DE102024110897A1 - Tool half of a casting tool and additive manufacturing process for producing the tool half - Google Patents

Abstract

The invention relates to a tool half (1) of a casting tool having a three-dimensional body (K) for connection to a clamping plate of a casting machine and a first side (2) of the body (K) for connection to the clamping plate of the casting machine. Furthermore, at least one cooling channel (6) is present for cooling. The tool half (1) has at least one sensor unit (7), optionally also at least one sensor contact (8) for the at least one sensor unit (7), wherein the at least one sensor unit (7), optionally also the at least one sensor contact (8), are formed together with the body (K) in an additive multi-material printing process using different materials. The invention further relates to an additive manufacturing process for producing such a tool half.

Description

The invention relates to a tool half of a casting tool and an additive manufacturing method for producing such a tool half.

As is well known, tool halves of a casting tool are milled from one or more blocks of metal. However, it is only possible to place sensors in mechanically critical areas of a tool half with great effort.

Two tool halves are usually assembled to form a casting tool and together form a cavity in the interior in which a cast part is formed. In general, however, a casting tool can also be made up of more than two parts, so that the term "tool half" is also to be understood here as part of a casting tool that, together with other tool parts, forms a casting tool with a common cavity for forming a cast part in this cavity.

The DE 10 2011 101 957 A1 relates to a mold for die-casting a component, comprising at least two mold parts that enclose a cavity and have corresponding outer surfaces and inner surfaces, the inner surfaces defining a shape of the cavity. The outer surfaces of the at least two mold parts are designed in such a way that they correspond to the contour of the cavity and thus to the inner surfaces of the at least two mold parts.

The DE 10 2011 078 167 A1 relates to a method in which molten thermoplastic material is introduced into a cavity of an injection mold. Furthermore, a device for controlling the temperature of a workpiece production section in the thermoplastic injection mold is present. For this purpose, a temperature sensor is arranged on the surface of the cavity.

It is an object of the present invention to provide a tool half of a casting tool and a manufacturing method for producing such a tool half, which can be produced cost-effectively or with which a tool half can be produced cost-effectively, as well as to place sensors in mechanically critical areas of a tool half.

This object is achieved for the tool half by the features of independent patent claim 1. Further advantageous developments are the subject of subclaims 2 to 5.

• - einen dreidimensionalen Körper K zur Verbindung mit einer Aufspannplatte einer Gussmaschine,
• - wobei eine erste Seite des Körpers K zur Verbindung mit der Aufspannplatte der Gussmaschine ausgebildet ist,
• - wobei eine zweite Seite des Körpers K eine Kavität der Form F für ein zu erstellendes Gussteil aufweist,
• - wobei die erste und zweite Seite gegenüberliegende Seiten des Körpers K bilden,
• - wobei die Form F wenigstens einen Vorsprung und/oder wenigstens einen Rücksprung bezugnehmend auf eine den wenigstens einen Vorsprung und/oder Rücksprung umgebende Oberfläche E der zweiten Seite aufweist,
• - wenigstens einen Kühlkanal zur Kühlung der Form F für ein zu erstellendes Gussteil,
• - wobei der wenigstens eine Kühlkanal im Inneren des Körpers K verläuft und im Bereich der Kavität zur zweiten Seite bereichsweise parallel verläuft und variierende Abstände zur Form F im Bereich des wenigstens einen Vorsprungs und/oder des wenigstens einen Rücksprungs der Form F aufweist,
• - wobei der Abstand zwischen dem wenigstens einen Kühlkanal und der Oberfläche des wenigstens einen Vorsprungs der Form F größer ist als der Abstand zwischen dem wenigstens einen Kühlkanal und der Oberfläche des wenigstens einen Rücksprungs der Form F,
• - wobei die Werkzeughälfte mindestens eine Sensoreinheit, optional weiterhin mindestens eine Sensorkontaktierung für die mindestens eine Sensoreinheit, aufweist.

