can additive manufacturing revolutionize the tooling industry? · high temperature tooling for...
TRANSCRIPT
ORNL is managed by UT-Battelle
for the US Department of Energy
Can Additive Manufacturing Revolutionize the Tooling Industry?
Lonnie Love
Corporate Fellow
Oak Ridge National Laboratory
July 2017
Oak Ridge, Tennessee
2 MDF Overview, May 2014
Why should tooling industry consider additive?
Low volume, complex parts = TOOLING
3 MDF Overview, May 2014
Big Area Additive Manufacturing (BAAM)
Conventional AM• Small (< 1 cubic ft)
• Slow (< 5 ci/hr)
• Expensive (~$100/lb)
Big Area Additive Manufacturing• Large (> 1000 cubic ft)
• Fast (>2500 ci/hr)
• Inexpensive (<$5/lb)
4 MDF Overview, May 2014
Partnership withCRADA
ORNL and Cincinnati Incorporated collaborate to create commercial large-scale system
Partnership to establish US-based large-scale AM equipment manufacturer
• Targets tooling lead time and cost reduction
• Based on existing ORNL gantry system
• Cincinnati providing >$1M in cost share year one
– First large-scale polymer AM system delivered to MDF, April 2014
• Interest from multiple automotive, aerospace and tooling industries
• Stretch form and hydroform tools demonstrated
5 MDF Overview, May 2014
Rapid Prototyping
6 MDF Overview, May 2014
First attempt at Coatings
7 MDF Overview, May 2014
The Role of AM in Low Temp Composite ToolingVARTM – Vacuum Assisted Resin Transfer Molding
• Tool for hood took 4 hours to print, 4 hours to
machine, and 1 day to finish
– Total manufacturing time: 2 days
• Cost breakdown
– Materials: $500 (20% CF-ABS)
– Machining: $1,000
– Finishing: $2,000
• Pulled 10 parts; 0 degradation
Size 8’ x 20’ x 6’
Rate (mass) ~ 60 lb/hr
Rate (volume) ~ 2 ft3/hr (50% sparse)
Material Cost (mass) ~$4/lb or ~$250/ft3
Machine time ~ $250/hr
Cost/ft3 ~ $400/ft3
8 MDF Overview, May 2014
3D Printing Trim Tool for Boeing 777x
• A 3D printed trim-and-drill tool, developed by researchers at ORNL and evaluated at The Boeing Company,
received the title of the world’s largest solid 3D printed object by GUINNESS WORLD RECORDS™.
• The component will be used for setup prior to the production tool entering the industrial autoclave process
required for commercial aircraft parts.
• Channels within tool have been designed to use less material and meet stiffness and loading criteria.
9 MDF Overview, May 2014
Printed wind turbine mold with TPI
ORNL and collaborators worked
together to redesign and 3D print a
traditional wind turbine blade mold
in order to eliminate unnecessary
parts, procedures, time and labor
associated with conventional wind
turbine blade mold manufacturing
processes.
Using wind turbine blade molds from ORNL in order to fabricate wind turbine blades. Photo
courtesy of TPI Composites, Inc.
First wind turbine blade made from the
3D printed mold shown above.
10 MDF Overview, May 2014
High Temperature Tooling for Boeing/Navair
• Researchers at ORNL collaborated with 7 industry partners
to demonstrate the fabrication of 100% digitally
manufactured molds from high temperature thermoplastic
materials.
• Small-scale molds were testing in Boeing’s industrial
autoclave while mid-scale molds were tested in NAVAIR’s
industrial autoclave.
• High temperatures and pressures (350F, 90psi) achieved
during the autoclave curing process result in high quality
composite parts used in primary aircraft structures. The
tools can be reused to produce part replicates.
Example of 1 of the small-scale 3D printed molds tested in
Boeing’s industrial autoclave. This mold was printed in ~2 hours
and machined in ~4 hours.
Example of 1 of the mid-scale 3D printed molds tested
in NAVAIR’s industrial autoclave.
Results from laser scanner show
deformations less than 0.004” after 350F,
90psi autoclave cure cycle
Image of the 4 small-scale tools bagged and
ready to enter Boeing’s industrial autoclave
11 MDF Overview, May 2014
Compression Forming tool for Ford• Requirements:
– Up to 2000 psi, deflection on the range of 0.05 mm/300 mm in any direction
– 170 to 180 C Temperature
Printed part Finished partCompression form at Ford
Final Part
12 MDF Overview, May 2014
Casting Patterns for Emersys (1)
• Patterns for sand casting
– Use AM to print casting patterns
13 MDF Overview, May 2014
Casting Patterns for Emersys (2)
• Patterns for sand casting
– Use AM to print casting patterns
– 4 hours to print
– $400 material cost
– 4 hours finish machining
Parts in printer
Parts in printer
Machined partFinal pattern
Final part
14 MDF Overview, May 2014
Precast Concrete Patterns for Gates
• Precast cement patterns (9’ x 4’ x 1’)
– Conventional pattern hand manufactured from hardwood
• Cost approx. $10K per pattern and last 5 to 10 pours
– Additive Precast pattern
• Cost ~$6K per pattern
• Over 30 pours without sign of degradation
15 MDF Overview, May 2014
Where are we going?Large Scale Metal AM
• Robotic MIG arc welding
– Partnership with Lincoln Electric and Wolf Robotics
– Currently depositing ~8 lb steel/hr (target 100 lb/hr)
– Named Best New Technology at 2016 FABTECH
• Manufactured operational excavator boom with integrated hydraulics at 2017 CONEXPO/AGG
– 500 lbs, 7 ft x 2 ft x 1 ft
• Manufactured compression forming tool
– 10 hours to manufacture, $3/lb, 30 cm x 30 cm x 8 cm
– Near net shape with 1 mm finish cut
Composite AM Tool
• Temperature: Temperature (150 F)
• Dwell Time: 90 sec
• Pressure: 10 Tons (total 15 samples)
16 MDF Overview, May 2014
Is there interest in AM tooling consortium?
17 MDF Overview, May 2014
Lonnie Love
865.576.4630
Contact Us
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