HRS - - SLM Cycle time Reduction
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Transcript of HRS - - SLM Cycle time Reduction
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Recoater
Laser beam
Collector bin
Dispenser
Part onprocess
SLM : How the Machine works
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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
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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
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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
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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
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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
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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
HYBRID BUILDSTYLE INSERT
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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
HYBRID BUILDSTYLE INSERT
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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
HYBRID BUILDSTYLE INSERT
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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
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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
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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
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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
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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
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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
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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
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1. Know how from:Mold design
Hot runner design
Molding process
MORE THAN 20 YEARS KNOW HOW IN MOLDMAKING AND TRY OUTS
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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
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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
TOOLS AND SKILLS FOR COOLING OPTIMIZATION
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4. SLM technology for inserts with conformal cooling channels
TOOLS AND SKILLS FOR COOLING OPTIMIZATION
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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
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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
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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
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Standard insert
Hot spot
Mold temperature
REAL CASE n°1 : Automotive air conditioning component
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SLM insert
Mold temperature
REAL CASE n°1 : Automotive air conditioning component
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Standard insert SLM insert
Cycle time reduction: 5
seconds
Standard insert replaced bySLM insert
Size: 230 x 230 x 50
mm
REAL CASE n°1 : Automotive air conditioning component
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Standard insert
Hot spot
Mold temperature
REAL CASE n°2 : Slide for Automotive Lens
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SLM insertMold temperature
REAL CASE n°2 : Slide for Automotive Lens
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Standard slide SLM slide
Warpageproblem fully
solved
Standard insertreplaced by SLM
insert
Size: 230 x 230 x
80 mm
REAL CASE n°2 : Slide for Automotive Lens
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Optimizedcooling
SLM insert choice at design phase
Size: 80 x 60 x 210
mm
REAL CASE n°3 : Insert for air conditioning component
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Optimizedcooling
SLM insert choice at design phase
Size: 160 x 160 x 200
mm
REAL CASE n°4 : Insert for engine cover
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Bad cooling area => - high cycletime - bad ejection
REAL CASE n°5 : Insert for automotive lighting housing
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Rib thickness5.5mm
Cycle time reduction: 9 seconds
Warpage problem fullysolved
Standard insertreplaced by SLM insert
Size: 120 x 180 x 25
mm
REAL CASE n°5 : Insert for automotive lighting housing
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Optimizedcooling
SLM insert chioce at design phase
Size: 80 x 30 x 70
mm
REAL CASE n°6 : Insert for automotive lighting housing
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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
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102.9 s 109.7 s 91.9 s 105.4 s
Time to freeze Time to freeze
MoldMax
inserts
REAL CASE n°7 : Two step element for Truck
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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
REAL CASE n°7 : Two step element for Truck
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Cooling circuit aroundthe gate
REAL CASE n°8 : SLM inserts for gate conditioning 16 cavity mold
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