The considerations for mould design involve several factors that ensure the efficient production of high-quality parts while minimizing costs and potential defects. These considerations include:
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Force Distribution: Moulds should be designed to apply forces over large areas to avoid localized stress concentrations. This helps in minimizing tensile stresses and preventing material failure.
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Geometry and Stress Conversion: The design should avoid sharp corners and edges, which can lead to stress concentrations. It is beneficial to convert tensile stress into compressive stress through appropriate construction techniques, including compressive pre-stressing, to enhance the durability of the part.
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Material Flow and Densification: The mould should facilitate good material densification and avoid sudden changes in cross-section, which can impede material flow and lead to uneven material distribution. This is crucial for maintaining the structural integrity of the part.
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Finishing and Machining: Preferring green machining over final finishing can reduce the overall manufacturing cost and time. The design should allow only small and limited machined surfaces and define non-machined roundings and chamfers to maintain efficiency.
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Manufacturing Specifics: Attention should be paid to the specific requirements of different manufacturing steps such as wet and dry pressing, extrusion, sintering, and glazing. This ensures that the mould is compatible with the manufacturing process and can produce parts efficiently.
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Removal from the Mould: The design should facilitate easy removal from the mould to avoid damage to the part. Avoiding thin walls is crucial as they can deform or break during removal.
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Special Manufacturing Processes: For processes like CIP (Cold Isostatic Pressing), the mould design should be scalable and flexible to accommodate batch production and different part shapes and sizes. The use of reusable tools in CIP can significantly reduce costs compared to processes like P-HIP.
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Sintering Considerations: During sintering, issues such as warping and sagging can occur. Mould designs should incorporate features like spacers, support ribs, and special setters to prevent these issues.
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Material Properties: The mould should be designed considering the material properties such as moisture absorption, fluidity, and tendency to decompose. For materials that are prone to decomposition and produce corrosive gases, the mould should be heated and the gating system should be designed to have low resistance to material flow.
By considering these factors, mould designers can create efficient and effective moulds that produce high-quality parts while minimizing costs and potential defects.
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