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Conventional methods and materials to produce forming tools result in certain disadvantages: Not only the production process takes too much time, but also the whole process is expensive. One of the main factors affecting the cost of the metal forming process is tool costs.
PRODUCTION TOOL SERIES
For instance, metal forming is known to be economical for large series production. The increasing number of variant types and also the decreasing number of the same parts affect the manufacturing processes deeply. In all industries, customized and tailored design is gaining importance, and therefore small series production has increased in the last decade. Design of deep drawing tools produced by rapid tooling technologies RapidSteel, however, needs finishing and polishing that can take time scheme of the SLS process can be seen in Figure 3. The technique enables complicated geometries, and molds from RapidSteel can resist injection molding circumstances. Hundreds of aluminum, zinc, and magnesium components were casted using RapidSteel molds. The technique generates a durable mold that can be used as well as die-casting apps for injection mold tooling. Then the inserts are completed, drilled for ejector pins, and fitted to the base of the mold. This method generates a completely thick tool consisting of approximately 60% steel and 40% bronze. The furnace removes the polymer binder and by capillary action infiltrates bronze into the inserts of the mold. The Sinterstation generates green components that fire in a furnace afterwards. This material comprises of mild stainless-steel particles that are covered with a thin layer of a material for a polymer binder. Digital core and cavity geometry models are developed and sent to a Sinterstation manufacturing device in RapidSteel powder with DTM’s RapidSteel (also known as RapidTool, earlier similar methods are known as Indirect Metal Selective Laser Sintering). Just as a cavity can be produced directly by stereolithography, the laser sintering method can also be used to construct tool cavities directly. Also, SLA models were tried process of the spray metal tooling depicted in Figure 2. In addition to them, a reflective coating could be protective. In this technique, the material consisting of pattern must have increased strength and durability to withstand the thermal impact inherent: in this regard, the use of ABS FDM masters, polycarbonate SLS masters, and machinable wax gave positive results some of the indirect methods which uses AM, and their advantages and disadvantages are shown in Table 2. The process of spraying with, for example, an electrical compressed air gun gets applied until the required shell thickness is met (0.5 mm + − mm is reported). The order of steps is like the one applied to manufacture epoxy molds, with the exception that the pattern is sprayed first with metal and then supported by epoxy resin filled with metal. Currently, the improvements in spray metals and spraying methods give rise to its use in injection molding. Metal spray molds had been used effectively in low-pressure procedures including RIM, vacuum forming, and rotational molding. The comparison of numerical prediction and experimental results are shown to be in good agreement.
PRODUCTION TOOL VERIFICATION
Finally, a methodology to identify the tool life will be suggested, and its validation and verification on a simplified deep drawing geometry will be depicted. Also, most important points will be highlighted to select the most appropriate tool material and manufacturing method. Following that, on an example of metal forming tools, different materials coupled with different additive production techniques will be compared. The advantages as well as disadvantages will be discussed. In this chapter, first, an overview on the additive technologies to produces tools, also called rapid tooling, will be given. With the advances in additive manufacturing (AM) technologies, tools can be produced efficiently in short lead times and costs with additive manufacturing. The production of these special tools becomes one of the most important costs for the production process. Precision shut-off clutch with Cmk > 1.In the last decade, customized design and small series production gained importance in various industries. In assembly situations where cables or pneumatic hoses get in the way, the EXACT ION series enables you to optimize processes, build better products and reduce your costs.Īdvantages resulting from product features: The EXACT ION and ANGLE EXACT ION tools from Bosch are cordless shut-off screwdrivers for industry – offering the greatest accuracy, longevity and energy efficiency.