Laminate Tooling for Injection Moulding

Glozer, G.; Brevick, Jerald

doi:10.1243/pime_proc_1993_207_056_02

Cited by 18 publications

(5 citation statements)

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“…Different aspects of the RT approaches have been addressed by researchers such as Nakagawa and Kunieda (1984), Vouzelaud et al (1992), Glozer and Brevick (1992), Walczyk and Hardt (1996) Although the proposed slicing algorithm is applicable to a variety of five-axis processes that allow variable thickness layering and slicing in different orientations (e.g. AWJ cutting, laser cutting, plasma cutting, or electro discharge machining), …”

Section: Curved-form Adaptive Slicing Application: Rtmentioning

confidence: 99%

“…This is because fusing, sintering, soldering, ultrasonic welding, and printing of the dense collection of particles and molecules in any selected bulk region of a variable thick layer is unachievable using present technology. Methods of building functional metallic parts and tooling by means of abrasive waterjet (AWJ) and laser cutting of fully dense metal sheets in various thicknesses followed by alignment and attachment of layers have been reported (Bryden et al, 2001;CAM-LEM (2005); Conner et al, 2011;Glozer and Brevick, 1992;Nakagawa and Kunieda, 1984;Vouzelaud et al, 1992;Walczyk and Hardt, 1996).…”

Section: Introductionmentioning

confidence: 99%

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Close to CAD model curved-form adaptive slicing

Hayasi

Asiabanpour

2014

Rapid Prototyping Journal

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Purpose -The main aim of this study is to generate curved-form cut on the edge of an adaptive layer. The resulting surface would have much less geometry deviation error and closely fit its computer aided design (CAD) model boundary. Design/methodology/approach -This method is inspired by the manual peeling of an apple in which a knife's orientation and movement are continuously changed and adjusted to cut each slice with minimum waste. In this method, topology and geometry information are extracted from the previously generated adaptive layers. Then, the thickness of an adaptive layer and the bottom and top contours of the adjacent layers are fed into the proposed algorithm in the form of the contour and normal vector to create curved-form sloping surfaces. Following curved-form adaptive slicing, a customized machine path compatible with a five-axis abrasive waterjet (AWJ) machine will be generated for any user-defined sheet thicknesses. Findings -The implemented system yields curved-form adaptive slices for a variety of models with diverse types of surfaces (e.g. flat, convex, and concave), different slicing direction, and different number of sheets with different thicknesses. The decrease in layer thickness and increase of the number of the sloped cuts can make the prototype as close as needed to the CAD model. Research limitations/implications -The algorithm is designed for use with five-axis AWJ cutting of any kind of geometrical complex surfaces. Future research would deal with the nesting problem of the layers being spread on the predefined sheet as the input to the five-axis AWJ cutter machine to minimize the cutting waste. Practical implications -The algorithm generates adaptive layers with concave or convex curved-form surfaces that conform closely to the surface of original CAD model. This will pave the way for the accurate fabrication of metallic functional parts and tooling that are made by the attachment of one layer to another. Validation of the output has been tested only as the simulation model. The next step is the customization of the output for the physical tests on a variety of five-axis machines. Originality/value -This paper proposes a new close to CAD design sloped-edge adaptive slicing algorithm applicable to a variety of five-axis processes that allow variable thickness layering and slicing in different orientations (e.g. AWJ, laser, or plasma cutting). Slices can later be bonded to build fully solid prototypes.

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Section: Curved-form Adaptive Slicing Application: Rtmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Close to CAD model curved-form adaptive slicing

Hayasi

Asiabanpour

2014

Rapid Prototyping Journal

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“…Most of the previous studies were conducted with steel sheets, used brazing as a joining process and employed lasers in the cutting process. In the early 1990s, Glozer and Brevick and Nakagawa separately introduced laminate tooling methods for moulding processes [1,2]. In 1997, Dickens analyzed some effects of various clamping methods, distortions and alignments in laminate tooling [3].…”

Section: Introductionmentioning

confidence: 99%

Application of laser joining process for elimination of stair steps in steel laminate tooling

Yoon

Na²

2004

AMT

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Laminate tooling is a relatively fast and simple method of making large metal tools directly for various moulding processes in the rapid prototyping and manufacturing field. Metal sheets are usually cut, stacked, aligned and joined. In most cases, lasers are used only for the cutting of steel sheets in laminate tooling, but in this study, the use of the laser was expanded for improved laminate tooling. First, the laser was applied to eliminate the stair steps of steel laminates by filling them with molten filler metals. Then application of hard particles to molten filler metals for improved surface hardness of laminate tools was investigated. To achieve this goal, a CO 2 laser system composed of a CO 2 laser, a five-axis CNC table, an automatic feeding equipment of filler metal and flux and a personal computer was developed. Various experiments on filling stair steps and hardening were performed and the results were verified and estimated.

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“…Tools have been manufactured previously using the sheet-additive technique; blanking tool and die set (Yokoi et al, 1984), polyurethane foam moulding tool (Dickens, 1996), metal forming dies (Walczyk, 1994(Walczyk, , 1998Wimpenny, 1999), injection moulding dies (Bryden, 1999;Glozer, 1992;Wimpenny et al, 2000) and aluminium die-casting tools (Soar and Dickens, 1998a). It has only been in recent years that laminated tooling has been researched with aluminium die-casting and high-pressure die-casting in mind (Soar, 2000).…”

Section: Introductionmentioning

confidence: 99%

Rapid laminated die‐cast tooling

Gibbons¹,

Hansell²,

Norwood³

et al. 2003

Assembly Automation

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This paper details the development of a rapid tooling manufacturing route for the gravity and high-pressure die-casting industries, resulting from an EPSRC funded collaborative research project between the Universities of Warwick, Loughborough and DeMontfort, with industrial support from, amongst others, MG Rover, TRW Automotive, Sulzer Metco UK Ltd and Kemlows Diecasting Products Ltd. The developed process offers the rapid generation of mould tools from laser-cut laminated sheets of H13 steel, bolted or brazed together and finish machined. The paper discusses the down-selection of materials, bonding methods and machining methods, the effect of conformal cooling channels on process efficiency, and the evaluation of a number of test tools developed for the industrial partners. The paper also demonstrates the cost and time advantages (up to 50 and 54 per cent, respectively) of the tooling route compared to traditional fabrication methods.

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Laminate Tooling for Injection Moulding

Cited by 18 publications

References 0 publications

Close to CAD model curved-form adaptive slicing

Close to CAD model curved-form adaptive slicing

Application of laser joining process for elimination of stair steps in steel laminate tooling

Rapid laminated die‐cast tooling

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