View
217
Download
0
Category
Tags:
Preview:
Citation preview
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: mognol@bretagne.ens-cachan.fr
(2) ENS Cachan - Antenne de Bretagne, Campus de ker Lann 35 170 BRUZ
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
HRT manufacturing : 2) Topological and processes analysesHRT manufacturing : 2) Topological and processes analyses
DMLS or HSM DMLS HSM EDMDMLS
or HSM
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
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.
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
Test for a mould : Manufacturing a HRT.Test for a mould : Manufacturing a HRT.
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
AEPR 2004 14-15 September
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.
AEPR 2004 14-15 September
Sj
Sl
Sk
Si
Sm
SnSo
Sp
HSM EDMDMLS
Test for another applicationTest for another application
« Color code »
AEPR 2004 14-15 September
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
Test for a mould : Manufacturing a HRT.Test for a mould : Manufacturing a HRT.
Winnings estimationWinnings estimation
18%
15%
DMLS
Hybride
Hyb
rid
eD
ML
S
AEPR 2004 14-15 September
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
AEPR 2004 14-15 September
Thanks for your attentionThanks 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
Recommended