July/August 2018
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MBrack@datateam.co.uk Small Flat Belt Conveyors
947
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Metal Seals
Brakes 948 Plastic Extrusions
Enclosures for Harsh Environments
Seals for Extreme Environments Hinges
Connectors
Clutches and Brakes Geared Motors
949 950
Hinges 951 Levelling Feet
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Fastenings and Adhesives Plastic Extrusions Springs Rail
Sensors
952 953 954
Connectors 955 Machine Safety Meta Seals
Fastening and Adhesives
Seals For Extreme Environments Enclosures for Harsh Environments Geared Motors
Mechanical Components Marine Applications
956 957 958 959 960
Springs 961 Rail 962
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METAL ADDITIVE MANUFACTURING OFFERS BENEFITS TO TOOLMAKING
by Marcel Gowers, metal hybrid AM manager, OGM
Plastic injection moulding allows manufacturers to make large volumes of identical parts efficiently. Investment costs, though, can be steep – including the injection moulding machine and a mould tool. So, toolmaking is often sub- contracted to lower-cost economies such as China, meaning lead-times of around 12 to 14 weeks. Now, however, rather than relying only on traditional subtractive CNC
machining techniques to produce mould tool parts, toolmakers have the opportunity to use additive metal manufacturing (AM) methods to speed up production and reduce production costs. The use of the latest hybrid metal additive manufacturing systems, for
example, allow mould tool inserts to be created and finished in a single operation, using laser metal sintering technology combined with CNC machining in an integrated machine. This eliminates the need for post- production operations and produces inserts with high quality in a range of metals. By building the mould tool insert and cavity onto standard tooling parts it is possible to reduce production time to around six weeks or less. Cooling channels are a vital element of injection mould tools and have,
traditionally, been drilled in the tool. These run in straight lines, which makes it difficult for them to reach deep into the mould where there are complex features and geometries, and to be close enough to the moulding surface to perform optimal cooling. So, to avoid component warpage, the moulding process will have to be slowed down, adding cost. Conformal cooling – in which the channels follow the surface geometry of the mould tool – achieves more effective cooling as it enables the water to reach previously inaccessible areas of the mould. This is where additive manufacturing now comes in. AM works by building up a structure layer-by-layer. Direct metal laser
sintering (DMLS) systems deposit a thin layer of metal powder, which is then solidified by curing it with a laser. This happens after each layer is deposited, allowing the production of highly complex shapes with internal and external forms, which would be impossible to achieve using conventional methods. The downside of DMLS is that it is relatively expensive and creates parts
with rough surfaces that must be post-machined – adding more cost to the process. Using the hybrid metal additive manufacturing system described above overcomes these issues, to build steel cores and cavities with mould quality surface finishes with built-in conformal cooling channels. The technique ensures that internal features such as flow channels are
smooth, which helps fluid flow and reduces the risk of channel blockage that can occur in sintered cores. Hybrid Metal AM also reduces or eliminates the need for Electrostatic Discharge Machining (EDM), a time-consuming process used in tool production, to further reduce production times and costs. The machine that creates the parts has a build volume of 250 x 250 x
185mm, so it can make medium-sized mould tools and many other products. Materials made on the machine are hard enough to meet the needs of many production applications without the need for extra heat treatment. At present, the hybrid metal additive manufacturing solution is said to be
Latest Injection Moulding Technology
Medical Moulding
In-house Design and
Mouldflow
Machining and
Assembly Large
Moulding Expertise (up to 1.5m sq)
www.rutlandplastics.co.uk
TCT, at the NEC 25-27th September. Talk to us on stand H49 EDS, at the NEC 18 & 19th October. Talk to us on stand G58
Rapid Prototyping
unique to OGM in the UK. The company calls inserts with cooling channel designs that are made using this process ‘ConformL Cool’ inserts. As well as allowing cooling channels to take any route through the tool, the process removes the need for those channels to be round – shapes such as elliptical, rectangular and teardrop designs can boost heat transfer in a range of applications. At the same time, the channels can incorporate special features that promote turbulent coolant flow, which further increases the heat transfer rate. Moulds made with ConformL technology have seen cycle time reductions of up to 20% over conventionally made tools. These inserts can be made and incorporated into existing and new traditionally made tools in order to reach hard-to-cool areas. The technique can also be used to make a range of standard inserts, including ejector units with built-in cooling channels. Making complete core and cavity inserts for mould tools with complex
cooling channel geometries and designs – in a single automated process – can shrink the time it takes to reach full production.
www.ogm.uk.com
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