Deforming tool and process for manufacturing thereof

Abstract

Deforming tool and process for manufacturing thereof in the deformation of work pieces the outer force acts on the deforming tool and/or the work piece, which causes a flow of the work piece material and its plastic deformation into a shape determined by the tool shape. Therein the tool is subjected to high friction wear forces. In the framework of the ever shorter production cycles it is also necessary that deforming tools must be produced ever more rapidly, wherein their friction wear resistance must be maintained to the greatest extent possible. The inventive deforming tool includes a lower and an upper tool, wherein lower and/or upper tool include a shape determining shell and a backfill for supporting thereof, wherein lower and/or upper tool are comprised at least in part of laminated material layers or powder particles joined to each other, wherein the deforming tool includes an elastic intermediate layer between lower and/or upper tool (backfill) and the shape determining shell. The elastic intermediate layer serves for evenly distributing or minimizing tension or pressure peaks in the pressure load in the deforming process, and thus to reduce the friction wear of the tool.

1 . A deforming tool, including lower and upper tool, 
 wherein lower and/or upper tool are comprised of a shape determining shell and a backfill for supporting thereof;    wherein lower and/or upper tool are at least partially comprised of laminated material layers, wherein    the laminated material layers are oriented in such a manner, that as many as possible step stages occur in the direction towards the shape determining shell.    
   
   
       2 . The deforming tool according to  claim 1 , 
 wherein    the deforming tool includes an elastic intermediate layer between upper and/or lower tool (backfill) and shape determining shell.    
   
   
       3 . The deforming tool according to  claim 2 , wherein 
 the elastic intermediate layer has a thickness of 0.5 to 2 mm.    
   
   
       4 . The deforming tool according to  claim 2 , wherein 
 the elastic intermediate layer is comprised of one single piece or of a flowable material.    
   
   
       5 . The deforming tool according to  claim 1 , wherein 
 the shape determining shell and/or the laminated material layers or the powder particles are metal.    
   
   
       6 . (canceled)  
   
   
       7 . The deforming tool according to  claim 1 , wherein 
 the shape determining shell has a surface structure adapted for formation of micro lubricant pockets into the surface of the work piece to be deformed.    
   
   
       8 . A process for manufacturing a deforming tool which includes lower and upper tool, wherein, beginning with a three-dimensional data set a volume model of the deforming tool, a Laminated Object Manufacturing (LOM) rapid process is used to build up the deforming tool or parts thereof in layers, wherein for the lower and/or upper tool a shape determining shell and a backfill for supporting thereof are produced, wherein 
 a three-dimensional data set of the volume model of the shape determining shell is created, and    from the three-dimensional data set, the volume model of the deforming tool (shell) is extracted, so that a three dimensional model of the supporting backfill results, which is then built up by the LOM process, and    that the material layer to be laminated are oriented in such a manner that as many as possible steps occur in the direction towards the shape determining shell.    
   
   
       9 . (canceled)  
   
   
       10 . The process for manufacturing a deforming tool according to  claim 8 , wherein 
 for the deforming tool to be produced, an elastic intermediate layer is provided between lower and/or upper tool (backfill) and the deforming shell, wherein the three-dimensional set of a volume model of the elastic intermediate layer is created and subtracted from the first three-dimensional set of the volume model of the supporting backfill, so that a second three-dimensional set of the volume model of the supporting backfill results, which then can be built up in layers by the rapid LOM process.    
   
   
       11 . The process for manufacturing a deforming tool according to  claim 8 , wherein 
 a flat shell preform and a work piece to be deformed are introduced in the lower or upper tool, optionally with inlaying or introduction of an elastic intermediate layer, and    with action of the corresponding upper or lower tool, these are deformed in such a manner that from the flat shell pre-form the form-determining shell results.    
   
   
       12 . The deforming tool according to  claim 1 , wherein at least one of the upper and lower tools is made at least in part of joined powder particles.