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Rapid Tooling Rapid Tooling

Most applications in Most applications in


Mold for injection
molding
Mold for die casting
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g
Core and Cavity Core and Cavity
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Insert &molded component Insert & molded component
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Insert &molded component Insert & molded component
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Insert &molded component Insert & molded component
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Typical die cast parts Typical die cast parts
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Global Market Global Market
Injection molded parts: $ 20 billion
Die cast components: $ 10 billion Die cast components: $ 10 billion
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Conventional approach for fabrication Conventional approach for fabrication
CNC milling, grinding, EDM, etc. have design restrictions,
accuracy problem and more fabrication time accuracy problem, and more fabrication time.
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Modular Tooling Modular Tooling
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Injection Moulding Inserts Injection Moulding Inserts
Ejector pins
Conformal colling channels Conformal colling channels
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Cavity inserts Cavity inserts
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Rapid Tooling Definition Rapid Tooling Definition
Techniques employed to develop required
tooling quickly enough so as to reduce g q y g
lead-time drastically.
More stricter definition: Tooling More stricter definition: - Tooling
developed using rapid prototyping
technology, directly or indirectly, at some
point. p
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Classification Classification
I di t T li Indirect Tooling
Tooling generated using a master pattern g g g p
(often a rapid prototype model, but also
hand made or machined pattern). p )
1. Cast Resin
2 Cast Metal 2. Cast Metal
3. Metal Spray
4 Nickel Shell &Galvanoforming 4. Nickel Shell & Galvanoforming
5. Sintered Metal Tooling
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Classification Classification
Direct Tooling
Tooling directly manufactured on rapid Tooling directly manufactured on rapid
prototyping machine.
6 Di t AIMSt lith h T li 6. Direct AIM Stereolithography Tooling
7. Laser Sintered Metal Tooling
8. Laser Powder Melting Tooling
9. Laminated Tooling 9. Laminated Tooling
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1 Cast Resin Tooling 1. Cast Resin Tooling
M t l d (t i ll Al i i ) fill d E Metal powder (typically Aluminium) filled Epoxy
Resin
C t d ti l id t t Cast around a conventional or rapid prototype
master to form the tool cavity
M t i d ft i iti l i Master is removed after initial curing
Cast Tool is post cured at elevated temperature
Specially formulated for injection molding
Placed inside a steel bolster during injection
molding to sustain the clamping/injection forces.
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Cast resin tool of an automotive
part
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Di d t Ad t Disadvantages
Limited production
l
Advantages
Very quick to
d volume
Prone to surface
d d ti
produce
Relatively cheap
degradation
Due to poor
d ti it f th
Can be repaired
quickly
conductivity of the
resin moulding
cycle time is cycle time is
significantly (2-3
times) longer times) longer.
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While aluminum molds will cool the part much faster, p
polymer molds show a bad thermal conductivity.
This leads to long cycle times and differing part properties,
especially with semicrystalline materials like polypropylene especially with semicrystalline materials like polypropylene
or nylon.
Longer cooling times lead to increased strength, but Longer cooling times lead to increased strength, but
reduce toughness.
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Typically 50 parts in polypropylene and 50 parts in nylon could be
manufactured with this cast resin mold
Both the cast resin molds were 100%aluminumfilled But the Both the cast resin molds were 100% aluminum filled. But the
second one was made of a different resin of low mechanical
strength.
While the parts fromthe first mold showed a very smooth surface While the parts from the first mold showed a very smooth surface,
the others became rough due to the high pressure .
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Combination of techniques:
Plastic vacuum casting
P P i i l Process Principle
Casting of a (RP)-master pattern in silicon
rubber & reproduction
Characteristics Characteristics
Very detailed reproduction
Undercuts are possible
Siliconrubber mold can be used several Silicon rubber mold can be used several
times
Suited for small lots < 50
Material
Various reaction resins (like Poly-
Urethane)
Properties comparable to numerous
plastics
Housing for drilling machine
plastics
Max. part size & accuracy
1000x1000x1000 mm
3
max
Accuracy high Depends on master
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Accuracy high. Depends on master.
