Method for applying variable magnetic properties to a induction heated tool face and manufacturing parts using the tool
View Patent ↗In accordance with an exemplary embodiment, a method for manufacturing a tool comprises applying at least one ferro-magnetic material to at least a portion of a tool face of a different material. The method produces a tool face with varying magnetic properties facilitating substantially uniform induction heating of the tool face.
1. A method, comprising:
applying a first ferro-magnetic material to at least a first portion of a tool face, the first ferro-magnetic material having a first amount of chromium and being a different material than the tool face with different magnetic properties;
applying a second ferro-magnetic material to at least a second portion of the tool face, the second ferro-magnetic material having a second amount of chromium being different than the first amount of chromium and also being a different material than the tool face with different magnetic properties;
whereby, substantially uniform temperature is provided across the tool face during induction heating thereof.
2. The method of claim 1 , wherein applying further comprises laser deposition of the first and second ferro-magnetic material to the tool face.
3. The method of claim 1 , wherein applying further comprises applying the first and second ferro-magnetic material to the tool face via closed-loop direct metal deposition.
4. The method of claim 1 , wherein applying further comprises applying the first and second ferro-magnetic material to the tool face via a three-dimensional printing process.
5. The method of claim 1 , wherein applying further comprises applying the first and second ferro-magnetic material to voids formed in the tool face.
6. The method of claim 1 , wherein applying further comprises applying the first and second ferro-magnetic material to substantially all of the tool face.
7. The method of claim 1 , further comprising processing dimensions of the tool face in a processor to model electromagnetic heating of the tool face via a finite element analysis program.
8. The method of claim 7 , further comprising determining via the processor the portions of the tool face to which the first and second ferro-magnetic material will be applied.
9. A method, comprising:
applying, via a three-dimensional printing process, a first and second steel-based ferro-magnetic material to at least a portion of a tool face, the first and second steel-based ferro-magnetic material having different amounts of chromium and being a different material than the tool face with different magnetic properties, and providing substantially uniform temperature across the tool face during induction heating thereof.
10. The method of claim 9 , wherein applying further comprises applying the first and second steel-based ferro-magnetic material to voids formed in the tool face.
11. The method of claim 9 , wherein applying further comprises applying the first and second steel-based ferro-magnetic material to substantially all of the tool face.
12. The method of claim 9 , further comprising processing dimensions of the tool face in a processor to model electromagnetic heating of the tool face via a finite element analysis program.
13. The method of claim 12 , further comprising determining via the processor the at least a portion of the tool face to which the first and second steel-based ferro-magnetic material will be applied.
14. The method of claim 9 , wherein applying further comprising applying, via the three-dimensional printing process, the first and second steel-based ferro-magnetic material in layers to at least a portion of a tool face.
15. A method, comprising:
determining a temperature profile of a tool face;
determining, via a processor, at least a portion of the tool face to which first and second steel-based ferro-magnetic material will be applied; and
applying, via a three-dimensional printing process, the first and second steel-based ferro-magnetic material to the at least a portion of a tool face, the first and second steel-based ferro-magnetic material having different amounts of chromium and being a different material than the tool face with different magnetic properties, and providing substantially uniform temperature across the tool face during induction heating thereof.
16. The method of claim 15 , wherein applying further comprises applying the first and second steel-based ferro-magnetic material to voids formed in the tool face.
17. The method of claim 15 , wherein applying further comprises applying the first and second steel-based ferro-magnetic material to substantially all of the tool face.
18. The method of claim 15 , wherein applying further comprising applying, via the three-dimensional printing process, the first and second steel-based ferro-magnetic material in layers to the at least a portion of a tool face.