PECASE: Rapid Tooling with Laminated Dies and Molds

PECASE：使用层压模具进行快速加工

• 批准号: 9734231
• 负责人: Daniel Walczyk
• 金额: $ 50万
• 依托单位: Rensselaer Polytechnic Institute
• 依托单位国家: 美国
• 项目类别: Continuing Grant
• 财政年份: 1998
• 资助国家: 美国
• 起止时间: 1998-04-15 至 2003-02-28
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=9734231&HistoricalAwards=false
• 关键词: PECASE; Rapid; Tooling; Laminated; Dies

DMI-9734231 Walczyk Metal tooling made of a laminated construction offers advantages over tooling made by more conventional methods (e.g., CNC machining) in terms of tooling accessibility, reduced die geometry limitations, quicker fabrication with hard tool materials, easier incorporation of sensors for process control, and more flexibility with conformal cooling passages. The research objectives of this CAREER project are to first identify the various manufacturing processes that can benefit from a laminated tooling construction. Once all of the tooling requirements are established, a structural/thermal model for clamped and bonded laminated tools will be developed and experimentally verified. The aim of this model is to give a tooling designer the means to predict the structural/thermal behavior of a laminated tool subjected to various loads, pressures, and temperatures. Next, an efficient technique will be developed for creating kinematically and dynamically desirable trajectories for abrasive waterjet or laser cutting of laminations based on a solid or surface CAD model of the tool. An algorithm will also be developed for varying lamination thicknesses based on geometrical constraints of the tool (e.g., vertical walls) and/or manufacturing process requirements. Methods for improving the accuracy and quality of abrasive waterjet or laser-cut lamination beveled edges will also be investigated. Finally, methods for bonding laminations into a solid die (e.g., with adhesives) and ways of automating this procedure will be developed and experimentally verified. The education part of this project will be on enhancing and developing undergraduate and graduate courses in the design of mechanical elements and systems including the consideration of rapid tooling, fixturing and assembly. The development of a comprehensive set of design tools, fabrication procedures, predictive models is important to the science and technology base of rapid tooling. Industry can use the case studies to develop laminated tooling. The potential proliferation of laminated tooling within US industry can lead to significant savings in the cost and lead-time of tooling development.

由叠层结构制成的DMI-9734231 Walczyk金属模具在以下方面比更传统方法(例如，数控加工)制造的刀具具有优势：模具可访问性、减少模具几何限制、使用硬质刀具材料更快地制造、更容易地集成用于过程控制的传感器、以及更灵活的共形冷却通道。这个职业项目的研究目标是首先确定可以从叠层模具结构中受益的各种制造工艺。一旦确定了所有的工具要求，将开发用于夹紧和粘结的叠层工具的结构/热模型，并进行实验验证。该模型的目的是为模具设计者提供预测叠层刀具在各种载荷、压力和温度下的结构/热行为的方法。下一步，将开发一种有效的技术，用于基于刀具的实体或表面CAD模型来创建磨料水射流或激光切割薄片的运动学和动力学上所需的轨迹。还将开发基于工具(例如，垂直壁)的几何约束和/或制造工艺要求来改变层压厚度的算法。还将研究提高磨料水射流或激光切割层压斜面边缘的精度和质量的方法。最后，将开发将层压板粘合到固体模具中的方法(例如，使用粘合剂)以及使该过程自动化的方法，并进行实验验证。该项目的教育部分将加强和发展机械部件和系统设计方面的本科生和研究生课程，包括考虑快速模具、夹具和组装。开发一套全面的设计工具、制造过程和预测模型是快速模具科学技术基础的重要组成部分。行业可以利用案例研究来开发层压模具。叠层模具在美国行业内的潜在扩散可以显著节省模具开发的成本和交货期。