rapid tooling ppt.ppt

8/18/2019 rapid tooling ppt.ppt

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Rapid ToolingRapid Tooling

Guided By Presented ByDr. K.G.Dave Parikh Ravi Rajesh Kumar

Assistant Professor Enroll. o!"#$%#%##%Dept. of 'e(h. Eng.) "th *em. 'E +AD,+A'-D+E) Ahmeda ad Dept. of 'e(h. Eng.)

-D+E) Ahmeda ad1


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Introduction of Rapid prototypingRapid toolingDifferences Between Rapid Tooling And The ConventionalMethodRapid Tooling Methods

1.direct method.indirect method!oft tooling"ard toolingRapid Tooling Techni#ues

1.!ilicon ru$$er tooling.%po&y tooling

'.!pray metal tooling(. Rapid !olidification )rocess*. Cast +ir,site )rocess

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Rapid prototyping

Rapid Prototyping (RP) techniques are methods that allowdesigners to produce physical prototypes quickly.

It consists of various manufacturing processes by which asolid physical model of part is made directly from 3 !"model data without any special tooling.

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Why is Prototyping Important?

Product designers want to have a physical model of a new partor product design rather than #ust a computer model or linedrawing

!reating a prototype is an integral step in design" virtual prototype (a !" model of the part) may not besufficient for the designer to visuali$e the part adequately%sing RP to make the prototype& the designer can see and feelthe part and assess its merits and shortcomings

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Why Rapid tooling?

• %nfortunately with RP techniques& there is only a limited rangeof materials from which prototypes can be made. !onsequentlyalthough visuali$ation and dimensional verification are possible&functional testing of prototypes often is not possible due todifferent mechanical and thermal properties of prototypecompared to production part.

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Rapid tooling

Rapid 'ooling refers to mould cavities that are either directly orindirectly fabricated using Rapid Prototyping techniques.'hese are primarily used to create multiple prototypes. Rapid

prototyping techniques are not economical when more than one prototype needs to built for the same component.

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Rapid Tooling Methods

'wo approaches for tool making*. Indirect R'+ method,. irect R'+ method

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Indirect RTM method

Pattern is created by RP and the pattern is used to fabricatethe tool- amples

Patterns for sand casting and investment casting

Direct RTM methodRP is used to make the tool it self

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Soft Tooling:-

!ilicone molds and the urethane process are used when a lowervolume of parts is needed -1 1//0. This is $ecause the toolingand piece price is more economical for lower #uantities. 2naverage3 silicone tools usually cost in the hundreds tothousands of dollars3 pending on the part geometry.!ilicone molds can $e used for prototype3 $ridge andproduction of low volumes from one part to hundreds of parts.Most silicone molds are good for a$out * shots per cavity.!ilicone molds are typically in4ected with material that is

manually gravity fed through a tu$e. )ending on the type ofmaterial3 it can ta,e anywhere $etween 1 ( hours to cure.2nce the parts within the mold cure3 the molds are manuallyopened3 and any necessary finishing is done $y hand.

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Soft Tooling:-

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Hard Tooling:

!teel5aluminum tools are used for the in4ectionmolding process for prototype or $ridge3 $ut thesetools are mostly used for high volume production-1//6s 1//3///6s0.!teel5aluminum tools typically range in price fromthousands to tens of thousands of dollars. And pendingon the material and part geometry3 the tool life canrange from thousands to millions of parts.!teel5aluminum tools are in4ected with material froman in4ection mold machine. The machine in4ects moldinto the mold with less man power when compared tosilicone molds. The curing of material will ta,e$etween a few seconds to a few minutes3 thus yieldingmore parts much #uic,er than silicone tools. 12


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Hard Tooling:

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Comparison of Soft Hard Tooling:-

Soft Tooling /ow !ost 'ooling0igher Piece Part !ost1aster /ead 'ime "nd

Response+ore 1le ibility 'o !hange

esignIncreased Product 2ariance

Hard Tooling

0igher !ost 'ooling/ower Piece Part !ost

4 esign 1le ibilityRepeatability/onger /ead 'ime ue 'o

'ooling /ead 'imeProcess 1or 0igh 2olumes

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Rapid Tooling Techni!"es

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5ilicon Rubber 'ooling

4ne of the most popular tooling applications for RP is the production of room temperature vulcani$ing (R'2) siliconerubber tooling'he purpose of R'2 tools is to create urethane or epo y

prototypes& often under vacuum (hence the term vacuumcasting)

'he process of making a rubber mould consists of+aking a master pattern& usually on an RP machine.

1inishing the pattern to the desired appearance.!asting R'2 silicone rubber around the pattern to form themould& and then in#ecting the mould with two part thermosetmaterials to create moulded plastic parts. 16


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5ilicone rubber tooling provides fast& ine pensivemoulds& e cellent partcosmetics& and the optionof using multiple materials

'he process is suitable forsmall or medium si$ed parts"nother benefit of siliconerubber tooling is thenegative draft (undercuts)that can be achieved due tothe fle ibility of the mouldmaterial

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#po$y tooling:

Its also known as 6!omposite 'ooling7/ike silicone rubber tooling& epo y based composite toolingrequires a master pattern.'his pattern is created by RP process.

'he pattern is finished and then embedded in a parting line block to create the parting line of the mould.+etal inserts are placed in areas where the epo y is unlikely towithstand the pressures of the in#ection moulding process.-po y is then cast against the pattern and parting line block

combination to create the first side of the tool.4nce the epo y has cured& the assembly is inverted& and the

parting line is removed& leaving the pattern embedded in thefirst side of the tool.'he second side of the tool is then cast against the first.

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#po$y tooling:

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Spray metal tooling:

It is very similar to aluminium filled epo&yIn this process3 against the R) pattern low temperaturemetal alloys is sprayedA thin metal coating is then arc sprayed on theresultant mould surfaceIt gives higher strength and ma&imum tool lifeThis process is suita$le for larger parts

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Spray metal tooling:

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RP ModelMetal spraying

Finished Model


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RSP Tooling

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Cast %ir&site

• ;irksite is a $inc aluminum alloy with e cellent wearresistance. ( ?n& @> "l) with a melting point of 3A !) 5

• 'he process for making cast kirksite tooling begins much likethe process for epo y based composite tooling& e cept that two

additional reversals are required to permit the creation oftooling in a more durable material

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Cast Kirksite Process:1irst& a shrink compensated master pattern of the part is

produced& typically using an RP process." rubber or urethane material is then cast against the partmaster to create patterns for the core and cavity set& which will

be cast in kirksite.Plaster is then cast against the core and cavity patterns tocreate moulds into which the kirksite is cast.4nce the kirksite is cast into the plaster moulds& the plaster is

broken away& and the kirksite core and cavity are fit into amould base

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Cast Kirksite Process:

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Process chain of 3D Keltool:

Master pattern

Silicone cast ing

Casting with a tool steel/Tungsten carbide/epoxy mixture

Burn-out of binder, sintering and inltration with copper in

an oven

Tool insert ready for production 29


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Than,

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