PECASE: Rapid Tooling with Laminated Dies and Molds

与传统方法（如CNC加工）相比，由层压结构制成的金属模具在工具可及性、减少模具几何形状限制、使用硬工具材料更快地制造、更容易集成用于过程控制的传感器以及更灵活的保形冷却通道方面具有优势。本CAREER项目的研究目标是首先确定可以从层压模具结构中受益的各种制造工艺。一旦确定了所有工具要求，将开发夹紧和粘合层压工具的结构/热模型并进行实验验证。该模型的目的是为工具设计人员提供预测复合工具在各种载荷、压力和温度下的结构/热行为的方法。接下来，将开发一种有效的技术，用于基于工具的实体或表面CAD模型，为磨料水射流或激光切割薄片创建运动学和动态所需的轨迹。还将根据工具的几何约束（例如，垂直壁）和/或制造工艺要求，开发一种算法来改变层压厚度。本文还将探讨提高磨料水射流或激光切割层压斜边精度和质量的方法。最后，将开发和实验验证粘合层合成固体模具的方法（例如，用粘合剂）和自动化此过程的方法。该项目的教育部分将加强和发展机械元件和系统设计的本科和研究生课程，包括考虑快速工装，夹具和装配。开发一套完整的设计工具、制造程序、预测模型是快速模具的重要科学技术基础。工业界可以使用案例研究来开发层压模具。层压模具在美国工业中的潜在扩散可以大大节省模具开发的成本和交货时间。

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.