Method for producing a metal machining tool and metal machining tool produced thereby

Abstract

A method for producing a first mold element for a metal machining tool, wherein the first mold element is configured as a holding-down mechanism, for producing the first mold element, a main body made of plastics material is provided, wherein a surface of the main body is subdivided into a plurality of regions, on at least one region of the surface of the main body, at least one casting mold is arranged, wherein the at least one casting mold and the at least one region of the surface enclose at least one cavity, which forms a negative mold for a layer of plastics material to be applied, wherein plastics material is filled into the at least one cavity and cured, wherein the plastics material in the at least one region is connected to the surface of the main body and applied to it, forming the layer.

Claims

1. A method comprising: providing a main body, wherein a surface of the main body is subdivided into a plurality of regions; arranging, on at least one region of the surface of the main body, at least one casting mold, wherein the at least one casting mold and the at least one region of the surface of the main body enclose at least one cavity; applying a layer of plastics material to the at least one region, wherein the layer of the plastics material is filled into the at least one cavity and cured; applying the layer of the plastics material in the at least one region to the surface of the main body, thereby forming a first mold element for a metal machining tool.

2. The method according to claim 1, further comprising: applying a plurality of layers of plastics material, which differ from each other in terms of at least one material property, on at least two different regions of the surface of the main body.

3. The method according to claim 1, wherein the plastics material has at least one material property, wherein the at least one material property is at least one of a spring hardness of the plastics material, a spring rate of the plastics material, a n elasticity modulus of the plastics material, a coefficient of friction of the plastics material, and a thickness of the layer of the plastics material.

4. The method according to claim 1, further comprising: processing the at least one region before arranging the at least one casting mold.

5. The method according to claim 1, further comprising: casting the main body using the at least one casting mold.

6. The method according to claim 1, further comprising: providing a second mold element made of steel that is configured as a counter piece to the first mold element.

7. The method according to claim 1, further comprising: applying the plastics material to the at least one region of the surface of the main body.

8. The method according to claim 1, further comprising: in the at least one region of the surface of the main body, removing the plastics material to form a recess; wherein the at least one casting mold and the recess at the at least one region of the surface enclose the at least one cavity; filling the plastics material into the at least one cavity; and curing the filled plastics material, wherein the cured plastics material is connected to the surface of the main body.

9. The method according to claim 2, wherein the plastics material has at least one material property, wherein the at least one material property is at least one of a spring hardness of the plastics material, a spring rate of the plastics material, an elasticity modulus of the plastics material, a coefficient of friction of the plastics material, and a thickness of the layer of the plastics material.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) The invention is illustrated schematically on the basis of embodiments in the drawings and will be described schematically in detail with reference to the drawings.

(2) FIG. 1 shows, in schematic illustration, steps of an embodiment of the method according to the invention, in which a first embodiment of the metal machining tool according to the invention is produced.

(3) FIG. 2 shows, in schematic illustration, a detail of a second embodiment of the metal machining tool according to the invention.

DETAILED DESCRIPTION

(4) The figures will be described in connection with each other and in an overarching manner; identical components are assigned the same reference numbers.

(5) On the basis of FIGS. 1a, 1b, 1c, and 1d, it is illustrated schematically how, when the embodiment of the method according to the invention is implemented, a first mold element 4 is produced from a main body 2 made of at least one first plastics material as a component of the embodiment of the metal machining tool 6 according to the invention. In this case, it is provided that the first mold element 4 to be produced is configured as a holding-down means of the metal machining tool 6 and/or is to be used as such. It is provided here that the main body 2 is produced by carrying out a casting method using a casting mold. This first mold element 4 is to be configured, for example, as a holding-down means and/or is to be referred to as such.

(6) Furthermore, on an original surface 8 of the main body 2, at least one region 10, 12—here, two regions or surface areas 10, 12—is chosen, on which, in the scope of the method, in each case, a layer 14, 16 made of at least one second plastics material is to be applied or is to be bonded. In this case, for each of the two regions 10, 12 on the surface 8, a surface treatment measure is carried out. A first region—here, even or flat region 10—which is provided for a first layer 14, is situated in this case directly at and/or on the surface 8. In a second region 12 of the surface 8, plastics material is initially removed and a recess 13 or depression and/or pocket is formed at the originally flat or smooth surface 8: the second layer 16 is arranged in this case at or on the second region 12 of the surface 8 in the recess 13.

