Slide 1

WELCOME

USE OF RAPID PROTOTYPING IN RAPID TOOLING

PROTOTYPE

ITs A SCALED DOWN OR UP VERSION OF A REAL SIZED OBJECT GENERALLY USED TO TEST PERFORMANCE OF OBJECT

PHASES OF DEVELOPMENT OF PROTOTYPING RAPID PROTOTYPING

ITs A CLASS OF TECHNOLOGIES THAT AUTOMATICALLY GENERATE MODELS FROM CAD DATA ALSO CALLED AS LAYERED OR TOOLFREE MANUFACTURING IT IS AN ADDITIVE PROCESS RAPID IS A RELATIVE TERM, AS IT TAKES SEVERAL HOURS TO BUILD A PROTOTYPE BUT IT IS MUCH FASTER THAN CONVENTIONAL MANUAL PROTOTYPING

PROCESS CHAIN OF RAPID PROTOTYPING

CLASSIFICATION OF RAPID PROTOTYPING PROCESS

RAPID TOOLING IT IS A PROCESS THAT COMBINES RP AND CONVENTIONAL TOOLING METHODS TO PRODUCE MOULDS IT EITHER USES RP MODEL AS A MASTER PATTERN TO PRODUCE MOULD OR USES RP PROCESS TO FABRICATE A MOULD CLASSIFICATION OF RT

DIRECT SOFT TOOLING

IN THIS TYPE MOULD IS PREPARED DIRECTLY WITH THE HELP OF ONE OF THE RP TECHNIQUE BY USING SOFT MATERIALS LIKE EPOXY RESINS, SILICON RUBBER etc. SLS OF SAND CAST MOULD

SAND MOULDS ARE PREPARED BY USING SLS TECHNIQUE PROCESS SAND GRAINS ARE COATED WITH POLYMERIC BINDER LASER ENERGY IS APPLIED TO MELT THIS BINDER THIS RESULTS IN BONDING OF SAND IN SHAPE OF MOULD INDIRECT SOFT TOOLING

IN THIS TYPE MOULD IS PREPARED WITH HELP OF A COMPONENT MANUFACTURED BY RP TECHNIQUE BY USING SOFT MATERIALS LIKE EPOXY RESINS, SILICON RUBBER etc.

ROOM TEMPERATURE VULCANIZATION

THIS IS AN OLD METHOD BUT MASTER PATTERN USED IS DEVELOPED BY ONE OF THE RP PROCESSES MATERIALS USED SILICON RUBBER, POLYURETHANE, POLYESTER, EPOXY TYPES 2 TYPES OF RTV 1) ONE PIECE MOULD APPROACH2) TWO PIECE MOULD APPROACH

ONE PIECE MOULD APPROACH

TWO PIECE MOULD APPROACHPROCESSMOULD BOX IS FILLED UP TO PARTING LINE WITH MOULD CLAYMASTER PATTERN ALONG WITH ATTACHED GATING SYSTEM IS PALCED IN MOULD BOX3) SILICON RUBBER IS POURED IN HALF FILLED MOULD BOXAFTER SOLIDIFICATION OF RUBBER, CLAY IS REMOVED AND WE GET A HALF PART OF MOULDTHE OTHER HALF OF MOULD IS PREODUCED BY LAYING THE MASTER PATTERN UPSIDE DOWN AND CARRYING OUT SAME PROCESS ADVANTAGES OF 2PIECE MOULD APPROACH OVER 1 PIECE MOULD APPROACH 1) IT IS USEFUL WHEN PARTING LINE IS DIFFICULT TO BE DETERMINED2) LESS SKILLED WORKERS ARE REQUIRED

DISADVANTAGES OF 2PIECE MOULD APPROACH OVER 1PIECE MOULD APPROACH 1) TIME REQUIRED TO PRODUCE MOULD BY 2 PIECE MOULD APPROACH IS MORE

PHOTOS

Left; one-piece mould Right; two-pieces mould

DIRECT HARD TOOLING

IN THIS TYPE MOULD IS PREPARED DIRECTLY WITH THE HELP OF ONE OF THE RP TECHNIQUE BY USING HARD MATERIALS LIKE TOOL STEEL etc.

DIRECT METAL LASER SINTERING (DMLS)

THE WORD SINTERING IS CONFUSINGIT IS ACTUALLY LASER WELDING OF METAL POWDER INDIRECT HARD TOOLING

IN THIS TYPE MOULD IS PREPARED WITH HELP OF A COMPONENT MANUFACTURED BY RP TECHNIQUE BY USING HARD MATERIALS LIKE MIXTURE OF EPOXY RESIN AND Al POWDER etc.

METAL FILLED EPOXY TOOLING

THE PROCESS OF PRODUCING EPOXY TOOLING IS SIMILAR AS MAKING RTV TWO- PIECE MOULD BUT USUALLY DOUBLE DUPLICATION METHOD IS USED

PROCESS

1) MASTER PATTERN SURFACE IS APPLIED WITH MOULD RELEASE AGENTAFTER HAVING AN IMPRESSION OF MASTER PATTERN ALONG WITH GATING ON CLAY IN MOULD BOX IT IS REMOVEDSILICON RUBBER IS POURED IN TO IT WHICH UPON SOLIDIFICATION ACTS AS NEGETIVE MOULD MASTER PATTERN4) THIS NEGETIVE MOULD MASTER PATTERN IS PLACED IN MOULD BOX ON WHICH METAL EPOXY IS POURED TO GET METAL TOOLINGADVANTAGES OF RAPID TOOLING

SHORTENS TOOLING LEAD TIMEMISINTERPRETATIONS ABOUT DRAWING CAN BE AVOIDED IN INITIAL STAGESLOW DESIGN FAILURES

THE ONLY DISADVANTAGE OF RT IS HIGH COST

FUTURE DEVELOPMENT1) TO REDUCE PROCESS TIME TO PRODUCE METAL PROTOTYPETO REDUCE THE COST OF PROTOTYPING

CONCLUSION

TOOLING i.e MOULD MAKING CAN BE DONE AT A FASTER RATE BY COMBINING RP AND CONVENTIONAL TOOLING METHOD.