Direct metal laser sintering, using conformal cooling, for high volume production tooling
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Date
2017Author
Van As, B.
De Beer, D.J.
Combrinck, J.
Booysen, G.J.
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Show full item recordAbstract
Existing techniques to manufacture conventional tool steel inserts for the plastic injection moulding process are expensive and time-consuming. Complex mould inserts, difficult to manufacture with conventional processes, can be produced using Direct Metal Laser Sintering (DMLS) with Maraging tool steel (MS1). MS1 is an additive manufacturing (AM) material made available by Electro Optical Systems (EOS) GmbH. Contrary to material removal processes, DMLS can produce MS1 tool steel inserts directly from Computer-Aided Design (CAD) files suitable for high volume plastic injection moulding. Through DMLS it is possible to create conformal cooling channels inside the MS1 inserts that have advantages in reducing heat rapidly and evenly. This can result in a reduction of cycle times, cost per product as well as improving part quality by eliminating defects such as warpage and heat sinks. This paper will present a comparison between Finite Element Analysis (FEA) simulations of the injection mould inserts with actual mould trails of AM and conventional manufactured inserts. It also includes the design and manufacturing of conventional and DMLS inserts and compares the manufacturing costs and lead times. Using FEA simulations, the design of conformal cooling channels is optimised by comparing the mould temperature of different cooling channel layouts Bestaande
vervaardigingstegniek
van matryse vir die plastiek
-
inspuit giet tegniek is duur en tydrowend.
Ingewikkelde
matrysinsetsels, wat moeilik is om met konvensionele pros
esse te
vervaardig, kan met direkte lasermetaalsintering (DMLS) met
Maraging
-
staal (MS1) vervaardig word. MS1 is ʼn toevoegings
-
vervaardiging materiaal wat deur Electro Optical Systems (EOS)
GmbH verskaf word.
In teenstelling met materiaal verwyderings
-
pros
esse (masji
nering
), kan DMLS MS1 staal matryse of insetsels wat
direk vanaf rekenaar
gesteunde ontwerp
prosesse vervaardig word.
Dit maak dit geskik vir hoë volume produksie. Deur
DMLS kan
daar
ook vir vorm
getroue verkoelings kanale in matryse voorsiening
ge
maak
word
, wat tot die vinnige en eweredige verspreiding van
hitte
lei.
Dit
behoort tot ’n aansienlike verlaging in produksie
-
siklus
tye en
-
koste
te lei saam met
’n verbetering in die
gehalte
van
die vervaardigde
parte
a
s
g
evolg
v
an
die voorkoming van defekte
soos kromtrekking en hitte
-
putte.
Hierdie artikel vergelyk
ʼn
eindige
element analise van die
insetsels
wat
met
DMLS tegnieke en
konvensionele tegnieke vervaardig is. Dit sluit ook die ontwerp en
vervaardiging van konvensionele e
n DMLS insetsels in en vergelyk
vervaardigingskostes en leitye. Die ontwerp van vormgetroue
verkoelingskanale word deur middel van eindige element analise
optimeer deur die gietvorm temperatuur met verskillende
verkoelingskanaaluitlegte te vergelyk
URI
http://hdl.handle.net/10394/26163http://dx.doi.org/10.7166/28-4-1470
http://sajie.journals.ac.za/pub/article/view/1470/832