Generating A Spray Formed Rapid Tooling
Creating a spray formed speedy tooling involves the methods of generating a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The approach also consists of the actions of heating the ceramic pattern and thermally spraying a metal material against the ceramic pattern to type a preferred tool.
It is known to make a spray formed rapid tooling. In spray forming, a master model of a preferred tool is produced using a cost-free kind fabrication method. This master model is then employed to generate a ceramic pattern, which is the reverse of the desired tool to be made. The resulting ceramic pattern is the receptor onto which metal is sprayed to form a deposit in the shape of the preferred tool.
Generally, the spray forming process utilizes a wire-arc spraying. In wire-arc spraying, electric current is carried by two electrically conductive, consumable wires with an electric arc forming in between the wire tips. A high-velocity gas jet blowing from behind the consumable wires strips away the molten metal, which continuously types as the wires are melted by the electric arc. The high-velocity gas jet breaks up or atomizes the molten metal into finer particles in order to develop a fine distribution of molten metal droplets. The atomizing gas then accelerates the droplets away from the wire tips to the ceramic pattern exactly where the molten metal droplets impact the ceramic pattern to incrementally type a deposit in the shape of the preferred tool. The completed preferred tool is then mounted and utilized to generate parts in standard stamping, die casting, or molding approach.
Although the above process for making a spray formed fast tooling has worked nicely, it suffers from the disadvantage that chip making with heat-treating is necessary to make the spray formed fast tooling. These methods are both laborious and time consuming. Therefore, there is a require in the art to make a spray formed rapid tooling that would remove these methods.
Accordingly, the present invention is a strategy of generating a spray formed fast tooling. The approach consists of the methods of producing a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The strategy also involves the methods of heating the ceramic pattern and thermally spraying a metal material against the ceramic pattern to form the desired tool.
1 benefit of the present invention is that a technique is provided of generating a spray formed speedy tooling at the very same time the spray material is being deposited. Another benefit of the present invention is that the method of generating a spray formed speedy tooling shortens product development cycle time. However another benefit of the present invention is that the technique eliminates chip making with heat-treating when forming a spray formed rapid tooling. Nevertheless an additional advantage of the present invention is that the strategy reduces material loss. Yet a further advantage of the present invention is that the technique improves yield, top quality, and repeatability.
Other features and positive aspects of the present invention will be readily appreciated, as the very same becomes greater understood, following reading the subsequent description taken in conjunction with the accompanying drawings.
The method advances to block and consists of the step of thermally spraying a metal material against the ceramic pattern to kind a spray formed fast tooling as the preferred tool. Such step is desirably carried out by the wire arc method previously described. Another strategy to carry out the step of thermally spraying is the osprey method wherein a semi-solid slurry of hardenable metal material is sprayed from an induction heated nozzle supply and is impelled against the ceramic pattern with a higher velocity due to the high-stress gases that atomize the molten fluid. Metal droplets are formed from a melt that is atomized by gas (not from wire or powder). Continuous spraying is carried out to create up a layer that exceeds at least one quarter inch in thickness, at its thinnest section. As the spray is applied and constructed up, the preferred tool is formed. It should be appreciated that the approach could incorporate adjusting the gun parameters to preserve constant temperature.
Metals usable for this purpose incorporate metals such as zinc and high temperature high strength carbon steel. These incorporate particular rapid tooling steels such as plain carbon steel with (.eight% carbon by weight) as nicely as maraging steels. Maraging steels are difficult to machine and are seldom employed for tooling, but can be readily spray formed to produce a desirable microstructure.
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