AEPR 2004 14-15 September A first approach to choose between HSM, EDM and DMLS processes in Hybrid...

AEPR 2004 14-15 September

A first approach to choose between HSM, EDM and DMLS processes in

Hybrid Rapid Tooling

P. Mognol1, M. Rivette2, L. Jégou1, T. Lesprier1

(1) IRCCyN, 1 rue de la noé, BP92101, 44321 Nantes Cedexemail: [email protected]

(2) ENS Cachan - Antenne de Bretagne, Campus de ker Lann 35 170 BRUZ


Outline:Outline:

Introduction: general Context

Hybrid Rapid Tooling (HRT)

Hybrid Rapid Tooling (HRT) manufacturing : A method to optimize the processes in Hybrid Rapid Tooling.

Validation of method : Test with an industrial mould

Conclusions and prospect


Introduction: general ContextIntroduction: general ContextThese last years the moulded products are increasingly present

in the technical systems:

products have become more complex

life-cycle become more shorter

Appearance of the

« Hybrid Rapid Tooling »

Launching time and cost

must be reduce

Real prototypes are necessary to test style, technical

functions, or industrial diesEvery functions must be tested


For every results witch don’t match with functional

requirements we must Re-designing and manufacturing only one component of mold.

Prototype Part Design

Test

Hybrid manufacturing

Validation of part design

Re-designing of one or several component(s)

Test OKTest not OK

HRT : Validation of part design and evolution productHRT : Validation of part design and evolution product

Multi components Prototype partitioning

Assembly components

Hybrid rapid Tooling with same

characteristic as cast solid tools

Rapid Tooling


Hybrid rapid tooling : AnalysisHybrid rapid tooling : Analysis

Multi component prototype MCP

Assembly analysis

Feasibility Analysis

geometry analysis

Assembly must respect initial

positioning of the geometric features in the single piece part

and technical constraints

Analyzes functional (ISO specifications),

evolutionary criterions and topologic configuration.

Propose the best manufacturing process for each component of the

studied MCP.

Propose a 3D puzzle of the part with the

topologic and geometrical criterions

Manufacturing analysis


Time

Cost Qua

lity

HSMDMLS

( EDM if pb)

Triptych CDC Hybrid Rapid tooling

Hybrid rapid tooling manufacturing: Need method for choiceHybrid rapid tooling manufacturing: Need method for choice

Need method for making a judicious choice between

HSM, DMLS and EDM

Volume of DMLS

€

Temps

To compress the total time

To reduce !Simultaneous manufacture

Fin

ishHSM

DMLS

EDM


Hybrid rapid tooling manufacturing: Help choice processHybrid rapid tooling manufacturing: Help choice process

Feature recognition

Sj

Si

6 types of geometry + Associated choice process

Topological and processes analyses

DMLS or HSM DMLS HSM EDM

Feature with choice: “HSM or DMLS”Featurewithout Choice: “HSM” or “DMLS”

SiHSM or DMLS

SjHSM or DMLS

SkHSM or DMLS

Sl / DMLS DMLS DMLS DMLS

Sm / HSM HSM HSM HSM

Solution HSM HSM HSM

Table of propagation

Final choice

DMLS or HSM


Hybrid rapid tooling manufacturing : 1) feature recognitionHybrid rapid tooling manufacturing : 1) feature recognition

Topological AnalyzeTopological Analyze Feature

Exterior volume

Manufacturing problems

Topological association because same Pb of manufacture

Topological association because same Pb of manufacture

Simple feature

Large complex feature

Little complex feature

Simple feature

Large complex feature

Little complex feature

DMLSEDMHSM

DMLSEDMHSM

DMLSEDMHSM

DMLSEDMHSM

DMLSEDMHSM

DMLSEDMHSM

Particular case

Interior volume


HRT manufacturing : 2) Topological and processes analysesHRT manufacturing : 2) Topological and processes analyses

DMLS or HSM DMLS HSM EDMDMLS

or HSM


HRT manufacturing :HRT manufacturing : 3) Table of propagation3) Table of propagation

Sm

Sn

Geometrical intersection

Feature without choice

Ex: HSM

Feature with choice

Ex: HSM or DMLS

HSM

Propagation


HRT manufacturing :HRT manufacturing : 3) Table of propagation. (example)3) Table of propagation. (example)

Iteration as long as there are features « with choice »

Feature with choice: “HSM or DMLS” Featurewithout Choice: “HSM” or “DMLS”

SiHSM or DMLS

SjHSM or DMLS

S…HSM or DMLS

SoHSM or DMLS

Sa / HSM HSM No intersection

… No intersection

S… … … … …

Sf / DMLS DMLS DMLS … No intersection

Solution HSM DMLS …HSM or DMLS


To validate the DMLS Process for obtaining Rapid tooling for preproduction of connections in "ABS charged glass fibres".

