Direct metal laser sintering, using conformal cooling, for high volume production tooling
Existing techniques to manufacture conventional tool steel inserts for the plastic injection moulding process are expensive and time-consuming. Complex mould inserts, difficult to manufacture with conventional processes, can be produced using Direct Metal Laser Sintering (DMLS) with Maraging tool st...
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| Vydané v: | South African Journal of Industrial Engineering Ročník 28; číslo 4; s. 170 - 182 |
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| Hlavní autori: | , , , |
| Médium: | Journal Article |
| Jazyk: | English |
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South African Institute of Industrial Engineers (SAIIE)
01.12.2017
South African Institute for Industrial Engineering The Southern African Institute for Industrial Engineering Stellenbosch University |
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| ISSN: | 1012-277X, 2224-7890, 2224-7890 |
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| Abstract | Existing techniques to manufacture conventional tool steel inserts for the plastic injection moulding process are expensive and time-consuming. Complex mould inserts, difficult to manufacture with conventional processes, can be produced using Direct Metal Laser Sintering (DMLS) with Maraging tool steel (MS1). MS1 is an additive manufacturing (AM) material made available by Electro Optical Systems (EOS) GmbH. Contrary to material removal processes, DMLS can produce MS1 tool steel inserts directly from Computer-Aided Design (CAD) files suitable for high volume plastic injection moulding. Through DMLS it is possible to create conformal cooling channels inside the MS1 inserts that have advantages in reducing heat rapidly and evenly. This can result in a reduction of cycle times, cost per product as well as improving part quality by eliminating defects such as warpage and heat sinks. This paper will present a comparison between Finite Element Analysis (FEA) simulations of the injection mould inserts with actual mould trails of AM and conventional manufactured inserts. It also includes the design and manufacturing of conventional and DMLS inserts and compares the manufacturing costs and lead times. Using FEA simulations, the design of conformal cooling channels is optimised by comparing the mould temperature of different cooling channel layouts. Bestaande vervaardigingstegniek van matryse vir die plastiek-inspuit giet tegniek is duur en tydrowend. Ingewikkelde matrysinsetsels, wat moeilik is om met konvensionele prosesse te vervaardig, kan met direkte lasermetaalsintering (DMLS) met Maraging-staal (MS1) vervaardig word. MS1 is ʼn toevoegings-vervaardiging materiaal wat deur Electro Optical Systems (EOS) GmbH verskaf word. In teenstelling met materiaal verwyderings-prosesse (masjinering), kan DMLS MS1 staal matryse of insetsels wat direk vanaf rekenaargesteunde ontwerpprosesse vervaardig word. Dit maak dit geskik vir hoë volume produksie. Deur DMLS kan daar ook vir vormgetroue verkoelings kanale in matryse voorsiening gemaak word, wat tot die vinnige en eweredige verspreiding van hitte lei. Dit behoort tot ’n aansienlike verlaging in produksie-siklustye en -koste te lei saam met ’n verbetering in die gehalte van die vervaardigde parte as gevolg van die voorkoming van defekte soos kromtrekking en hitte-putte. Hierdie artikel vergelyk ʼn eindige element analise van die insetsels wat met DMLS tegnieke en konvensionele tegnieke vervaardig is. Dit sluit ook die ontwerp en vervaardiging van konvensionele en DMLS insetsels in en vergelyk vervaardigingskostes en leitye. Die ontwerp van vormgetroue verkoelingskanale word deur middel van eindige element analise optimeer deur die gietvorm temperatuur met verskillende verkoelingskanaaluitlegte te vergelyk. |
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| AbstractList | Existing techniques to manufacture conventional tool steel inserts for the plastic injection moulding process are expensive and time-consuming. Complex mould inserts, difficult to manufacture with conventional processes, can be produced using Direct Metal Laser Sintering (DMLS) with Maraging tool steel (MS1). MS1 is an additive manufacturing (AM) material made available by Electro Optical Systems (EOS) GmbH. Contrary to material removal processes, DMLS can produce MS1 tool steel inserts directly from Computer-Aided Design (CAD) files suitable for high volume plastic injection moulding. Through DMLS it is possible to create conformal cooling channels inside the MS1 inserts that have advantages in reducing heat rapidly and evenly. This can result in a reduction of cycle times, cost per product as well as improving part quality by eliminating defects such as warpage and heat sinks. This paper will present a comparison between Finite Element Analysis (FEA) simulations of the injection mould inserts with actual mould trails of AM and conventional manufactured inserts. It also includes the design and manufacturing of conventional and DMLS inserts and compares the manufacturing costs and lead times. Using FEA simulations, the design of conformal cooling channels is optimised by comparing the mould temperature of different