The tool half of a casting tool has the following:

• - a three-dimensional body K for connection to a clamping plate of a casting machine,
• - wherein a first side of the body K is designed for connection to the clamping plate of the casting machine,
• - wherein a second side of the body K has a cavity of the form F for a casting to be produced,
• - where the first and second sides form opposite sides of the body K,
• - wherein the shape F has at least one projection and/or at least one recess with respect to a surface E of the second side surrounding the at least one projection and/or recess,
• - at least one cooling channel for cooling the mold F for a casting to be produced,
• - wherein the at least one cooling channel runs in the interior of the body K and runs partially parallel to the second side in the region of the cavity and has varying distances from the form F in the region of the at least one projection and/or the at least one recess of the form F,
• - wherein the distance between the at least one cooling channel and the surface of the at least one projection of the mold F is greater than the distance between the at least one cooling channel and the surface of the at least one recess of the mold F,
• - wherein the tool half has at least one sensor unit, optionally further at least one sensor contact for the at least one sensor unit.

The object is now achieved for the tool half in that the at least one sensor unit, optionally also the at least one sensor contact, are formed together with the body K in an additive multi-material printing process using different materials and the at least one sensor unit is arranged in a space below the surface of the mold F in a region between the at least one cooling channel and the second side.

With more precise data acquisition at specific and predetermined locations within a casting tool, in particular with a precise pressure and/or temperature measurement, by means of at least one sensor unit, safety thresholds can be reduced, whereby the combination of casting machine and casting tool can operate closer to the "limit". This further increases the performance of a casting machine and reduces the costs of creating a suitable casting tool.

In a preferred embodiment of the tool half, the at least one sensor unit can be contacted wirelessly or by means of the at least one optional sensor contact, which is designed in the form of at least one printed conductor track.

The body K is preferably additively manufactured from at least one electrically conductive, metallic material. The at least one sensor unit and the optionally present at least one sensor contact are manufactured in one piece from at least one electrically conductive, metallic material and at least one electrically insulating material together with the body K via multi-material printing.

This therefore includes a tool half of a casting tool, manufactured in an additive multi-material printing process, wherein at least one sensor unit, in particular in the form of a strain and/or temperature sensor, is introduced into a tool half of the casting tool. The tool half can be used and/or adapted for the ejector side or the nozzle side of a casting machine.

The first side of the body K is designed to be connected to a clamping plate of a casting machine, with a second side of the body K having a mold F for a cast part to be produced. The mold F, together with another tool half, can form part of a so-called cavity in the closed state of the casting tool, into which liquefied plastic, for example, is injected in order to produce a component or cast part. The first and second sides form opposite sides of the body K.

The shape F comprises at least one projection and/or at least one recess with respect to a surface of the second side surrounding the at least one projection and/or recess. The at least one projection and/or recess form the outer shape of a cast part to be produced. The at least one projection and/or recess can form a functional section of the cast part to be produced.

Furthermore, the tool half has at least one cooling channel for cooling the mold F for a cast part to be produced. In this way, a plastic injected into a closed mold consisting of at least two tool halves can be quickly brought to a temperature at which the plastic hardens and thus holds the shape.

The at least one cooling channel runs inside the body K and has varying distances from the mold F or from at least one projection and/or at least one recess of the mold F. The distance between the at least one cooling channel and the surface of the at least one projection of the mold is greater than the distance between the at least one cooling channel and the surface of the at least one recess of the mold. Due to the varying distances from the at least one cooling channel, for example, a projection is cooled less than a recess. The at least one cooling channel can have two or three or more sections, each of which has a straight course. This is easy and inexpensive to produce.

The optionally present at least one sensor contact can run within the tool half and bridge the space between the at least one sensor unit and one or more evaluation devices, with which, for example, the strain and/or temperature can be displayed as a value that is detected by means of the at least one sensor unit.

The at least one sensor unit and/or the at least one optional sensor contact is arranged in the space or at the distance between the surface of the mold F and the at least one cooling channel. The at least one sensor unit and/or the at least one optional sensor contact can also be arranged in the space or at the distance between the surface of the at least one projection and/or recess of the mold and the at least one cooling channel. In addition, the at least one sensor unit and/or the at least one optional sensor contact is fixed in the space or at the distance between the surface of the mold F and the at least one cooling channel and fused to the rest of the body K. The at least one sensor unit and/or the at least one optional sensor contact are formed in one piece or in one part with the three-dimensional body K of the tool half. The entire three-dimensional body K of the tool half including the sensor unit(s) and/or optional sensor contact(s) and/or including at least one projection of the mold F and/or at least one recess of the mold F are formed in one piece or in one part. The units and shapes resulting in the body K are thus inseparably connected to one another.