(7) Here, each region 10, 12 is roughened and a bonding agent is applied to the roughened regions 10, 12 (FIG. 1b). In a further step (FIG. 1c), it is provided that, on the surface of the main body 2, a casting mold 18 is arranged.

(8) In this case, the casting mold 18 comprises a recess 20, which is assigned to the first—here, flat—region 10 on the surface 8 of the main body 2. Furthermore, it is provided that the first region 10 on the surface 8 of the main body 2 and the recess 20 enclose a first cavity 24. Moreover, a first channel 54, which extends inside of the casting mold 18, is assigned to the recess 20 and thus to the first cavity 24.

(9) A second even, flat, and/or smooth region of a surface of the casting mold 18 is assigned to the second region 12 and thus to the recess 13 at and/or on the surface 8 of the main body 2. The second region 12 with the recess 13 in the surface 8 of the main body 2 and the surface of the casting mold 18 enclose a second cavity 26. Assigned to the second cavity 26 and/or to the recess 13 at the surface 8 of the main body 2 in this case is a channel 56, which extends inside of the casting mold 18.

(10) Furthermore, at least one second plastics material in liquid form is filled into the two cavities 24, 26 through the channels 54, 56. In this case, it is conceivable that a first kind or type of plastics material is filled into the first cavity 24 and a second kind or type of plastics material is filled into the second cavity 26, with one or both kinds of plastics material differing, as a rule, from the first plastics material of the main body. Accordingly, it is possible to use different plastics materials, which have different material properties and different chemical compositions and/or properties. The plastics materials cure inside of the cavities 24, 26.

(11) Formed on the first region 10 is the first layer 14 made of the first kind of plastics material, which is bonded to the roughened region 10 of the main body 8 that is furnished with the bonding agent. In this case, the first layer 14 made of the first kind plastics material comprises a first thickness or height, a first coefficient of friction, and a first spring hardness or spring rate.

(12) Furthermore, the second layer 16 made of the second kind of plastics material is bonded on the second region 12 of the surface 8 and/or in the recess 13 arranged there, wherein, here, this second layer 16 has a second thickness or height, a second coefficient of friction, and a second spring hardness or spring rate, which, in each case, may differ from the first thickness, the first coefficient of friction, and the first spring hardness or spring rate of the first layer 14.

(13) A thickness of a particular layer 14, 16 is defined, in a first step, by a height and/or depth of a respective recess. In this case, the thickness is defined by the depth of the recess 20 of the casting mold 18, which is arranged on the flat region 10 of the surface 8, and by the depth of the recess 13 at the second region 12 of the surface 8, on which a flat region of the casting mold 18 is arranged, with a cavity 24, 26 being provided in each case. Another possibility for controlling the thickness is to control the amount of the respective plastics material to be filled through the respective channel 54, 56, which, however, in both cases, can be altered for fine adjustment in a second step by post-processing, if necessary.

(14) Through bonding of the two layers 14, 16 to the regions 10, 12 of the surface 8, the first mold element 4 and thus the holding-down means of the metal machining tool 6 are formed from the main body 2. FIG. 1d also shows a second mold element 28 as another component of the metal machining tool 6. In this case, said second mold element 28 has a surface 30, which is complementary in shape to the surface 8 of the main body 2 with the layers 14, 16 made of the first plastics material bonded to it. The second mold element 28 here has two recesses 42, 44, which are complementary in shape to the layers 14, 16 made of the at least second plastics material on the surface 8 of the first mold element 4.

(15) For forming a structural part from metal, usually from sheet metal, said metal is to be arranged between the two mold elements 4, 28 of the metal machining tool 6.

(16) Afterwards, the two mold elements 4, 28 are to be moved toward each other, whereby the structural part is pressed between the mold elements 4, 28.

(17) FIG. 2 shows another example for a first mold element 32 as a component of the second embodiment of the metal machining tool according to the invention. This first mold element 32 is also configured as a holding-down means and has a main body 34 made of plastics material, to which, here, a plurality of layers 36, 38, 44* made of different kinds of plastics material having different thicknesses are bonded.

(18) The presented first mold elements 4, 32 of the metal machining tool are configured as a holding-down means in order to control a material flow for a structural part to be processed, wherein a warping, a formation of creases, and/or a crumpling of the structural part is prevented by the holding-down means.