in a box formwork working surface up, covered the surface of the same layer, set the valves and fill the formwork with a mixture of the polymer with the surface of the tool attachment of the punch press. After solidification of the polymer monolith representing the punch tooling was separated from the matrix. The tooling for forming the tailgate of the car ready. The use of these layers of the liquid material is allowed to obtain a smooth working surface of the punch and die. Production amounted to 0.006% from the traditional way with complete exclusion from the process of alloy steel commonly used for the production of tools. Production costs amounted to 0.14% of the traditional method. In dalnas is m cost is further diminished because of the presence of the finished model of the trunk, which again is used for the production of tools.

When the tooling for forming the shade table lamp original polystyrene model was made of shade in 1:1 scale. Then was formed the formwork for the production of matrix, and the model was used as the bottom. Model lampshade smeared with a layer of oligoneuriidae filled with sand from Garbo thickness of 80-100 μm. Then in the formwork was installed steel reinforcement and fill the formwork with a mixture of fiber-reinforced concrete, installing on the surface of the tool mounting matrix in the press. After curing of fiber-reinforced concrete monolith separated from the model of the lampshade. His strength was 320 kg/cm2. The resulting monolith was placed in a box formwork working surface up, covered the surface of the same layer, set the valves and fill the formwork with a mixture of fiber-reinforced concrete, with its surface means mounting the punch press. After curing, the monolith representing the punch tooling was separated from the matrix. Tooling for stamping shade finish. The use of these layers of the liquid material is allowed to obtain a smooth working surface of the punch and die. The time of manufacture was 0.007% from the traditional way with complete exclusion from the process of alloy steel, usually remenieras for production tooling. Production costs amounted 0,009% from the traditional way. In the future, the cost is further diminished because of the presence of the finished model of the lampshade, which is re-used for the production of tools.

As follows from the above examples, the application of the proposed method significantly reduces the time of manufacture of the equipment, as well as its cost.

1. A method of manufacturing tooling for stamping, including preliminary formation of the free-cutting material layout of one of the elements of the snap-in 1:1 scale, creating a casing for the manufacture of reinforced concrete using the specified layout as the bottom of the formwork, floor layout layer of liquid material, the filler, the installation in the casing of the valve, filling the formwork with concrete, remove after hardening of the concrete mix formwork, the coated surface of the obtained element snap-mentioned liquid material and the formation using a set of the first element of the snap-in and additional formwork from the concrete and reinforcement of the second element of the snap-in, used concrete grade not lower than 500 different the fact that as the liquid filler material used quartz sand or crushed to a size of 2-3 mm basalts, Garbo or gneiss.

2. The method according to claim 1, characterized in that specified the initial layout may be made from wood.

3. The method according to claim 1, characterized in that the layout is made from binders.

4. The method according to claim 1, characterized in that the layout is made from a polymeric material.

5. The method according to any one of claims 1 to 4, characterized in that the use of polymer concrete.

6. The method according to any one of claims 1 to 4, characterized in that use fiber-reinforced concrete.

7. The method according to any one of claims 1 to 6, characterized in that used as the liquid material acrylic polymers.

8. The method according to any one of claims 1 to 7, characterized in that the liquid material is applied with a layer thickness of from 10 to 100 microns.



 

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FIELD: plastic working of materials, preferably metals, possibly in machine engineering for making tools for forming processes.

SUBSTANCE: method comprises steps of preliminarily making of easy-to-work material model of one member of tool in scale 1:1; making concrete form for producing reinforced concrete at using said model as bottom of form; applying layer of liquid material containing filler onto model; placing reinforcement in concrete form; then filling form with concrete; after curing of concrete, removing form and applying liquid material onto working surface of formed member of tool; using formed first member of tool and additional concrete form for making second member of tool from concrete kind no less than 500 and using as filler quartz sand, basalts or gneisses.

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8 cl, 3 ex

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10 cl, 19 dwg

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12 cl, 3 dwg

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5 cl, 3 dwg

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