Thus, sensor data such as strain and/or temperature can be measured at such a critical Location whose distance to at least one cooling channel varies.

Furthermore, the tool half has several materials that are designed or constructed in one piece or in one part. Various metallic, ceramic, glass-like or polymeric materials can be combined with one another.

In addition, the tool half can have on its outside a connection for an evaluation device provided on the at least one optional sensor contact, which is further designed as an interface to the sensor unit inside the body K, so that data from the sensor unit can be received by means of the connection and/or the sensor unit can be supplied with energy.

The problem is solved for the additive manufacturing process by the features of patent claim 6.

• - Aufbringen einer Schicht pulverförmigen Materials auf einen Werkstückträger oder auf eine bereits vorhandene Schicht, um den Körper K sowie die mindestens eine Sensoreinheit, optional die mindestens eine Sensorkontaktierung der Werkzeughälfte zu erzeugen,
• - wobei beim Aufbringen einer Schicht mehrere Pulver unterschiedlicher Werkstoffe selektiv nebeneinander in einer Ebene auftragbar sind, um eine Schicht aus mindestens einem Material oder eine Schicht aus zwei oder mehr Materialien zu bilden,
• - selektives Schmelzen einzelner Bereiche der Schicht und/oder eines aufgebrachten Materials und/oder einer gesamten Schicht mithilfe eines Lasers,
• - wobei nach dem selektiven Schmelzen einzelner Bereiche der Schicht und/oder eines Materials und/oder einer gesamten Schicht diese zu einer festen Materialschicht erstarren,
• - Absenken des Werkstückträgers um den Betrag einer Schichtdicke der festen Materialschicht, und
• - iteratives Wiederholen der obigen Schritte beginnend mit dem erneuten Aufbringen einer Schicht pulverförmigen Materials.

The additive manufacturing process according to the invention for producing the tool half of the casting tool comprises the following steps:

• - applying a layer of powdered material to a workpiece carrier or to an existing layer in order to produce the body K and the at least one sensor unit, optionally the at least one sensor contact of the tool half,
• - wherein, when applying a layer, several powders of different materials can be applied selectively next to one another in one plane in order to form a layer of at least one material or a layer of two or more materials,
• - selective melting of individual areas of the layer and/or an applied material and/or an entire layer using a laser,
• - after the selective melting of individual regions of the layer and/or a material and/or an entire layer, these solidify to form a solid material layer,
• - Lowering the workpiece carrier by the amount of one layer thickness of the solid material layer, and
• - iteratively repeating the above steps starting with the re-application of a layer of powdered material.

The additive manufacturing process for producing the tool half of a casting tool comprises the following steps, whereby the additive manufacturing process involves producing the tool half layer by layer using a multi-material printing process.

One step of the method comprises applying a layer of powdered material to a workpiece carrier or to an existing layer in order to produce the body K of the tool half. The layer can have a layer thickness between 15 and 500 µm.

When applying a layer, several powders of different materials can be selectively applied to form a layer with one material or a layer with two or more materials. This can also be referred to as a so-called "selective powder deposition" process.

One material can be thermally conductive and another material electrically conductive. An electrically insulating material can also be used.

A further step of the method involves selectively melting individual areas and/or an applied material and/or an entire or applied layer using a laser. In this way, specific areas and/or materials can be converted from a powdery state to a liquefied state.

After the selective melting of individual areas and/or a material and/or an entire layer, these solidify to form a solid material layer. In other words, the powdery material applied in the layer is partially or completely liquefied by means of laser radiation from a laser and then solidified by cooling. This process not only serves to solidify the powdery material, but also to connect it to the already solid material layer underneath, in order to further build up the body K.

A further step of the method then involves lowering the workpiece carrier by the amount of one layer thickness of the solid material layer.

The next step in the process is an iterative repetition of the above steps, starting with the renewed application of a layer of powdered material.

