HRS - - SLM Cycle time Reduction

1 R&D Technologies REV 1.0


Recoater

Laser beam

Collector bin

Dispenser

Part onprocess

SLM : How the Machine works


Conformal cooling channels means:

channels shaped according to molding surface (impossible to realize with drilling technology),

short and constant distance between channel wall and molding surface,

any channel cross section geometry is possible (elliptical, squared, etc…),

surface cooling possibility.

SLM FOR INSERTS WITH CONFORMAL COOLING


Surface cooling means perfectly uniform temperature on molding surface

Advantages:

- uniform temperature on molding surface,

- no warpage due to uneven cooling time,

- shortest achievable cycle time.

Disadvantages:

- good water quality required to avoid channel obstruction

SURFACE COOLING


Fluid dynamic simulation for cooling channels design optimization:

flow rate balancing in cooling channel ramification,

pressure losses control,

velocity increase in areas critical for incrustation.

CHANNEL DESIGN AND FLUIDODYNAMIC SIMULATION


Smaller channel diameter (starting from Ø0.5mm) :

permits to cool critical areas that standard technology cannot reach,

needs to use de-mineralized and clean water to avoid risk of channel obstruction due to calcareous incrustation.

Channel wall nickel coating is possible in order to avoid:

calcareous incrustation,

oxidation.

Channel wall roughness is approximately 40 µm.

CHANNEL SIZE AND WALL ROUGHNESS


Hybrid insert obtained by laser melting on a preformed milled base:

laser melting only for the insert part where conformal channels cannot be machined with standard drilling;

lower manufacturing time and costs;

SLM part

Preformed milled base

HYBRID BUILDSTYLE INSERT


In hybrid inserts, locating pins and no stock in the bottom base allow fast clamping for machine finishing.

Finished bottom base

Locating pins

Stock to remove

Locating pins

Threaded holes



Test have been performed to prove the optimal adhesion between SLM part and base manufactured from forged steel.

Ultimate tensile strength 1050 MPa up to 1200MPa according to base material.

Base

SLM part

Surface adhesion between SLM and base



Tested base materials:

1.2311 / 12

1.2343 hardened at 48 HRc

AISI 420

Toolox 40

Adhesion line between SLM and machined base doesn’t affect aesthetic of the moldedpart

As built Finishing machined Adhesion line



Parts manufactured with SLM technology have the same mechanical properties as those machined from forged steel

100 x enlargement of an SLM surface part

Laser stripes

Laser melting means fully dense part!

SELECTIVE LASER MELTED STRUCTURE


Maraging 300 (W.1.2709)

Characteristics:

same mechanical properties as W.1.2311 or W.1.2343 according to heat treatment,

low stresses and deformation after precipitation hardening (much lower than quenching),

less brittle than W.1.2343 at same hardness,

good standing wear and tear,

nitriding, nicheling, PVD coating possible,

weldable,

easily machinable with milling machine, lathe and spark erosion machine (EDM),

texture possible.

STEEL FOR SLM Injection molding Applications


High gloss polishing:

gloss polishing possible,

light pitting defects may affect transparent aesthetical parts quality

tests are going on to find special coating and / or remove inclusion forming during building process

Maraging 300 (W.1.2709)

Mechanical properties:

“As built”:

Hardness: 35-37 HRc

Yield strenght: 1000 MPa

After precipitation hardening:

Hardness: from 48 HRc up to 54 HRc

Yield stress: from 1400 MPa up to 1900 MPa

STEEL FOR SLM Injection molding Applications


Required data:

insert 3D file

molding surfaceidentification

Forged base

SLMCutting plane

1. Cutting plane positioning 2. Channel design on:

preformed base

SLM part

INGLASS HRS DESIGN CAPABILITIES for SLM Inserts


3. Fluidodynamics simulations 4. Base machining and SLM manufacturing

5. Thermal treatment and / or coating

6. Insert with stock shipping

INGLASS HRS DESIGN CAPABILITIES for SLM Inserts


SLM inserts warranty runs for the entire mold life

Delivery time may vary between 2 and 4 weeks according to geometry complexity and required heat treatment or coating

