Linear AMS Capabilities

Transcription

1 Linear AMS Capabilities

2 Linear History: LinearAMS LLC. Linear Mold & Engineering Founded in June 2003 Specialized in prototyping of plastic injection molds & low volume production molding Led the industry as an early adopter of DMLM technology Combined DMLM Technology with mold-making for cycle time improvements Used DMLM technology to print production parts for Oil/Gas & Energy Industries Company Sold to Moog Inc in December 2015 for Metal AM Production Capability Company founder purchased tooling and manufacturing business back from Moog Inc in July 2017

3 Think Linear Know the Difference Capabilities Engineering Design & Feasibility Moldex3D / UG / Catia /Magics / Black Box capabilities / Advanced Process Support Rapid Prototyping SLA / SLS / FDM / CNC Cut parts / MUD Base Tool Building Aluminum Prototype Molds / Production Injection Molds / Compression Molds / Bridge Tooling Injection Molding - 9 Presses (110ton 1650ton) Prototype Molding / Low Volume Production / Assembly / Laser Etching / Tryouts / R&D Projects / PPAP Fully Supported Machine Shop Models & Fixtures Additive Manufacturing (AM) 3D Metal Printing Conformal Cooling Using AM Founded in 2003, Linear AMS is a customer-focused solutions-oriented partner for plastics mold tooling and production. Our strengths lie in product design and engineering, shortening production times and trouble shooting. These competencies, along with our expertise in Additive Manufacturing for Mold inserts (Including Conformal Cooling) and our full machine shop capabilities have meant production successes for our customers in the automotive industry.

4 Conformal Cooling

5 Conformal Cooling What is Conformal Cooling? It is the optimization of cooling or heating channels that follow the shape of the molded part surface for productivity and quality improvements It is a way of reaching area in a mold that have hot or cold spots to help control the part temp. during molding. How does Conformal Cooling help make a molder more Lean? Reducing Scrap Reducing Cycle Time Increased Capacity How are Conformal Cooling inserts built? Simulation Design and Optimization Laser Sintering (A.K.A. Additive Manufacturing) Post Processing

6 Why Conformal Cooling?

7 Benefits of Conformal Cooling Reduced cycle times Minimized scrap Widened process window Noted quality improvements Isolated thermal control Increased flexibility in water line designs

8 Moldex3D Linear has adopted Moldex3D software to validate and optimize our designs of plastic parts and molds. This software allows our tool designers to visualize flow capabilities and thermal properties, as well as embrace process conditions ahead of physical production. Automotive tooling insert with conventional cooling Hottest temperature point, 114ºF. Same insert with conformal cooling lines created by using the DMLS process. Hottest temperature point, 50ºF.

9 Conformal cooling Inserts: How they are built Source: Linear Mold & Engineering, Inc.

10 The Conformal Cooling Process Step One: Simulation Software (MoldEx 3D) used to identify areas with uneven temps. This software allows our tool designers to visualize flow capabilities and thermal properties, as well as embrace process conditions ahead of physical production. Cooling Simulation Example Mold deformation study Source: Linear Mold & Engineering, Inc.

11 The Conformal Cooling Process Step Two: Water lines designed to address results of simulation Core Block Insert Cavity Block Insert Source: Linear Mold & Engineering, Inc.

12 The Conformal Cooling Process Step Three: Grow the inserts using a Direct Metal Laser Sintering Process Benefits of Laser Sintering Technology Part built layer by layer Impressive geometric flexibility; perfect for making cooling channels of any shape and size. Materials that match conventional tool steels MS1: In the 300 series of stainless. Great to Machine, wieldable, can be hardened to 58hrc Source: Linear Mold & Engineering, Inc.

13 The Conformal Cooling Process Step Four: Post Processing of The Conformal Cooled Inserts Stress Relief / Heat Treatment EDM wire part from platform CNC or EDM inserts as required Polish part surface as required (Up to B2 finish) Polish conformal water lines if required * CMM Insert Source: Linear Mold & Engineering, Inc.

14 Best Fit CC Applications for Injection Molding Structural Components Parts normally designed with thick wall conditions and made from high melt temp engineered resins (Nylons, PBT s, Etc.). Handles Most handle parts are good candidates because they are designed to withstand high load conditions. High Scrap Rates: Existing production parts with existing issues like part defects, warp, and dimensional issues. Cycle Time Issues: Existing production parts with higher then Expected cycle times. Long Cooling Cycle: Any part where the cooling portion of the cycle time is over 20% of the overall cycle would typically benefit from conformal cooling. High Volumes: Parts with very high volumes (250K or more per year) make great candidates because even small cycle time, or quality improvements have a large impact on capacity and profitability.

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16 Conformal Cooling Applications

17 Conformal Cooling Candidate Material : 30% GF Nylon (435 F operating temp) Mold : 2 cavity injection mold, P- 20 material Banana cores: P-20 material, no cooling Production : 350,000 parts/year Only 12 shots before severe deformation in this area Banana core reaches temperature of 300 F 100% scrap

18 Conformal Cooling Results Banana cores redesigned and grown using DMLS with conformal cooling lines extending to the problem area, and cooling entire length Banana core maintains temperature of 72 F during 11 hours of production. No scrap Cycle time reduced from 35 to 16 seconds (54% reduction) Total savings: 19 seconds X 350,000 parts = 1,847 hours (76 days production) The quoted cycle was 35 seconds, and we are making the handle in 16. Before we added the redesigned core, it was not possible to run the tool after 12 shots. So, I would say we have achieved nirvana. - Customer Feedback Problem Area

19 Case Study

20 Traditional baffle style cooling travels up and into an isolated area

21 The conventional water cooling design was molded at a 78 second cycle with a 230º F delta.

22 Utilizing FEA analysis, Linear provided a re-design of the water cooling circuit, implementing existing inlets and outlets from the conventional design.

23 The revised cooling circuit predicted a 61% cycle time reduction, however, the actual reduction brought cycle time to 42 seconds due to the press limitations.

24 Benefits of Thermal Stabilization (Conformal Cooling) - Hybrid components such as the one just seen allow quicker processes and less cost by creating the lower portion with the print plate. Conventional procedure is used on the print plate. The conformal portion is printed on top and machined after. The result is nearly endless possibilities.

25 Updated tool produced warp free product Reduced scrap Shortened cycle time

26 Using hybrid insert technology This tool used conventionally prepared base material then the top portion was printed onto the base Printed portion Hybrid Design Conventional base

27 Thank you: Brian Garvey Business Development Manager (586) Globe Street Livonia MI 48150