Experimental assessment of hybrid mould performance

Pontes, Antonio J.; Queirós, Miguel P.; Martinho, Pedro G.; Bártolo, Paulo J.; Pouzada, António S.

http://hdl.handle.net/10400.8/14938

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Experimental assessment of hybrid mould performance.pdf	Hybrid moulds are a novel approach for rapid tooling of injection moulds that combines conventional machining for the mould structure and rapid prototyping techniques for the moulding blocks (core and cavity). In this study, two routes were used for producing the moulding blocks: selective laser sintering of stainless steel-based powder (hard tool) and epoxy resin vacuum casting (soft tool). The experimental work was based on a complex tridimensional commercial part. The mouldings were made in polypropylene, and the processing performance was monitored online in terms of pressure and temperature at the impression. The performance of the moulding blocks was analysed in terms of thermal and cycle performance and structural integrity. The epoxy tooling route is more adequate for fine detailing than selective laser sintering but is not adequate for parts with extensive ribs or deep bosses. The structural integrity of the less costly epoxy composite can be compromised during ejection, this suggesting the need to evaluate the stress field by simulation at the design stage of the mould.	407.05 KB	Adobe PDF	Download

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Abstract(s)

Hybrid moulds are a novel approach for rapid tooling of injection moulds that combines conventional machining for the mould structure and rapid prototyping techniques for the moulding blocks (core and cavity). In this study, two routes were used for producing the moulding blocks: selective laser sintering of stainless steel-based powder (hard tool) and epoxy resin vacuum casting (soft tool). The experimental work was based on a complex tridimensional commercial part. The mouldings were made in polypropylene, and the processing performance was monitored online in terms of pressure and temperature at the impression. The performance of the moulding blocks was analysed in terms of thermal and cycle performance and structural integrity. The epoxy tooling route is more adequate for fine detailing than selective laser sintering but is not adequate for parts with extensive ribs or deep bosses. The structural integrity of the less costly epoxy composite can be compromised during ejection, this suggesting the need to evaluate the stress field by simulation at the design stage of the mould.

Keywords

Hybrid mould Moulding blocks Injection Moulding Rapid tooling SLS Epoxy casting

URI

http://hdl.handle.net/10400.8/14938

Citation

Pontes, A.J., Queirós, M.P., Martinho, P.G. et al. Experimental assessment of hybrid mould performance. Int J Adv Manuf Technol 50, 441–448 (2010). https://doi.org/10.1007/s00170-010-2546-1.