DIRECT METAL LASER SINTERING, USING CONFORMAL COOLING, FOR HIGH VOLUME PRODUCTION TOOLING

Authors

  • Bertus van As Vaal University of Technology http://orcid.org/0000-0001-7628-4984
  • J Combrinck Central University of Technology, South Africa
  • G J Booysen Central University of Technology, South Africa
  • D J De Beer North-West University, Potchefstroom, South Africa

DOI:

https://doi.org/10.7166/28-4-1470

Keywords:

Injection moulding, Rapid Tooling, Conformal cooling, finite element analysis, Additive Manufacturing.

Abstract

Existing techniques to manufacture conventional tool steel inserts for the plastic injection moulding process are expensive and time-consuming. Complex mould inserts, difficult to manufacture with conventional processes, can be produced using Direct Metal Laser Sintering (DMLS) with Maraging tool steel (MS1). MS1 is an additive manufacturing (AM) material made available by Electro Optical Systems (EOS) GmbH. Contrary to material removal processes, DMLS can produce MS1 tool steel inserts directly from Computer-Aided Design (CAD) files suitable for high volume plastic injection moulding. Through DMLS it is possible to create conformal cooling channels inside the MS1 inserts that have advantages in reducing heat rapidly and evenly. This can result in a reduction of cycle times, cost per product as well as improving part quality by eliminating defects such as warpage and heat sinks. This paper will present a comparison between Finite Element Analysis (FEA) simulations of the injection mould inserts with actual mould trails of AM and conventional manufactured inserts. It also includes the design and manufacturing of conventional and DMLS inserts and compares the manufacturing costs and lead times. Using FEA simulations, the design of conformal cooling channels is optimised by comparing the mould temperature of different cooling channel layouts.

Author Biography

Bertus van As, Vaal University of Technology

Bertus van As, a BTech (Mechanical Engineering) graduate from the Central University of Technology and currently employed by the Advanced Manufacturing Precinct at the Vaal University of Technology, as HOD of the Mould and Die Manufacturing unit. Specialising in Manufacturing, supporting Research, Design and Development projects. Currently studying towards his MTech degree in the field of advanced manufacturing technologies.

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Published

2017-12-13

How to Cite

van As, B., Combrinck, J., Booysen, G. J., & De Beer, D. J. (2017). DIRECT METAL LASER SINTERING, USING CONFORMAL COOLING, FOR HIGH VOLUME PRODUCTION TOOLING. The South African Journal of Industrial Engineering, 28(4), 170–182. https://doi.org/10.7166/28-4-1470

Issue

Vol. 28 No. 4 (2017)

Section

Case Studies

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