Rapid Tooling

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Jyh Hwa Tzou - One of the best experts on this subject based on the ideXlab platform.

  • ICRA - Automated Desktop Manufacturing: Direct Metallic Rapid Tooling System
    Proceedings of the 2005 IEEE International Conference on Robotics and Automation, 2005
    Co-Authors: Ren C. Luo, Jyh Hwa Tzou, Cheng Lung Chang, Zhong Hong Huang
    Abstract:

    In recent years, Rapid Tooling (RT) has become more important because of the requirement of Rapid manufacturing. RT can be used to produce temporary mold, even permanent mold in mass production. RT makes more benefit from design stage to mass production. The objective of this research is to develop the Direct Metallic Rapid Tooling System and identify process parameters of laser cladding. A metallic powder feeder system, a three-axis motion control system, a 500W Nd-YAG laser system, a shielding gas supply system, and a powder nozzle are incorporated for the hardware architecture in Direct Metallic Rapid Tooling System. Besides, the designed software that includes slicing algorithm with bucket sorting, contour generation and tool path generation algorithm are presented briefly. Effort was attempted to find out the better process parameters of laser cladding using single clad and cladding layer techniques. Based on the investigation, some metallic RT parts were fabricated and discussed.

  • Rapid Tooling using laser powered direct metallic manufacturing process
    31st Annual Conference of IEEE Industrial Electronics Society 2005. IECON 2005., 2005
    Co-Authors: Cheng Lung Chang, Jyh Hwa Tzou
    Abstract:

    Rapid Tooling (RT) has recently become more important due to the requirement of Rapid manufacturing in industrial automation field. RT can be used to produce temporary mold even permanent mold in mass production and to speed up compressed time into market. It makes more benefit from design stage to mass production. This study aims to develop the Rapid Tooling using laser powered direct metallic manufacturing process and identify process parameters of laser cladding. A metallic powder feeder system, a three-axis motion control system, a Nd:YAG laser system, a shielding gas supply system, and dual powder nozzle are integrated into the hardware architecture of laser powered direct metallic Rapid Tooling system. We attempt to find out the better process parameters of laser cladding by the Taguchi's method. This system has been successfully demonstrated and some metallic RT molds and plastic injection molded part are fabricated through this proposed method.

  • Rapid Tooling for automated desktop manufacturing
    30th Annual Conference of IEEE Industrial Electronics Society 2004. IECON 2004, 2004
    Co-Authors: Cheng Lung Chang, Zhong Hong Huang, Jyh Hwa Tzou
    Abstract:

    A new Rapid Tooling (RT) system based on pre-placed metallic powder has been proposed. A 500 W Nd-YAG laser, a pre-placed powder mechanism, a linear planar motor based working table, and PC-based controller are incorporated for the hardware architecture. In this research, we propose a software technique that includes slicing with bucket sorting, direct slicing, and tool path generation algorithms. The slicing method provides the direct slicing of the CAD model in IGES geometric format to improve the accuracy of desired part. Effort was attempted to find out the better parameters of laser cladding using single clad and cladding layer techniques. The process of the proposed system involves path control, laser cladding of layer by layer, milling, and finishing. Based on the investigation, some metallic components were fabricated.

  • ICRA - Investigation of a linear 2-D planar motor based Rapid Tooling system
    Proceedings 2002 IEEE International Conference on Robotics and Automation (Cat. No.02CH37292), 2002
    Co-Authors: Ren C. Luo, Jyh Hwa Tzou
    Abstract:

    Rapid prototyping (RP) has been widely known as being able to fabricate 3-D objects with complex geometric shapes. Rapid Tooling has become more important because of the requirement of Rapid manufacture. Rapid Tooling can be used to produce a temporary mold, even a permanent mold in mass production. The objective of the paper is to develop a Rapid Tooling system. The software technique includes a slicing algorithm and tool path generation algorithm. The hardware architecture includes a 500 W Nd:YAG laser, metallic powder feeder, substrate preheat system, shielding gas (N/sub 2/) supply system, CNC milling system and linear planar motor based working table. The system controller is a PC-based control system which includes 4-axis DSP motion control and an I/O control card. The system control software is written in Visual Basic language. The experimental result shows that the linear 2-D planar motor based X-Y table has fast response and can make an accurate tool path.

  • Investigation of a linear 2-D planar motor based Rapid Tooling system
    Proceedings 2002 IEEE International Conference on Robotics and Automation (Cat. No.02CH37292), 2002
    Co-Authors: Jyh Hwa Tzou
    Abstract:

    Rapid prototyping (RP) has been widely known as being able to fabricate 3-D objects with complex geometric shapes. Rapid Tooling has become more important because of the requirement of Rapid manufacture. Rapid Tooling can be used to produce a temporary mold, even a permanent mold in mass production. The objective of the paper is to develop a Rapid Tooling system. The software technique includes a slicing algorithm and tool path generation algorithm. The hardware architecture includes a 500 W Nd:YAG laser, metallic powder feeder, substrate preheat system, shielding gas (N/sub 2/) supply system, CNC milling system and linear planar motor based working table. The system controller is a PC-based control system which includes 4-axis DSP motion control and an I/O control card. The system control software is written in Visual Basic language. The experimental result shows that the linear 2-D planar motor based X-Y table has fast response and can make an accurate tool path.

Anders Håkansson - One of the best experts on this subject based on the ideXlab platform.

