PECASE: Rapid Tooling with Laminated Dies and Molds

由层压结构制成的金属工具提供了优于由更传统的方法（例如，CNC加工）在工具可达性、减少模具几何形状限制、使用硬工具材料更快制造、更容易结合传感器进行过程控制以及使用保形冷却通道更灵活方面的优势。 这个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。 一旦确定了所有的工具要求，将开发夹紧和粘接层压工具的结构/热模型，并进行实验验证。 该模型的目的是为模具设计者提供一种方法来预测受到各种载荷、压力和温度的层压模具的结构/热行为。 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模型来创建用于磨料水射流或激光切割叠层的运动学和动态期望的轨迹。 还将开发一种算法，用于基于工具的几何约束（例如，垂直壁）和/或制造工艺要求。 还将研究提高磨料水射流或激光切割层压斜边的精度和质量的方法。 最后，提供了用于将叠片接合到实心管芯中的方法（例如，用粘合剂）和使该过程自动化的方法将被开发和实验验证。 该项目的教育部分将加强和发展本科生和研究生课程的机械元件和系统的设计，包括快速模具，夹具和装配的考虑。 开发一套完整的设计工具、制造工艺、预测模型对快速模具的科学和技术基础至关重要。工业界可以利用这些案例研究来开发层压模具。 在美国工业中，层压模具的潜在扩散可以显著节省模具开发的成本和交付周期。

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.