marco andreetta product marketing analyst
TRANSCRIPT
Marco AndreettaProduct Marketing Analyst
LMF technology for the tooling industryA case study
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Additive manufacturing – Advantages for Tooling
Additive manufacturing advantages for the tooling business
Cycle time reduction
Warpage reduction
Defects reduction
Str
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Additive manufacturing – Advantages for Tooling
Cycle time reduction
. Cooling is the most critical cycle time phase
. Cycle time reduction can be achieved with conformal cooling
. Conformal cooling is possible only with additive manufacturing technologies
Str
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Additive manufacturing – Advantages for Tooling
Warpagereduction
. There is a strive for strict tolerances in technical parts, and it is not always easy to maintain this kind of performances
. Conformal cooling can lead to:- scrap rate reduction- freedom of geometry in plastic part design
Str
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Str
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Additive manufacturing – Advantages for Tooling
Defectsreduction
. New trends in plastic processing can lead to difficulties in plastic processing and overheating metal replacement and
technical polimers, recycled plastic
Common defects that can be solved with good cooling are- Whitening- Sink marks
Str
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Case Study
Str
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Str
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Case Study
Suspension Blockautomotive componentCycle time reduction through conformal cooling
Str
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Suspension block – Case Study
Plastic product: Suspension Block
. Material: POM
. Part Weight: 150 gr
. Simple part with very high wall thickness
. Disposable but very important to keep the car safe during transport
Since the part will be
uninstalled before the car delivery it is crucial to reduce the production costs as much as possible.
Str
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Suspension block – Case Study
POM Sample Cycle time
. Material: POM
. Gate temperature: 225°C
. Mould temperature: 25°C
. Cooling time is a big part of the cycle time
Open mold
14%
Filling
5%
Hold time
33%
Cooling time
48%
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Suspension block – Case Study
Suspension Block Cycle time
. Wall thickness over 5mm
. Cycle time is 65’’
. Cooling time is 52’’
even small improvement in cooling time can have a huge impact on cycle time
Open mold
8% Filling
1%
Hold time
11%
Cooling time
80%
Str
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Suspension block – Case Study
Solution: Conformal Cooling
. Two different cooling channels
. Parallel cooling to lower pressure losses
. Co-design with the customer engineering department to ensure feasibility of the part
. Cooling time is a big part of the cycle time and it can be addressed with proper cooling
Str
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Suspension block – Case Study
Solution: Integration with existing mould
. Additive manufacturing is a slow process
To minimize costs only a
tool insert is built
. Cooling connection with the standard mould can be done with o-rings
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Suspension block – Case Study
Construction report: Time and material used
. 1.2709 maraging steel
. Dimension Ø97x45mm
. Layer thickness 20µm
. Integral building strategy
. Aging to reach more than 50 Hrc
. Construction time: 45 hours per part
Str
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Suspension block – Case Study
Construction report: Milling the existing mold base
Mould base cavity milling for the tool insert
The tool insert is
fixed to the mold base with metric threads
and cooling channels are connected trough o-rings.
Str
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Suspension block – Case Study
Construction report: Milling the existing mold
Milling the cavities for tool insert can be used as a strategy to adapt to future changes in plastic part geometry without reworking the mould.
Str
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Suspension block – Case Study
Construction report: Finishing the tool insert
Special care needs to be taken when dealing with conformal cooling.
Wisely, the customer decided to machine threads with EDM to close the cooling channels inlets and outlets with plugs during the machining operation.
Str
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Suspension block – Case Study
Construction report: Finishing the tool insert
Contour Milling
Bottom surface milling
Top, contour and injection channel milling
Additive manufactured tool inserts require less machining than traditional parts because the stock material is constant and CAD defined.
Str
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Suspension block – Case Study
Construction report: Final steps: EDM and adjustment
EDM electrode can be re-used from the previous mold
Thanks to the stock material uniformity, EDM roughing can be avoided. Only the finishing phase is done, with machining time reduction.
The end results is comparable to traditional steel but with the added benefits of conformal cooling.
Str
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Suspension block – Case Study
Plastic Injection Moldflow Simulation
Moldflow simulation has been performed by Prisma Tech, an Autodesk Gold Partner with huge experience in simulation.
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Suspension block – Case Study
Plastic Injection Moldflow Simulation
The simulation proved that the traditional cycle time of 65’ is already very short:
Most of the plastic in the core is still liquid at the ejection time.
This could cause heat shrink porosity in the center of the part and reduce the mechanical properties.
