Applications of laser assisted metal rapid tooling process to manufacture of molding & forming tools - state of the art

International Journal of Precision Engineering and Manufacturing

Volumn 12, Issue 5, 2011, Pages 925-938

  Ahn, Dong Gyu ^a  

^a Chosun University   (South Korea)

Author keywords

Eco friendly tools; Green manufacturing; Laser assisted metal rapid tooling; Molding Forming tools

Indexed keywords

EID: 80355139150     PISSN: 12298557     EISSN: None     Source Type: Journal    
DOI: 10.1007/s12541-011-0125-5     Document Type: Article

References (91)

1. Levy, G. N., Schindel, R. and Kruth, J. P., "Rapid Manufacturing and Rapid Tooling with Layer Manufacturing (LM) Technologies, State of the Art and Future Perspectives," Annals of CIRP-Manuf. Technol., Vol. 52, No. 2, pp. 589-609, 2003.
2. Wohlers T. T., "Wohlers Report 2007: Rapid Prototyping & Manufacturing - State of the Industry Annual Worldwide Progress Report," Wholer's Associates, 2007.
3. 3D Systems, http://www.3dsystems.com/products/sls/index.asp
4. EOS GmbH, http://www.eos.info/en/home.html
5. SLM Solutions GmbH, http://www.slm-solutions.com/
6. Peng, L., Shengqin, J., Xiaoyan, Z., Qianwu, H. and Weihao, X., "Direct Laser Fabrication of Thin-walled Metal Parts under Open-loop Control," Int. J. Mach. Tools Manuf., Vol. 47, No. 6, pp. 996-1002, 2007.
7. Optomec, http://www.optomec.com//Additive-Manufacturing-Technology/Laser-Additive -Manufacturing
8. POM Group, http://www.pomgroup.com/
9. InssTek Inc., http://www.insstek.com/
10. Kruth, J. P., Levy, G., Klocke, F. and Childs, T. H. C., "Consolidation Phenomena in Laser and Powder-bed Based Layered Manufacturing," Annals of CIRP-Manuf. Technol., Vol. 56, No. 2, pp. 730-759, 2007.
11. Morrow, M. R., Qi, H, Kim, I., Mazumder, J. and Skerlos, S. J., "Environmental Aspects of Laser-based and Conventional Tool and Die Manufacturing," J. Clean Prod., Vol. 15, No. 10, pp. 932-943, 2005.
12. Simchi, A., Petzoldt, F. and Pohl, H., "On the Development of Direct Metal Laser Sintering for Rapid Tooling," J. Mater. Process, Technol., Vol. 141, No. 3, pp. 319-328, 2003.
13. Osakada, K. and Shiomi, M., "Flexible Manufacturing of Metallic Products by Selective Laser Melting of Power," Int. J. Mach. Tools Manuf., Vol. 46, No. 11, pp. 1188-1193, 2006.
14. Jee, H. S. and Suh, J. H., "Laser-aided Direct Metal Deposition (DMD) Technology," Transactions of the Society of CAD/CAM Engineers, Vol. 8, No. 3, pp. 150-156, 2003.
15. Chua, C. K., Teh, S. H. and Gay, R. K. L., "Rapid Prototyping Versus Virtual Prototyping in Product Design and Manufacturing," Int. J. Adv. Manuf. Technol., Vol. 15, No. 8, pp. 597-603, 1999.
16. Karapatis, N. P., van Griethuysen, J. P. S. and Glardon, R., "Direct Rapid Tooling: a Review of Current Research," Rapid Prototyping J., Vol. 4, No. 2, pp. 77-89, 1998.
17. Rosochowski, A. and Matuszak, A., "Rapid Tooling: the State of the Art," J. Mater. Process. Technol., Vol. 106, No. 1-3, pp. 191-198, 2000.
18. Yang, D. Y., Ahn, D. G., Lee, C. H., Park, C. H. and Kim, T. J., "Integration of CAD/CAM/CAE/RP for the Development of Metal Forming Process," J. Mater. Process. Technol., Vol. 125-126, No. 9, pp. 26-34, 2002.
