Mold for injection molding Mold for die casting 11/11/2013 P Saha IIT Kharagpur 2 g Core and Cavity Core and Cavity 11/11/2013 P Saha IIT Kharagpur 3 Insert &molded component Insert & molded component 11/11/2013 P Saha IIT Kharagpur 4 Insert &molded component Insert & molded component 11/11/2013 P Saha IIT Kharagpur 5 Insert &molded component Insert & molded component 11/11/2013 P Saha IIT Kharagpur 6 Typical die cast parts Typical die cast parts 11/11/2013 P Saha IIT Kharagpur 7 Global Market Global Market Injection molded parts: $ 20 billion Die cast components: $ 10 billion Die cast components: $ 10 billion 11/11/2013 P Saha IIT Kharagpur 8 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. 11/11/2013 P Saha IIT Kharagpur 9 Modular Tooling Modular Tooling 11/11/2013 P Saha IIT Kharagpur 10 Injection Moulding Inserts Injection Moulding Inserts Ejector pins Conformal colling channels Conformal colling channels 11/11/2013 P Saha IIT Kharagpur 11 Cavity inserts Cavity inserts 11/11/2013 P Saha IIT Kharagpur 12 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 11/11/2013 P Saha IIT Kharagpur 13 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 11/11/2013 P Saha IIT Kharagpur 14 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 11/11/2013 P Saha IIT Kharagpur 15 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. 11/11/2013 P Saha IIT Kharagpur 16 Cast resin tool of an automotive part 11/11/2013 P Saha IIT Kharagpur 17 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. 11/11/2013 P Saha IIT Kharagpur 18 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. 11/11/2013 P Saha IIT Kharagpur 19 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 . 11/11/2013 P Saha IIT Kharagpur 20 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 11/11/2013 P Saha IIT Kharagpur 21 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 11/11/2013 P Saha IIT Kharagpur 22 Reproduction with silicon mold Reproduction with silicon mold silicon rubber ld mold Cast part 11/11/2013 P Saha IIT Kharagpur 23 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. 11/11/2013 P Saha IIT Kharagpur 24 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 11/11/2013 P Saha IIT Kharagpur 25 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. 11/11/2013 P Saha IIT Kharagpur 26 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 11/11/2013 P Saha IIT Kharagpur 27 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. 11/11/2013 P Saha IIT Kharagpur 28 Bridge tooling methods may produce several hundred to as many as several y thousand parts in 1 to 6 weeks time. 11/11/2013 P Saha IIT Kharagpur 29 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. 11/11/2013 P Saha IIT Kharagpur 30 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 11/11/2013 P Saha IIT Kharagpur 31 Direct AIM TM Process Direct AIM Process The SLA insert fitted SLA cavities and core into the mould base inserts for AIM mould 11/11/2013 P Saha IIT Kharagpur 32 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 11/11/2013 P Saha IIT Kharagpur 33 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. 11/11/2013 P Saha IIT Kharagpur 34 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. 11/11/2013 P Saha IIT Kharagpur 35 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 11/11/2013 P Saha IIT Kharagpur 36 11/11/2013 P Saha IIT Kharagpur 37 11/11/2013 P Saha IIT Kharagpur 38 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. 11/11/2013 P Saha IIT Kharagpur 39 4. Nickel Vapor Deposition Technology Ni + 4Co <-> Ni(CO) 4 Heat at 110 -190 0 C 11/11/2013 P Saha IIT Kharagpur 40 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. 11/11/2013 P Saha IIT Kharagpur 41 (A) Electroformed nickel (B) NVD nickel ( ) ( ) 11/11/2013 P Saha IIT Kharagpur 42 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. 11/11/2013 P Saha IIT Kharagpur 43 efficient as rapid prototyping. Time savings with Rapid Tooling Time savings with Rapid Tooling 11/11/2013 P Saha IIT Kharagpur 44 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) 11/11/2013 P Saha IIT Kharagpur 45 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. 11/11/2013 P Saha IIT Kharagpur 46 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$ 11/11/2013 P Saha IIT Kharagpur 47 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 11/11/2013 P Saha IIT Kharagpur 48 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 11/11/2013 P Saha IIT Kharagpur 49 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. 11/11/2013 P Saha IIT Kharagpur 50 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 11/11/2013 P Saha IIT Kharagpur 51 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 11/11/2013 P Saha IIT Kharagpur 52 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 11/11/2013 P Saha IIT Kharagpur 53 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 11/11/2013 P Saha IIT Kharagpur 54 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 11/11/2013 P Saha IIT Kharagpur 55 g 11/11/2013 P Saha IIT Kharagpur 56 11/11/2013 P Saha IIT Kharagpur 57 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 11/11/2013 P Saha IIT Kharagpur 58 g 11/11/2013 P Saha IIT Kharagpur 59 Thank you