TECHNICAL FIELD
[0001] This invention relates to a method for carrying out a compression molding of granulated
particles of ceramic, metal etc. using an upright pressing apparatus.
BACKGROUND ART
[0002] Particulate material is prepared by mixing binder such as wax into particles of ceramic
or metal. The particulate material thus prepared is compressed in a mold of a pressing
machine, and then sintered in a furnace to be used as a carbide tip, a precision machinery
component and so on.
[0003] According to a conventional method for compressing the particulate material using
a conventional pressing machine, an upper punch and a lower punch of the pressing
machine are reciprocated slowly by a crank mechanism or a hydraulic mechanism. In
addition, friction between the particulate materials is rather high. Therefore, the
particulate material cannot be compressed densely by a conventional pressing machine,
and density distribution of the particulate materials thus compressed by the conventional
pressing machine is not sufficiently homogeneous.
[0004] One example of a conventional powder pressing machine is disclosed in Japanese Patent
Laid-Open No.
2004-174596. According to the teachings of Japanese Patent Laid-Open No.
2004-174596, a punch is attached individually to an upper and lower rams through a lamination
type piezoelectric element, and powder filled in a metal mold is compressed smoothly
into a desired shape by applying impact force intermittently. Therefore, the powder
pressing machine taught by Japanese Patent Laid-Open No.
2004-174596 is capable of resolving the above-explained disadvantages.
[0005] The impact-type powder pressing machine taught by Japanese Patent Laid-Open No.
2004-174596 is shown in Fig. 11. As shown in Fig. 11, the powder pressing machine taught by Japanese
Patent Laid-Open No.
2004-174596 comprises: a frame 1; an intermediate frame 11; an upper ram 2; a ball screw 21 for
reciprocating the upper ram 2; a lamination type piezoelectric element 23; an upper
punch 3 attached to the upper ram 2 through the piezoelectric element 23; a die 4
fixed to the intermediate frame 11; a lower ram 5; a ball screw 51 for reciprocating
the lower ram 5; a lamination type piezoelectric element 52; and a lower punch 6.
[0006] For example, a Piezo-Electric Transducer (abbreviated as PZT) is known as the piezoelectric
element in the prior art. Specifically, PZT is a ceramic element which is deformed
instantaneously by applying driving voltage thereto.
[0007] However, as explained in paragraph [0030] of Japanese Patent Laid-Open No.
2004-174596, a range of deformation of the piezoelectric element is not very wide e.g., within
several µm and several 10 µm. Therefore, according to the powder pressing machine
taught by Japanese Patent Laid-Open No.
2004-174596, a plurality of piezoelectric elements have to be laminated to form the lamination
type piezoelectric element. Further, the lamination type piezoelectric element cannot
function effectively if a spring back amount of the powder material (i.e., a difference
between thicknesses thereof when compressed and after compressed) is larger than a
deformation amount thereof.
[0008] Basically, the impact force is not oriented to the specific direction. Therefore,
the powder pressing machine taught by Japanese Patent Laid-Open No.
2004-174596 has to be improved to concentrate the impact force to vertical direction.
[0009] In addition to the above-explained disadvantages, the inventors of the present invention
have found a fact that the impact force cannot be transmitted effectively in the powder
material and voids would remain in the powder material, without applying predetermined
pressure to the powder material in advance of applying the impact force thereto. Therefore,
according to the teachings of Japanese Patent Laid-Open No.
2004-174596, the impact force cannot propagate entirely into the powder material to compress
the powder material homogeneously.
DISCLOSURE OF THE INVENTION
[0010] The present invention has been conceived noting the technical problems thus far described,
and its object is to compress particulate matter homogeneously without remaining voids
therein by applying an impact force effectively to the particulate material.
