IUM 2008 E-Manufacturing Solutions for Tooling Rainer Salzberger 16.04.2008
Content Tooling Applications New EOS-products Design Rules Conformal Cooling Softwaresolutions for Molddesign and Simulation EOS 2008 EOSINT_M_Tooling RSA Page 2
Typical Tooling Applications EOS 2008 EOSINT_M_Tooling RSA Page 3
Established Tooling Applications Prototype Tooling Typical DirectMetal 20 Small series production Fast and economic solution Hybrid Tooling Combinations of several materials e.g.: Core in DirectMetal20, Cavity in Aluminium, Epoxytools with removable DMLS-inserts, Source: GeneralPattern, Linear Mold&Engineering EOS 2008 EOSINT_M_Tooling RSA Page 4
Established Tooling Applications Serial Tooling ( Plastic Injection ) Typical EOS MaragingSteel MS1 Conformal Cooling often used Benefits in better part quality, process control, shorter cycletimes and longer lifetime of the mold Vulcanisation Typical EOS MaragingSteel MS1 reduced cycle times due to tempering channels Source: PEP and Antiope Project, TEKLAS EOS 2008 EOSINT_M_Tooling RSA Page 5
New and Special Tooling Applications Moldrepair Typical EOS MaragingSteel MS1 Economic solution, avoids extra costs of complete manufacturing Diecasting Typical EOS MaragingSteel MS1 Cycle time reduction, better microstructure of cast parts Source: Ecoparts, LBC EOS 2008 EOSINT_M_Tooling RSA Page 6
EOS-developments and customersolutions EOS 2008 EOSINT_M_Tooling RSA Page 7
EOS has developed a complete solution for e-manufacturing in tooling Design rules data generation data preparation laser- sintering process post- processing application Conformal cooling case studies etc. Optimal materials for various tooling situations (DM20, MS1, PH1) Ground build platforms with reference position 40 and 20µm layer parameters for MS1 PSW incl. interfaces powder materials other consumables machine HW HW peripherals Heat treatment recommendations (hardening etc.) Referencing feature for absolute positioning Positioning pins in platform carrier Erowa clamping system; platform handling system SOURCE EOS EOS 2008 EOSINT_M_Tooling RSA
EOS offers an optional Erowa clamping system to interface to other machines with Erowa interface Use of the Erowa clamping system in EOSINT M270 Source: EOS EOS 2008 EOSINT_M_Tooling RSA Page 9
Positioning pins integrated into EOSINT M270 to allow easy and accurate build on preforms Building a hybrid core in EOSINT M270 Similar solution with positioning pins is soon available as an upgrade for existing M270. In the near future it will be included in all new M270 systems. Source: EOS, LaserBearbeitungsCenter GmbH EOS 2008 EOSINT_M_Tooling RSA Page 10
University of Wolverhampton has implemented a positioning system to fulfil their requirements Setup Plate Impression Pad Grid Plate Sub Plate Machine Platform The setup and grid plates can be precisely and repeatably located on the sub plate, which remains attached to the EOSINT M2x0 platform carrier Source: EOS, University of Wolverhampton EOS 2008 EOSINT_M_Tooling RSA Page 11
Designrules for Cooling Channels EOS 2008 EOSINT_M_Tooling RSA Page 12
Designrules for Cooling Channels EOS Whitepaper/Designrules Recommendations about distances, diameters, shapes of channels Background knowledge about optimised mould temperature control Competitive advantage vs. conventionel tooling Wallthickness of injection moulding part (in mm) Hole diameter (in mm) Centreline spacing between holes Distance between centre of holes and cavity 0-2 4-8 b a c 2-4 8-12 2-3 x b 1.5-2 x b 4-6 12-14 Source: EOS EOS 2008 EOSINT_M_Tooling RSA Page 13
Software for Design and Simulation EOS 2008 EOSINT_M_Tooling RSA Page 14
Softwaretools for Design and Simulation Materialise 3-matic Cooling Channel for Tooling automatic creation of cooling channels VISI CAD-system for moldmakers Simulation for filling, distortion and tempering Other Suppliers + Solutions HIPERMOULDING (EU-project) Moldex3D (Simulation) Other suppliers under investigation Source: Materialise, VISI EOS 2008 EOSINT_M_Tooling RSA Page 15
www.eos.info EOS 2008 EOSINT_M_Tooling RSA Page 16