Process chain for vacuummolding Process chain for vacuum molding
1 M t tt 1. Master pattern
2. Casting with silicon rubber under vacuum
3. Cutting off of mold in parting plane
4. Vacuum casting with reaction resin
5. Curing under heat
6. Removal of cast model
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Reproduction with silicon mold Reproduction with silicon mold
silicon rubber
ld mold
Cast part
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2 Cast Metal Tooling 2. Cast Metal Tooling
Sand casting
used for manufacturing relatively large tools in g y g
aluminium or cast iron for low pressure
molding process. g p
Requires final machining.
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EOSSINT S 750
L i t i t f Laser-sintering system for
the direct, tool-less production
of sand cores and moulds for
Uses different corning sands
which are used in foundries
Light weight casting using
metal castings
Light weight casting using
Aluminum and Magnesium
Also cast iron & steel
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Cast Metal Tooling Cast Metal Tooling
Rubber-plaster casting (and very
infrequently investment casting) q y g)
A silicon rubber copy of the required tool
cavity is cloned froma master pattern cavity is cloned from a master pattern.
A plaster of paris is cast around the silicon
rubber copy rubber copy.
It is suitable for casting non-ferrous (Zinc or
Al i i ) t l i t Aluminium) tool inserts.
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Advantages
Conformal cooling is
possible p
High integrity solid metal
tools are produced
Repair of tool is possible
With rubber-plaster casting
multiple tools can be
produced from one master
pattern pattern
Disadvantages
Machining and good
amount of manual polishing
may be required.
Diffi l h ld i h
Cast metal tools by rubber
plaster casting
Difficult to hold tight
tolerances with large tools
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Bridge Tooling Bridge Tooling
Bridge tooling is, a way to bridge the typical 12
- 14 weeks gap between design confirmation
and actual part production with a hard tool.
At this point in the production cycle, y
the design has been approved by sales and
marketing, the functionality has been checked by
engineers, and
now 200 to 2000 parts are needed in order to
t bli h bl li h t b ild establish assembly lines or perhaps to build
market interest.
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Bridge tooling methods may produce
several hundred to as many as several y
thousand parts in 1 to 6 weeks time.
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Direct AIM
TM
Direct AIM
Di t AIM
TM
t d f Di t ACES Direct AIM
TM
stands for Direct ACES
Injection Molding.
Process of directly injection molding
thermo-plastics p
Core and cavity inserts are built with
stereolithography using ACES build style stereolithography, using ACES build style.
These inserts can then be mounted into a
prepared mold frame and s itable plastics prepared mold frame, and suitable plastics
can be injected directly.
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The highest glass transition temperature for an g g p
stereolithography resin is about 100
0
C. But
these AIM inserts may withstand injection
0
temperatures of about 300
0
C.
Parameter LDPE HDPE PS PP ABS
I j ti 1600 2300 2400 1900 3200 Injection pressure
(psi)
1600 2300 2400 1900 3200
Injection
temperature (
0
C)
180 220 200 205 240
Cycle time (minutes) 3.5 4.5 4.0 4.0 5.0
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Direct AIM
TM
Process Direct AIM Process
The SLA insert fitted SLA cavities and core
into the mould base inserts for AIM mould
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Direct AIM
TM
Process Direct AIM Process
After the alloy solidified,
Alloy of low melting point is
After the alloy solidified,
excess alloy is removed and
ejector pins are added. The
assembled mould is then
Alloy of low melting point is
poured into the void at back
side of the mould. Copper
tube is placed in the void so
assembled mould is then
installed on injection
machine.
tube is placed in the void so
that it will be embedded in
the solidified alloy
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Direct AIM
TM
Process Direct AIM Process
Advantages
Fast Tooling - No other
post-processing, like building p p g, g
up parting surface and
casting of silicone rubber is
required. q
Precision - Directly
produced from the CAD
model. Therefore the
Finished product and the
SLA core
accuracy of the mould is only
dependent on the accuracy
of the SLA process. An
accuracy of +/-0.05 mm is
achievable.