Applying a layer of powdered material optionally includes creating at least one sensor contact. In other words, the at least one sensor contact forms an electrical connection from at least one sensor unit to an exterior of the Tool half. The at least one sensor contact is formed in particular via conductor tracks made of metal, in particular coated with electrical insulation made of ceramic, produced using a multi-material printing process. This must be formed layer by layer, in accordance with the process. The electrically conductive, powdery material, here made of metal, can form part or a strip-shaped part of the entire sensor contact.

Furthermore, the application of a layer of powdered material can include the production of at least one sensor unit. For example, electrically conductive, powdered material is applied in regions in the layer to be created as an additional material alongside a thermally conductive material in order to form part of an electrically conductive sensor unit.

Alternatively, the at least one sensor unit can also be contacted wirelessly. The sensor unit can be designed similarly to an NFC chip, which sends information in response to the receipt of energy.

Furthermore, when creating at least one sensor contact, at least one boundary region to the at least one sensor unit can be designed in such a way that this ensures contact with the at least one sensor unit via the sensor contact. In other words, the at least one boundary region must be designed in such a way that an electrical contact can be made to the at least one sensor unit so that data and/or electrical energy can be transmitted.

As a final step in the process, the finished tool half can be cleaned of excess powder, machined as required, or used immediately.

Furthermore, it should be noted that the additive manufacturing process can be or include laser powder bed fusion (L-PBF), binder jetting or pressure-assisted sintering.

Finally, it should be mentioned that a casting tool can be an injection molding tool or a die casting tool. A casting machine can also be an injection molding machine or a die casting machine.

• 1 eine Schnittansicht einer erfindungsgemäßen Werkzeughälfte eines Gusswerkzeuges; und
• 2 eine vergrößerte Ansicht im Bereich der Sensoreinheit aus 1.

The invention is explained in more detail below using an embodiment in conjunction with the accompanying drawings. The drawings show schematically:

• 1 a sectional view of a tool half of a casting tool according to the invention; and
• 2 an enlarged view in the area of the sensor unit 1 .

In the following description, the same reference symbols are used for the same items.

1 shows a sectional view of a tool half 1 of a casting tool according to the invention.

Shown in more detail 1 a tool half 1 of a casting tool. The tool half 1 can be used or adapted for the ejector side or the nozzle side of a casting machine.

The tool half 1 has a three-dimensional body K for connection to a clamping plate of a casting machine. The tool half 1 has several materials A, B and is designed or constructed in one piece.

In addition, 1 that the tool half 1 is designed with a first side 2 of the body K for connection to a clamping plate of a casting machine, wherein a second side 3 of the body K has a mold F for a cast part to be produced. The mold F can form part of a so-called cavity in a casting tool, into which, for example, liquefied plastic is injected in order to produce a component or cast part. The first side 2 and the second side 3 form opposite sides of the body K.

The shape F has a projection 4 and a recess 5 with respect to a surface E of the second side 3 surrounding the projection 4 and the recess 5.

Furthermore, the tool half 1 has a cooling channel 6 for cooling the mold F for a cast part to be produced. The cooling channel 6 runs inside the body K and has varying distances X, Y to the mold F or to the projection 4 and the recess 5 of the mold F. The cooling channel 6 has three sections, each with a straight course.

More specifically, the distance X between the cooling channel 6 and the projection 4 of the form F is greater than the distance Y between the cooling channel 6 and the recess 5 of the form F. The cooling channel 6 runs in some areas parallel to the surface E surrounding the projection 4 and the recess 5.

In addition, 1 shows that the tool half 1 has a sensor unit 7 and a sensor contact 8. The sensor unit 7 and the sensor contact 8 are arranged in the space or at the distance X between the surface of the projection 4 and the cooling channel 6. The sensor unit 7 or the sensor contact 8 can also be arranged in the space or at the distance Y between the surface of the recess 5 and the cooling channel 6.

Furthermore, 1 that the tool half 1 has a connection 9 for an evaluation device on its outside and functions as an interface for contacting the sensor unit 7 in its interior, so that data from the sensor unit 7 can be received by means of the connection 9 and/or the sensor unit 7 can be supplied with energy.

