Abstract:Hot embossing stamp fabricated from aluminumfilled epoxy resin can be employed for short-run productions. However, the cooling time is much longer compared to metallic stamps due to poorer thermal conductivity. Therefore, developing a hot embossing stamp with high cooling efficiency is an important issue. In this study, three different coolingchannel layouts were employed to fabricate hot embossing stamps using rapid prototyping and rapid tooling techniques. Effects of different hot embossing stamps on the coo… Show more
“…A low-cost wax injection mold with high cooling efficiency was developed [ 16 , 17 ]. A hot embossing stamp with CCCs for microreplication was developed [ 18 ]. Results showed that the reduction in cooling time of about 92% was obtained when a hot embossing stamp had conformal cooling channels compared to the hot embossing stamp, which has conventional cooling channels.…”
Rapid tooling technology (RTT) provides an alternative approach to quickly provide wax injection molds for the required products since it can reduce the time to market compared with conventional machining approaches. Removing conformal cooling channels (CCCs) is the key technology for manufacturing injection mold fabricated by rapid tooling technology. In this study, three different kinds of materials were used to fabricate CCCs embedded in the injection mold. This work explores a technology for rapid development of injection mold with high cooling performance. It was found that wax is the most suitable material for making CCCs. An innovative method for fabricating a large intermediary mold with both high load and supporting capacities for manufacturing a large rapid tooling using polyurethane foam was demonstrated. A trend equation for predicting the usage amount of polyurethane foam was proposed. The production cost savings of about 50% can be obtained. An optimum conformal cooling channel design obtained by simulation is proposed. Three injection molds with different cooling channels for injection molding were fabricated by RTT. Reductions in the cooling time by about 89% was obtained. The variation of the results between the experiment and the simulation was investigated and analyzed.
“…A low-cost wax injection mold with high cooling efficiency was developed [ 16 , 17 ]. A hot embossing stamp with CCCs for microreplication was developed [ 18 ]. Results showed that the reduction in cooling time of about 92% was obtained when a hot embossing stamp had conformal cooling channels compared to the hot embossing stamp, which has conventional cooling channels.…”
Rapid tooling technology (RTT) provides an alternative approach to quickly provide wax injection molds for the required products since it can reduce the time to market compared with conventional machining approaches. Removing conformal cooling channels (CCCs) is the key technology for manufacturing injection mold fabricated by rapid tooling technology. In this study, three different kinds of materials were used to fabricate CCCs embedded in the injection mold. This work explores a technology for rapid development of injection mold with high cooling performance. It was found that wax is the most suitable material for making CCCs. An innovative method for fabricating a large intermediary mold with both high load and supporting capacities for manufacturing a large rapid tooling using polyurethane foam was demonstrated. A trend equation for predicting the usage amount of polyurethane foam was proposed. The production cost savings of about 50% can be obtained. An optimum conformal cooling channel design obtained by simulation is proposed. Three injection molds with different cooling channels for injection molding were fabricated by RTT. Reductions in the cooling time by about 89% was obtained. The variation of the results between the experiment and the simulation was investigated and analyzed.
“…Likewise, Kuo and Wang 45,46 proposed a plasma surface modification method to manufacture precision micro-hot embossing moulds with high surface finishes.Figure 6.Schematic diagrams of manufacturing hot embossing stamp: (a) Master model; (b) Designing cooling channels; (c) Pouring aluminium-filled epoxy resin; (d) Removal of mould frame; (e) Removal of master model; (f) Removal of cooling channels. 41 …”
Section: Recent Investigations Of Epoxy Toolingmentioning
confidence: 99%
“…Figure 6. Schematic diagrams of manufacturing hot embossing stamp: (a) Master model; (b) Designing cooling channels; (c) Pouring aluminium-filled epoxy resin; (d) Removal of mould frame; (e) Removal of master model; (f) Removal of cooling channels 41. …”
The technology of epoxy tooling, at present under continuous development, is used for the rapid manufacture of cost-effective tools for small batch production. It is a valid alternative with no need for expensive investment in metallic moulds for the development of new products. Current investigations are focused on improvements to the production system, improved tool performance, the cost reduction of moulds and tool manufacturing sustainability. In this paper, both the advantages and the disadvantages of epoxy tooling in injection moulding, wax injection, metal stamping and hot embossing are compared with conventional techniques. Following a brief introduction of rapid tooling technologies, the latest advances of epoxy tooling and their implementation in different manufacturing processes are all analysed. These developments refer to the production of new ad-hoc epoxy composites, increased productivity using conformal cooling channels, the reduction of the tooling manufacturing costs through waste reuse and the emerging industry 4.0 technologies for smart manufacturing and tooling. The main objective is to identify both the challenges facing epoxy tooling techniques and future research directions.
“…It was found that the hybrid tools withstand the high mechanical and thermal loads which occur during hot aluminum extrusion. However, the structural strength of the injection molding tooling with the conformal cooling channels will reduce signi cantly [12][13][14][15]. Figure 1 shows the schematic illustration of a cooling channel cell under high injection pressure.…”
Injection molding of wax patterns faces increasing demands for production rate. Proper thermal management of the injection molding tooling is capable of improving the production rate. Precise temperature control is a key to shorten the cooling time using the conformal cooling channels which are conformal to the molding cavity. However, the service life of the injection molding tooling with cooling channels will reduce significantly because the structural strength will reduce obviously. In this study, the feasibility of applying the increase in the mold thickness to maintain the structural strength of the injection molding tooling with cooling channels was verified through simulation and experiments conducted. It was found that the average variation between the results of simulation and the experiment is about 24.9%. The approximately amount of the increase in the thickness required for different diameters of cooling channels can be determined according to the trend equation of y=1.3429x-2.3429. The results can provide a reference for the conformal cooling channel design.
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