19. Nowotny, S., Scharek, S., Beyer, E. and Richter, K. H., "Laser Beam Build-up Welding: Precision in Repair, Surface Cladding, and Direct 3D Metal Deposition," J. Thermal Spray Technol., Vol. 16, No. 3, pp. 344-348, 2007.
20. Shin, K. H., Natu, H., Dutta, D. and Mazumder, J., "A Method for the Design and Fabrication of Heterogeneous Objects," Mater. Des., Vol. 24, No. 5, pp. 339-353, 2003.
21. Jiang, W. and Molian, P., "Laser Based Flexible Fabrication of Functionally Graded Mould Inserts," Int. J. Adv. Manuf. Technol., Vol. 19, No. 9, pp. 646-654, 2002.
22. Smurov, I., "Laser Cladding and Laser Assisted Direct Manufacturing," Surf. Coat. Technol., Vol. 202, No. 18, pp. 4496-4502, 2008.
23. Ahn, D. G. and Park, S. H., "Manufacturing Technology of Injection Mold with a High Cooling Rate Using DMT Rapid Prototyping Process," Proc. of KSPE Autumn Conference, pp. 17-18, 2006.
24. Kar, N. J. and Calif, W., "Process for Laser Hardfacing Drill Bit Cones Having Hard Cutter Inserts," US Patent No. 4781770, 1988.
25. Sexton, C. L., "Application for Repair and Remanufacturing of Engineering Components Laser Cladding," http://www.laserage.ie/files/papers/Laser%20Cladding%20of%20Engineering% 20Components.pdf
26. Mihelcic, J. R., Crittenden, J. C., Small, M. J., Shonnard, D. R., Hokanson, D. R., Zhang, Q., Chen, H., Sorby, S. A., James, V. U., Sutherland, J. W. and Schnoor, J. L., "Sustainability Science and Engineering: The Emergence of New Metadiscipline," Environ. Sci. Technol., Vol. 37, No. 23, pp. 5314-5324, 2003.
27. Gutowski, T., Murphy, C., Allen, D., Bauer, D., Bras, B., Piwonka, T., Sheng, P., Sutherland, J., Thurston, D. and Wolff, E., "Environmentally Benign Manufacturing: Observations from Japan, Europe and the United States," J. Clean Prod., Vol. 13, No. 1, pp. 1-17, 2005.
28. Sreenivasn, R., Goel, A. and Bourell, D. L., "Sustainability Issues in Laser-based Additive Manufacturing," Physics Procedia, Vol. 5, Part A, pp. 81-90, 2010.
29. Chang, Y. J., "Evaluation of the Productivity and Environmental Effects of Laser Aided Direct Metal Deposition Process for Remanufacturing," Clean Technology, Vol. 13, No. 3, pp. 228-234, 2007.
30. th International Conference on Numerical Method in Industrial Forming Process, pp. 185-191, 2010.
31. Simchi, A., Petzoldt, F. and Pohl, H., "On the Development of Direct Metal Laser Sintering for Rapid Tooling," J. Mater. Process. Technol., Vol. 141, No. 1-3, pp. 319-328, 2003.
32. Shi, D. and Gibson, I., "Improving Surface Quality of Selective Laser Sintered Rapid Prototype Part Using Robotic Finishing," Proc. IMechE Part B: J. Engng. Manuf., Vol. 214, No. 3, pp. 197-203, 2000.
33. Jeng, J. Y. and Lin, M. C., "Mold Fabrication and Modification Using Hybrid Processes of Selective Laser Cladding and Milling," J. Mater. Process. Technol., Vol. 110, No. 1, pp. 98-103, 2001
34. Mognol, P., Jegou, L., Rivette, M. and Furet, B., "High Speed Milling, Electro Discharge Machining and Direct Metal Laser Sintering: A Method to Optimize These Processes in Hybrid Rapid Tooling," Int. J. Adv. Manuf. Technol., Vol. 29, No. 1-2, pp. 35-40, 2006.
35. Ahn, D. G., Lee, S. H., Kim, M. S., Han, G. S., Kim, J. S., Moon, H. S. and Yoon, Y. S., "Investigation into the Development of Deep Drawing Tools with Small Size for Electronic Parts Utilizing the CAE and RP/RT Technology," Proc. of KSPE Autumn Conference, pp. 334-337, 2005.
