Powder Injection Molding Process Technology (PIM) is a new metal and ceramic part forming process technology developed in the late 1980s. It uses the principles of plastic forming and traditional powder metallurgy, integrating other scientific and technological fields (chemical, plastic). The fifth-generation metal part forming process technology has been comprehensively developed from the technical achievements of metallurgy, machinery, electronics, automatic control and materials.
PIM technology has been scaled since the late 1980s, and it has been used in industrial production and processing since the late 1990s. It is an emerging part processing technology.
Powder injection molding (PIM) is generally divided into metal powder injection molding (MIM) and ceramic powder injection molding (CIM), which are used for the processing and manufacturing of metal parts and ceramic parts, respectively. Its application in the field of machining.
The schematic diagram of the PIM process technology flow is as follows:
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1. Advanced PIM technology ( 1) Excellent part forming capability: PIM technology can batch process extremely complex shapes of parts, including thin-walled, inner-cavity, non-linear holes, and special-shaped parts.
(2) Excellent mechanical properties: The density of PIM parts can reach 95%~100% of theoretical density, which has better mechanical properties than powder metallurgy products (product density is only 60%~80% of theoretical density). At the same time, it can be used for any Post-processing process.
(3) Good surface characteristics: Due to the mold control forming, the parts processed by the PIM process have good surface characteristics, and the surface finish treatment is generally no longer required.
(4) Strict tolerance control: The tolerance control range of PIM process parts is within 0.5% of the part size, and the special requirements can be controlled within 0.2%.
(5) Superior economy and batch processing: The processing cost of PIM is generally 20-60% of other processing methods, and the processing capacity of single machine is 1500-20000 pieces/day, which is especially suitable for processing tasks with large batch size and short delivery period.
(6) Green processing: PIM process technology parts processing belongs to one-time processing and forming, basically no processing waste is generated, no environmental pollution, it is a green environmental protection processing technology.
Jiarun's existing MIM materials and their applications
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2. Comparison of PIM technology manufacturing with other manufacturing technologies
MIM processing technology has great advantages, but it must be combined with other processing technology, such as machining, electric processing, precision casting, powder metallurgy, to give full play to the advantages of different processes. The following table lists the special processes. Features.
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3. Jiarun's PIM process technology and its application in rolling functional components Since its establishment in 1991, Jiarun has specialized in PIM research and development. It is one of the earliest companies engaged in PIM process technology in China. In 1995, it entered the small scale of cemented carbide. Industrial production, the development of stainless steel materials began in 1996, stainless steel products began small-scale industrial production in 1998, while research and development of other materials. In 2000, it established an industrial production base in Huairou District, Beijing. Now it has a complete set of R&D and production systems for mold, feeding, injection, debonding, sintering and processing. ISO900-2000 and TS/QS16949 management systems and global CRM, ERP business management system, 22 material systems, more than 350 product series, can produce a variety of metal parts from 30mg to 500g in batches, with more than 60 stable customer groups.
