Cutting die and method of forming
AssigneeBernal, Inc.
InventorsTzyh-Chyang Cherng, Yu Zhang
Life of this patent
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Abstract
A cutting die is formed by scanning a laser beam along a path corresponding to a blade pattern, and introducing a selected powder to build up an integral blade of high grade, and hard-to-wear material on the relatively softer die body. The final blade shape is machined or produced by EDM or milling. Further hardening by heat treatment is optional. Other heat sources and cladding materials could be used.
Claims26
A process for producing a cutting die having a metal base which carries a sharpened ridge extending along a predetermined path thereon, said ridge being of a composition distinct from said metal base, comprising the steps of;
- a) scanning in an area along said path with a laser beam to heat the metal base to form a puddle, an area of said puddle being greater than an area of said metal base on which said laser beam directly impinges and simultaneously supplying powdered metal having a composition distinct from said metal base to said puddle along said predetermined path via a tube moving concurrently with and radially spaced from an axis of said laser beam so that said laser beam melts a thin layer of the metal base to form said puddle along said path and the metal powder being delivered to the base is melted in said puddle and at a surface thereof and thus forms a band of fused metal powder along said path,
- b) repeating steps a) so as to heat and melt a thin layer of the previously deposited metal along with additional metal powder to form an additional layer metallurgically bonded to the first layer, and
- c) repeating step b) to produce multiple layers until a ridge of metal is formed along said path, said ridge having a substantially uniform height and width, and
- d) sharpening the ridge so formed to suit it for use in cutting.
A method of manufacturing a cutting die, said cutting die including a die body and a cutting blade formed in a pattern and integral with said die body and extending outwardly from said die body;
- said method comprising steps of:
- a) heating an area of said die body by scanning an area with a laser to form a puddle of melted die body material in said area in the surface of said die body along a path corresponding to said pattern, said area being greater than an area of said die body on which said laser directly impinges;
- b) upon forming said puddle, applying a blade material in the form of a powder to said puddle while continuing said step of heating said die body corresponding to said path such that said powder is melted in said puddle and at a surface thereof to form a deposit comprising said blade material extending from said surface, said blade material having a hardness greater than said die body material;
- c) continuing performance of steps a) and b) along the entirety of said pattern;
- and
- d) machining at least side surfaces of said deposit comprising blade material to form said blade corresponding to said pattern and extending from said die body surface.
A cutting die including a die body and a cutting blade formed in a pattern and integral with said die body and extending outwardly from said die body, said cutting die being formed by steps of:
- a) heating an area of said die body by scanning said area with a laser to form a puddle of melted die body material in said area in the surface of said die body along a path corresponding to said pattern, said area being greater than an area of said die body on which said laser directly impinges;
- b) upon forming said puddle, applying a blade material in the form of a powder to said puddle while continuing said step of heating said die body corresponding to said path such that said powder is melted in said puddle and at a surface thereof to form a substantially half elliptical deposit comprising said blade material extending from said surface, said blade material having a hardness greater than said die body material;
- c) continuing performance of steps a) and b) along the entirety of said pattern;
- and
- d) machining at least side surfaces of said deposit comprising blade material to form said blade corresponding to said pattern and extending from said die body surface.
Dependencies are inferred from the claim text.