• Title, Summary, Keyword: Rapid Tooling

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Development of Rapid Tooling Processes Based on Three-Dimensional CAD/CAM (3차원 CAD/CAM 기반 초단납기 금형제작기술 개발)

  • Ahn, J. H.;Park, K.;Kim, C. K.;Park, B. C.;Choi, S. R.
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • pp.3-6
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    • 2001
  • The present work concerns rapid tooling technology based on three-dimensional CAD/CAM. Two types of tooling processes have been introduced : the quick delivery molding(QDM) process and the rapid tooling(RT) process using a rapid prototyping system. Both processes are based on three-dimensional CAD/CAM technology and realize a paperless manufacturing system with a high efficiency. The proposed approach has been applied to the product development for various electrical parts, and the final delivery has been reduced as compared with the traditional approach.

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Rapid Tooling : Challenge to Net Shape by Powder Casting (급속금형제작 (1): 분말주조에 의한 정형(正形)에의 도전)

  • 임용관;김범수;정해도;배원병
    • Journal of the Korean Society for Precision Engineering
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    • v.15 no.7
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    • pp.85-90
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    • 1998
  • The business of manufacturing is increasingly becoming time-compressing, precise and long-life oriented, owing to various needs from the consumers and harsh global competition. With the emergence of the layer laminate manufacturing method, it is possible to produce prototypes directly from 3D CAD and additive process, the production time and cost have shortened dramatically. However there are some problems like surface-step, dimensional deviation and warp. A newly developed powder casting is suitable for rapid-manufacturing metallic tools. Powder casting can serve as a promising rapid tooling method because of high density characteristics and low dimensional shrinkage below 0.1% during sintering and infiltration. By this process, we have realized significant time savings bypassing the wait for prototype tooling and cost savings eliminating the expense of conventional prototype tooling process.

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Rapid Product Fabrication using Wire Welding with $CO_2$ Laser Irradiation and Milling Process Technology (레이저 용접공정과 밀링공정에 의한 쾌속 금속 시작품 제작)

  • 최두선;신보성;윤경구;황경현;박진용;이종현;송용억;박세형
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • pp.763-766
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    • 2000
  • The Rapid Prototyping and Tooling technology has been developed. However, most commercial ones currently use resins or waxes as the raw materials. These days. the direct metal deposition methods are researched as a true rapid prototyping and tooling technology. A fundamental study on rapid prototyping and tooling with wire welding technology using $CO_2$ laser radiation was carried out in this paper. The main focus is to develop a simple commercial rapid prototyping and tooling system with the exiting laser welding technology. The process is investigated as a function of laser parameters and process variables. Basic parts were fabricated as out-put and their microstructure, hardness and tensile strength are examined for the reliability. In addition, Its advantages and disadvantages are discussed as a rapid prototyping and tooling system.

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Rapid Product Fabrication using Wire Welding with CO2 Laser Irradiation and Milling Process Technology (레이저 용접공정과 밀링공정에 의한 쾌속 금속 시작품)

  • Choi, Du-Seon;Lee, Su-Hong;Sin, Bo-Seong;Yun, Gyeong-Gu;Hwang, Gyeong-Hyeon;Park, Jin-Yong
    • Journal of the Korean Society for Precision Engineering
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    • v.18 no.1
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    • pp.104-110
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    • 2001
  • The rapid prototyping and tooling technology has been developed. However, most commercial ones currently use resins or waxes as the raw materials. These days, the direct metal deposition methods are being investigated as new rapid prototyping and tooling technology. A fundamental study on rapid prototyping and tooling with wire welding technology using CO2 laser radiation was carried out in this paper. The main focus is to develop a simple commercial rapid prototyping and tooling system with the exiting laser welding technology as output and their microstructure, hardness and tensile strength are examined for the reliability. In addition, its advantages and disadvantages are discussed as a rapid prototyping and tooling system.

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An Adaptive Slicing Algorithm for Profiled Edge laminae Tooling

  • Yoo, Seung-Ryeol;Walczyk, Daniel
    • International Journal of Precision Engineering and Manufacturing
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    • v.8 no.3
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    • pp.64-70
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    • 2007
  • Of all the rapid tooling (RT) methods currently available, thick-layer laminated tooling is the most suitable for large-scale, low-cost dies and molds. Currently, the determination of a lamina's contour or profile and the associated slicing algorithms are based on existing rapid prototyping (RP) data manipulation technology. This paper presents a new adaptive slicing algorithm developed exclusively for profiled edge laminae (PEL) tooling PEL tooling is a thick-layer RT technique that involves the assembly of an array of laminae, whose top edges are simultaneously profiled and beveled using a line-of-sight cutting method based on a CAD model of the intended tool surface. The cutting profiles are based on the intersection curve obtained directly from the CAD model to ensure geometrical accuracy. The slicing algorithm determines the lamina thicknesses that minimize the dimensional error using a new tool shape error index. At the same time, the algorithm considers the available lamination thicknesses and desired lamina interface locations. We demonstrate the new slicing algorithm by developing a simple industrial PEL tool based on a CAD part shape.

