The metal spraying rapid mold is mainly composed of a metal sprayed layer, a brush plating layer and a backing material, and exhibits a gradient structure characteristic, wherein the brush plating layer improves the surface hardness of the mold (greater than HV500) and wear resistance (up to 3 to 10 times), the glass steel The layer and epoxy layer improve the overall mechanical properties of the mold, and the high strength cement backing reduces mold manufacturing costs. This technology is suitable for automobile manufacturing and mold manufacturing enterprises. It can realize the rapid manufacturing of large-scale stamping dies and meet the requirements of rapid mold manufacturing for general automotive panels. The manufacturing cost is only 1/10 of that of traditional machining steel molds. The manufacturing cycle is the latter. 1/4 to 1/5, the economic benefits are very impressive, very suitable for prototype production and small batch production in the development of new models.
This technology can also be used for rapid manufacturing of injection molds. In the rapid prototyping of injection molds, the metal arc spray molding method takes the sample mold as the standard. The mold cavity size and geometric precision depend entirely on the sample mold. The cavity surface and its fine pattern are formed at the same time, so the mold making speed is fast. The manufacturing cycle is short, the die life is long, and the cost is low. It is only 1/3 to 1/5 of the numerical control method for processing steel molds. The mold surface has good surface finish, simple process and low equipment requirements, and is more suitable for injection molding die, die-casting die and board. Rapid manufacturing of the calendering die.
4.2 Metal arc spraying molding method specific process
The process of metal arc spray molding is roughly divided into five steps:
(1) Model preparation. The model can be made of plastic, gypsum, rubber, wood and other materials. First, a three-dimensional model is built, then layered and sliced, and the prototype is made by a rapid prototyping mechanism. The most important part of the model preparation is to clean the surface of the model and apply the release agent.
(2) Metal spraying model. After the release agent is dried, the best spraying parameters can be selected to start spraying the metal on the mold. When spraying, the spray gun should be continuously moved to prevent the coating from overheating and deformation. The thickness of the coating is generally controlled at 2 to 3 mm.
(3) Making a mold frame. If the mold is subjected to internal pressure during operation or the mold must be installed on the molding machine, the mold must have a skeleton structure and the finished skeleton should have a filler.
(4) Filling material for the casting mold. The filler material should have high thermal conductivity and low solidification shrinkage as well as high compressive strength and wear resistance. The general choice of filler material is a mixture of epoxy resin and metal powder such as aluminum powder and aluminum particles. .
(5) Demoulding and surface polishing of the mold cavity. After demolding, the release agent remaining on the surface of the metal coating is cleaned, and then the mold is polished and post-production according to different needs.
(6) Assembling the test pattern.
4.3 Limitations of metal arc spray molding
The material used for arc spraying molding should have better mechanical properties and dense coating structure as far as possible under the condition of low melting point and low shrinkage. At present, the wire materials for arc spraying provided by the market include aluminum, zinc, copper, nickel, stainless steel, aluminum bronze, babbitt, composite wire and the like. However, high-melting-point metals, such as steel, nickel, copper, etc., have relatively large coating shrinkage, thermal stress, and porosity during spraying. The coating is easy to crack, warp, and peel off. Therefore, only low-melting zinc and aluminum wires are currently available. Suitable for mold making.
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