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Limitations of Direct AIM Limitations of Direct AIM
E i C d t th RT Expensive - Compared to other RT processes
of plastics mould, this is relatively expensive for
the large size of the ACES mould. the large size of the ACES mould.
Relatively weak in strength - Mould is quite
fragile. Tool life is around 100 shots. g
Poor thermal conductivity - Very long molding
cycle is needed.
Uncertainty - The process still needs quite a
number of refinements before it can be widely
applied in industry applied in industry.
Can be used for plastic parts only.
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3 Metal Spray Tooling 3. Metal Spray Tooling
Metal spray coating of
zinc from SLA master
(showing excellent (showing excellent
replication detaail)
Arc spraying
process
Spray forming p y g
process for creating
thick steel shells
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Metal Spray Tooling Metal Spray Tooling
Advantages
Low Melting Point
Disadvantages
Line-of-sight
materials give
excellent reproduction
of master pattern
limitations
Low melting point
t l h li it d
of master pattern
surface.
Process suitable for
metals have limited
durability.
Spraying of higher
Process suitable for
manufacture of
relatively large tools
Spraying of higher
melting point materials
is relatively complex is relatively complex
process.
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4. Nickel Vapor Deposition
Technology
Ni + 4Co <-> Ni(CO)
4
Heat at 110 -190
0
C
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Galvano Forming Galvano Forming
It i th d t d C d it i t It is a method to produce
molds quickly and cheaply
is to use plastic plating
Core and cavity inserts
are built by rapid
prototyping methods. p p g
technology.
p yp g
The inserts are plated
with a 2 - 4 mm layer of
i k l th t h nickel or other tough,
anti-corrosive metal.
The material is removed The material is removed
by melting and draining,
and the shell of a tool is
fill d ith filled with an epoxy
bonded filler.
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(A) Electroformed nickel (B) NVD nickel ( ) ( )
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Motivation behind Direct Tooling Motivation behind Direct Tooling
T diti l h d t l d i i b th ti i d Traditional hard tool design is both time consuming and
costly. A large block of steel is typically CNC machined
to create cores and cavity inserts. An experienced y p
designer must machine the mold keeping in mind correct
sprue placement, draft angles, vents, cooling lines, and
ejection pin locations Fine details require EDM ejection pin locations. Fine details require EDM.
Polishing and grinding is usually required to achieve a
good surface finish.
If a mistake is made, the entire steel block may have to
be scrapped and the process begins again.
It ld b t i t t b bl t b ild It would be most convenient to be able to build
something as complex as a hard mold with something as
efficient as rapid prototyping.
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efficient as rapid prototyping.
Time savings with Rapid Tooling Time savings with Rapid Tooling
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3D Systems Keltool
TM
Process 3D Systems Keltool
TM
Process
Master pattern is built on a SLA machine
Master pattern is placed in a box.
Box is filled with RTV silicone rubber.
Extracting the master leaves a cavity Extracting the master leaves a cavity.
Cavity is filled with mixture of powder metal and binder.
(normally tool steel/ tungsten carbide and expoxy ( y g y
mixture.
Green or week part is fired in a furnace. Binder burns off.
Copper is infiltrated into the space between remaining Copper is infiltrated into the space between remaining
metal.
Finally we get a metallic duplicate of SLA master which
i 100%d is 100% dense.
The tool steel insert (70% tool steel, 30% copper is
ready for production)
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eady o p oducto )
3D Systems Keltool
TM
Process 3D Systems Keltool
TM
Process
F t Features
Keltool inserts are restricted to about 6" in all
directions, which limits part size to about 4".
3 weeks is typically required to turn around
the Keltool insert (plus time to prepare the SL
pattern), as opposed to months to prepare a
t diti l h d t l traditional hard tool.
Keltool can generate 50,000 to 1 million parts
I j ti ldi hi d di on an Injection moulding machine, depending
on the injected material.