cooling channel layouts. Existing techniques to manufacture conventional tool steel inserts for the plastic injection moulding process are expensive and time-consuming. Complex mould inserts, difficult to manufacture with conventional processes, can be produced using Direct Metal Laser Sintering (DMLS) with Maraging tool steel (MS1). MS1 is an additive manufacturing (AM) material made available by Electro Optical Systems (EOS) GmbH. Contrary to material removal processes, DMLS can produce MS1 tool steel inserts directly from Computer-Aided Design (CAD) files suitable for high volume plastic injection moulding. Through DMLS it is possible to create conformal cooling channels inside the MS1 inserts that have advantages in reducing heat rapidly and evenly. This can result in a reduction of cycle times, cost per product as well as improving part quality by eliminating defects such as warpage and heat sinks. This paper will present a comparison between Finite Element Analysis (FEA) simulations of the injection mould inserts with actual mould trails of AM and conventional manufactured inserts. It also includes the design and manufacturing of conventional and DMLS inserts and compares the manufacturing costs and lead times. Using FEA simulations, the design of conformal cooling channels is optimised by comparing the mould temperature of different cooling channel layouts. Bestaande vervaardigingstegniek van matryse vir die plastiek-inspuit giet tegniek is duur en tydrowend. Ingewikkelde matrysinsetsels, wat moeilik is om met konvensionele prosesse te vervaardig, kan met direkte lasermetaalsintering (DMLS) met Maraging-staal (MS1) vervaardig word. MS1 is ʼn toevoegings-vervaardiging materiaal wat deur Electro Optical Systems (EOS) GmbH verskaf word. In teenstelling met materiaal verwyderings-prosesse (masjinering), kan DMLS MS1 staal matryse of insetsels wat direk vanaf rekenaargesteunde ontwerpprosesse vervaardig word. Dit maak dit geskik vir hoë volume produksie. Deur DMLS kan daar ook vir vormgetroue verkoelings kanale in matryse voorsiening gemaak word, wat tot die vinnige en eweredige verspreiding van hitte lei. Dit behoort tot ’n aansienlike verlaging in produksie-siklustye en -koste te lei saam met ’n verbetering in die gehalte van die vervaardigde parte as gevolg van die voorkoming van defekte soos kromtrekking en hitte-putte. Hierdie artikel vergelyk ʼn eindige element analise van die insetsels wat met DMLS tegnieke en konvensionele tegnieke vervaardig is. Dit sluit ook die ontwerp en vervaardiging van konvensionele en DMLS insetsels in en vergelyk vervaardigingskostes en leitye. Die ontwerp van vormgetroue verkoelingskanale word deur middel van eindige element analise optimeer deur die gietvorm temperatuur met verskillende verkoelingskanaaluitlegte te vergelyk. |
| Author | Van As, B. Booysen, G.J. Combrinck, J. De Beer, D.J. |
| AuthorAffiliation | North-West University Central University of Technology |
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| Copyright | Copyright South African Institute for Industrial Engineering Dec 2017 This work is licensed under a Creative Commons Attribution 4.0 International License. |
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| References | Vorster, O.C.; Rabé, W.P.J. 2005 Gibson, I.; Rosen, D.W.; Strucker, B. 2010 Maraging, Ni 2012 Costa, N.; Ribeiro, B. 1999 Saifullah, A.B.M.; Masood, S.H.; Sbarski, I. 2009 Booysen, G.; de Beer, D.; Truscott, M.; Combrinck, J.; Mosimanyane, D. 2010; 8 Hsu, A.; Ren, L. 2012 Van Rensburg, S. 2001 Agazzi, A.; Sobotka, V.; LeGoff, R.; Jarny, Y. 2013; 52 |
| References_xml | – year: 2010 publication-title: Additive manufacturing technologies – start-page: 17 year: 2012 end-page: 19 publication-title: Moldex3D R11 European – start-page: 1081 year: 1999 end-page: 87 publication-title: Proceedings (Cat. No.99EX378) – volume: 52 start-page: 170 issue: 1 year: 2013 end-page: 178 article-title: Optimal cooling design in injection moulding process: A new approach based on morphological surfaces publication-title: Applied Thermal Engineering – start-page: 3 year: 2009 end-page: 6 – year: 2012 publication-title: Material data sheet for EOS Titanium Ti64 for EOSINT M 270 systems – start-page: 111 year: 2005 publication-title: KUNSTSTOFFVERARBEITUNG Translated as Plastics processing – start-page: 1 year: 2001 end-page: 14 – volume: 8 start-page: 9 issue: 2 year: 2010 end-page: 21 article-title: Combining additive fabrication and conventional machining technologies to develop a hybrid tooling approach publication-title: Annals of DAAAM & Proceedings |
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| SubjectTerms | Additive manufacturing CAD Channels Computer aided design Computer simulation conformal cooling Cooling Design optimization Engineering, Industrial finite element analysis Finite element method Heat sinks Injection molding injection moulding Inserts Laser cooling Laser sintering Maraging steels Molding (process) Molds Product development Production costs Rapid prototyping rapid tooling Tool steels Tooling |
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| Title | Direct metal laser sintering, using conformal cooling, for high volume production tooling |
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