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Study on Formation of High-performance Metal Mold Surface by EDM with Hybrid Metal Powder Mixed Fluid

Research Project

Project/Area Number 20H02050
Research Category

Grant-in-Aid for Scientific Research (B)

Allocation TypeSingle-year Grants
Section一般
Review Section Basic Section 18020:Manufacturing and production engineering-related
Research InstitutionOkayama University

Principal Investigator

Okada Akira  岡山大学, 環境生命自然科学学域, 教授 (60263612)

Co-Investigator(Kenkyū-buntansha) 岡本 康寛  岡山大学, 環境生命自然科学学域, 准教授 (40304331)
北田 良二  崇城大学, 工学部, 教授 (60540276)
篠永 東吾  岡山大学, 環境生命自然科学学域, 助教 (60748507)
Project Period (FY) 2020-04-01 – 2024-03-31
Project Status Completed (Fiscal Year 2023)
Budget Amount *help
¥18,200,000 (Direct Cost: ¥14,000,000、Indirect Cost: ¥4,200,000)
Fiscal Year 2023: ¥1,820,000 (Direct Cost: ¥1,400,000、Indirect Cost: ¥420,000)
Fiscal Year 2022: ¥1,950,000 (Direct Cost: ¥1,500,000、Indirect Cost: ¥450,000)
Fiscal Year 2021: ¥3,120,000 (Direct Cost: ¥2,400,000、Indirect Cost: ¥720,000)
Fiscal Year 2020: ¥11,310,000 (Direct Cost: ¥8,700,000、Indirect Cost: ¥2,610,000)
Keywords放電加工 / 金型 / 粉末混入加工液
Outline of Research at the Start

工業製品を構成する各部品は小型化.軽量化が求められているため,樹脂部品が多用され,これらの大量生産でのコスト低減のために金型による成形が一般に行われる.従って複雑微細形状の金型加工やその表面仕上げ,表面高機能化のための表面処理やコーティングが必要であるが,時間やコストを要する.本研究では金型の微細形状加工に応用される放電加工を用いて,形状加工,表面仕上げ,表面高機能化を連続して効率的に行うために,金型表面平滑化効果を持つ金属粉末,ならびに金型表面の耐食性や離型性を向上させる効果をもつ異なる粉末を加工液に混入して放電加工を行う,新しい表面仕上げ,高機能表面形成プロセスの確立を目指す.

Outline of Final Research Achievements

This study found firstly that a hard surface layer containing chromium carbide can be formed on the EDM finished surface by using a chromium powder mixed working fluid. Then, the effect of hybrid powder-mixed EDM with using chromium powder and silicon one, was investigated, and sufficiently small surface roughness with a practical level for metal mold could be obtained.
On the other hand, by applying EDM conditions with large electrode wear, the formation of surface layer containing electrode components was also succeeded. By using a chromium electrode and a cemented WC one in sequence, we succeeded the formation of a two-layer structure surface layer containing chromium carbide and tungsten carbide.
Furthermore, in order to quantitatively evaluate the releasability of molded resin from the finished surface of metal mold, we built a new device to measure the resin releasing force, and accurate evaluation of the mold releasability from metal surface became possible.

Academic Significance and Societal Importance of the Research Achievements

放電加工を用い,加工液に混入した金属粉末や電極材質の成分を仕上げ面に含有できる現象を確認し,そのメカニズムを解明したところに学術的な意義がある.また,加工液の熱分解炭素と化合した硬質炭化物を含有する表面層を形成できること,異なる電極を順に用いることで2層構造表面層を創成できることは産業的な意義も大きい.放電加工のみで金型形状創成から表面仕上げ・改質が達成できる可能性があり,金型加工プロセス全体の高能率低コスト化が期待できる.