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Suspension block – Case Study
Conformal Cooling Traditional Cooling
45’ 45’55’ 55’65’ 65’
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Suspension block – Case Study
Conformal Cooling Traditional Cooling
45’ 65’
Str
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Suspension block – Case Study
Plastic Injection: Moldflow results
. Traditional Cycle time: 65’’
. Conformal Cycle time: 45’’
. Cycle time reduction
30%
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Suspension block – Case Study
Additive manufacturingCost calculation
Conformal cooling designFile preparationMachine setupAdditive constructionUnpackingAging
Manufacturing costs (2 parts) 3700€
Str
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onfidential. S
ism
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Suspension block – Case Study
Traditional FinishingCost calculation
File preparation (CAM)Machine setupMillingEdmManual finishing
Finishing costs (2 parts) 1850€
Str
ictly c
onfidential. S
ism
a S
pA r
eserv
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Suspension block – Case Study
Mold adaptationCost calculation
Mold redesignDrillingMillingManual finishing
Mold reworking costs 550€
Str
ictly c
onfidential. S
ism
a S
pA r
eserv
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of use a
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Suspension block – Case Study
Break Even Point:
Standard ConformalCycle time 65’ 45’Mold 8000€ 14100€*Injection cost 1,43€ 1,1€(plastic+injection time)
Plastic product value
15000 parts 1,97€ 2,00€30000 parts 1,70€ 1,55€ (-8%)100000 parts 1,51€ 1,24€ (-17%)
*we added all the additive manufacturing related costs to the standard mold.
Str
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onfidential. S
ism
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eserv
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Suspension block – Case Study
Standard Conformal
15000 parts 1,97€ 2,00€ +1.5%Days for production1 shift 39 days 27 days - 12 days3 shifts 13 9 - 4
30000 parts 1,70€ 1,55€ - 8%Days for production1 shift 78 days 54 days - 24 days3 shifts 26 18 - 8
100000 parts 1,51€ 1,24€ -17%Days for production1 shift 259 days 179 days - 80 days3 shifts 84 58 - 26
Str
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onfidential. S
ism
a S
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eserv
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of use a
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.P.R
., a
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onfidential. S
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pA r
eserv
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ll r
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Sisma – Machines
MYSINT
Str
ictly c
onfidential. S
ism
a S
pA r
eserv
es a
ll r
ights
of use a
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isposal, u
nder
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Sisma – Machines
Machine used: MYSINT100 DUAL
. LMF (Laser Metal Fusion Technology)
. Building envelope Ø100x100mm
. Dual laser (2x200W) to increase productivity in industrial application
. Fastest coating time on the market (patented coating system)
Str
ictly c
onfidential. S
ism
a S
pA r
eserv
es a
ll r
ights
of use a
nd d
isposal, u
nder
the p
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f th
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, als
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.P.R
., a
s w
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Str
ictly c
onfidential. S
ism
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pA r
eserv
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ll r
ights
of use a
nd d
isposal, u
nder
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.P.R
., a
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Sisma – Machines
Why choose SismaMYSINT systems:
Open systemEvery processing and preparation
parameter can be changed by the user
High performanceHigh building rate and Clean operation
Low consumptionof inert gas and power
Antonio VeneziaIndustry Head of Sales
1961Sisma establishment
1967First production plantin via Piemonte, Schio
1976Beginning of
Jewellery machines production
1978Second production plantin via Lombardia, Schio
2001Beginning of
Laser production
2012Sisma HQ and production plantin Piovene Rocchette
2016Additive
manufacturing production plant in
Schio
Sisma, a journey of growth over more than fifty years
2011Beginning ofLaser Metal Fusionproduction
Sisma in the world
HEADQUARTERSITALY
SISMA ESPAÑABARCELONA
SISMA MEAISTANBUL
SISMA MEXICOMEXICO CITY
SISMA GMBHSTUTTGART
SISMA USANEW JERSEY
Innovation, research and development: internal laboratory at Sisma HQs
High precision manufacturing solutions: machinery & laser systems
Marco [email protected]
Antonio [email protected]
Str
ictly c
onfidential. S
ism
a S
pA r
eserv
es a
ll r
ights
of use a
nd d
isposal, u
nder
the p
rote
ction o
f th
e law
, als
o in c
onnection
with I
.P.R
., a
s w
ell a
s c
opyin
g a
nd p
assin
g to t
hird p
art
ies.
Sisma S.p.A.
Via dell’Industria, 1 - 36013 Piovene Rocchette (VI) [email protected] – sisma.com