Goal

• Low dimensions

• the mould requires EDM to obtain the thin feature (special threading, forms interiors of the head, mini blending radius…).

Problematic

Test for a mould :Test for a mould : Validation of the DMLSValidation of the DMLS


Prototype part design

CAM

Rapid tooling (DMLS)

Plastic injection

Validation of process DMLS for obtaining the connections in "charged ABS"

Test for a mould :Test for a mould : Validation of the DMLSValidation of the DMLS


Feature recognition

Sl

Sk

Sj

Si

Sm

Example: « lower and higher mould »

Topological and processes analyses

R 7.5

R 4

R=0 if not not specified in CAD

Test for a mould : Manufacturing a HRT.Test for a mould : Manufacturing a HRT.


Test for a mould :Test for a mould : Manufacturing a HRT.Manufacturing a HRT.

Tool specifications

Si Littlecomplex

l/h = 1.01and l = 15 and IT>0.1

L/d(tool)=1 and h=7.5

HSM or DMLS

Interior feature

Surfaces identification Topological analysis

Sj Thin complex

l/h = 1,5and l = 5 and IT>0.1

L/d = 0.5 and h =6

Interior feature

HSM or DMLS

Sk Thin complex

l/h = 0.8and l = 8 and IT>0.1

L/d=1 and h=4Interior feature

HSM or DMLS

Sm Simple L*l = 33.2*25 L/d = 3 and h = 5

Exterior Feature

HSM

Sl Thin complex

l = 0.18IT>0.1

r = 0d(tool)=0.18

Interior Feature

DMLS

Stage 1 Stage 2

DMLS

HSM

HSM or DMLS

HSM or DMLS

HSM or DMLS



Feature with choice: “HSM or DMLS”Featurewithout Choice: “HSM” or “DMLS”

SiHSM or DMLS

SjHSM or DMLS

SkHSM or DMLS

Sl / DMLS DMLS DMLS DMLS

Sm / HSM HSM HSM HSM

Solution HSM HSM HSMTable of propagation

Stage 3

We choose the HSM process for manufacturing Si, Sj, Sk et Sm


Application of a Application of a color codecolor code

Integration of the different parts and

obtaining the "hybrid" mould

Hybrid rapid tooling Hybrid rapid tooling manufacturing:manufacturing:

HSM

DMLS

Test for a mould :Test for a mould : Manufacturing a HRT.Manufacturing a HRT.


Sj

Sl

Sk

Si

Sm

SnSo

Sp

HSM EDMDMLS

Test for another applicationTest for another application

« Color code »


Time

Time

Time

Time 1

Time 2

Time 3

Cost

CostCAM DMLS

Prepa DMLS

DMLS

Shot pen

Cutting-up /Fitting

CAM HSM

Prepa HSM

HSM


Winnings estimationWinnings estimation

18%

15%

DMLS

Hybride

Hyb

rid

eD

ML

S


Conclusions and prospectConclusions and prospect

Multi component prototype MCP

Assembly analysis

Feasibility Analysis

geometry analysis

Assembly must respect initial positioning of the geometric features in the single piece part

and technical constraints

Analyzes functional (ISO specifications),

evolutionary criterions and topologic configuration

Propose the best manufacturing

process for each component of the

studied MCP

Propose a 3D puzzle of the part with the

topologic and geometrical criterions

Manufacturing analysis

method validated on these examples

automation of the feature recognition

Synthesis


Thanks for your attentionThanks for your attention

Contacts:Mickaël Rivette

ENS Cachan - Antenne de Bretagne -

[email protected]

Pascal Mognol

ENS Cachan - Antenne de Bretagne -

[email protected]

AEPR 2004 14-15 September A first approach to choose between HSM, EDM and DMLS processes in Hybrid...

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