cnc milling of plugs and direct-machined mold tools ibex 2010 – session 303 september 29, 2010...
TRANSCRIPT
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CNC Milling of Plugs and Direct-Machined Mold Tools
IBEX 2010 – Session 303September 29, 2010Doug Blount – DLBA Robotics, Ltd.JP Schroeder – ATC Formulated Polymers, Inc.
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I. Introduction
•Plugs, Molds, and Limited Production Molds
•CNC Tooling Manufacturing Process•Limited Production Molds in Action•Limited Production Mold Options•Open Discussion
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II. Plugs and Molds
•Plugs, Patterns, and Master Patterns•Molds and Limited Production Molds
(LPMs)•Advantages and Disadvantages•LPM Materials •Manufacturing Times•General Cost Economics
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Plugs, Patterns, and Master Patterns•An exact replica of the final desired product
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Production Molds (Hard Tooling)•A cavity from which a substance is shaped
(Webster’s dictionary)
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Limited Production Molds (LPM)
•Mold Tooling in which only limited number of parts can be constructed
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Advantages / Disadvantages of Production Molds•Advantages
▫Durable – many parts may be produced▫Provides a Quality finish
•Disadvantages▫Expensive▫Requires a long time to manufacture▫Requires a Plug or Master Pattern▫Requires a skilled labor force▫Difficult to modify
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Advantages / Disadvantages of Limited Production Molds•Advantages
▫Provides a Quality finish▫Less expensive to manufacture▫Shorter lead time for the first production
part▫No Plug required
•Disadvantages▫Fewer parts produced▫Requires inside storage
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LPM Materials•Tooling Boards (Tooling Board, MDF, Foams)•Tooling Pastes or Compounds
▫Polyesters (Primary focus for this presentation)▫Epoxies ▫Polyurethanes
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LPM Materials: Polyester Compounds• The best cost/performance ratio• Applied with off the shelf equipment• Conventional MEKP catalyst• Application
▫Spray▫Extrude
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LPM Materials: Epoxy Compounds•Higher specifications than polyester compounds•Applied with dedicated & expensive equipment•Accepts conventional finish systems•Application
▫Extrude only
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LPM Materials: Urethane Compounds
• Applied with dedicated equipment• Need to manage worker exposure to uncured
material• Application
▫Extrude only
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LPM Materials: Application
•Spray▫Multiple thin layers▫Longer cycle on smaller parts▫Need to manage overspray
•Extrude▫Applied in one layer▫Requires attention to prevent air entrapment▫Best for smaller parts
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Relative Manufacturing Times for Production Molds•Produce the Plug (1 time unit)•Finish the Plug (0.5 time units)•Produce the Mold Tool from the Plug (1
time unit)
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Relative Manufacturing Time for Limited Production Mold (LPM)•Produce the LPM (1 time unit)•Finish the LPM (0.5 time units)
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General Cost Economics
•Plug ~ 1 cost unit•LPM ~ 1.25 cost units•Production Mold ~ 2.5 cost units
(including plug)
Cost Units
Number of parts being Produced
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The Tooling Compound•Tooling compound is an important consideration in
your economic and quality decision▫ Accounts for approximately 20% of the overall cost▫ A significant impact on the performance of the tool!
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III. CNC Tooling manufacturing Process•How does the process begin?
A Great Idea
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Plug / LPM Construction Plan
•Computer Surface Model•Base Structure•Low Density Layer•Glass shell•Tooling Resin•Surface Finishing
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Computer Models
•3-D Surface models of the Project▫Many formats are acceptable▫Designers can start with a sketch
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Base Structure•Supports the tool during shipping and
part production•Allows the tool to be moved safely•Necessary for Dimensional Stability
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Low Density Materials
•Typically Foam (Poly-Iso, Expanded PS, and Extruded PS are most common)
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Fiberglass Layer• Protects the foam by distributing the load• Improves adhesion between the foam and
tooling resin• Greatly aids in the de-molding process
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Tooling Compund is Applied
•Applied to the tool prior to the final machining
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Final Machining
•The tool is cut to match the original model
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Surface Finishing•The final Top Coat should be selected to best fit
the customer’s needs for his next step
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Part Inspection and Verification•Dimensions are checked against the
specifications
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Temperature•Best results are obtained when the tool is built under constant temperature and humidity• It applies to the chemistry but also to the machining•Tighter tolerances are possible in a controlled environment•The same applies to making the part from the tool!
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IV. LPMs in production
•LPMs can hold vacuum for bagging and infusions
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LPMs produce small and large parts
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V. Options for LPM Construction•A Tooling Compound substrate can be built without low density material•For example, it can be a wood substrate•Between 10 and 20 parts can be made from such tools, even with a complex deck
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LPMs Allow Changes•Should the part require a change, it is possible to do so with LPMs before
committing to hard tooling•Modular LPMs can make lengthening or widening easier
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VI. Open Discussion Questions on CNC manufactured tools•Why can’t I store tools outside?•How many parts will my limited
production mold produce?•Can I use low shrink polyester tooling
systems on my CNC plug?•Can I make an epoxy part on my polyester
CNC plug or LPM?•Cracking: what to watch for•Process service temperature?
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Thank You for your Time