[0011] In order to achieve the above-mentioned object, according to the present invention,
there is provided a compression molding method for particulate matter filled in a
cavity of a die by an upper punch arranged above the die, or by a lower punch arranged
underneath the die, characterized by comprising: compressing the particulate matter
filled in the cavity of the die to a predetermined pressure by moving the upper punch
downwardly or moving the lower punch upwardly; and thereafter further compressing
the particulate matter by applying an impact force thereto by actuating an impact
force applying means arranged between the upper punch and an upper ram to which the
upper punch is attached, or arranged between the lower punch and a lower ram to which
the lower punch is attached.
[0012] According to the method of the present invention, a clearance gap created between
the particulate matter further compressed by the impact force applying means and the
upper or lower punch is eliminated by moving the upper punch downwardly again or by
moving the lower punch upwardly again.
[0013] Specifically, according to the method of the present invention, said compression
of the particulate matter to the predetermined pressure by moving the upper punch
downwardly or moving the lower punch upwardly is carried out by applying a weight
of the upper punch falling gravitationally within a clearance created between a reciprocating
mechanism of the upper punch and the upper ram.
[0014] According to the method of the present invention, the compression of the particulate
matter to the predetermined pressure by moving the upper punch downwardly or moving
the lower punch upwardly, and the further compression of the particulate matter by
the impact force applying means, are carried out repeatedly.
[0015] Specifically, the impact force applying means includes a magnetostrictive actuator.
[0016] In addition, a stroke of the impact force applying means to further compress the
particulate matter is more than twice as an average grain diameter of the particulate
matter.
[0017] According to another aspect of the present invention, there is provided an upright
compression molding apparatus for particulate matter, which is adapted to compress
particulate matter filled in a cavity of a die by moving an upper punch arranged above
the die downwardly, or by moving a lower punch arranged underneath the die upwardly,
characterized by comprising: a magnetostrictive actuator functioning as an impact
force applying means, which is interposed at least between the upper punch and an
upper ram to which the upper punch is attached, or between the lower punch and a lower
ram to which the lower punch is attached.
[0018] The compression molding apparatus further comprises: a reciprocating mechanism, which
is adapted to reciprocate the upper punch. According to the particulate matter compressing
apparatus of the present invention, the reciprocating mechanism is engaged with the
upper ram while keeping a predetermined clearance thereby allowing the upper punch
to fall gravitationally in a vertical direction, and a weight of an assembly including
the upper punch and the upper ram is applied to the particulate matter to compress
the particulate matter to the predetermined pressure.
[0019] According to the present invention, an internal stress of the particulate matter
is reduced by thus applying the impact force to the particulate matter when compressing
the particulate matter. Therefore, the compressed particulate matter can be shrunk
homogeneously at a subsequent sintering step so that a quality of final product can
be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020]
Fig. 1 is a front view showing a compression molding apparatus according to the present
invention.
Fig. 2 is a partial sectional view showing a mold and peripheral equipments in an
enlarged scale.
Fig. 3 is an explanation drawing explaining a compression molding method according
to the present invention.
Fig. 4 is a perspective view showing a work to be compressed by the compression molding
method illustrated in Fig. 3.
Fig. 5 is a graph showing a relation between a moving distance of the punch and a
pushing force.
Fig. 6 is a graph showing a relation between a relative speed of the punch and a friction
coefficient.
Fig. 7 is a graph showing a relation between a density and a pushing force.
Fig. 8 is a schematic view showing a cycle of the compression molding method of the
present invention.
Fig. 9 is a partial sectional view showing a lower end portion of the reciprocating
mechanism and the upper ram.
Fig. 10 is an explanatory drawing explaining a clearance between the upper ram and
a ball screw.
Fig. 11 is a front view showing a conventional impact pressing machine.
BEST MODE FOR CARRYING OUT THE INVENTION
[0021] First of all, a compression molding method of the present invention will be explained
with reference to Fig. 3.