Report

(5 results)
  • 2023 Annual Research Report   Final Research Report ( PDF )
  • 2022 Annual Research Report
  • 2021 Annual Research Report
  • 2020 Annual Research Report
  • Research Products

    (11 results)

All 2024 2023 2022 2021 2020

All Journal Article (4 results) (of which Peer Reviewed: 4 results,  Open Access: 1 results) Presentation (7 results) (of which Int'l Joint Research: 1 results)

  • [Journal Article] 樹脂成型金型における離型s力測定と離型性の向上2024

    • Author(s)
      北田良二,岡田晃
    • Journal Title

      砥粒加工学会誌

      Volume: 68 Pages: 111-114

    • Related Report
      2023 Annual Research Report
    • Peer Reviewed
  • [Journal Article] Influence of surface roughness of die sinking EDM on mold releasability in compression molding of thermosetting phenol resin2022

    • Author(s)
      Kitada Ryoji、Wang Qin、Tsuetani Shun-ichiro、Okada Akira
    • Journal Title

      Procedia CIRP

      Volume: 113 Pages: 238-243

    • DOI

      10.1016/j.procir.2022.09.152

    • Related Report
      2022 Annual Research Report
    • Peer Reviewed / Open Access
  • [Journal Article] Possibility of Compositionally Graded Surface Formation by Electrical Discharge Machining2021

    • Author(s)
      Shun-ichiro TSUETANI, Yuki IKEUCHI, Akira OKADA, Ryoji KITADA
    • Journal Title

      Proceedings of the 10th International Conference on Leading Edge Manufacturing in 21st Century

      Volume: -

    • Related Report
      2021 Annual Research Report
    • Peer Reviewed
  • [Journal Article] Fundamental Study on Double-Layered Surface Formation by Electrical Discharge Machining,Proceedings of the 18th International Conference on Precision Engineering2020

    • Author(s)
      Yuki Ikeuchi, Shun-ichiro Tsuetani, Ryoji Kitada, Akira Okada
    • Journal Title

      Proceedings of the 18th International Conference on Precision Engineering (ICPE2020)

      Volume: 18

    • Related Report
      2020 Annual Research Report
    • Peer Reviewed
  • [Presentation] クロム粉末混入放電加工面の離型性に関する基礎評価2024

    • Author(s)
      北田良二,王欽,吉田光希,岡田晃
    • Organizer
      2024年度精密工学会春季大会学術講演会
    • Related Report
      2023 Annual Research Report
  • [Presentation] Fundamental Study on Influence of Ground Surface Characteristics on Mold Releasability in Compression Molding of Thermosetting Phenol Resin2023

    • Author(s)
      Qin Wang, Ryoji Kitada, Koki Yoshida, Akira Okada
    • Organizer
      The 10th Asian Society for Precision Engineering and Nanotechnology
    • Related Report
      2023 Annual Research Report
    • Int'l Joint Research
  • [Presentation] 研削加工面に対する熱硬化性フェノール樹脂の圧縮成形における離型性の基礎的評価2023

    • Author(s)
      王欽,大庭侑太郎,北田良二,杖谷俊一郎,岡田晃
    • Organizer
      2023年度精密工学会春季大会学術講演会
    • Related Report
      2022 Annual Research Report
  • [Presentation] 放電加工仕上げによる組成傾斜表面層形成に関する基礎的研究2022

    • Author(s)
      杖谷俊一郎,岡田晃,北田良二
    • Organizer
      日本機械学会中国四国支部第60期総会・講演会
    • Related Report
      2022 Annual Research Report 2021 Annual Research Report
  • [Presentation] 熱硬化性フェノール樹脂の圧縮成形における形彫り放電加工面と切削加工面の離型抵抗比較2021

    • Author(s)
      王欽,川口和大,北田良二,松岡将平,岡田晃
    • Organizer
      電気加工学会全国大会(2021)
    • Related Report
      2021 Annual Research Report
  • [Presentation] 放電加工による二層構造表面層形成に関する基礎的検討2020

    • Author(s)
      池内祐貴,杖谷俊一郎,北田良二,岡田晃
    • Organizer
      2020年度精密工学会秋季大会学術講演会
    • Related Report
      2020 Annual Research Report
  • [Presentation] 熱硬化性フェノール樹脂の圧縮成形における形彫り放電加工面の離型性2020

    • Author(s)
      北田良二,秋山晃太朗,天本翔二,池内祐貴,岡田晃
    • Organizer
      電気加工学会全国大会(2020) 講演論文集
    • Related Report
      2020 Annual Research Report

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Published: 2020-04-28   Modified: 2025-01-30  

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