Method of reducing distortion in a spray formed rapid tool
First Claim
1. A method of reducing distortion in a spray formed rapid tool comprising the steps of:
- making a model of a desired tool;
constructing a ceramic pattern as the inverse of the model;
building a thermal model of the desired tool from a solid model of the ceramic pattern;
applying thermal boundary conditions to the thermal model based on known conditions;
running the thermal model to produce a temperature distribution of the desired tool and determining any temperature deviations in the temperature distribution above a predetermined value; and
thermally spraying a metal material against the ceramic pattern to form the desired tool if there are no temperature deviations in the temperature distribution above the predetermined value.
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Accused Products
Abstract
A method of reducing distortion in a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of building a thermal model of the desired tool from a solid model of the ceramic pattern and applying thermal boundary conditions to the thermal model based on known conditions. The method also includes the steps of running the thermal model to produce a temperature distribution of the desired tool and determining any temperature deviations in the temperature distribution above a predetermined value. The method further includes thermally spraying a metal material against the ceramic pattern to form the desired tool if there are no temperature deviations in the temperature distribution above the predetermined value.
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Citations
20 Claims
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1. A method of reducing distortion in a spray formed rapid tool comprising the steps of:
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making a model of a desired tool;
constructing a ceramic pattern as the inverse of the model;
building a thermal model of the desired tool from a solid model of the ceramic pattern;
applying thermal boundary conditions to the thermal model based on known conditions;
running the thermal model to produce a temperature distribution of the desired tool and determining any temperature deviations in the temperature distribution above a predetermined value; and
thermally spraying a metal material against the ceramic pattern to form the desired tool if there are no temperature deviations in the temperature distribution above the predetermined value. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of reducing distortion in a spray formed rapid tool comprising the steps of:
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making a model of a desired tool;
constructing a ceramic pattern as the inverse of the model;
separating the ceramic pattern from the mold;
building a thermal model of the desired tool from a solid model of the ceramic pattern;
applying thermal boundary conditions to the thermal model based on known conditions;
running the thermal model to produce a temperature distribution of the desired tool and determining any temperature deviations in the temperature distribution above a predetermined value;
thermally spraying a metal material against the ceramic pattern to form the desired tool if there are no temperature deviations in the temperature distribution above the predetermined value; and
separating the ceramic pattern from the desired tool. - View Dependent Claims (11, 12, 13, 14, 15, 16)
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17. A method of reducing distortion in a spray formed rapid tool comprising the steps of:
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making a model of a desired tool;
constructing a ceramic pattern as the inverse of the model;
building a thermal model of the desired tool from a solid model of the ceramic pattern;
applying thermal boundary conditions to the thermal model based on known conditions;
running the thermal model to produce a temperature distribution of the desired tool and determining any temperature deviations in the temperature distribution above a predetermined value;
adjusting either supplemental heating or cooling to eliminate any deviations if there are any temperature deviations in the temperature distribution above the predetermined value; and
thermally spraying a metal material against the ceramic pattern to form the desired tool. - View Dependent Claims (18, 19, 20)
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Specification