[0022] In the example shown in Fig. 3, an upper punch 3 and a lower punch 6 are individually
shaped into a cylindrical shape, and each radius r of those upper and lower punches
3 and 6 is approximately 2 mm. Meanwhile, a cylindrical cavity to which the upper
and lower punches 3 and 6 are inserted is formed in a die 4, and a radius of the cavity
is also approximately 2 mm. As shown in Fig. 4, particulate matter is filled in the
cylindrical cavity of the die 4 to be compressed as a work W. In case of compressing
the work W by lowering the upper punch 3 while fixing the lower punch 6, a reaction
force P
S as a static load of the fixed lower punch 6 can be obtained by the following formula:

where P
D represents compressive load of the upper punch 3. That is, a friction resistance
can be calculated by the formula in the bracket.
[0023] In order to eject the compressed work W from the cavity of the die 4 by moving the
lower punch 6 upwardly, the lower punch 6 is required to push the work W by a pushing
force P
E larger than the friction resistance. The required pushing force P
E can be obtained by the following formula:

[0024] The internal stress in the above-formula (2) can be calculated by measuring the pushing
force P
E, and substituting the measured pushing force P
E into the formula (2). The internal stress thus calculated can be used as an index
for estimating homogeneity of density in the compressed particulate matter.
[0025] Fig. 5 is a graph showing one example of a relation between a moving distance of
the lower punch 6 and the pushing force for pushing the work W. As indicated in Fig.
5, the pushing force is increased steeply and proportionally in the beginning of a
movement of the lower punch 6, that is, static friction acts between the work W and
the cavity in this range. Then, the static friction turns into kinetic friction and
the pushing force becomes smaller to a value about half of the pushing force in the
range where the static friction is acting.
[0026] A relation between coefficient of friction and relative speed of the punch changes
exponentially as shown in Fig. 6. However, such relation is expressed as a diagonal
line inclining downwardly toward right side in a single logarithmic plot. In Fig.
6, coefficient of static friction is indicated at an intersection between a vertical
axis and a curved line, that is, at a point where the relative speed of the punch
is zero. Meanwhile, coefficient of kinetic friction is indicated in a range where
the speed of the punch is increasing. According to a normal pressing machine, a speed
of the punch is approximately within a range from 10 to 100 mm per second. On the
other hand, a speed of the punch becomes almost 1 meter per second in case of the
impact pressing. That is, the friction coefficient under the impact pressing is much
smaller than that under a normal pressing.
[0027] The friction coefficient is varied according to the kind of particulate matter. However,
the inventors of the present application have experimentally found a fact that the
friction coefficient of the individual particulate matter will not be changed before
and after compressing.
[0028] Fig. 7 is a graph indicating a relation between a pushing force for pushing the work
W and a density of the work W In an example shown in Fig. 7(a), agglomerated particles
of tungsten carbide (WC) are used to form the work W. Meanwhile, alumina particles
are used to form the work W in an example shown in Fig. 7(b).
[0029] Here, a grain diameter of tungsten carbide particle is approximately 10 µm. Thus,
the particles of tungsten carbide are too fine, and the particles of tungsten carbide
are therefore difficult to be filled in the cavity as it is. In this example, therefore,
the particles of tungsten carbide are agglomerated to form a particle of approximately
50 µm by being mixed with a blinder
[0030] In Fig. 7, a broken line represents the relation between a pushing force pushing
the work W and a density of the work W under the normal compression molding, and a
solid line represents said relation under the compression molding while applying an
impact force. As can be seen from Fig. 7, the pushing forces of both cases increase
in accordance with an increase in the density of the work W, and the pushing force
of the case in which is the impact force is applied is reduced 25-45% in comparison
with that of the case in which the impact force is not applied. Such a difference
in the pushing forces of those cases is widened more significantly in accordance with
an increase in the density of the work W.
[0031] However, the pushing force cannot be reduced effectively by merely applying the impact
force to the work W when compressing. The inventors of the present invention have
found a fact that it is preferable to compress the particulate matter to a predetermined
pressure by a conventional procedure (that is, by applying a precompression force
to the particulate matter), and then applying an impact force to the particulate matter.