36. Kolleck, R., Pfanner, S. and Warnke, E. P., "Development of Cooled Tools for Press Hardening of Boron Steel Sheet," Key Engng. Mater., Vol. 344, pp. 225-232, 2007.
37. Nakamoto, T., Shirakawa, N., Ueda, N., Miyata, Y. and Sone, T., "Plasma Nitriding to Selective Laser Sintering Parts Made of SCM430 Powder," Surf. Coat. Technol., Vol. 202, No. 22-23, pp. 5484-5487, 2008.
38. TM)," Proc. of the Solid Freeform Fabrication Symposium, pp. 125-131, 1996.
39. Mazumder, J., Choi, J., Nagarathnam, K., Koch, J. and Hetzner, D., "The Direct Metal Deposition of H13 Tool Steel for 3-D Components," JOM, Vol. 49, No. 5, pp. 55-60, 1999.
40. Abe, F., Osakada, K., Shiomi, M., Uematsu, K. and Matsumoto, M., "The Manufacturing of Hard Tools from Metallic Powders by Selective Laser Melting," J. Mater. Process. Technol., Vol. 111, No. 1-3, pp. 210-213, 2001.
41. Ahn, D. G. and Kim, H. W., "Study on the Manufacture of a Thermal Management Mould with Three Different Materials Using a Direct Metal Tooling Rapid Tooling Process," Proc. IMechE Part B: J. Engng. Manuf., Vol. 224, No. 3, pp. 385-402, 2010.
42. Mognol, L., Rivette, M., Jegou, P. and Lesprier, T., "A First Approach to Choose between HSM, EDM, and DMLS Processes in Hybrid Rapid Tooling," Rapid Prototyping J., Vol. 13, No. 1, pp. 7-16, 2007.
43. Subburaj, K. and Ravi, B., "Computer Aided Rapid Tooling Process Selection and Manufacturability Evaluation for Injection Mold Development," Comput. Ind., Vol. 59, No. 2-3, pp. 262-276, 2008.
44. Mohammed, J., "Manufacturing Die Casting Molds via Direct Metal Deposition (DMD)," SME Technical Paper, TP07PUB70, pp. 1-7, 2007.
45. Lin, Z. C. and Chou, M. H., "Design of the Cooling Channels in Nonrectangular Plastic Flat Injection Mold," J. Mfg. Systs., Vol. 21, No. 3, pp. 167-186, 2002.
46. Tang, L. Q., Chassapis, C. and Manoochehri, S., "Optimal Cooling System Design for Multi-cavity Injection Molding," Finite Elements in Analysis and Design, Vol. 26, No. 3, pp. 229-251, 1997.
47. Hopkinson, N. and Dickens P., "Conformal Cooling and Heating Channels Using Laser Sintered Tools," Proc. of the Solid Freeform Fabrication Symposium, pp. 490-497, 2000.
48. Mazumder, J., Dutta, D., Kikuchi, N. and Ghosh, A., "Closed Loop Direct Metal Deposition: Art to Part," Opt. Lasers Eng., Vol. 34, No. 4-6, pp. 397-414, 2000.
49. Dimla, D. E., Camilotto, M. and Miani, F., "Design and Optimisation of Conformal Cooling Channels in Injection Moulding Tools," J. Mater. Process. Technol., Vol. 164-165, No. 15, pp. 1294-1300, 2005.
50. Behalek, L. and Dobransky, J., "Process of Cooling Injection Mould and Quality of Injection Parts," Acta Technica Corviniensis - Bulletin of Engineering, Tome II, Fascicule 3, pp. 19-24, 2009.
51. Knights, M., "Rapid Tooling: It's Faster in Molding, Too," Plastic Technology Online Article, 2005. http://www.ptonline.com/articles/rapid-tooling-its-faster-in-moldi ng-too
52. Jacobs, P. F., "New Frontiers in Mold Construction: High Conductivity Materials & Conformal Cooling Channels. Rapid Prototyping, Rapid Tooling, and Solid Freeform Fabrication for the Next Millennium," ASME-Publications-MED, Vol. 11, pp. 389-396, 2000.
53. Beaman, J. J., Atwood, C., Bergman, T. L., Bourell, D., Hollister, S. and Rosen, D., "WTEC Panel Report on Additive/Subtractive Manufacturing Research and Development in Europe," World Technology Evaluation Center, Panel Report, pp. 63-75, 2004.
