Applications of laser assisted metal rapid tooling process to manufacture of molding &amp; forming tools — state of the art

Ahn, Dong‐Gyu

doi:10.1007/s12541-011-0125-5

Cited by 118 publications

(91 citation statements)

References 51 publications

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“…In addition, the re-design of cooling channel is so expensive that it is difficult to carry out the experiment. Fortunately, additive manufacturing technology is recently used and the application to molding and forming tools is reported [29]. With the additive manufacturing technology, it is attractive to develop the conformal cooling channel and to examine the cooling performance through the experiment.…”

Section: Introductionmentioning

confidence: 99%

Multi-objective optimization of injection molding process parameters for short cycle time and warpage reduction using conformal cooling channel

Kitayama

Miyakawa

Takano

et al. 2016

Int J Adv Manuf Technol

124

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In this paper, cooling performance of conformal cooling channel in plastic injection molding (PIM) is numerically and experimentally examined. To examine the cooling performance, cycle time and warpage are considered. Melt temperature, injection time, packing pressure, packing time, cooling time, and cooling temperature are taken as the design variables. A multi-objective optimization of the process parameters is then performed. First, the process parameters of conformal cooling channel are optimized. Numerical simulation in the PIM is so intensive that a sequential approximate optimization using a radial basis function network is used to identify a pareto-frontier. It is found from the numerical result that the cooling performance of conformal cooling channel is much improved, compared to the conventional cooling channel. Based on the numerical result, the conformal cooling channel is developed by using additive manufacturing technology. The experiment is then carried out to examine the validity of the conformal cooling channel. Through numerical and experimental result, it is confirmed that the conformal cooling channel is effective to the short cycle time and the warpage reduction.

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Section: Introductionmentioning

confidence: 99%

Multi-objective optimization of injection molding process parameters for short cycle time and warpage reduction using conformal cooling channel

Kitayama

Miyakawa

Takano

et al. 2016

Int J Adv Manuf Technol

124

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show abstract

“…One benefit of using additive manufacturing in casting dies is the possibility to create conformal cooling channels that follows the geometry of the cast part [2]. The technology is already used in the making of tools in the plastic injection moulding industry [3,4], but the use of additive manufacturing in the making of dies for low pressure die casting is still limited.…”

Section: A Additive Manufacturing Processesmentioning

confidence: 99%

“…Conformal cooling has become a wellestablished principle when producing moulds in additive manufacturing with cooling channel closely following the surface profile of the cavity. The use of conformal cooling channels is already seen in industries such as plastic injection moulding, blow moulding, sheet metal forming, and to some extent bulk forming such as extrusion, rolling, and forging [3,6]. Conformal cooling enhances thermal control and can potentially drastically lower cycle times.…”

Section: Moulds and Dies Based On Additive Manufacturingmentioning

confidence: 99%

Additive Manufacturing for Enhanced Cooling in Moulds for Casting

Hovig¹,

Brøtan²,

Sørby³

2016

Proceedings of the 6th International Workshop of Advanced Manufacturing and Automation

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Abstract-Additive manufacturing allows new design solutions for moulds and dies that can improve quality and productivity in casting processes. Complex cooling channels made by additive manufacturing give fast and reliable cooling and a more accurate control of the solidification. The paper shows a comparison of the cooling time of a die insert with a conventional cooling system and an insert with improved cooling channels. It is shown that improved cooling channels are highly efficient even with air cooling. Air could replace water as cooling medium, which will eliminate the explosion hazard in aluminium casting.

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“…During Laser Additive Manufacturing (LAM) [1][2][3][4], the design and development of powder feeder is the critical technology of LAM equipment. The LAM can be classified as presetting method and synchronous powder feeding method according to the ways of materials supply.…”

Section: Introductionmentioning

confidence: 99%

Flowrate Calibration of Coaxial Powder Feeder During Laser Additive Manufacturing

Zhang¹,

Zhang²,

Jiang³

2017

dtetr

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The fabrication of metal parts is the backbone of the modern manufacturing industry. Laser Additive Manufacturing (LAM) is combination of five common technologies: laser cladding (LC), rapid prototyping (RP), computer-aided design (CAD), computer-aided manufacturing (CAM), and powder metallurgy. The resulting process creates part by focusing an industrial laser beam on the surface of processing work piece to create a molten pool of metal. A small stream of powdered alloy is then injected into the molten pool to build up the part gradually. By moving the laser beam back and forth and tracing out a pattern determined by a CAD, the solid metal part is fabricated line by line, one layer at a time. During LAM, the design and development of powder feeder is the critical technology of LAM equipment. During the synchronous powder feeding method, the machining quality mainly depends on the machining rate, powder feeding rate, laser power density, spot diameter and powder delivery speed. The powder feeding rate and powder delivery speed are determined by the delivery features of powder feeder. In the case of constant outlet pressure of throttling valve of gas bottle, with the increase of rotary speed of powder feeding disk, the pressure at the outlet of powder feeding pipe shows the upward tendency on the whole. The faster the rotary speed, the higher the pressure at the outlet of powder feeding pipe. It can be concluded from the changing rules of powder feeding flowrate at the different outlet pressure of gas bottle and rotary speed of powder feeding disk, in order to better realize the stable control of powder feeding flowrate, the outlet pressure of gas bottle should choose the middle grade. Then, the powder feeding flowrate could be precisely adjusted by controlling the rotary speed of powder feeding disk. 1

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Applications of laser assisted metal rapid tooling process to manufacture of molding & forming tools — state of the art

Cited by 118 publications

References 51 publications

Multi-objective optimization of injection molding process parameters for short cycle time and warpage reduction using conformal cooling channel

Multi-objective optimization of injection molding process parameters for short cycle time and warpage reduction using conformal cooling channel

Additive Manufacturing for Enhanced Cooling in Moulds for Casting

Flowrate Calibration of Coaxial Powder Feeder During Laser Additive Manufacturing

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