Otherwise, the impact force cannot be transmitted entirely in the particulate matter,
that is, the impact force is applied only to a surface of the particulate matter.
Specifically, a preferable range of the precompression force applied to the particulate
matter in advance is 4.9 to 14.7 MPa (50 to 150 kg / cm
2) depending on a size of the mold and a kind of the particulate matter. If the precompression
force applied to the particulate matter is smaller than the above-mentioned range,
remaining porosity of the particulate matter thus compressed preliminary is still
too large to compress the particulate matter effectively by applying the impact force
subsequently. To the contrary, in case the precompression force applied to the particulate
matter is larger than the above-mentioned range, voids in the particulate matter are
crushed excessively and it is also unfavorable.
[0032] In case of compressing the particulate matter by applying the impact force thereto,
a stroke of the punch is also an important factor. As described, an average grain
diameter of the particles of ceramic or the like is approximately 50 µm. In this case,
a length of the stroke is required to be at least twice as much as the grain diameter,
that is, the length of the stroke has to be more than 100 µm. If the length of the
stroke is shorter than 100 µm, it is difficult to apply the impact force to the particulate
matter effectively, like a conventional method for compressing the particles by a
static pressure. Therefore, longer stroke is preferable to compress the particulate
matter.
[0033] For this purpose, a magnetostrictive device such as a magnetostrictive actuator is
used as the impact force applying means. Specifically, the magnetostrictive actuator
is a rod member whose length is approximately 50 mm, and a coil is wrapped around
the magnetostrictive actuator. When the coil is excited, the magnetostrictive actuator
is immediately elongated approximately 200 µm. Therefore, in case of connecting two
of the magnetostrictive actuator in series, a total length of the stroke will be 400
µm. In this case, the impact force to be applied to the particulate matter will be
approximately 98MPa (i.e., 1 ton/cm
2).
[0034] Alternatively, PZT can also be used as the impact force applying means. However,
a length of elongation of the PZT is not sufficiently long, e.g., approximately 0.5
µm per 1mm thickness. Therefore, in this case, some improvement is required to elongate
the stroke of the PZT.
Example 1
[0035] Hereinafter, a first example of the method and apparatus for compressing particulate
matter according to the present invention will be explained with reference to the
accompanying figures.
[0036] Fig. 1 is a front view showing a compression molding apparatus according to the first
example, and Fig. 2 is a partial sectional view showing the mold thereof. As can be
seen from Figs. 1 and 2, in addition to the elements shown in Fig. 11 previously explained,
the compression molding apparatus of the first example comprises: a guide bar 12 for
guiding the upper and lower rams 2 and 5 to move longitudinally; a pressure sensor
24 adapted to measure the pushing force; and an magnetostrictive actuator 52 configured
to be elongated when exited. Here, in the example shown in Fig. 1, the pressure sensor
24 is arranged in an upper punch 3 side. However, according to the present invention,
the pressure sensor 24 may also be arranged in a lower punch 6 side depending on the
pushing force to be measured.
[0037] In the compression molding apparatus shown in Fig. 1, the magnetostrictive actuator
52 is interposed between the lower punch 6 and the lower ram 5. However, the magnetostrictive
actuator 52 may also be arranged in the upper punch 3 side. Alternatively, the magnetostrictive
actuator 52 may be arranged in both of the upper punch 3 side and the lower punch
6 side.
[0038] Next, the compression molding method according to the first example will be explained
hereinafter.
[0039] First of all, the lower punch 6 is moved upwardly by rotating the ball screw 51 using
a not shown motor thereby closing a cavity of the die 4 from a bottom side, and the
particulate matter is filled in the cavity of the die 4 to a level of an upper surface
of the die 4. Then, the particulate matter in the cavity is compressed to a predetermined
pressure by a static pressure (that is, the aforementioned preferable precompression
is applied), by rotating the ball screw 21 in a manner to lower the upper punch 3
using a not shown another motor. Then, impact force or impulse energy is applied to
the particulate matter intervening between the upper punch 3 and the lower punch 6
by exciting the magnetostrictive actuator 52.