54. Timothy Ruffner, http://www.engineeringexchange.com/profiles/blogs/conformal-cooling-usin g-dmls
55. Sanjay, K. and Sisa, P., "Laser-based Additive Manufacturing of Metals," Advanced Materials Research, Vol. 227, pp. 92-95, 2011.
56. Ahn, D. G., Kim, H. W. and Lee, K. Y., "Design of the Thermally Conductive Mould to Improve Cooling Characteristics of Injection Mould for a Mouse," Transactions of the Korean Society of Mechanical Engineers-A, Vol. 33, No. 3, pp. 201-209, 2009.
57. Park, S. J. and Kwon, T. H., "Optimal Cooling System Design for the Injection Molding Process," Polym. Engng. Sic., Vol. 38, No. 9, pp. 1450-1462, 1998.
58. Au, K. M. and Yu, K. M., "A Scaffolding Architecture for Conformal Cooling Design in Rapid Plastic Injection Moulding," Int. J. Adv. Manuf. Technol., Vol. 34, No. 5-6, pp. 496-515, 2007.
59. Ahn, D. G., Park, S. H. and Kim, H. S., "Manufacture of an Injection Mould with Rapid and Uniform Cooling Characteristics for the Fan Parts Using a DMT Process," Int. J. Precis. Eng. Manuf., Vol. 11, No. 6, pp. 915-924, 2010.
60. Ahn, D. G., Park, M. W., Park, S. W. and Kim, H. S., "Design of the Conformal Cooling Channels for the Mould of a Plastic Drawer of Refrigerator by Analysis of Three-Dimensional Injection Moulding," Transactions of the Korean Society of Mechanical Engineers-A, Vol. 34, No. 10, pp. 1487-1492, 2010.
61. Kim, H. S., Lee, K. Y., Suh, J. H. and Ahn, D. G., "Final Report on Strategy Project of Development of Leading Innovation Technology for Medium and Small Industries - Manufacture and Evaluation of the Injection Mould Incorporating Conformal Cooling Channels Using DMF Technologies," Woosung Inc., Final Project Report, 2010.
62. Ferreira, J. C. and Mateus, A., "Studies of Rapid Soft Tooling with Conformal Cooling Channels for Plastic Injection Moulding," J. Mater. Process. Technol., Vol. 142, No. 2, pp. 508-516, 2003.
63. Mayer, S., "Optimised Mould Temperature Control Procedure Using DMLS," EOS Whitepaper, EOS GmbH Ltd., pp. 1-10, 2005.(http://www.eos.info/uploads/media/EOS_WP_DMLS2_ENG_12.pdf)
64. Dalgarno, K. W. and Stewart, T. D., "Manufacture of Production Injection Mould Tooling Incorporating Conformal Cooling Channels via Indirect Selective Laser Sintering," Proc. of IMechE Part B: J. Engng. Manuf., Vol. 215, No. 10, pp. 1323-1332, 2001.
65. Ilyas, I., Taylor, C., Dalgarno, K. and Gosden, J., "Design and Manufacture of Injection Mould Tool Inserts Produced Using Indirect SLS and Machining Processes," Rapid Prototyping J., Vol. 16, No. 6, pp. 429-440, 2010.
66. Park, H. P., Cha, B. S., Lee, S. Y., Kim, O. R., Kim, Y. G. and Kwon, C. O., "Production of Pre-form Mould by Direct Metal Laser Sintering (DMLS) Process," Proc. of 2006 KSPE Autumn Conference, pp. 193-194, 2006.
67. MTT Technology Group, http://www.renishaw.com/mtt-group/us/selective-laser-melting.html
68. INglass-HRS Flow, http://www.inglass.it/
69. Fraunhofer ILT, http://www.ilt.fraunhofer.de/eng/101937.html
70. Plastic Technology, "Hot-Runner Mold Inserts Offer Cooling Enhancement," 2008. http://www.ptonline.com/products/hot-runner-mold-inserts-offer-cooling-e nhancement