With reference to the 1 and 2 An additive manufacturing process for producing the tool half 1 is described below. 2 an enlarged view 1 in the area of sensor unit 7.

An additive manufacturing process for producing a tool half 1 of a casting tool can realize a more complex structure of a tool half 1.

One step of the method comprises applying a layer 20-30 of powdered material to a workpiece carrier W (indicated by dashed lines) or to an already existing layer in order to produce a body K of the tool half 1. The layer 20-30 has a layer thickness between 15 and 500 µm.

When applying a layer 20-30, several powders of different materials A, B can be applied selectively in order to form a layer 20-24, 26-30 with one material A or a layer 25 with two materials A, B next to each other on one level. This is also known as the so-called "selective powder deposition" process. One material A is thermally conductive and the other material B is electrically conductive.

A further step of the method involves selectively melting individual areas and/or the applied material and/or an entire or applied layer using a laser. After selectively melting individual areas and/or a material and/or an entire layer, these solidify to form a solid material layer. In other words, the powdered material A, B applied in the layer is liquefied in parts or completely using laser radiation from a laser and solidifies when it cools. This process not only serves to solidify the powdered material A, B, but also to bond it to the solid material layer underneath in order to further build up the body K.

This is followed by a lowering of the workpiece carrier W by the amount of one layer thickness of the solid material layer.

The above steps are then repeated iteratively, starting with the reapplication of a layer of 20-30 mm of powdered material.

The application of a layer 20-30, such as layer 25, of powdered material includes the creation of a sensor contact 8. When creating a sensor contact 8 or when applying a layer 25, electrically conductive, powdered material B is applied in regions in the layer 25 to be created as an additional material next to another, thermally conductive material A (cf. layer 25 in 1 ) to form part of the electrically conductive sensor contact 8.

The application of a layer 20-30, such as layer 26, of powdered material also includes the production of a sensor unit 7. Depending on the required sensor technology, this is built up layer by layer from different electrically conductive and electrically insulating materials. The sensor unit 7 can thus generate/supply/provide measurement data, such as strain and/or temperature, for this location.

As already mentioned, the application of a layer 20-30 of powdered material includes the creation of a sensor contact 8 so that a sensor unit 7 can be contacted within the tool half 1 to be created.

When creating a sensor contact 8, electrically conductive, powdery material B is applied in an area that forms a boundary area G to the sensor unit 7 to be created. The electrically conductive, powdery material B forms a part or a strip-shaped part of the entire sensor contact 8 (cf. 2 ).

Furthermore, when creating the sensor contact 8, the boundary region G is designed in such a way that it ensures contact with the sensor unit 7. The sensor contact 8 is designed as a connection to a sensor unit 7, so that data from the sensor unit 7 can be received using the sensor contact 8 and the sensor unit 7 can be supplied with energy.

As a final step of the process, the finished tool half 1 is cleaned of excess powder, machined as required, or used immediately.

The additive manufacturing process presented can be laser powder bed fusion (L-PBF), binder jetting or pressure-assisted sintering.

list of reference symbols

1

tool half

2

first side of the body

3

second side of the body

4

projection

5

rebound

6

cooling channel

7

sensor unit

8

sensor contacting

9

Connection

20-30

layers

A

Material A

B

Material B

E

surface of the second side

F

form

G

border area

K

Body

W

tool carrier

X

Distance

Y

Distance

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• DE 10 2011 101 957 A1 [0004]
• DE 10 2011 078 167 A1 [0005]

Claims (9)