[0040] Specifically, the impact force is applied to the particulate matter by applying a
voltage to the magnetostrictive actuator 52 instantaneously. For example, a pulse
voltage of approximately 300 volt and 100 ampere is applied to the magnetostrictive
actuator 52 for 200 µ second by a not shown power source.
[0041] As a result of thus compressing the particulate matter and applying the impact force
thereto, a volume of the particulate matter is reduced. The particle matter whose
volume is thus reduced is compressed again to a desired pressure by applying a static
pressure by moving the upper punch 3 or the lower punch 6, and then the impact force
is applied again to the particulate matter by exciting the magnetostrictive actuator
52.
[0042] The above-explained cycle is repeated as necessary, e.g., 10 to 20 times.
[0043] Then, the work W thus formed is ejected from the cavity by moving the lower punch
6 upwardly. Here, a spring back amount of the ejected work W thus formed is less than
half of that of a work compressed only by a static pressure.
[0044] In case of using ceramic particles to form the work W, a volume thereof will be reduced
approximately by half after compressed entirely and homogeneously. Meanwhile, in case
of using particles of tungsten carbide to form the work W, a volume thereof will be
reduced approximately by one-third after compressed entirely and homogeneously. As
a result, voids of the work W are eliminated, and therefore the work W thus formed
will not be shrunk to crack even after sintered at a subsequent sintering step. For
this reason, a flawless interim product can be produced.
Second Example
[0045] Next, a second example of the method and apparatus for compressing particulate matter
according to the present invention will be explained with reference to the accompanying
figures.
[0046] In case of applying an impact force to the particulate matter, the punch actuated
instantaneously by the impact force applying means excited by the pulse voltage is
returned immediately to an initial position. However, a volume of the particulate
matter thus compressed instantaneously tends to spring back slightly toward an initial
volume. This situation is illustrated schematically in Fig. 8 (a) in chronological
order from left to right.
[0047] First of all, the upper punch 3 is lowered to compress the particulate matter to
the predetermined pressure by a static pressure. Then, the lower punch 6 is actuated
by the impact force applying means to apply an impact force to the particulate matter,
and returned to the initial position after approximately 1/10000 second. As a result,
a clearance is created between a lower end of the compressed particulate matter and
the lower punch 6. A volume of the particulate matter thus compressed returns gradually
toward an initial volume thereof by a spring back and the aforementioned clearance
is thereby narrowed. However, in this situation, a static friction is acting between
the particulate matter and an inner wall of the cavity. Therefore, the spring back
of the particulate matter is delayed by such a high resistance resulting from the
static friction. In addition, density of the particulate matter becomes inhomogeneous
as a result of occurrence of the spring back. Nonetheless, the aforementioned clearance
remains between the compressed particulate matter and the lower punch 6 after the
termination of the spring back. Then, the lower punch 6 is moved upwardly to the lower
end of the work W formed by thus compressing the particulate matter, and this is a
final step of a cycle of the compression molding. This cycle is repeated from the
first step illustrated in the left end of Fig. 8 (a) thereby applying the impact force
again to the work W
[0048] Thus, according to the example shown in Fig. 8 (a), the lower punch 6 has to be moved
upwardly to be contacted with the compressed work W at the end of the cycle thereby
eliminating the clearance therebetween. Such step of eliminating the clearance by
moving the lower punch 6 upwardly is a time-consuming task, and it has to be repeated
in every cycle.
[0049] In order to solve the above-explained disadvantage, according to the second example,
an upper ram 2 is engaged with a reciprocating mechanism while keeping a clearance
therebetween. Fig. 9 is a partial sectional view showing a lower end portion of the
reciprocating mechanism and the upper ram 2. Specifically, as shown in Fig. 9, the
upper ram 2 is engaged with a (leading end of) ball screw 21 functioning as the reciprocating
mechanism by a stopper 22, and a punch holder 31 holding the upper punch 3 is attached
to a lower face of the upper ram 2.