Case Study for Hybrid Tooling Using High Speed Cutting and RP(Rapid Prototyping) Technologies (괘속조형기술과 고속가공을 이용한 하이브리드 금형 개발에 대한 사례연구)

  • Kwon, Hong-Kyu;Jang, Moo-Kyung;Hong, Jung-Eui
    • Journal of the Society of Korea Industrial and Systems Engineering
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    • v.33 no.4
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    • pp.159-166
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    • 2010
  • The speed at which products are developed and released to market is tightly linked to profitability and market share. Hence, many companies are still in a desperate need of real Rapid Tooling (RT) technologies which can really help to expedite their prototype tooling and pre -production tooling for injection molding. Many other companies that have been very skeptical of RT technologies developed so far are working on Hybrid Tooling (HT) that can really meet the market standards. With the conviction that HT can be a reliable alternative for current RT technologies, this paper describes the experimentation how HT process has been being successfully established and effectively applied with typical case studies. Through the experimentation, Ceramic-filled SLA tooling was found to be aptly suited for the low grade mold, and Metal SLS tooling was found to be aptly suited for the medium volume mold both in terms of the lead time, dimensional accuracy, and tooling cost.

A study on rapid tooling technology using thermal spray process (아크 용사를 이용한 쾌속 금형 제조 기술)

  • Kim, Kyung-Hwa;Kim, Sun-Kyung;Yu, Young-Eun;Jea, Tae-Jin;Choi, Doo-Sun
    • Journal of the Korea Society of Die & Mold Engineering
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    • v.2 no.2
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    • pp.20-24
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    • 2008
  • Recently, the study for production technology is focused on cycle time reduction as various products are manufactured. In order to manufacture tool and die, rapid prototyping and rapid tooling are researched. Stereolithography apparatus, selective laser sintering, 3D printing, laminated object manufacturing are developed in rapid prototype. The purpose of this study is to develop rapid tooling technology using thermal spray process. This technology is not well-known to korea, but this study will be contributed in development of domestic molds industry through continuous research and development.

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Development of Rapid Tooling using Investment Casting & R/P Master Model (R/P 마스터 모델을 활용한 정밀주조 부품 및 쾌속금형 제작 공정기술의 개발)

  • Jeong, Hae-Do;Kim, Hwa-Young
    • Journal of Korea Foundry Society
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    • v.20 no.5
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    • pp.330-335
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    • 2000
  • Functional metal prototypes are often required in numerous industrial applications. These components are typically needed in the early stage of a project to determine form, fit and function. Recent R/P(Rapid Prototyping) part are made of soft materials such as plastics, wax, paper, these master models cannot be employed durable test in real harsh working environment. Parts by direct metal rapid tooling method, such as laser sintering, by now are hard to get net shape, pores of the green parts of powder casting method must be infiltrated to get proper strength as tool, and new type of 3D direct tooling system combining fabrication welding arc and cutting process is reported. But a system which can build directly 3D parts of high performance functional material as metal park would get long period of system development, massive investment and other serious obstacles, such as patent. In this paper, through the rapid tooling process as silicon rubber molding using R/P master model, and fabricate wax pattern in that silicon rubber mold using vacuum casting method, then we translated the wax patterns to numerous metal tool prototypes by new investment casting process combined conventional investment casting with rapid prototyping & rapid tooling process. With this wax-injection-mold-free investment casting, we developed new investment casting process of fabricating numerous functional metal prototypes from one master model, combined 3-D CAD, R/P and conventional investment casting and tried to expect net shape measuring total dimension shrinkage from R/P pare to metal part.

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Rapid Tooling by Using Metal Powder Reinforced Resin (금속분말 강화수지를 이용한 쾌속금형 제작)

  • Kim, Beom-Su;Jeong, Hae-Do;Bae, Won-Byeong
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.24 no.1
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    • pp.1-6
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    • 2000
  • As dies and molds have become more and more complicated in the recent years, the demand for lower cost and shorter production time is also growing stronger. Rapid prototyping and Tooling technologies are expected to be used for more rapid and lower cost tool fabrication. However the rapid tooling methods have not yet reached the level of application to the manufacturing of metallic dies and molds which require high dimensional accuracy. As the rapid tooling technology, there are the slurry casting, the powder casting, the direct laser sintering, and so on. Generally, in the slurry casting, the alumina powder and the water soluble phenol were mainly used. However, the mechanical properties of the phenol were not good enough to apply to molds directly. In this study, pure epoxy and two types of aluminium powder reinforced resin are applied to the slurry casting. The mechanical and thermal properties are better than phenol because the epoxy is the thermosetting resin. And mechanical characteristics such as shrinkage rate, hardness, surface roughness are measured for the sake of comparison. Metal powder reinforced resin molds are better than the resin tool form the viewpoint of shrinkage rate and hardness. Finally, it has been shown that the application possibility of this process is high, because the manufacturing time and cost savings are significant.