Influence of dry and solid lubricant-assisted MQL cooling conditions on the machinability of Inconel 718 alloy with textured tool

Darshan, Chetan; Jain, Sumit; Dogra, Manu; Gupta, Munish Kumar; Mia, Mozammel; Haque, Raisul

doi:10.1007/s00170-019-04221-z

Cited by 70 publications

(16 citation statements)

References 28 publications

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“…However, the mechanical properties of the injection molds fabricated by Al-filled epoxy resins are inferior to metallic molds. Thus, some reinforcing fillers such as wollastonite, molybdenum disulfide [ 52 ], glass sphere, zirconia [ 53 , 54 , 55 ], silica sand, glass fibers , or silicon nitride [ 56 , 57 , 58 ] were recommended to add in the matrix materials. Additionally, metal AM technologies such as DB [ 59 ], SLS [ 60 , 61 ], SLM [ 62 ], electron beam melting, or direct metal laser sintering were recommended for manufacturing injection molds with optimum CCCs for mass production of wax patterns.…”

Section: Resultsmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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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.

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Section: Resultsmentioning

confidence: 99%

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

et al. 2021

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“…Thus, optimization of CCC is also an important research issue using the Taguchi method [ 62 , 63 , 64 , 65 ]. Further improvements in the mechanical properties of the SRM with CCC by adding fillers or reinforcing additives, such as wollastonite, glass fibers, carbon fibers, glass sphere, molybdenum disulfide [ 66 , 67 , 68 , 69 ], zirconia [ 70 , 71 , 72 ], silica sand, or silicon nitride [ 73 , 74 , 75 ] into the SRB is also an important research issue. In addition, the internal surface of CCC has high surface roughness [ 76 , 77 , 78 ] and result in reduction in mold life due to stress concentration [ 79 , 80 , 81 , 82 ].…”

Section: Resultsmentioning

confidence: 99%

Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

Kuo

2021

Polymers

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Silicone rubber mold (SRM) is capable of reducing the cost and time in a new product development phase and has many applications for the pilot runs. Unfortunately, the SRM after injection molding has a poor cooling efficiency due to its low thermal conductivity. To improve the cooling efficiency, the thermal conductivity of the SRM was improved by adding fillers into the SRM. An optimal recipe for fabricating a high cooling efficiency low-pressure injection mold with conformal cooling channel fabricated by fused deposition modeling technology was proposed and implemented. This study proposes a recipe combining 52.6 wt.% aluminum powder, 5.3 wt.% graphite powder, and 42.1 wt.% liquid silicon rubber can be used to make SRM with excellent cooling efficiency. The price–performance ratio of this SRM made by the proposed recipe is around 55. The thermal conductivity of the SRM made by the proposed recipe can be increased by up to 77.6% compared with convention SRM. In addition, the actual cooling time of the injection molded product can be shortened up to 69.1% compared with the conventional SRM. The actual cooling time obtained by the experiment is in good agreement with the simulation results with the relative error rate about 20%.

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“…Ordinarily, the main disadvantage of the precision injection mold is that the mold service life was limited by the characteristics of injection mold materials. Therefore, some reinforcing additives, such as wollastonite, molybdenum disul de [39][40][41], silica sand, glass sphere, zirconia [42][43][44], silicon nitride [45][46][47], or silica sand were recommended for adding to the injection mold. In this study, the injection mold was employed in wax injection molding for manufacturing precision wax patterns.…”

Section: Resultsmentioning

confidence: 99%

A Cost-Effective Method for Rapid Manufacturing a Precision Mold With Microstructures Using Hybrid Manufacturing Technologies

Kuo¹,

Lin²,

Luo³

2021

Preprint

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Injection molding is a cost-effective to manufacture molded products by injection molding machine. A precision part with microstructures can be fabricated effectively through a precision mold. In this study, a cost-effective method for rapid manufacturing a precision component and a precision injection mold with microstructures by integrating additive manufacturing, rapid tooling, and computer numerical control milling. It was found that of the dimensional accuracy of a precision component in the length, width, and height can be controlled at approximately 30 µm. Injection molding was performed using an injection mold with microstructures with a microstructure of 950 µm and the dimensional accuracy of a molded part in the length, width, and microstructure can be controlled at approximately 60 µm, 50 µm, and 10 µm, respectively. The remarkable findings of this study can be used for the fabrication of molds or dies efficiently and economically for trial production in the mold industry since the quality of the precision component and the precision mold can meet the standards of the general industry.

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Influence of dry and solid lubricant-assisted MQL cooling conditions on the machinability of Inconel 718 alloy with textured tool

Cited by 70 publications

References 28 publications

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Rapid Development of an Injection Mold with High Cooling Performance Using Molding Simulation and Rapid Tooling Technology

Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

A Cost-Effective Method for Rapid Manufacturing a Precision Mold With Microstructures Using Hybrid Manufacturing Technologies

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