The inverter is a very important component in the scrolling function. It not only has a very important role, but also has great difficulties for batch processing due to its very complicated shape and dimensional accuracy requirements. The traditional machining process is milling using a milling machine. Despite the scientific development of manual milling machines, CNC milling machines can not meet the batch processing of high-precision inverters. The development of new plastic materials brings a glimmer of light and high performance. The plastic material processing inverter solves the problem of precision and batch size, but the new problem also arises. The plastic reverse phase is applied on the low speed, small load ball screw, no problem, not only meets the technical requirements, but also the price. low. However, in the application of high-speed heavy-duty ball screw, its high speed, heavy load resistance and long life can not meet the requirements. To solve this problem, in 2001, our company cooperated with Beijing Machine Tool Research Institute and Hanjiang Machine Tool Factory. Jining Bote Screw Co., Ltd. carried out research and development work on MIM internal circulation inverter. In 2004, it jointly developed MIM external circulation (tubular) inverter with Dalian Machine Tool Group. Now MIM internal circulation inverter has been developed. There are 135 types available in volume, covering most of the commonly used internal loop inverters. Four types of MIM external loop inverters have been developed, and subsequent developments are underway. Review the development process as follows:
(1) Material selection: The working environment of MIM inverter is high impact, oil-water or decomposable oil-water environment. The material requirements are high impact resistance, certain impact toughness, anti-corrosion performance, and good cost economy. Sex. After repeated material analysis, we selected SUS630 and MIM4650 for testing. The main chemical composition of SUS630 is Cr 15.5%~17.5%, Ni 3.0%~5.0%, Cu 3%~5%, Fe balance; the main chemical composition of MIM4650 is Ni 1.5%~2.5%, Mo 0.2%~0.5%, C 0.4%~0.6%; although the test found that MIM4650 has good cost economy and mechanical strength, its impact toughness and resistance to harsh environment are insufficient. We terminated the test work of MIM4650 and focused on the test of SUS630. In the test, we found that the impact resistance of SUS630 is still insufficient, and the working noise is obviously higher than that of plastic inverter. For this reason, we adjusted the material. The composition (improved to J-MIM630) and the production process parameters meet the customer's requirements for the inverter's product parameters.
(2) Analysis of product function of reverser: The important functional position of the inner loop inverter is the return groove and its supporting structure. The surface of the return groove must be smooth and smooth, the size data is accurate, and the support structure (both ears, shape) size Must be accurate.
3 Product blank drawing and mold design: Since several manufacturers cooperated with our company are technical leaders in ball screw, they have a very strong technical background, and the product documents and technical requirements are very clear. After technical exchange, Based on the customer's product data and our company's J-MIM630 material shrinkage index, our company designs 2D and 3D product blanks and mold drawings to process and manufacture molds.
(4) MIM process of MIM inverter: The injection blank of MIM inverter is processed through injection process. After the injection blank is debonded, the debonded blank is produced, and the debonded blank is sintered at 1350~1380 °C. After that, it becomes a sintered blank, which is finished after surface treatment.
(5) Quality control of MIM reverser production: According to the company's quality control procedures, the raw materials, processes and finished products are fully controlled.
4. Further development direction of MIM inverter:
(1) High-intensity inverter: The current MIM inverters are all sintered material structures. The current screw speed can still be satisfied. There may be problems for the higher speed screw, so the post-development treatment (heat treatment, surface) The processing of the MIM inverter is inevitable for the next step, but the difficulty lies in the post-processing deformation control method.
(2) Development of composite structure MIM inverter: With the development of new ball screw, the composite material, composite device and composite function inverter will inevitably appear. Our company will cooperate with relevant manufacturers to closely track the technological progress of the industry and develop Come out of the composite inverter.
(3) Development of the rail MIM inverter: The rail inverter is an important part of the inverter series. Our company plans to develop a MIM conduit inverter.
(4) Improve the development of the catheter MIM inverter: The catheter MIM inverter has been basically developed successfully in the process technology, but the product needs to be perfected and needs to be serialized and standardized.
(5) Development of high-precision MIM inverters: As the demand for ball screws for ball screw users continues to increase and the competition between screw manufacturers becomes increasingly fierce, screw manufacturers are bound to have higher and higher precision requirements for lead screws. Developing high-precision MIM inverters is a very urgent task.
(6) Standardization and serialization of MIM inverter: With the standardization and serialization of lead screw, accelerating the standardization and serialization of MIM inverter, and forming standardized product data standards, serialized product reserve is our task.
(7) Reducing the production cost of the MIM inverter: Users of the MIM inverter generally believe that the product is good and the price is much higher than that of the plastic inverter, but the cost of the MIM inverter is currently high, resulting in high price. Therefore, improving the process to reduce costs and allowing more customers to use MIM inverters is our next step.
Just as MIM technology itself is an emerging and promising technology, the work of MIM inverters is only the beginning, there are many technical problems, many products, many jobs waiting for us. Work together.
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