11-OPM-3D异型水路模具系统设计原理与实务

OPMTechnologyDesigntechniqueforconformalcoolingchannelConforomalcoolingdesignOPM-3D異型水路模具系統設計原理與實務應用株式会社松井制作所上海松井机械有限公司MoldingprocessdwellingCoolingmoldopenProductreleaseinjectionfilling・moldclampinggaugingplasticizingejection／Timeismoney.IssueoftheplasticinjectionmoldingVideoConformalcoolingchannel。。。。。。CavityCoreCorepinCasestudyCavity8φConformalcoolingchannel。。。。。。EjectionpinonfirstdesignModifiedCoreConformalcoolingchannel。。。。。。CoreconformalcoolingCorepinconformalcoolingCavityconformalcooling3curcitsShowningreencolorisaproductConformalcoolingchannel。。。。。。Φ3×6Φ3×2Φ4×2Φ4x2Caseexample◆水管について【S-139】CaseexampleOurtechnology(Comparison)LasermeltingtechnologyHighspeedmillingSelectivelasermelting(Additiveprocess)Highspeedmilling(Subtractiveprocess)ConceptofSelectivelasermeltingwithmillingalternatelyworkSelectivelasermeltingandhighspeedmillingalternatelyworktoproducesinteredobjects.GoVideoLasermeltingwithmillingGalvanosystemFeederSpindleLasermeltingwithmillingSLM＋Milling・machinedsurfaceMeasuresinteredobjectonmachineHeattreatmentOptimized3dmodelMeasureThefollowingprocessSetbaseplate・flatnessmeasurementmeasuredresultmeasuredresult・surplusarea・machinedsurface・linearcoefficientofexpansionSuitableforhighaccuracypartMeasureonLUMEXflatnessmeasurementonLUMEXpositioningparallelismaccuracymeasurementOurtechnology(Comparison)WarpageproblemBaseplate2mmSinteredCaseexample２：Coreforconnecter（210mm×210mm）WarpageCenterXZYUnmeasurablestateMisalignmentbetweencaddataandsinteredobjectonconditionthatisusedgalvanoThebaseplateandsinteredobjectarewarpedbyinnerstresses.Itcan’tmeasureaccuratedimensionsfromfiducialsurfacesoftheplateXZYMeasurablestateMillingGalvanoscannerBeforesinteredobjectisdismountedfrommachine,machinedsurfacehastobemadereadyatthesametimeAtleastmachinedsurfaceCycleofexpansionandcontractionMisalignmentSolelylasermeltingOurtechnology+measuringsurfaceLasermeltingandhighspeedmillingMillingfollowinglasermeltinginsequencewithoutdismountingSinteredobject+measuringsurfaceforthefollowingprocesslaserlaserMillingMillingYoucanchoosefrom3ways.ConventionalmethodLasermeltingwithmillingWecanprovideadequatematerialstosatisfyyou.MATERIALTENSILESTRENGTH(MPa)ELASTICITY(%)0.2%YIELDSTRESS(MPa)YOUNGSMODULUS(GPa)VICKERSHARDNESSHVROCKWELLHARDNESSHRCOPM-SUS420Sintered74024.7-200-52～56OPM-YAGSintered981（2010）18(11）686（1910）--34(52)OPM-ThetaSintered52～54SUS316LSintered60632455170200-SOLIDOver480Over40Over175193200-SUS630Sintered9282065014334034SOLIDOver930Over10Over72520035035Co-CrSintered10251166019433736SOLIDOver655Over8Over44820036037Ti-6Al-4VSinteredNoDataNoDataNoDataNoData473NoDataSOLID9801492112037538Ti-6Al-7NbSintered718358511444045SOLID950589012332032CRMSintered64426490115191-Ourtechnology(Widevarietyofmaterialpowders)NAKNAKMaragingsteelborderlineOPM-YAGFatiguespecimenofmaragingsteelMaragingsteelx400FatiguetesttoughnessLasermeltedNAKlasersurfacealloyedOPM-SUSAfterheattreatment590HV380HV230HV200HVS50Cx400SUSx400RockwellS50C58.0HRA≒40HRCSUS42079.1HRA≒56.1HRCinternalcompositionstableRelative-specularglossinessPhase1:33-68mesureresultμm2（wholearea）%11146.930.052817.260.033338.000.014680.990.035547.490.026617.010.037514.950.028307.490.0191313.160.0610869.950.04111420.220.0612660.090.03131009.180.0414376.460.0215712.970.030.03Wholeaverage1.4mm1.38mmDigitalizationx15timesOPM-SUSwholeaverageMeltingaverage99.97%TruecircleTruecircleEllipsewidth1.5㎜=4diameterINLETOUTLETInside3DcoolingchannelSectionofpartImprovingtheinnersurfaceofacoolingchannelOPMtechnologyOnlylasermeltingImprovingtheinnersurfaceofacoolingchannelImprovingtheinnersurfaceofacoolingchannelSoonafterinnersurfacewithonlylasermeltingAftertreatmentofourtruecircletechnologyBeforeAfterNewMachineBeforeWehavedevelopedthemethodofimprovingtheinnersurfaceofacoolingchannel.Thisisstillalimitedarea,butwehavestartedtoservicethis.26Ourmethodcanmakeaone-piecemouldwithhighaccuracy.Withtheconventionalmethod,thecoreiscomposedof25coremembers.SuitableforprecisionindustryFinetexture,smoothmilledsurfacesDimensionalaccuracy±1/100～±5/1000Caseofhighaccuracypartswithourtechnology27IN１OUT１IN２OUT２Conformalcoolingchannelscanbemadeinsidecore.CoolingsystemofcoremodelforimpactdriverCaseofhighaccuracypartswithourtechnology28CaseofhighaccuracypartswithourtechnologyToolingsystemofimpactdriverfixedsidemovableside29CaseofhighaccuracypartswithourtechnologysolidificationconditionofresinConventionalcoolingCoolingtime30secConformalcoolingCoolingtime30secBettercoolingefficiency30CaseofhighaccuracypartswithourtechnologyConformalcooling+SpiralSprueBushwithwaterpassagecoolingtime：30secMoldingcycle53sec29seccoolingtime：30secMoldingresinABSApplicabletomoldingNormalcooling+SpiralSprueBushwithoutwaterpassageInapplicabletomoldingTheCoolingtimecanbeshortenedby50%.Coolingtime：15secApplicabletocontinuousmoldingDeformedonthesprue(withlargelybended)21secShrinkmarkUnderthesamemoldingconditions(resintemperaturedwellpressureetc)Weverifiedthestateofproducts/sprue/runnermadeundereachconditions.GuideCCCcancreatecenterlinewitheverypointequidistant