Complex cast parts with rapid tooling: rapid manufacturing point of view

Pessard, Etienne; Mognol, Pascal; Hascoët, Jean-Yves; Gerometta, C.

doi:10.1007/s00170-007-1281-8

Cited by 39 publications

(21 citation statements)

References 9 publications

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“…Initial concerns were related to the higher thermal stresses and to possible loss of accuracy and structural integrity; such issues were succesfully verified on direct metal laser sintering [41], direct metal deposition [42] and spray-metal processes for soft tools [43].…”

Section: Introductionmentioning

confidence: 99%

SLM tooling for die casting with conformal cooling channels

Armillotta

Baraggi

Fasoli³

2013

Int J Adv Manuf Technol

152

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The paper reports an experimental study of die-casting dies with conformal cooling fabricated by direct-metal additive techniques. The main objective is to compare the benefits and limitations of the application to what has been widely discussed in literature in the context of plastics injection molding.Selective laser melting was used to fabricate an impression block with conformal cooling channels, designed according to part geometry with the aid of process simulation. The tool was used in the manufacture of sample batches of zinc alloy castings, after being fitted on an existing die in place of a machined impression block with conventional straight-line cooling channels. Different combinations of process parameters were tested to exploit the improved performance of the cooling system. Test results show that conformal cooling improves the surface finish of castings due to a reduced need of spray cooling, which is allowed by a higher and more uniform cooling rate. Secondary benefits include reduction of cycle time and shrinkage porosity. KeywordsSelective laser melting; rapid tooling; die casting; conformal cooling; spray cooling; surface finish. 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 1 Title pageClick here to download Manuscript: titlepage.doc Click here to view linked References 1 2 3 4 5 6 7 8 SLM tooling for die casting with conformal cooling channels AbstractThe paper reports an experimental study of die-casting dies with conformal cooling fabricated by direct-metal additive techniques. The main objective is to compare the benefits and limitations of the application to what has been widely discussed in literature in the context of plastics injection molding.Selective laser melting was used to fabricate an impression block with conformal cooling channels, designed according to part geometry with the aid of process simulation. The tool was used in the manufacture of sample batches of zinc alloy castings, after being fitted on an existing die in place of a machined impression block with conventional straight-line cooling channels. Different combinations of process parameters were tested to exploit the improved performance of the cooling system. Test results show that conformal cooling improves the surface finish of castings due to a reduced need of spray cooling, which is allowed by a higher and more uniform cooling rate. Secondary benefits include reduction of cycle time and shrinkage porosity.

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Section: Introductionmentioning

confidence: 99%

SLM tooling for die casting with conformal cooling channels

Armillotta

Baraggi

Fasoli³

2013

Int J Adv Manuf Technol

152

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“…This feature as well as the ability to create highly complex geometrical shapes, which are often not possible, or at least very difficult to make by conventional manufacturing processes, promote these technologies as perfect candidates for moulding and rapid tooling (RT) (Simchi et al, 2003;Pessard et al 2008). This is why MLS technologies attract a great attention of mouldmakers for more than a decade.…”

Section: Introductionmentioning

confidence: 99%

Metal Laser Sintering for Rapid Tooling in Application to Tyre Tread Pattern Mould

Milovanović¹,

Stojković²,

Trajanović³

2012

Sintering - Methods and Products

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“…Hanumaiah [37] manufactured numerous benchmark parts to assess geometric errors of the various features incorporated in the designs. Similarly, Pessard [38] created a test part used to evaluate the dimensional accuracy of embedded features. Delgado [39] followed with another test part used to assess geometric accuracy, but this structure was fabricated in many locations and orientations throughout the build platform in an attempt to evaluate the accuracy and repeatability of position (see Fig.…”

Section: Additive Manufacturing Test Artifactsmentioning

confidence: 99%

An Additive Manufacturing Test Artifact

Moylan¹,

Slotwinski²,

Cooke³

et al. 2014

J. RES. NATL. INST. STAN.

119

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A test artifact, intended for standardization, is proposed for the purpose of evaluating the performance of additive manufacturing (AM) systems. A thorough analysis of previously proposed AM test artifacts as well as experience with machining test artifacts have inspired the design of the proposed test artifact. This new artifact is designed to provide a characterization of the capabilities and limitations of an AM system, as well as to allow system improvement by linking specific errors measured in the test artifact to specific sources in the AM system. The proposed test artifact has been built in multiple materials using multiple AM technologies. The results of several of the builds are discussed, demonstrating how the measurement results can be used to characterize and improve a specific AM system.

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Complex cast parts with rapid tooling: rapid manufacturing point of view

Cited by 39 publications

References 9 publications

SLM tooling for die casting with conformal cooling channels

SLM tooling for die casting with conformal cooling channels

Metal Laser Sintering for Rapid Tooling in Application to Tyre Tread Pattern Mould

An Additive Manufacturing Test Artifact

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