[0050] According to the engaging structure shown in Fig. 9, the upper ram 2 is engaged with
the ball screw 21 at the stopper portion 22 to be pulled upwardly by the ball screw
21. However, a clearance g is maintained between a leading end face of the ball screw
21 and an upper face of the upper ram 2 thereby allowing the upper ram 2 to move vertically
[0051] A function of the engaging structure is illustrated schematically in Fig. 8(b). As
the previously explained Fig. 8 (a), steps of compressing the particulate matter are
illustrated schematically in Fig. 8(b) in chronological order from left to right.
[0052] As in the example shown in Fig. 8(a), the upper punch 3 is lowered to compress the
particulate matter by a static pressure to a predetermined pressure. Then, the ball
screw 21 is moved upwardly by being rotated inversely to be detached from the upper
ram 2.
[0053] The above-explained "detached state" will be explained with reference to Fig. 10.
Specifically, a standby state of the compressing apparatus before carrying out a compression
molding is illustrated in Fig. 10 (a). In this situation, the upper ram 2 hangs from
the leading end of the ball screw 21, and the clearance is created between the leading
end of the ball screw 21 and the upper ram 2. Then, the ball screw 21 is moved downwardly
to apply a static pressure to the particulate matter as shown in Fig. 10 (b), and
in this situation, the leading end of the ball screw 21 is contacted with the upper
ram 2. Then, as shown in Fig. 10 (c), the ball screw 21 is rotated inversely to be
detached from the upper ram 2. In this situation, a pushing force of the ball screw
21 is not applied to the upper ram 2. That is, in the situations shown in Figs. 10
(b) and 10 (c), the upper punch 3 is pushed upwardly by a reaction force of the particulate
matter, and a depression of the upper ram 2 is stopped by the particulate matter.
[0054] In other words, only a total weight of an assembly of the ram 2 including the punch
holder 31 and the upper punch 3 is applied to the particulate matter by moving the
ball screw 21 upwardly within a range of the clearance g. That is, the total weight
of the assembly of the ram 2 is the above- explained predetermined pressure to be
applied to the particulate matter as the precompression force. If the precompression
force is smaller than the above explained preferable range, the weight of the ram
2 is increased.
[0055] In this situation, an impact force is applied to the particulate matter. In this
case, the total weight of the assembly of the ram 2 including the upper punch 3 is
sufficiently heavy. Therefore, the work W formed of the particulate matter and the
upper punch 3 will not be pushed upwardly by the impact force applied to the work
W. For this reason, the impact force can be transmitted entirely in the work W. As
in the case shown in Fig. 8 (a), the lower punch 6 is returned immediately to the
initial position and a clearance is therefore created instantaneously between the
work W and the lower punch 6. However, in this case, the upper punch 3 falls gravitationally
and simultaneously with the spring back of the work W thereby eliminating the clearance
between the work W and the lower punch 6. Moreover, a resistance of kinetic friction
acting between the work W being lowered by the upper punch 3 and the inner wall of
the cavity is rather small. Consequently, a difference between a load on the upper
punch 3 and a load on the lower punch 6 is almost eliminated. In addition, since the
final step of the method shown in Fig. 8(a) for moving the lower punch 6 upwardly
to be contacted with the work W is omitted, a cycle time of the method shown in Fig.
8(b) can be shortened. Therefore, productivity of the compressing apparatus can be
improved.
[0056] Thus, the clearance g maintained between the ball screw 21 and the upper ram 2 allows
the upper punch 3 to eliminate the clearance created between the particulate matter
and the lower punch 6 as a result of applying the impact force to the particulate
matter. For this purpose, a preferable amount of the clearance g is approximately
0.2 mm.