Verified Digital Optimization Arena for Tool/Die/Mold Production by 3D Metal Printing
|Coordinator||Örebro universitet - Maskinteknik, Institutionen för naturvetenskap och teknik|
|Funding from Vinnova||SEK 4 000 000|
|Project duration||December 2016 - November 2018|
Purpose and goal
Tool design and manufacturing is an important phase in the development of new products. The project aimed to create a verified digital optimization arena for tool production through 3D metal printing to achieve a lead time reduction, reasonable manufacturing costs, a more efficient use of materials and reuse / rejuvenation of tools. The project, which included both stamping tools and injection molding tools, achieved these goals. Resonable manufacturing costs require a depreciation period of at least 15 years for the 3D printing machine.
Expected results and effects
In this project, the lead time for the industrial - stamping tool was reduced by 54%. - injection molding tool was reduced by 75%. The material usage was decreased by 44% for the industrial stamping tool. The cooling could be greatly improved. Therefore, the water flow in the injection molding tool could be reduced by 86.4% compared to injection molding in a conventionally manufactured tool. The best result is obtained, if the tool is redesigned from scratch before 3D printing. Optimized 3D-printed copies of conventional design provide good but not the best results.
Planned approach and implementation
The project focused on the following work packages (WP): WP1: Digital optimization arena incl. CAE WP2: Lab & semi-industrial testing - tools for car body components WP3: Lab & semi-industrial testing - injection molding tool WP4: Quality Comparison & Assurance in AM / 3DP WP5: Business cases, industrial verification and sustainability WP6: Project management, dissemination of results etc. Good collaboration between the work packages and project participants led to an efficient and pleasant implementation.