SLM WARRANTY AND DELIVERY TIME


Mold cooling phase:

represents 60-75% of the entire cycle time

affects aesthetic of the part

controls warpage of the part

INglass offers a cooling optimization support in order to:

reduce / optimize cycle time

improve aesthetic of the part

control the warpage

cost reductionparts better qualityscrap reduction

MOLD COOLING OPTIMIZATION SUPPORT


1. Know how from:Mold design

Hot runner design

Molding process

MORE THAN 20 YEARS KNOW HOW IN MOLDMAKING AND TRY OUTS


2. Mold Flow and EFDLab software:

Mold Flow (filling, packing, cooling,

warpage analysis and fiber orientation)

EFDLab (for thermo-fluidodynamics simulation)

TOOLS AND SKILLS FOR COOLING OPTIMIZATION


3. Standard technology tools:

circuit modification by double thread screw barblers, added drilled holes, etc…

high thermal conductivity inserts,

isopipes.

Add baffle

Add cooling lines Ø14.27 closer to molding surfaces

adding drilled channels

isopipes

fountains



4. SLM technology for inserts with conformal cooling channels



Case 1: engineering during mold design phase

Customer provides mold 3D files including cooling lines design

INglass offers:

Mold Flow simulations including filling, packing, cooling and warpage to check correct gates location, hot spots (critical areas for cooling), deformation of the part, etc..

mold design and cooling system modifications (gate location, new cooling lines design, SLM conformal channels insert, etc…)

new Mold Flow analysis to check modification effectiveness

Time required: 10 working days

MOLD COOLING ENGINEERING DURING MOLD DESIGN PHASE


Case 2: mold cooling engineering to solve cooling problems faced during production (high cycle time and / or part deformation)

problems analysis and identification of a solution through standard technology or SLM conformal channel inserts

if required Mold Flow cooling analysis to prove the modification effectiveness and identify cycle time reduction

MOLD COOLING OPTIMIZATION AFTER PRODUCTION START


Cooling optimization during design phase rather than modification during production ensures:

shorter design time for cooling engineering support during design phase (10 working days),

no costs for cooling system modification (drilling new cooling channels, machinery of SLM insert pocket, etc…),

no production stop for mold modification,

no waste of time for extra tryouts,

scrap reduction.

COOLING IN DESIGN PHASE ADVANTAGES


Standard insert

Hot spot

Mold temperature

REAL CASE n°1 : Automotive air conditioning component


SLM insert

Mold temperature



Standard insert SLM insert

Cycle time reduction: 5

seconds

Standard insert replaced bySLM insert

Size: 230 x 230 x 50

mm



Standard insert

Hot spot

Mold temperature

REAL CASE n°2 : Slide for Automotive Lens


SLM insertMold temperature



Standard slide SLM slide

Warpageproblem fully

solved

Standard insertreplaced by SLM

insert

Size: 230 x 230 x

80 mm



Optimizedcooling

SLM insert choice at design phase

Size: 80 x 60 x 210

mm

REAL CASE n°3 : Insert for air conditioning component


Optimizedcooling

SLM insert choice at design phase

Size: 160 x 160 x 200

mm

REAL CASE n°4 : Insert for engine cover


Bad cooling area => - high cycletime - bad ejection

REAL CASE n°5 : Insert for automotive lighting housing


Rib thickness5.5mm

Cycle time reduction: 9 seconds

Warpage problem fullysolved

Standard insertreplaced by SLM insert

Size: 120 x 180 x 25

mm



Optimizedcooling

SLM insert chioce at design phase

Size: 80 x 30 x 70

mm



3D part with 4 Moldmax inserts on bosses (hot spots affecting cycle time)

3D part with conformal channelSLM inserts on critical bosses

REAL CASE n°7 : Two step element for Truck


102.9 s 109.7 s 91.9 s 105.4 s

Time to freeze Time to freeze

MoldMax

inserts



89.2 s 102.0 s 79.6 s 88.8 s-13.7s

- 7.5s -12.3s

-16.6s

Time to freeze Time to freeze

SLM in

serts



Cooling circuit aroundthe gate

REAL CASE n°8 : SLM inserts for gate conditioning 16 cavity mold


Documents

HRS - - SLM Cycle time Reduction