  • Rapid Tooling for small and medium sized enterprises : Part 2: implementing Rapid Tooling in small companies
    2016
    Co-Authors: Anders Håkansson
    Abstract:

    Rapid Tooling for small and medium sized enterprises : Part 2: implementing Rapid Tooling in small companies

  • Industrial design Rapid Tooling for small and medium sized enterprises
    2003
    Co-Authors: Anders Håkansson
    Abstract:

    This licentiate thesis combines three different topics, the small business environment, industrial design and Rapid Tooling. Smaller companies often suffer from lack of resources in many ways and since most theoretical product development methods are formulated for larger companies, this is a problem. The possibility to design and give their products the desired form is therefore difficult. Rapid Tooling is a new way of producing forming tools that cut the cost and lead time compared to conventional Tooling methods. The aim of this thesis is to investigate and clarify if Rapid Tooling is a solution to the problem of using forming tools in smaller companies. These tools can be used both as early prototype tools to verify a design and make a basis for decision of acquiring conventional tools for long production series, and as production tools for shorter production series. Paper A explains the initial problem formulation and the combining of the three topics. Also a small case study is included to help clarifying the aim to find a way for smaller companies to use forming tools that are adapted to their specific situation. Paper B focuses on the implementation of Rapid Tooling methods in smaller companies and whether to make the tools in-house with an own RT-machine, or buy the service externally from a service provider. Paper C deals with the question of how to choose the right RT-method for your specific situation. Each RT-method has its own advantages as well as disadvantages and are more suited for certain types of applications. It is therefore important to choose the right RT-method that is best for your product and what kind of tool you need. The thesis is concluded with plans for further research.

Haiko Pohl - One of the best experts on this subject based on the ideXlab platform.

  • on the development of direct metal laser sintering for Rapid Tooling
    Journal of Materials Processing Technology, 2003
    Co-Authors: A Simchi, Frank Petzoldt, Haiko Pohl
    Abstract:

    Abstract An iron based powder blend has been developed for Rapid Tooling using a direct laser sintering process. The powder consists of a mixture of different elements including Fe, C, Cu, Mo and Ni. High sintering activities were obtained by tailoring the powder characteristics and optimizing the chemical constituents. The manufacturing of complex-shaped parts is possible at rates of 6.75 cm 3 /h according to CAD data. The residual porosity is less than 5 vol.%. The bending strength is around 900 MPa and the artifact hardness is 490 HV30. To further improve the service life of tools, the processed parts are sintered again in a vacuum furnace at 1260 °C for 30 min. This enables to manufacture precision parts with the density around 7.7 g/cm 3 (sintering shrinkage is nearly zero). The dimensional accuracy of the sintered parts is improved by using a beam compensation technique that is integrated in the computer program of the laser sintering system. In this article the sintering behavior, mechanical properties, and microstructural features of the multi-component iron based powder are given and implications of the material for industrial applications are presented. A case study was performed to present the applicability of the material for Rapid Tooling.

Farrokh Mistree - One of the best experts on this subject based on the ideXlab platform.

  • The Rapid Tooling testbed: a distributed design‐for‐manufacturing system
    Rapid Prototyping Journal, 2003
    Co-Authors: David W. Rosen, Yong Chen, Shiva Sambu, Janet K. Allen, Farrokh Mistree
    Abstract:

    A new design‐for‐manufacturing method, called the geometric tailoring (GT), and the associated digital interface concept have been developed that enable the design activities to be separated from the manufacturing activities. Conditions for the successful application of this method are investigated. The GT method is demonstrated for Rapid prototyping and Rapid Tooling technologies, where prototype parts are required to match the production properties as closely as possible. This method is embodied in a system called the Rapid Tooling testbed (RTTB). Research work is presented on GT and the distributed computing environment underlying the RTTB. Examples are summarized from the usage of this method and testbed.

  • the Rapid Tooling testbed a distributed design for manufacturing system
    Rapid Prototyping Journal, 2003
    Co-Authors: David W. Rosen, Yong Chen, Shiva Sambu, Janet K. Allen, Farrokh Mistree
    Abstract:

    A new design‐for‐manufacturing method, called the geometric tailoring (GT), and the associated digital interface concept have been developed that enable the design activities to be separated from the manufacturing activities. Conditions for the successful application of this method are investigated. The GT method is demonstrated for Rapid prototyping and Rapid Tooling technologies, where prototype parts are required to match the production properties as closely as possible. This method is embodied in a system called the Rapid Tooling testbed (RTTB). Research work is presented on GT and the distributed computing environment underlying the RTTB. Examples are summarized from the usage of this method and testbed.

R.i. Campbell - One of the best experts on this subject based on the ideXlab platform.

  • A review of research into the effects of Rapid Tooling on part properties
    Rapid Prototyping Journal, 2001
    Co-Authors: J. I. Segal, R.i. Campbell
    Abstract:

    Rapid prototyping technologies have introduced a new generation of Rapid Tooling processes. Many of these Rapid tools have been used for injection moulding where the thermal properties of the tool material are critical to the quality of parts produced. Rapid tools are often made from materials with substantially different thermal properties than conventional metal tools. Engineers wishing to make use of these technologies to produce technical prototypes must be aware of the effect this will have on final part properties. Some previous research has been undertaken in this area. Reviews the work done in the field of Rapid Tooling used for injection moulding. The review shows that, whereas a range of techniques and final part materials has been studied, the results obtained are incomplete and often unexplained. The authors draw conclusions as to why this is so and go on to identify areas for further work that will be pursued.