Method of forming green part and manufacturing method using same

Abstract

A method of manufacturing a part, including providing a green body made of powder injection molding material and connected to a solid support member partially contained in the green body. The support member is engaged with a retaining fixture of a machine tool. While supporting the green body through the engagement between the support member and the retaining fixture, the green body is machined to obtain a machined green part. The machined green part is debound and sintered. A method of forming a powder injection molding part in a green state including machining a molded body using a machine tool while supporting the blank with a retaining fixture, and a machining blank having a green body and a solid support member including one locating feature of a pair of complementary locating features snuggly engageable with one another are also discussed.

1 . A machining blank comprising:
 a green body made of powder injection molding material, the powder injection molding material including a solidified binder and a powder material mixed with the binder; and   a solid support member having a greater rigidity than the green body, the support member having an inner portion embedded within the green body and an outer portion extending out of the green body, the outer portion including one locating feature of a pair of complementary locating features snuggly engageable with one another, the outer portion being adapted to be engaged with a retaining fixture including the other locating feature of the pair of complementary locating features.   
     
     
         2 . The blank as defined in  claim 1 , wherein the support member is made of solid metal. 
     
     
         3 . The blank as defined in  claim 1 , wherein the one locating feature is a locating pin protruding from the outer portion. 
     
     
         4 . The blank as defined in  claim 1 , wherein the outer portion of the support member surrounds a perimeter of the green body, and the inner portion includes a plurality tabs protruding inwardly from the second portion into the green body. 
     
     
         5 . The blank as defined in  claim 1 , wherein the support member and the green body have a common axis of axisymmetry, the support member defining a shaft. 
     
     
         6 . A method of forming a powder injection molding part in a green state, the method comprising:
 providing a blank having a molded body, the molded body being in the green state and made of powder injection molding material, the powder injection molding material including a solidified binder and a powder material mixed with the binder material;   engaging the blank with a retaining fixture of a machine tool; and   while supporting the blank with the retaining fixture, machining the molded body using the machine tool to obtain a machined green part in the green state.   
     
     
         7 . The method as defined in  claim 6 , wherein providing the blank includes molding the molded body by injecting a feedstock of the powder injection molding material into a mold cavity containing an inner portion of a solid support member to connect the inner portion with the molded body, and removing the connected molded body and support member from the mold cavity, and wherein engaging the blank with the retaining fixture of a machine tool is performed by engaging an outer portion of the support member with the retaining fixture, the machining being performed while supporting the blank through the engagement between the outer portion of the support member and the retaining fixture. 
     
     
         8 . The method as defined in  claim 7 , further comprising disengaging the support member from the machined green part. 
     
     
         9 . The method as defined in  claim 8 , wherein:
 machining the molded body is performed to obtain the machined green part and a retaining portion engaged to the inner portion of the support member and connected to the machined green part;   after the machining, the machined green part remains connected to the support member only through the retaining portion; and   disengaging the support member from the machined green part is performed by separating the machined green part from the retaining portion.   
     
     
         10 . The method as defined in  claim 6 , wherein engaging the blank with the retaining fixture maintains the molded body in a fixed position during the machining. 
     
     
         11 . The method as defined in  claim 6 , wherein machining the molded body includes rotating the blank with the retaining fixture.