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3D Systems Keltool
TM
Process 3D Systems Keltool
TM
Process
P P i i l Process Principle
Duplicate molding of SL-master
patterns by long low temp. sintering
Characteristics Characteristics
Very high hardness, stiffness and
surface quality
Process chain two weeks
Material
Tool steel/ WC mixture infiltrated with
copper
Max. part size & accuracy
150x215x120 mm
3
max
Tolerance +/- 0.2% Tool inserts made by Keltool
Facility Costs
System price approx. 200 000 US$
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Process chain of Keltool process Process chain of Keltool process
1. Master pattern
2 Silicon casting 2. Silicon casting
3. Casting with tool steel/ WC/ epoxy mixture
4. Burn out of binder, sintering and infiltration with copper 4. Burn out of binder, sintering and infiltration with copper
in a furnace
5. Tool insert ready for production
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Direct Tooling Developments Direct Tooling - Developments
Three Dimensional Printing ExtrudeHone Corp. USA
RapidTool 3D System USA
DMLS EOS, Germany
LENS Optomec, USA
EBM Arcam, Sweden
Ultrasonic consolidation Solidica, USA
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3D Printing Direct Metal Tools for Injection Moulding
(Li d t E t d H C ti USA) (Licensed to ExtrudeHone Corporation, USA)
Injection molding tools and molded Metal tool with 3D truss structure for j g
part (conformal cooling) thermal isolation of injection mold cavity
A cooling
Fast thermal response
t li ith f l
g
passage printed
conformable to
the tooling cavity.
tooling with conformal
cooling passages with
a cellular/truss
structure behind it for
thermal isolation.
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Indirect Metal Laser Sintering
3D Systems RapidTool Process
P P i i l Process Principle
Indirect selective laser sintering of
metal powders
Burning out polymers and infiltration Burning out polymers and infiltration
with copper
Characteristics
Production of tool inserts for injection j
molding and die casting
Tool life upto 50000 shots
Material
Approximately 60% steel and 40%
copper
Max. part size & accuracy
380x330x440 mm
3
max Tool insert 380x330x440 mm
3
max
Accuracy +/- 0.1 mm
Facility Costs
Systemprice approx 275 000 US$
Tool insert
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System price approx. 275 000 US$
Process chain of RapidToolprocess Process chain of RapidTool process
1. SLS of polymer coated steel powder
2. Burning out binder &infiltration with copper 2. Burning out binder & infiltration with copper
3. Polishing and insertion into tool frame
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M ld D i
Th DTM R id T l P
Infiltration & Furnace Treatment
3D System's RapidTool Process
Sinterstation 2000 System
Polymer Infiltration
and Drying Oven
Mold Design
The DTM Rapid Tool Process
Infiltration & Furnace Treatment
CAD Workstation with
Green Part
Controlled atmosphere Furnace
3D Software for Part
and Mold Design
Infiltration
of Copper
Fully-Dense Part
Debinding
Injection Molding
Injection Molding Machine
Polish and Integrate with
Mold Base
50,000+
Finished Part
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Injection Molding Machine
Finished Part
Direct Metal Laser Sintering
3D Systems DirectTool Process
P P i i l Process Principle
Direct SLS of metal powder particles
(DMLS)
Characteristics Characteristics
Production of tool inserts for injection
molding and die casting
No burn-out of binder required, q
advantages in accuracy and time
Material
Steel or bronze nickel, infiltration with
ibl epoxy possible
Max. part size & accuracy
250x250x150 mm
3
max
Accuracy +/ 0 1 mm DMLS insert in tool frame Accuracy +/- 0.1 mm
Facility Costs
System price approx. 320 000 US$
DMLS insert in tool frame
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Process chain of DirectToolprocess Process chain of DirectTool process
1. SLS of meta powder directly
2. Bronze or nickel powder: infiltration with copper 2. Bronze or nickel powder: infiltration with copper
3. Steel powder: not necessarily required
4. Polishing and insertion into tool frame
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g
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Rapid tooling process for
injection moulding inserts
Batch Size
10-200
Batch Size
200-2,000
Batch Size
2,000-20,000
Stereolithography
Cast resin
Cast resin
Metal spraying
Metal spraying
Galvano forming
3D-Keltool
Laser sintering
3D-Keltool
Laser sintering g
(metal)
Aluminum
g
(metal)
Aluminum and
Investment casting steel investment
casting
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g
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Thank you

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