Tool half (1) of a casting tool comprising: - a three-dimensional body (K) for connection to a clamping plate of a casting machine, - wherein a first side (2) of the body (K) is designed for connection to the clamping plate of the casting machine, - wherein a second side (3) of the body (K) has a cavity of the mold (F) for a cast part to be produced, - wherein the first and second sides (2, 3) form opposite sides of the body (K), - wherein the mold (F) has at least one projection (4) and/or at least one recess (5) with respect to a surface (E) of the second side (3) surrounding the at least one projection (4) and/or recess (5), - at least one cooling channel (6) for cooling the mold (F) for a cast part to be produced, - wherein the at least one cooling channel (6) runs inside the body (K) and runs partially parallel to the second side (3) in the region of the cavity and has varying Distances (X, Y) to the mold (F) in the region of the at least one projection (4) and/or the at least one recess (5) of the mold (F), - wherein the distance (X) between the at least one cooling channel (6) and the surface of the at least one projection (4) of the mold (F) is greater than the distance (Y) between the at least one cooling channel (6) and the surface of the at least one recess (5) of the mold (F), - wherein the tool half (1) has at least one sensor unit (7), optionally further at least one sensor contact (8) for the sensor unit (7), characterized in that - the at least one sensor unit (7), optionally further the at least one sensor contact (8), are formed together with the body (K) in an additive multi-material printing process using different materials and the at least one sensor unit (7) is arranged in a space below the surface of the mold (F) in a region between the at least one cooling channel (6) and the second side (3). Tool half (1) after claim 1 , characterized in that - the at least one sensor unit (7) can be contacted wirelessly, or that - the at least one sensor unit (7) is contacted by means of the at least one sensor contact (8), which is designed in the form of at least one printed conductor track. Tool half (1) after claim 1 or 2 , characterized in that the body (K) is additively manufactured from at least one electrically conductive, metallic material and that the at least one sensor unit (7) and the optionally present at least one sensor contact (8) are manufactured in one piece from at least one electrically conductive, metallic material and at least one electrically insulating material via the additive multi-material printing process. Tool half (1) according to one of the Claims 1 until 3 , characterized in that the at least one sensor unit (7) is designed as a strain and/or temperature sensor. Tool half (1) according to at least one of the preceding claims, characterized in that the tool half (1) has on its outside a connection (9) for an evaluation device provided on the at least one sensor contact (8), which is further designed as an interface to the at least one sensor unit (7) in the interior of the body (K), so that with the help of the connection (9) data of the at least one sensor unit (7) can be received and/or the at least one sensor unit (7) can be supplied with energy. Additive manufacturing process for producing the tool half (1) of the casting tool according to one of the Claims 1 until 5 comprising the following steps: - applying a layer (20-30) of powdered material to a workpiece carrier (W) or to an existing layer in order to produce the body (K) and the at least one sensor unit (7), optionally the sensor contact (8), of the tool half (1), - wherein when applying a layer (20-30), several powders of different materials can be applied selectively next to one another in a plane in order to form a layer (20-30) made of at least one material or a layer (25) made of two or more materials (A, B), - selectively melting individual areas of the layer (20-30) and/or an applied material and/or an entire layer using a laser, - wherein after the selective melting of individual areas of the layer (20-30) and/or a material and/or an entire layer, these solidify to form a solid material layer, - lowering the workpiece carrier (W) by the amount of a layer thickness of the solid material layer, and - iteratively Repeat the above steps starting with the re-application of a layer (20-30) of powdered material. Additive manufacturing process according to claim 6 , - wherein the application of a layer (20-30) of powdery material comprises creating the at least one sensor unit (7), optionally the at least one sensor contact (8), - wherein when creating the at least one sensor contact (8) or when applying a layer, electrically conductive, powdery material (B) is applied in regions in the layer (24) to be created as a further material alongside a thermally conductive material (A) in order to form part of an electrically conductive sensor contact (8), - or wherein when creating at least one sensor unit (7) or when applying a layer, electrically conductive, powdery material (B) is applied in regions in the layer (24) to be created as a further material alongside a thermally conductive material (A) in order to form part of at least one sensor unit (7). Additive manufacturing process according to one of the preceding Claims 6 or 7 , - wherein the application of a layer (20-30) of powdery material comprises creating the at least one sensor contact (8) so that the at least one sensor unit (7) can be contacted within the tool half (1) to be created, and - wherein when creating the at least one sensor contact (8), electrically conductive, powdery material (B) is applied in a region which forms at least one boundary region (G) to the at least one sensor unit (7) to be created. Additive manufacturing process according to claim 8 , - wherein the at least one sensor contact (8) is designed as a connection to at least one sensor unit (7), so that data from the at least one sensor unit (7) is received by means of the at least one sensor contact (8) and/or the at least one sensor unit (7) is supplied with energy.

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