71. MoldMaking Technology, "DMD Conformal Mold Cooling Lines Offer Reduced Part Production Cycle Times," 2008. http://www.moldmakingtechnology.com/columns/dmd-conformal-mold-cooling-l ines-offer-reduced-part-production-cycle-times
72. Ahn, D. G., Park, M. W. and Kim, H. S., "Design of Cooling System for Multi-Sliced Mould with Volumetric Heat Skin via Three-Dimensional Injection Moulding Analysis," Proc. of KSPE Autumn Conference, pp. 883-884, 2010.
73. Beal, V. E., Erasenthiran, P., Ahrens, C. H. and Dickens, P., "Evaluating the Use of Functionally Graded Materials Inserts Produced by Selective Laser Melting on the Injection Moulding of Plastics Parts," Proc. of IMechE Part B: J. Engng. Manuf., Vol. 221, No. 6, pp. 945-954, 2017.
74. Menges, G., Michaeli, W. and Mohren, P., "How to Make Injection Molds, Third Edition," HANSER, pp. 12-18, 2001.
75. Fraunhofer Institute of Laser Technology, "Components made from copper powder open up new opportunities," 2011. http://www.ilt.fraunhofer.de/eng/ilt/pdf/eng/press/PR_SLM-of-CopperAlloy s.pdf
76. Photonics.com, "Selective Laser Melting Used on Copper," 2011. http://www.photonics.com/Article.aspx?AID=46066
77. The Engineering ToolBox, "Thermal Conductivity of Metals," http://www.engineeringtoolbox.com/thermal-conductivity-metals-d_858.html
78. Mazumder, J., Schifferer, A. and Choi, J., "Direct Materials Deposition: Designed Macro and Microstructures," Mat. Res. Innovat., Vol. 3, No. 3, pp. 118-131, 1999.
79. Szszek, T., "Laser Deposition for Improved AHSS Die Ware," Presentations of Great Designs in Steel 2003 Seminar, POM Group Inc., 2003. http://www.a-spdev.com/AM/Template.cfm?Section=A_SP_Home&TEMPLATE=/C M/HTMLDisplay.cfm&CONTENTID=10151
80. Waerman, P. J., "Direct Metal Comes on Strong-Metal Parts and Tooling Take the Spotlight in the Additive Processing World," DE, 2005. http://www.deskeng.com/articles/aaabdh.htm
81. th ICTP, pp. 999-1004, 1999.
82. th European Conference on Rapid Prototyping and Manufacturing, pp. 163-172, 2000.
83. Muller, D. H. and Muller, H., "Experiences Using Rapid Prototyping Techniques to Manufacture Sheet Metal Forming Tools," Proc. of ISATA 2000, pp. 1-9, 2000.
84. Levy, G. N., "Overview of Layer Manufacturing Technologies, Opportunities, Options and Applications for Rapid Tooling," Proc. of IMechE Part B: J. Engng. Manuf., Vol. 216, Special Issue, pp. 1621-1634, 2002.
85. Cheah, C. M., Chua, C. K., Lee, C. W., Lim, S. T., Eu, K. H. and Lin, L. T., "Rapid Sheet Metal Manufacturing. Part 2: Direct Rapid Tooling," Int. J. Adv. Manuf. Technol., Vol. 19, No. 7, pp. 510-515, 2002.
86. Baptista, R., Silva, M. B. and Saraiva, C., "Developments for Rapid Tooling Application in Sheet Metal Forming," Advanced Materials Forum, Vol. 514-516, pp. 1516-1520, 2006.
87. POM Group Inc., "Tooling Reconfiguration Process," http://pomgroup.com/images/stories/NuTool.pdf
88. POM Group Inc., "Surface Hardfacing," http://www.pomgroup.com/index.php?Itemid=98&id=32&option=com_con tent&task=view
89. TWI, "Laser Additive Manufacturing," http://www.twi.co.uk/content/dmd_lasertwi.html
90. Ahn, D. G., Kim, S. H., Lee, S. Y. and Lee, C. H., "Wear Characteristics of Hardfaced Surface via Rapid Tooling Process," Proc. of Spring Annual Meeting for Design and Manufacturing Sector, pp. 116-117, 2010.
91. POM Group Inc., "Tooling Repair Process," http://pomgroup.com/images/stories/ToolRX.pdf