Transcript Composite Tooling Technologies

Hybrid Tooling
Vs
P-20 Injection Molds
Benefits of Hybrid Tooling as alternative to low volume
production P-20 Steel tools or as an option to improve
quality of parts off low cost Prototype tooling.
01/13/2007
Hybrid vs P-20
Past Problems with AL Tooling
• Aluminum Production Methods (past issues)
– Block thickness limitations, especially with higher quality AL
– Inconsistent ‘through-thickness hardness’
• Tool Shop Machining with Aluminum (past issues)
– Previous or inferior grades of Aluminum would ‘gum up’ during machining
– Lack of experience with Hot Manifold ‘set pressures’ (leakage vs crush)
• Injection Molding Processing with Aluminum (past issues)
– Lack hot manifold use would result in higher mold pressures and higher
stress on low quality aluminums
– Excessive machine clamp pressure used from molder’s P-20 experience
too much and not necessary for AL molding applications
Hybrid vs P-20
Recent Solutions for AL Tooling
• Aluminum Production Methods (recent improvements)
– Very high quality AL is now available in block thickness of up to 24”
– More uniform ‘through-thickness hardness’
• Tool Shop Machining with Aluminum (recent improvements)
– High grades of AL (QC10, Alcamax, etc) have tight grain structure for outstanding
machinability with small chips, outstanding surface finish & very fast CNC
cutting speeds; This grain structure can be highly polished or textured
– Increased experience with Hot Manifold ‘set pressures’ (leakage vs crush)
• Injection Molding Processing with Aluminum (recent improvements)
– Frequent use of hot manifolds allow for reduced mold pressures & stress
– Increasing knowledge of reduced clamp pressure needs and
requirements for AL tooling combined with ability of new higher quality AL
to withstand more stress and/or use of Hybrid tooling applications
Hybrid vs P-20
Benefits of Hybrid-AL Tooling
• Tool Design & Construction with Hybrid-AL
– Position and number of water lines are less critical
– Allows for placement of additional ejector pins where needed
– Cutting speeds for AL are up to 10X’s faster than with P-20 steel
– Heavier cuts with larger step-overs are possible
– Stress Relief or Heat Treating not required
– AL lends itself to Hybrid tooling with steel supports or grown insert details
• Injection Molding Processing with Aluminum
– Faster tool pre-heat and set-up time in molding press
– Lighter molds (30-60%) are easier to move and less wear on equipment
– Better Thermal Conductivity for wider process window, faster cycle times
and improved part dimensional stability
Hybrid vs P-20
CAD of Hybrid Inserts to be
Grown for Tooling
Hybrid vs P-20
Hybrid Inserts used for Tooling & Parts
Hybrid vs P-20
Hybrid Part Made Without Tooling
Hybrid vs P-20
Hybrid Inserts Grown for Tooling
Hybrid vs P-20
Hybrid Inserts used in Tooling
Hybrid vs P-20
Hybrid Inserts used in Tooling
Hybrid vs P-20
Hybrid Inserts used in Prototype Tooling
Note: Hybrid tooling can also be used in low cost prototype tooling to increase tool
durability and give special consideration to particular tool/part features. (As shown above)
Hybrid vs P-20
Hybrid Inserts used in Production Tooling
Hybrid vs P-20
Steel Support Pillars for Hybrid-AL Tools
Example of steel support
pillars used around the
peripheral of tool cavity
to increase longevity.
• Reduces tool wear on parting line
• Reduces clamp load on tool surface
• Optional use of steel or grown inserts for lifters & slides
Hybrid vs P-20
Benefits of Hybrid-AL Tooling
• Hybrid-AL Tooling Benefits, what does it mean in the end?
– Lower tooling investment cost of 15-30% over P-20 steel tools
– Tool lead time improvement of 4-6 weeks over P-20 steel tools
– Thermal Conductivity improvement of 4-5 times over P-20 steel tools
• Wider processing window for more consistent parts
• Dimensional Stability of parts greatly improved over P-20 steel tools
• Faster Part Cycle Times provide $ savings as volumes increase
• Limitations with Hybrid-AL Tooling
– Higher volume part runs 250,000 pcs +, or Glass Filled resins
– Molding facility education & awareness with Hybrid-AL tool processing
– Cavity side welds (insert, weld, plate-coat or re-cut are available options)