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

1. 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 Cedex email: mognol@bretagne.ens-cachan.fr (2) ENS Cachan - Antenne de Bretagne, Campus de ker Lann 35 170 BRUZ

2. 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

3. Introduction: general Context These last years the moulded products are increasingly present in the technical systems: life-cycle become more shorter Launching time and cost must be reduce products have become more complex Real prototypes are necessary to test style, technical functions, or industrial dies Every functions must be tested Appearance of the « Hybrid Rapid Tooling »

4. HRT : Validation of part design and evolution product Prototype Part Design For every results witch don’t match with functional requirements we must Re-designing and manufacturing only one component of mold. Multi components Prototype partitioning  Hybrid manufacturing Rapid Tooling Assembly components Re-designing of one or several component(s) Test Test not OK Hybrid rapid Tooling with same characteristic as cast solid tools Test OK Validation of part design

5. Hybrid rapid tooling : Analysis Propose a 3D puzzle of the part with the topologic and geometrical criterions Propose the best manufacturing process for each component of the studied MCP. geometry analysis Manufacturing analysis Multi component prototype MCP Assembly analysis Assembly must respect initial positioning of the geometric features in the single piece part and technical constraints Feasibility Analysis Analyzes functional (ISO specifications), evolutionary criterions and topologic configuration.

6. Time HSM DMLS ( EDM if pb) Quality Cost Hybrid rapid tooling manufacturing: Need method for choice €  Volume of DMLS Triptych CDC Hybrid Rapid tooling Temps HSM Finish DMLS Need method for making a judicious choice between HSM, DMLS and EDM EDM To compress the total time Simultaneous manufacture To reduce !

7. Hybrid rapid tooling manufacturing: Help choice process Feature recognition Si 1 6 types of geometry + Associated choice process Sj Topological and processes analyses 2 DMLS or HSM DMLS or HSM DMLS HSM EDM Table of propagation 3 Final choice

8. Hybrid rapid tooling manufacturing : 1) feature recognition Topological Analyze Feature Particular case Manufacturing problems Exterior volume Interior volume Topological association because same Pb of manufacture Topological association because same Pb of manufacture Large complex feature Little complex feature Large complex feature Simple feature Little complex feature Simple feature Type of Geometry HSM HSM HSM HSM HSM HSM EDM EDM EDM EDM EDM EDM DMLS DMLS DMLS DMLS DMLS DMLS

9. DMLS or HSM DMLS HSM EDM HRT manufacturing : 2) Topological and processes analyses DMLS or HSM

10. HRT manufacturing :3) Table of propagation Feature without choice Ex: HSM Sm Geometrical intersection Feature with choice Ex: HSM or DMLS Sn Propagation HSM

11. HRT manufacturing :3) Table of propagation. (example) Iteration as long as there are features « with choice »

12. Test for a mould :Validation of the DMLS Goal To validate the DMLS Process for obtaining Rapid tooling for preproduction of connections in "ABS charged glass fibres". Problematic • Low dimensions • the mould requires EDM to obtain the thin feature (special threading, forms interiors of the head, mini blending radius…).

13. Test for a mould :Validation of the DMLS Validation of process DMLS for obtaining the connections in "charged ABS" Prototype part design Rapid tooling (DMLS) Plastic injection CAM

14. Sj Sm Sk Sl Si Test for a mould : Manufacturing a HRT. Feature recognition Topological and processes analyses R 4 R 7.5 R=0 if not not specified in CAD Example: « lower and higher mould »

15. Test for a mould :Manufacturing a HRT. Topological analysis Surfaces identification Tool specifications Si HSM or DMLS HSM or DMLS l/h = 1.01 and l = 15 and IT>0.1 Interior feature Little complex L/d(tool)=1 and h=7.5 Sj HSM or DMLS HSM or DMLS Thin complex Interior feature l/h = 1,5 and l = 5 and IT>0.1 L/d = 0.5 and h =6 Sk HSM or DMLS HSM or DMLS l/h = 0.8 and l = 8 and IT>0.1 Interior feature Thin complex L/d=1 and h=4 DMLS Sl DMLS l = 0.18 IT>0.1 r = 0 d(tool)=0.18 Interior Feature Thin complex Sm HSM HSM Exterior Feature Simple L*l = 33.2*25 L/d = 3 and h = 5 Stage 1 Stage 2

16. Test for a mould : Manufacturing a HRT. Stage 3 Table of propagation We choose the HSM process for manufacturing Si, Sj, Sk et Sm

17. Test for a mould :Manufacturing a HRT. Application of a color code Hybrid rapid tooling manufacturing: Integration of the different parts and obtaining the "hybrid" mould HSM DMLS

18. Test for another application Sk Sm Sn So Sj Si Sl Sp HSM EDM DMLS « Color code »

19. Test for a mould : Manufacturing a HRT. Winnings estimation DMLS Hybride 15% Hybride 18% DMLS

20. Conclusions and prospect Propose a 3D puzzle of the part with the topologic and geometrical criterions Propose the best manufacturing process for each component of the studied MCP method validated on these examples geometry analysis Manufacturing analysis Assembly analysis Multi component prototype MCP Assembly must respect initial positioning of the geometric features in the single piece part and technical constraints Feasibility Analysis automation of the feature recognition Analyzes functional (ISO specifications), evolutionary criterions and topologic configuration Synthesis

21. Thanks for your attention Contacts: Mickaël Rivette ENS Cachan - Antenne de Bretagne - Rivette@bretagne.ens-cachan.fr Pascal Mognol ENS Cachan - Antenne de Bretagne - Mognol@bretagne.ens-cachan.fr