Powdered metal multi-lobular tooling and method of fabrication
A tool made of powdered metal, such as a modified T15 HSS in powdered form, and having a multi-lobular end profile for punching multi-lobular recesses into workpieces, such as into the heads of fasteners. The tool is homogenous and contains only carbides which are relatively small, such as in the 1-4 micron range. Also provided is a method of fabricating such a tool. The method requires that a powdered metal bar is cut and then the cut piece is worked to provide the multi-lobular tool. The final part is theoretically 100% dense, as opposed to being only 95-98% dense as in metal injection molded parts. In use, the final part, due to how it is fabricated, has increased column strength and increased impact resistance.
1 . A tool comprising a body and made of powdered metal, said body having a multi-lobular end profile for punching multi-lobular recesses into workpieces.
2 . A tool as recited in claim 1 , wherein said tool is made of high speed steel in powdered form.
3 . A tool as recited in claim 2 , wherein the high speed steel comprises T15 high speed steel.
4 . A tool as recited in claim 2 , wherein the high speed steel includes molybdenum.
5 . A tool as recited in claim 3 , wherein the T15 high speed steel includes molybdenum.
6 . A tool as recited in claim 1 , wherein said tool is configured to punch multi-lobular recesses into the heads of fasteners.
7 . A method of fabricating a tool made of powdered metal, where the tool has a multi-lobular end profile for punching multi-lobular recesses into workpieces, said method comprising: providing a rod formed of powdered metal; cutting a predetermined length from the rod, said predetermined length defining a part; applying a chamfer to at least one end of the part; grinding an outside diameter of the part to a predetermined size; extruding a multi-lobular configuration on one end of the part; grinding an outside diameter of the part to a predetermined size; and forming the part to a predetermined length.
8 . A method as recited in claim 7 , further comprising stress relieving the part in a heat treat furnace.
9 . A method as recited in claim 7 , further comprising coining a trademark onto the part.
10 . A method as recited in claim 7 , further comprising facing the part to a predetermined final length.
11 . A method as recited in claim 7 , further comprising shaving a nose angle on the part.
12 . A method as recited in claim 7 , further comprising heat treating the part to a predetermined hardness.
13 . A method as recited in claim 1 1 , further comprising polishing the nose angle to desired finish.
14 . A method as recited in claim 7 , wherein the step of cutting a predetermined length from the rod comprises cutting a predetermined length from a rod formed of high speed steel.
15 . A method as recited in claim 7 , wherein the step of cutting a predetermined length from the rod comprises cutting a predetermined length from a rod formed of T15 high speed steel.
16 . A method as recited in claim 7 , wherein the step of cutting a predetermined length from the rod comprises cutting a predetermined length from a rod formed of high speed steel which includes molybdenum.
17 . A method as recited in claim 7 , wherein the step of cutting a predetermined length from the rod comprises cutting a predetermined length from a rod formed of T15 high speed steel which includes molybdenum.
18 . A method as recited in claim 7 , wherein the step of applying a chamfer to at least one end of the part comprises applying a 47°/45° chamfer to both ends of the part.
19 . A method as recited in claim 7 , wherein the step of extruding a multi-lobular configuration on one end of the part further comprises applying oil to the part and extruding the multi-lobular configuration in an extrusion die that is secured in a punch press.